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PARADIP REFINERY PROJECT

PROJECT SPECIFICATION ASPECIFICATION FOR ISOLATION JOINTS

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CONTENTS

1.0 INTRODUCTION.................................................................................. 31.1 Scope................................................................................................... 31.2 Pipelines Description ......................................................................... 32.0 REFERENCES, CODES AND STANDARDS...................................... 42.1 Project Speci fic Documents .............................................................. 42.2 Codes and Standards ......................................................................... 42.3 Definit ions ........................................................................................... 52.4 Abbreviations ...................................................................................... 53.0 GENERAL REQUIREMENTS .............................................................. 63.1 Isolating Joint Components .............................................................. 63.2 Dimens ional Requirements ............................................................... 73.3 Loading Requirements ....................................................................... 74.0 AMENDMENTS/SUPPLEMENTS TO MSS SP-75 .............................. 84.1 Scope................................................................................................... 84.2 Pressure Rating .................................................................................. 84.3 Hydrostatic Testing ............................................................................ 84.4 Materials .............................................................................................. 84.5 Tensile Properties............................................................................... 94.6 Heat Treatment.................................................................................... 94.7 Hardness Testing................................................................................ 94.8 Tolerances of Welding Fitt ings ....................................................... 104.9 Manufacture ...................................................................................... 104.10 Inspection .......................................................................................... 114.11 Marking .............................................................................................. 125.0 COMPONENTS NOT COVERED BY MSS SP-75............................. 135.1 Ring Seals ......................................................................................... 135.2 Insu lating and Fil ler Materials ......................................................... 135.3 Coating .............................................................................................. 135.4 Electrical Checks .............................................................................. 146.0 QUALITY ASSURANCE .................................................................... 156.1 Transpor tation .................................................................................. 156.2 Quality Assurance System .............................................................. 156.3 Pre-manufacturing Documentation................................................. 156.4 Content of the Quality Plan.............................................................. 156.5 User Manual ...................................................................................... 167.0 APPENDIX ......................................................................................... 17

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1.0 INTRODUCTION

1.1 Scope

This document details the requirements of the isolation joints to be used forthe proposed Product onshore pipelines for the Indian Oil Corporation Ltd(IOCL) Paradip Refinery project.

1.2 Pipelines Descr ipt ion

1.2.1 Product Pipelines

The Product Pipelines comprise one (1) Crude Oil pipeline connecting theSouth Loading J etty to the Refinery; three (3) Utility Pipelines and eleven (11)Product Pipelines connecting the Refinery to the South Loading J etty; andfour (4) Product Pipelines connecting the Refinery to the Marketing Terminal.

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2.0 REFERENCES, CODES AND STANDARDS

2.1 Project Specific Documents

3210-8210-RP-0039 Pipeline Sizing Report

3210-8210-RP-0017 Raw Water Pipeline Mechanical Design Report

3210-8210-RP-0007 Product & Crude Oil Pipelines Basic Engineering dataReport

3210-8210-RP-0040 Product pipeline Pipe Wall Thickness Report

3210-8210-RP-0015 Product Pipeline Hyd & Surge Analysis Design Report.

3210-8210-RP-0031 Pipeline Basis of Design

2.2 Codes and Standards

The latest editions of the following codes and standards shall apply:

MSS SP-75 Specification for High Test Wrought Butt WeldingFittings

API 5L Line Pipe Specification

OISD-STD-141 Design and Construction Requirements for CrossCountry Hydrocarbon Pipelines

ISO 13623 Petroleum and Natural Gas industries PipelineTransportation Systems.

ISO 10005 Quality Management Guidelines for Quality Plans.

ISO 11126 Specification for Non-metallic Blast-cleaning Abrasives.

ISO 9001 Quality Systems Model for quality assurance indesign, development, production, installation andservicing.

ISO 9002 Quality systems Model for quality assurance inproduction, installation and servicing.

ISO 8501-1 Rust grades and preparation grades of uncoated steelsubstrates and of steel substrates after removal ofprevious coating.

ISO 10474 Steel and steel products, inspection documents.

ASTM E 112 Standard test method for determining average grainsize.

ASME VIII Boiler and pressure vessel code, Pressure vessels

ASME IX Boiler and pressure vessel code, Welding and brazingqualification.

ASME B16.9 Factory-made wrought steel butt welding fittings

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EN 1043-1 Destructive tests on weld in metallic metal in fusionwelded joints.

EN 876 Destructive tests on welds in metallic materialslongitudinal tensile test on weld metal in fusion welded

joints.

2.3 Definitions

Fitting Term used in MSS SP-75 which has the same meaningas isolating joint.

2.4 Abbreviations

IOCL Indian Oil Corporation Ltd.

