vol

SPECIFICATIONSFOR

FIELD JOINT COATINGS OF PIPELINEFOR HDD CROSSING

SPECIFICATION NO. MEC/S/05/62/074

(PROCESS & PIPELINE DESIGN SECTION)MECON LIMITED

DELHI - 110 092

CONTENTS

Sl.No. Description Page No.

1.0 SCOPE 01 - 01

2.0 REFERENCE DOCUMENTS 01 - 02

3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL 02 - 07

4.0 APPLICATION PROCEDURE 08 - 11

5.0 INSPECTION 11 - 12

6.0 TESTING 12 - 12

7.0 REPAIR OF FIELD JOINT COATING 13 - 13

8.0 REPAIR OF PIPE COATING DEFECTS 14 - 14

9.0 DOCUMENT 14 - 14

PREPARED BY CHECKED BY APPROVED BY

D:\Technical Specifications & Standards\Latest\074 - Specification for FPJ Coating for HDD Crossing .doc Page 1 of 14

1.0 SCOPE

1.1 General

This specification covers the minimum requirement for application of anti-corrosion field joints coating on welded pipe section and field tie-in jointsreferred to here in after as Joint(s). The contractor shall perform all work inaccordance with this specification, latest pipeline coating practices and tothe full satisfaction of the Owner. The anti-corrosion pipe joint coating shallbe compatible with yard applied, Ultra Violet (UV) radiation protected, 3layer side extruded polyethylene coating conforming to DIN-30670. Thesleeve width shall be suitable for cut back of 120 ± 20 mm to be left atboth the ends of coated pipes. The job includes supply of all materialsequipment, consumables, labour, supervision, quality control, inspectionrepairs.

1.2 Manpower, Material & Equipment

1.2.1 The Contractor shall supply wrap around heat shrinkable sleeves which iscomposed of two parts such as adhesive coated wrap around and acurable modified epoxy primer alongwith applicator pads.

1.2.2 The supply of wrap around heat shrinkable sleeve shall be underContractor’s scope.

1.2.3 The Contractor shall provide all skilled/ unskilled personnel required forexecution of this work.

1.2.4 The joint coating operation starting from cleaning and surface preparationtill application of joint coating and wrapping of the pipe joints shall beperformed under the supervision of skilled personnel who are well versedin the work.

1.2.5 Contractor shall at his own cost provide a fully equipped laboratory andtest facilities with adequate inventory to carry out tests required forprocedure qualification and during regular production, for testing of jointcoating system.

2.0 REFERENCE DOCUMENTS

2.1 Provision of the following documents/ codes shall generally be followed forstandard of specification and workmanship.

a) DIN – 30672 : Corrosion protection tapes and Heat ShrinkableSleeves.


b) SIS – 055900 : Pictorial surface preparation standard for paintingsteel surfaces.

c) SSPC – SP1 : Steel structure painting council – Solvent Cleaning.

2.2 In case of conflict between the requirements of this specification and thatof above referred documents/ codes, the requirements of thisspecifications shall govern.

3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL

3.1 General

This scope covers the minimum requirement of materials, equipmentrequired for installation of field joint coating by wraparound fibre-reinforcement heat-shrinkable sleeve used for corrosion protection andsealing of field joints in pipelines that are forced through the soil byHorizontal Directional Drilling technique. The sleeves shall be suitable for3LPE/FBE coated pipes operating up to 60°C continuously.

3.1.1 Each Joint Coating System shall consist of :

a) A wraparound heat shrinkable sleeve reinforced with fibre-glass.The sleeve shall be coated with a higher- shear- strengththermoplastic hot-melt adhesive.

b) A solvent-free, two component liquid epoxy primer

c) A specifically designed wear cone

d) A clamping belt

3.1.2 Sleeve Backing

The heat shrinkable sleeves shall be manufactured from minimum 1.0 mmthick radiation cross linked, thermally stabilized, UV -resistant heat-shrinkable fabric, composed of a fibre glass reinforcement and polyolefinfibres, embedded in a polyolefin matrix.


3.1.3 Sleeve Adhesive

The inner surface of the sleeves shall be coated with a controlledthickness of minimum 1mm of adhesive which in combination with themodified epoxy primer, will bond to and seal to the steel pipe and commonyard applied medium temperature yard coatings.

3.1.4 Epoxy Primer

The Epoxy primer shall be a solvent free, modified two components liquidepoxy type primer, which is applied to cleaned and dry steel surface.When the sleeve coatings, comes in contact with the liquid primer duringinstallation, a strong bond is formed upon full curing of the system.

3.2 Properties of Field Joint Coating Material

The pipe sleeves furnished under this specification shall be tested andshall meet the requirements specified in the table below:-

3.2.1 Heat-Shrinkable Sleeve Material

Property TestMethod

Condition Requirement

Cold Crack ISO 4675 Below 40°C

Chemicalresistance

ISO 175 168 hrs. immersion on either0.1 N

NaCl @ 23°C, 0.1N H2 SO4 @

23°C, 0.1 N NaOH @ 23°C,Fuel oil @ 23°C. Petroleum jelly@ 70°C

Followed by test forbursting strength

ISO 3303 23°C 1100 N Min.

Thermal ageing

Followed by test forbursting strength

ISO 188

ISO 3303

150°C 168 hrs.

23°C

1700 N Min.

3.2.2 Adhesive material

Property TestMethod


Softening point ASTM E28 85°C minimum

Peel Strength DIN 30672 23°C. CHS*100 mm/ min.60°C

200 N/cm minimum

60 N/ cm


Property TestMethod


Peel StrengthAfter immersion for 4 weeksat 23°C~NaOH pH12 H2SO4pH2 ground water solution:-1.2% H3PO41.6% KOH1.2NaCl1.0% Fe2O3

DIN 30672 23°C. CHS*100 mm/ min.

200 N/cm minimum

Peel Strength afterconditioning for 30cycles from -30°C to 60°C

DIN 30672 23°C. CHS*100 mm/ min.

60 N/cm minimum

Shear strength ISO 4587 23°C. CHS*50 mm/ min.

200 N/cm2 minimum

Corrosive effect ASTM D2671

120°C.16 hrs.

No corrosion

3.2.3 Primer Material

Property Test Method Condition Requirement

Density ASTM D1084 23 +/- 0.50 CPart A: 2 rpm, spindle #6Part B: 20rpm, spindle #3

Part A: 60+/- 30 PasPart B: 1.55+/-0.55 Pas

Mixing ratio By weightBy volume

23°C 100:40100:60

Shear strength ISO 4587 23°C. CHS*50 mm/ min.

1000 N/cm2 minimum

* CHS = Cross Head Speed

3.2.4 Functional Properties

Sl.No.


a) Impactresistance

DIN 30672 23°C.Class C

No holidays when testedat 20 KV

b) Penetrationresistance

DIN 30672 60°C.Class C

Minimum 70% of originalresistance thickness left;no holidays when testedat 20 KV

c) Specific coatingresistance

DIN 30672 23°C. 108 Ohm sq. m minimum;no oxidation on pipesurface

d) Cathodicdisbondmentresistance

ASTM G42 60°C.30 days

15 mm increase in radiusof disbondment max.

e) Resistance tosplitpropagation

TEST METHOD-1*

No cut propagation


Sl.No.


f) Resistance tocircumferentialedge loading

TEST METHOD-2*

50 KN minimum

g) Resistance tolocal edgeloading (chiseltest)

TEST METHOD-3*

6 KN minimum

*Test Methods

3.3 Test Methods

3.3.1 Resistance to split propagation (Test Method -1)

A rectangular piece of 50mm width by 150 mm length shall be cut from thematerial as delivered. A 5mm long, clean cut shall be made mid-way in thepiece along once of the long edges perpendicular to this edge. Thesample shall be mounted on a clamp that holds it securely and avoids anyshrinking during testing.

The assembly shall be placed in an air-circulating oven present at 1700C.

After 15 minutes, the sample shall be removed from the oven, allowed tocool down to room temperature and examined for cut propagation.

This test simulates the unlikely event when the sleeve gets cut during theinstallation phase. Sleeves based upon extruded polyelfin show a distincttendency to propagate the cut along the total width of the sleeve. Sleevessuitable for HDD works shall not exhibit this behaviour.

3.3.2 Resistance to circumferential edge loading (Test method -2)

The sleeve shall be installed on a DN 200 three -layer PE coated steelpipe piece. A thick wall steel ring that fits a DN 200 three-layer PE coatedsteel pipe with a tolerance of 0.2+-0.2 mm shall be positioned against thefront edge of the wear cone sleeve and then pushed towards the sleevesystem at a constant speed of 5 mm/ min over a distance of 50 mm. Theforces necessary shall continuously be registered. The minimum requiredforce shall be less than 50 KN.