SMYS Specified minimum yield stress

NDE Non-Destructive Examination

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3.0 GENERAL REQUIREMENTS

This specification shall be read in conjunction with MSS SP-75, where thisspecification does not amend or supplement MSS SP-75, they shall apply aswritten.

The purpose of isolating joints is to provide electrical separation betweenpipeline sections and adjoining and neighbouring structures and pipelines,and other sections of the same pipeline system, thereby preventingdetrimental electrochemical interaction and improving the effectiveness of the

cathodic protection system. Isolating joints are used also to ensure effectivecurrent distribution for cathodic protection systems.

Wherever practicable, the isolating joint is intended to be installed aboveground, in order to limit the possibility of electrical bridging across the joint. Itis intended to be girth welded between two pipeline sections.

The design of the isolating joint shall be compatible with the design codeOISD-STD-141. The isolating joint shall be suitable for operation under theenvironmental and operating conditions specified by the 3210-8210-RP-0031.

The isolating joint shall be suitable for pigging operations.

3.1 Isolating Joint Components

A typical isolating joint shall consist of the following components, referenceAppendix A.

Two spools, each consisting of a pipe segment with a bevelled end forwelding to the pipeline, and with a welded-on boltless flange at the otherend for encapsulation into insulating and filler material. Slip-on flangesshall not be used. The material used for the pipe segments shall becompatible with the pipeline material.

A rigid casing (retaining ring) for strength connection of the two spools.

Insulating and filler materials for electrical isolation between the twospools.

Double sealing arrangement for pipeline internal pressure containmentshall be used if the design pressure is greater than 51 kg/cm2 (50 barg) orthe fluid conveyed is classified as toxic. When neither of these are true asingle sealing arrangement can be used.

Two terminal connecting lugs on the outer surface of each spool. Each lugshall be suitable for M10 bolted cable connection. The lugs shall bewelded on double plates on the spools.

An internal coating to limit the possibility of electrically bridging the spools

due to deposits of a conductive medium.

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3.2 Dimensional Requirements

The internal diameter of the isolating joint shall not deviate by more than 2%of the nominal internal diameter of the pipeline for nominal diameters notexceeding DN 500 and 1.5% for nominal diameters above DN 500. Anytransition shall be tapered at an angle not exceeding 14 degrees measuredfrom the axis of the pipe (i.e. a taper of 1:4).

Pup sections of the parent line pipe will be provided by the contractor. Theminimum overall length of the joint shall be as specified by the Engineer-in-

Charge.If the Engineer-in-Charge specifies that post-weld heat treatment will be usedfor field welding, the Manufacturer/Supplier shall demonstrate that the lengthof the joint is suitable, i.e. the heat generated by the heat treatment is notdetrimental to the insulating and filler materials and the internal coating. If thisis not the case, the length of the joint shall be increased accordingly.

3.3 Loading Requirements

The isolating joint shall be able to resist the design pressure and the designtemperature, in combination with the anticipated external loads as specified

by the Engineer-in-Charge.

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4.0 AMENDMENTS/SUPPLEMENTS TO MSS SP-75

4.1 Scope

1.1 Add to this subsection:

Higher grade materials shall not be substituted for material ordered to a lowergrade without the approval of the Engineer-in-Charge, irrespective of strengthlevel.

4.2 Pressure Rating


The values of specified minimum yield strength S, wall thickness t anddiameter D shall be those of the pipeline section into which the isolating jointis to be welded.


The isolating joint shall be designed following the methodology described inASME VIII Division 1 Appendix 2, unless agreed otherwise by the Engineer-in-Charge, using the design pressure, design temperature and design factor

of the pipeline, and the anticipated external loads acting on the isolating joint.

4.3 Hydrostatic Testing

Replace this section by:

Each isolating joint shall be hydrostatically strength tested at the pressure Pcalculated as specified in this specification, with the fitting in an unrestrainedcondition. The pressure shall be held for a minimum of four hours.

A hydrostatic fatigue test shall be carried out after the strength test has beensuccessfully completed. The test shall comprise five cycles from atmosphereto 80 per cent of the strength test pressure. During the test the isolating joint

shall be in an unrestrained condition.

There shall be no leakage, loss in pressure or inelastic deformation during theabove tests.

4.4 Materials

6.1 Replace this subsection by:

The steel shall be made in a basic oxygen or electric arc furnace. It shall befully killed with a grain size of 7 or finer, as defined in ASTM E 112.

For quenched and tempered isolating joints, this grain size requirement shallnot apply.

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4.5 Tensile Propert ies


A tensile test shall be carried out on a sample for each heat of steel used inthe fabrication of the isolating joint.


If the isolating joint contains a longitudinal weld, an additional transverse weldtensile test shall be performed. For arc-welded isolating joints, an all-weldmetal tensile test should also be performed in accordance with EN 876.