During the pushing or pulling operation, any obstacle protruding from thesmooth pipe surface is loaded by the surrounding soil that passes by. Thistest simulates the shear forces that are exerted on to the sleeve by rigidsoil type.

3.3.3 Resistance to local edge loading (Chisel test: Test Method -3)


The sleeve shall be installed on a DN 200 three-layer-PE coated steelpipe piece.

A chisel as depicted in Figure -1 shall be positioned against the frontedge of the wear cone sleeve and, pushed parallel to the pipe surfacetowards the sleeve system at a constant speed of 5mm/ min over adistance of 50 mm. The forces necessary shall continuously beregistered. The minimum required force should not be less than 6 KN.

During the pushing or pulling operation, the pipe may traverse soil areacontaining solid particles, such as stones, pebbles or crushed rock. Theseparticles tend to rip away the pipe coating locally. Any obstacle protrudingfrom the smooth pipe surface is lifted, leading to soil undercutting. Thistest determines the resistance of sleeve against this type of abuse.

I5mm

35mm

View AA

Figure- 1 Chisel


3.4 Qualification for Contractor’s supplied Materials and theirManufacturer

3.4.1 Prior to procurement of coating materials, Contractor shall furnish thefollowing information for qualification of the Manufacturer and material:

a. Complete descriptive technical catalogs describing the materialsoffered along with samples of corrosion coating materials, itsproperties and application instruction as applicable specifically tothe project.

b. Reference list of previous supplies, in last 5 years, of the similarmaterial or manufacturer shall be notified to Company, whoseapproval in writing of all charges shall be obtained before thematerials are manufactured.

3.4.2 Contractor shall ensure that the coating materials supplied by him areproperly packed and clearly marked with the following :-

- Manufacturer’s name

- Material Qualification Certificate Number

- Batch Number

- Date of Manufacturing and date of expiry

3.4.3 Prior to shipment of materials from the Manufacturer’s Works. Contractorshall furnish the following documents:

a. Test certificate/results as per Manufacturer’s Quality ControlProcedure for each batch of materials complying with therequirements of relevant sub-clauses of clause no. 3.2 of the thisspecification.

b. Specific application instructions with pictorial illustrations.c. Specific storage and handling instructions.

3.4.4 All documents shall be in English language only.

3.5 Storage of Materials

Material shall be stored in sheltered storage by the Contractor in themanufacturer’s original packing and away from direct sunlight and inaccordance with manufacturer’s instructions.

4.0 APPLICATION PROCEDURE


4.1 General

a) The application procedure shall be in accordance withmanufacturer’s instruction and the minimum requirements requiredbelow whichever are the most stringent and shall be demonstratedto and approved by the Owner.

b) Contractor shall provide and maintain mobile facilities whichcontains all necessary tools, propane torches, epoxy primer pumps,silicon rollers, testing instruments, equipment, and spares forcleaning, coating, repairs, inspection and testing.

c) Contractor shall furnish sufficient number of the followingequipment and the required spares as a minimum for inspectionand testing purpose for each crew :

- Fully automatic full circle adjustable holiday detector withaudio and visual output signal for inspection of coating.

- Portable Tensile Strength Tester- Digital Thermometer- Solid state digital thickness gauge for measuring thickness

of joint coating.

4.2 Pipe Surface Preparation

a) The Contractor shall thoroughly clean and dry the joint surface bypower tool cleaning in accordance with SSPC-SP1. The completeprocedure and details of equipment used shall be prepared by theContractor for Owner’s approval prior to commencement of jointcoating work.

b) Prior to cleaning operation, Contractor shall visually examine thejoint surface area and shall ensure that all defects, flats and otherdamages have been repaired or removed.

c) Where oil, grease or other materials detrimental to the finishedcoating is present, it shall be removed with a continuous removalsolvents cleaning system to remove completely all such materials inaccordance with SSPC-SP1.

d) The standard of finish for cleaned pipe surface shall conform to SA2½ of Swedish Standard SIS-055900 latest edition. The degree ofpreparation required to obtain an end product that fulfil the


requirements of this specification may not be sufficiently coveredand is not limited by SIS-055900. Surface of pipe after shot blastingshall be have an anchor pattern of 50 to 70 microns. This shall bemeasured by a suitable instrument such as Elecometer.

e) Piper temperature immediately prior to blasting shall be minimum20°C. At no time shall be blast cleaning be performed when therelative humidity exceeds 85%. Surface temperature must be atleast 3°C above the dew point temperature.

f) The abrasive blast material shall be free of impurities andinclusions, water and oil. All abrasives shall be removed after blastby brush or vacuum type cleaner prior to applying joint coating.The abrasive shall be stored in a dry condition and maintained dryduring use.

g) The compressed air for blasting shall be free of water and oil.Contractor to verify air cleanliness at the start of the work and everyfour hours thereafter. Separators and the traps shall be provided atthe compressor and blasting station. Separators and traps shall bechecked daily for effective moisture and oil removal during coatingoperations.

h) The ends of existing line pipe protective coating shall be inspectedand chamfered. Unbonded portions of the coating shall beremoved and then suitably trimmed. Portions where parent coatingis removed shall be thoroughly cleaned as specified.

i) Pipe shall be visually inspected by Contractor immediately afterblast cleaning for surface defects such as slivers, laminations,leafing, scores, indentation slugs or any other defects consideredinjurious to the coating integrity. Such defects shall be reported toOwner and on permission from Owner, such defects shall beremoved by filling or grinding in such a way as not to “blue” thesteel.


4.3 Procedure

a) The application procedure shall be in accordance withmanufacturers instruction and the minimum requirements specifiedbelow whichever are the most stringent and shall be demonstratedto and approved by the owner.

b) Applicators for coating application shall be given necessaryinstructions and training before start of work by theCONTRACTOR. To verify and qualify the application procedures,all coating applied during the qualification test, shall be removed fordestructive testing until the requirements stated in sections‘Inspection’ and ‘testing’ of this specification are met.

c) Prior to surface cleaning, the surface shall be completely dry. Aneffective heating equipment which shall not give rise to depositsshall be used. Care shall be taken to avoid damage to existingcoating.

d) All pipe joint surfaces shall be thoroughly examined before theapplication of the coating in order to ensure that the surfaces arefree of oil, grease, rust, mud, earth or any other foreign matter.

e) Liquid epoxy primer shall be applied on the joints immediately afterthe completion of heating operation.

f) The heat shrink sleeve is then wraparound the joint while the primeris still wet and shall overlap the existing pipe coating by minimum100 mm on each side.

g) The wraparound sleeve is shrunk on pipe joint with a propane torchmoved back and forth over the surface when heated above 125°C,the sleeve shall shrink tightly around the substrate on to the wet-primer. At the time of application of the primer, th pipe surfacetemperature shall be at least 60°C at every point. To check this,approved temperature indicators shall be used . temperatureindicating crayons shall not be used.

h) The wraparound sleeve shall be entirely wrapped around the pipepositioning the closure patch off to one side of the pipe in 10m or 2O’clock position, with edge of the undergoing layer facing upwardand an overlap of min. 100 mm.

i) Heat shrinking shall be procedure shall be applied to shrink thesleeve in such a manner that all entrapped air is removed usinggloved hands and hand rollers. The complete shrinking of entire


sleeves shall be obtained without undue heating of existing pipecoating and providing due bonding between pipe, sleeve and pipecoating. A thermochrome paint shall be applied a an closure patchto indicate that sufficient heat/ temperature has been obtained. Thejoint coating shall have wear cone applied over the leading edge ofthe sleeve and the clamping belt tightened over it.

j) Application of Wear Cone - The leading edge will be given an extrawear cone. Start by heating the leading edge area of the mainsleeve to 700C. Wrap the leading edge sleeve over the transitionMill coating. Ensure that the closure is placed away from the mainsleeve closure Shrink the leading edge sleeve.

k) Application of Metal Belt - The metal belt shall be applied over thewear cone sleeve. The metal belt will be tightened using thestrapper tool supplied by the manufacturer.

l) Sufficient manpower working on opposite sides of each pipe jointare required for installation of the sleeve.

m) The installed sleeve shall not be disturbed until the adhesive hassolidified.

5.0 INSPECTION

5.1 For wraparound coating, a visual inspection shall be carried out for thefollowing :

- Mastic extrusion on either ends of the sleeves shall be examined- There shall be no sign of punctures or pinholes or bond failure.

The external appearance of the sleeves shall be smooth, free ofdimples, air entrapment or void formation.

- Weld bead profile shall be visible over the sleeves.- The entire closure patch shall have changed colour uniformly.

5.2 Holiday Inspection

5.2.1 The Holiday Detector used shall be checked and calibrated daily with anaccurate D.C. voltmeter. The detector electrode shall be in direct contactwith the surface of coating to be inspected.