4.6 Heat Treatment


If the isolating joint consists of several components assembled together bywelding, without further cold or hot forming, the individual components shallbe heat treated separately, i.e. prior to assembly.

The heat treating process shall be performed in accordance with adocumented procedure. The Manufacturer/Supplier shall also establish andfollow procedures for maintaining heat and/or lot identity. A record shall be

maintained of each heat treatment and shall be included in theManufacturer/Suppliers data report.

9.1.1 Replace this subsection by:

Stress relieving shall be performed at a temperature between 560 C and 600C unless otherwise agreed with the Engineer-in-Charge. Isolating joints shallbe held at the stress-relieving temperature for at least one hour per 25 mm ofmaximum section thickness, but never less than one half hour. Cooling shallbe in the furnace or in still air.

4.7 Hardness Testing

11.2.1 Location

A series of Vickers hardness tests (HV10) shall be carried out on a cross-section removed from a test isolating joint. The test method shall comply withEN 1043-1. The series of readings shall extend from unaffected base metalon one side across the weld to unaffected base metal on the other side.

Three traverses shall be made, one 2 mm from the outer edge, the secondacross the centre and the third 2 mm from the inner edge. The spacingbetween the hardness impressions shall be 0.75 mm. The hardnessimpressions within the HAZ shall be as shown in EN 1043-1.

11.2.2 Acceptance criteria

Hardness measurements shall not exceed the 325 HV10:

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4.8 Tolerances of Welding Fittings


For a distance of 100 mm from the welding ends, the internal diameter shall

not deviate by more than 1.5 mm from the nominal internal diameter of thepipeline or that permitted by ASME B16.9, whichever is the more stringent.

The entire end bevel shall be machined and root faces shall not be broughtinto tolerance by filing or grinding.

4.9 Manufacture


Isolating joints shall be made by forging, pressing, piercing, rolling, extruding,welding, or a combination of these processes. The forming procedure shall beapplied so that it will not produce injurious defects in the isolating joint.

The Manufacturer/Supplier shall prepare detailed manufacturing proceduresincluding welding and inspection. Any requirement for qualification testing ofthese procedures, and of welders/welding operators shall be documented aspart of the quality plan.


Welding, including repair welding, shall be performed in accordance withprocedures qualified to ASME Section IX. Welders and welding operatorsshall be qualified in accordance with ASME Section IX.

In addition to the mechanical tests specified in ASME IX, notch toughnesstests and hardness tests shall be performed on the qualification test welds inaccordance with (11 and 11A). Acceptance criteria for all tests shall be asstated in (8, 11 and 11A).

The results of all qualification tests shall be documented in a ProcedureQualification Record (PQR).

14.4.5 Add to this subsection:

Repair welding shall be executed using procedures qualified in accordancewith the requirements of (14.4.1).

The repaired area shall be non-destructively tested by radiographic testing,ultrasonic testing and magnetic particle testing.

14.5.2 Add to this subsection:

Imperfections of the following types exceeding the specified criteria shall beconsidered injurious defects:

a. Cold formed dents

All cold formed dents with a sharp bottom gouge and all sharp gouges(without dents) deeper than 1.0 mm.

b. Offset of plate edges

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For isolating joints having a nominal wall thickness of 12 mm or less, theradial offset of plate edges (misalignment) shall not exceed 2 mm. Fornominal wall thicknesses greater than 12 mm, the radial offset shall notexceed 3 mm or 12.5% of the wall thickness, whichever is smaller.

c. Height of weld reinforcement

The height of the weld bead shall not extend above the prolongation of theoriginal surface of the fitting by more than 3 mm. The surface of the weldbead shall never be below a prolongation of the surface of the isolating joint.

d. Arc strikes

Arc strikes may be removed by grinding provided the remaining wall thicknessis within the specified tolerances. The ground area shall be merged smoothlyinto the original contour of the isolating joint by grinding.

e. Undercuts

An undercut shall be repaired when it exceeds any of the following criteria:

Maximum depth of 1 mm and not exceeding 12.5% of the wallthickness with a maximum length of half the wall thickness, and notmore than two such undercuts in any 300 mm of weld length.

Maximum depth of 0.5 mm, any length.Repair shall be by grinding provided that the remaining wall thicknessremains within the specified tolerances.


Surface defects having a depth less than 6.5% of the nominal wall thicknessmay be repaired by grinding.

Whenever grinding repairs are made as a result of imperfections beingdisclosed by NDE, the part of the isolating joint containing such repair shall besubjected to additional NDE using the same technique, and magnetic particletesting after the grinding operation.

Repair of base material by welding is not permitted.

4.10 Inspection


The Manufacturer/Supplier shall provide the Engineer-in-Charge with aninspection certificate containing the results of all inspection and testing,including the requirements of Sections 7, 8, 9, 11 and 15. The certificate shallcomply with ISO 10474 Type 3.1.B.