5.2.2 The entire surface of the joint section shall be inspected by means of a fullcircle Holiday Detector approved by OWNER set to DC Voltage of at least25 kV for wraparound sleeves. Inspection of the heat shrink sleeve coatingshall be conducted only after the joint has cooled below + 50°C.


5.2.3 All the coated joints shall be subjected to Holiday Detection test.

5.2.4 An installed sleeve with more than two holiday shall be stripped and a newone be installed.

6.0 TESTING

a) OWNER reserves the right to test one out of every 30 joint coatingsubject to a minimum of 2 joints. CONTRACTOR shall provide allassistance in removing and testing of field joint coatings. Fromeach test sleeve, one or more strips of size 25 mm x 200 mm shallbe cut one perpendicular to the pipe axis and slowly peeled off.This test shall be conducted between either sleeve and metal orsleeve and mill coating as per direction of Owner/ Engineer-in-charge.

b) The required peel strength shall be 60 N/cm (min.) at 23°C. Thesystem shall fail only in the adhesive layer. No failure either inadhesion to steel or adhesion to backing shall be permitted. Theadhesive layer that remains on the pipe surface shall be free ofvoids resulting from air or gas inclusion.

c) If the sleeve taken away for test does not meet the requirement ofclause 6.0 (b), the adjacent two sleeves do not meet therequirements of clause 6.0 (b) the field joint coating shall bestopped until OWNER is satisfied with application methods.

d) For the test tensile strength, two parallel incisions spaced 1 CM.Apart are made right down to the surface of the steel. A furtherincision shall then be at right angles to the first angles to the firsttwo incisions. With the aid of a 1 cm. Wide knife the coating is liftedover a length of about 2 cm. And clamped into the tensile tester,where upon a uniform pull is exerted at an angle of 90 degree. Thetensile strength shall be more than a 2500psi.

e) Coating thickness shall be checked by non destructive method foreach field joint.


7.0 REPAIR OF FIELD JOINT COATING

7.1 If a field joint is detected to be unacceptable after inspection and testingas per clause no. 6.0 of this specification. The CONTRACTOR shall , athis own cost :

- determine the cause of the faulty results of the coatings.

- mobilise the services of expert of manufactures, if required.

- test to the complete satisfaction of the OWNER, already completedfield joint coatings.

- stop joint coating until remedial measures are taken against thecauses of such failures, to the complete satisfaction of theOWNER.

7.2 CONTRACTOR shall replace all the joints coating found or expected to beunacceptable as per clause no. 6.0 of this specification.

7.3 CONTRACTOR shall, at his own cost repair all areas where the coatinghas been removed for testing by the OWNER or by the CONTRACTORto the complete satisfaction of the OWNER.

7.4 The upright edges of the damaged areas shall be chamfered, in additionto the steel shall be free from rust, dirt, oil and grease. The coating aroundthe damaged area shall be roughened. After thorough mixing (inaccordance with the recommendations of the manufacturer) the filler shallbe applied, to sufficient Thickness with the aid of stooping knife, whilstobserving ample overlap hardening. The material will require the approvalof OWNER.

7.5 After the coating work on welded joints and repairs to the coating havebeen completed, The coating area as a whole shall be tested with spark-tester before pull back/ lowering/jacking the pipeline.

7.6 Company shall be entitled to check the coating on buried pipelines orparts of pipelines with equipment such as the “Pearson meter” and theresistance meter. If the coating defects are established, the Contractorshall be responsible for excavation at such points, repairing the coating,spark testing and backfilling the excavations without extra charge.


8.0 REPAIR OF PIPE COATING DEFECTS

8.1 Any defect or damage in pipe coating observed till incorporation onpermanent works shall be rectified by the Contractor at his risk and cost.However, for repair of damaged coating observed during taking over ofOwner supplied pipe, if any, shall be paid extra in accordance with therelevant items of Schedule of Rates.

8.2 Field repair of coated pipes shall be carried out by using same type ofwraparound sleeves used for joint coating.

8.3 The repair procedure shall be same as specified herein above forapplication of anti-corrosion field joint coating on welded pipe.

9.0 DOCUMENTATION

9.1 Prior to start the coating works at site Contractor shall furnish followingOwner/ Consultant’s approved documents in addition to that mentioned inclause no. 3.4 of this specification.

- Procedure for field joint coating & their repair- Procedure for repair of pipe line coating defects- Procedure qualification record- Inspection test plan- Inspection format

9.2 Final submission of all documents after finish the work shall be as perrelevant specification & SCC enclosed with the tender or as per directionof Engineer-in-charge.

\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\75 pipe line crossing using HDD method\Specification for PL CUHDDM 75.doc

SPECIFICATIONFOR

PIPELINE CROSSINGSUSING HORIZONTAL DIRECTIONAL

DRILLING METHOD

SPECIFICATION NO. : MEC/S/05/62/75

MECON LIMITEDDELHI - 110 092

MECON LIMITEDDelhi

PROCESS & PIPINGDESIGN SECTION

TECHNICAL SPECIFICATIONFOR

PIPELINE CROSSINGS USINGHORIZONTAL DIRECTIONAL

DRILLING METHOD

TECHNICAL SPECIFICATION NO. : MEC/S/05/62/75 REV-0 Page 1 of 11


C O N T E N T S


1.0 SCOPE 2

2.0 DESIGN AND ENGINEERING 3 – 6

3.0 CONSTRUCTION 6 – 10

4.0 DOCUMENTATION 10 – 11

PREPARED BY : CHECKED BY : APPROVED BY :

MECON LIMITEDDelhi




DRILLING METHOD



1.0 SCOPE

1.1 This specification covers the minimum requirements for various activities to becarried out by the Contractor for the engineering and construction of pipelinecrossing using directional drilling method.

1.2 This specification shall be read in conjunction with the requirements ofspecification and other documents included in the CONTRACT between ownerand Contractor.

1.3 Contractor shall, execute the work in compliance with laws, by laws, ordinanceand regulations. Contractor shall provide all services, labour, inclusive ofsupervision thereof, supply of all materials (excluding “Owner suppliedMaterial), equipment , appliances etc..

1.4 Contractor shall take full responsibility for the stability and safety of alloperation and methods involved in the work.

1.5 Contractor shall be deemed to have inspected and examined the work areaand its surroundings and to have satisfied himself as far as practicable with thesurface conditions, hydrological and climatic conditions, the extent and natureof the work and materials necessary for the completion of the work, and themeans of access to the work area.

1.6 Contractor shall be deemed to have obtained all necessary information withregard to risks, contingencies and all other circumstances, which may influencethe work.

1.7 Contractor shall, in connection with the work, provide and maintain at his owncosts all lights, guards, fencing, as necessary or directed by Owner or theirrepresentative.

1.8 For the purpose of this specification, the following definitions shall hold.

- The words `Shall’ and `Must’ are mandatory.

- The words `Should, May and Will’ are non mandatory, advisory, orrecommendatory.

1.9 Contractor shall provide free of charge reasonable facilities to Owner’spersonnel to witness all stages of construction.

MECON LIMITEDDelhi




DRILLING METHOD



2.0 DESIGN AND ENGINEERING

2.1 The limits of each crossing shall be determined by the Contractor on the basisof crossing profile based on survey drawings, design, equipment, installationtechnique and site condition. Contractor shall furnish all engineering designcalculation and crossing drawings etc. to owner for their approval prior toexecution of the work.

2.2 Within the entire limits of crossing, the minimum cover to top of coated pipeshall be as specified in the Special Conditions of Contract (SCC).

However, wherever the drilled length for a crossing includes the crossings ofobstacles such as roads, railroads, cannals, streams, etc. The followingminimum requirements of cover to the pipe shall be satisfied unless specifiedotherwise in the scope of work in SCC.

For Road Crossing : 1.4 m from top of road to top of pipe.

For railroad crossing : 1.7 m from base of Rail to top of pipe.

For canal crossing : 1.5 m from lowest bed level to top of pipe.

In case the pipeline crosses other utilities, viz., other pipelines, sewers, drainpipes, water mains, telephone conduits and other underground structures, thepipeline shall be installed with at least 500 mm free clearance from theobstacle or as specified in the drawing or such greater minimum distance asmay be required by authorities having jurisdiction. Also in all cases, theminimum covers specified above shall be maintained within the entire limits ofcrossing.

2.3 The entry and exit points of the pipeline at ground level shall not come withinthe limits of crossing as defined in the crossing drawings.

2.4 Contractor shall carry out calculations for determining the maximumpermissible overburden on pipe, to check that the empty pipeline is safe fromcollapse at any point along the drilled crossing section. Contractor shall submitthese calculations to Owner for approval.

MECON LIMITEDDelhi




DRILLING METHOD



2.5 Pipeline Axis

The plane containing the pipeline route axis shall be perpendicular to thehorizontal plane. There shall be no bending of the pipeline route axis atdepths shall lower than 2 meters below ground level.