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4.11 Marking

Add to this section:

f. Purchase order and item number

g. Serial number of the isolating joint

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5.0 COMPONENTS NOT COVERED BY MSS SP-75

5.1 Ring Seals

Elastomeric materials for ring seals shall resist explosive decompression, andshall be suitable for long-term exposure to the transported fluid at the designpressure and temperature conditions. The cross-section of the seals shall notexceed 7 mm diameter for design pressures of 150 bar and above.

Polybutadiene acrylonitrile and vinylidene fluoride-hexafluoropropylene maybe used.

5.2 Insulating and Filler Materials

The insulating materials and filler materials shall be suitable for long-termexposure to the transported fluid at the design pressure and temperatureconditions.

5.3 Coating

The isolating joint shall be coated internally to prevent electrical bridging of

the two spools through the transported fluid. The isolating joint shall becoated externally. The internal and external coatings shall terminate 50 mmfrom the isolating joint ends.

All surfaces to be coated shall be blast cleaned to ISO 8501-1 grade Sa 2or Sa 3, using non-metallic abrasive certified as being in accordance with theappropriate part of ISO 11126. The internal and external coatings shall

consist of an amine-cured epoxy, to a minimum dry film thickness of 300 mapplied in two coats. The application shall be in strict accordance with thecoating Supplier's specification.

Each coated isolating joint shall be visually inspected. The coating shall becontinuous, uniform and free of runs, sags, pinholes and other imperfections

indicative of incorrect coating application. Coating thickness tests, using amagnetic electronic type thickness gauge, shall be carried out on eachisolating joint, by taking four spot measurements at 90 degree intervalsaround the diameter. Each spot measurement shall meet the minimumthickness specified.

Following the hydrostatic pressure test ASME VIII (Part III, 5) and electricalchecks (Part IV, 1.4), the coatings shall be subject to holiday detection usinga wet sponge tester set at 60V. The acceptance level shall be zero pinholes.

Applied coating that fails to meet the requirements of this specification shallbe removed completely and the isolating joint shall be re-prepared and thecoating re-applied and inspected.

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5.4 Electrical Checks

Electrical checks, to be done after the hydrostatic pressure test, shall becarried out in the following sequence:

A voltage of 1500 V (AC) at 50 Hz shall be applied across the joint for 5minutes. There shall be no breakdown, flash-over or reduction in electricalresistance during this period.

A voltage of 1000 V (DC) shall be applied across the joint in a dried

condition. The resistance shall be at least 1 M.

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6.0 QUALITY ASSURANCE

6.1 Transportation

The isolating joint shall be protected against damage in transit. The bevelledends of the isolating joint shall be protected by plastic covers and care shallbe taken to prevent damage to the external and internal coatings. Isolating

joints shall be individually strapped on skid-mounted cradles and enclosed incrates.

6.2 Quality Assurance System

The Manufacturer/Supplier shall establish and maintain a quality system inaccordance with ISO 9001 or ISO 9002, or with an alternative standard ifagreed by the Engineer-in-Charge.

6.3 Pre-manufactur ing Documentation

The Manufacturer/Supplier shall produce a quality plan, specific to thepurchase order, covering the complete manufacturing and inspection process,including welding. The quality plan shall be submitted to the Engineer-in-Charge for agreement within an agreed time period.

6.4 Content of the Quality Plan

The format and issue of the quality plan shall be consistent with the documentcontrol requirements of the Manufacturer/Suppliers quality system.

The content of the quality plan should be based on ISO 10005 and shallinclude the following:

Identification of the product and purchase order to which the plan is to beapplied.

Reference to MSS SP-75 and this Specification.

Location of the manufacture of the isolating joint.

Identification of the individuals responsible for controlling the activitiesdefined in the plan.

Identification of the individuals with the authority to interface directly withthe Engineer-in-Charge.

Identification all sub-suppliers and sub-contractors.

The quality plans of all sub-suppliers and sub-contractors.

All sequenced activities for the purchase order and references to thequality system procedures and work instructions which will be applied to

these activities.

Copies of all the quality system procedures and work instructions coveringbase material production, fabrication and welding, test and inspection,

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special processes (e.g. heat treatment), control of non-conformingproduct, handling, storage, packing and shipping.

Test and inspection frequency and acceptance criteria, including theupper and lower process control limits where statistical process control isemployed.

The location of each inspection and test point in the process sequence.

Sub-suppliers data sheets and qualification test reports.

6.5 User Manual

In addition to the certificate of compliance, Section 4.10 theManufacturer/Supplier shall provide a user manual detailing the requirementsfor installation and inspection in service.

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7.0 APPENDIX

A Typical Isolation Joint

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Appendix A Typical Isolation J oint