2.6 Back-reamed hole and Pipeline Interface

2.6.1 Contractor shall derive combination of:

- Back-reamed hole diameter- Bentonite density- Pipeline submerged weight in bentonite (and means to achieve that

weight)

to optimise the crossing design in terms of pipeline stresses and powerrequirement

2.6.2 Contractor shall indicated what maximum shear stress in the pipeline coatingwill result from his choice of above parameters and other characteristicsdescribed in this section.

2.6.3 Contractor shall furnish all calculations for Onner’s approval. If shear stress inpipe coating is, in the opinion of Owner, beyond the permissible limits,Contractor shall revise his choice of parameters to reduce shear stress on pipecoating to permissible value.

2.7 Contractor shall determine in the minimum allowable elastic bend radius forpipe from the following consideration:

2.7.1 Maximum Longitudinal Stress During Installation

Total maximum longitudinal stress in the pipeline due to tension and bendingat any location shall not exceed 90% of the SMYS of the pipe material.

Contractor shall, in order to check this requirement, evaluate the maximumtensile forces to which the pipeline is subjected to at any phase of itsinstallation during the pulling operation.

MECON LIMITEDDelhi




DRILLING METHOD



2.7.2. Maximum Equivalent Stress During Final Hydrostatic Test

After installation, the pipeline shall be hydrostatically tested to a minimum testpressure equal to 1.4 times the design pressure or at a pressure stipulated inthe Special Conditions of Contract whichever is higher. However, duringhydrostatic testing, the combined equivalent stress in the pipeline due tobending and test pressure shall not exceed 90% of the SMYS of pipe material.

2.7.3 Maximum Equivalent Stress During Service

Permissible values of maximum equivalent stress during services shall begoverned by the requirements of ANSI B 31.8/B 31.4 as applicable. The detailsof pipeline operating parameters are provided in the Special Conditions ofContract.

2.7.4 The minimum allowable radius of curvature for the pipeline shall be thehighest value of the minimum pipeline elastic radius as computed from theconsiderations outlined in clause 2.7.1 to 2.7.3 above after correction fordrilling inaccuracies or multiplication by the factor 1.85. whichever results inthe highest permissible value of minimum elastic bend radius.

2.7.5 Contractor shall submit all calculations for Company’s approval alongwithprocedure.

2.8 Pipeline Configuration along the Support String Before Entry Point

2.8.3 Contractor shall determine the required pipeline configuration in order to allowsmooth pull in the crossing entry point and admissible stress in the supportedpipeline string. Pipeline combined stress shall not exceed 95% of the specifiedminimum yield strength for line pipe material.

2.8.4 Contractor shall furnish all calculation and specify the number of requiredsupports, description of the supports, their co-ordinates and capacity in metrictons.

2.8.5 Contractor shall also furnish a drawing of the launching ramp indicating thepipeline configuration.

2.8.6 The distance between each roller shall also be specified and justified.

MECON LIMITEDDelhi




DRILLING METHOD



2.9 Contractor shall, based on result of design and engineering carried out by him,prepare construction drawings for the crossing and shall submit the same forOwner’s approval. Construction drawings shall indicate the pipeline profile withlevels furnished at sufficient intervals for proper control during construction.Other relevant details viz., entry and exit angles, radius of bends, etc. shallalso be indicated. Contractor shall also calculated the total length of pipelinerequired as well as the maximum tension required on the pull head of the rig.

2.10 All construction works shall be carried out in accordance with the constructiondrawings approved by Owner.

2.11 Before commencement of any field work, Contractor shall furnish for Owner’sapproval all design calculations and construction drawings as stipulated in theabove clauses.

3.0 CONSTRUCTION

Contractor shall comply with all the conditions and requirements issued byAuthorities having jurisdiction in the area where the work is to be performed.

If no public road exists, Contractor shall arrange on his own for access to hiswork area at no extra cost to owner.

3.1.0 Installation Procedure

3.1.1 Contractor shall, before commencing any work at site, submit for Owner’sapproval a detailed installation procedure.

3.1.2 The installation procedure as a minimum shall include the following:

a) Project Organisation Chart:This shall indicate Contractor’s organisational set-up at site andmanpower deployment.

b) Details of fabrication yard and launching areas.

c) Details of Equipment :Contractor shall furnish the complete list of all equipment to bedeployed for preparation of pipe string and installation of crossing.Technical characteristics and capacity of each equipment includinginstrumentation, monitoring and control equipment shall be furnished indetails.

MECON LIMITEDDelhi




DRILLING METHOD



d) Pipeline string preparation details (hauling, stringing, welding etc.)

e) Hydrostatic test procedure (pre and post installation)

f) Disposal methodology of bentonite slurry.

g) Method of installation covering all steps of construction, viz. Rig up,Pilot hole, Back-Reaming, Pulling Down, Backfilling etc.

h) Calculation for maximum pulling force on the rig and recommendedmaximum pulling velocity.

i) Time schedule for construction.

3.1.3 The time schedule shall be in accordance with overall time schedule for theproject.

3.1.4 Approval by Owner of the methods used by Contractor shall in no way relieveContractor from the sole responsibility for safe and satisfactory installation,working and operational use of the pipeline crossing.

3.2 Pipe String Preparation

Complete pipe string shall be prepared as a single string for pulling. Welding,radiographic inspection of joints and joint coating of the string shall beperformed in accordance with the respective applicable specifications includedin the Contract document.

3.3 Pre-testing

3.3.1 Contractor shall hydrostatically pre-test the complete pipe string of eachcrossing before installation as per approved procedure for a minimum period of24 hours.

3.3.2 After pre-testing, joint coating of the welds shall be done as per specificationfor specific field joint coating of pipeline for HDD crossing included in thecontract document

3.3.3 The section of the pipeline corresponding to the crossing shall, beforeinstallation, be subjected to hydrostatic test pressure as stipulated in theSpecial Conditions of Contract. During the test, Contractor shall check all weldsfor leakage. Failure, if any, during the test shall be rectified by the Contractor.

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DRILLING METHOD



3.4 Gauging

3.4.1 Before pre and post installation hydrostatic testing, Contractor shall prove thediameter of the pipeline by passing a gauging pig through the pipeline. Thegauging pig shall have a diameter equal to 95% of the nominal internaldiameter of the pipe. Contractor shall supply and install all temporary scraperlaunchers/ receivers and other equipment, piping and materials andconsumables required for the purpose.

3.5 Installation

3.5.1 Installation shall be done in accordance with approval installation procedure.

3.5.2 The lateral offset of the actual exit point of the pilot hole from the calculatedand theoretical exit point shall not exceed half per cent (0.5%) of the length ofthe crossing.

3.5.3 The length tolerance shall not exceed one per cent of the crossing length,subject to the condition that the actual exit point shall not be within the limitsof crossing as defined in the approved drawings.

3.5.4 Back reaming shall be done separately from the pipeline pulling operation. Thesize of the back-reamed hole shall be adequate (approximately 1.5 times thepipeline diameter) to allow enough clearance for a smooth pull-back of thepipeline.

3.5.5 Contractor shall be responsible for maintaining the drilled hole till such timethe pipeline is pulled in.

3.5.6 During pulling operation, the buoyancy of the pipeline shall be controlled bysuitable approved methods so as to maintain the buoyancy as close as possibleto zero during pull-back in order to reduce friction forces of the pipeline in thehole.

3.5.7 Bentonite slurry of specified viscosity shall be pumped into the hole,preventing the wall from collapsing and protecting the pipeline coating.

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3.6 Contractor shall be responsible for the integrity of the corrosioncoating.

3.6.1 Before pull-back operation, megger test shall be done for the entire pipeline(externally corrosion coated) string made for crossing by HDD method.

3.6.2 After pull-back operation to ensure the integrity of pipeline coating, againmegger test shall be done for the bored string before tied-in to the mainlinepipe. The megger value before & after pulling operation of the pipeline stringshall be nearly same and acceptable to Owner.

3.6.3 However, if, in Owner’s opinion, the integrity of external corrosion coating ofbored pipeline string is not established by above (Clause No. 3.6.1 & 3.6.2),then further in order to ensure the integrity of coating of the bored pipelinestring, megger test of the coating shall be carried out in accordance with thefollowing steps:

a) The test must be carried out before the bored pipe is tied-in to themainline pipe

b) Measure the natural potential of the bored pipe at both ends.

c) Set up the temporary impressed current system with a digitalmultimeter connected to measure the output current. Position the testelectrode anode as far from the bored pipe as interconnecting cable willallow and no closer than 10 meters.

d) Place the reference electrode at the remote end (opposite to impressedcurrent system) to monitor the bored pipe potential

e) Impress a current into the bored pipe start at Zero amp. and increaseslowly until the bored pipe potential is depressed to 1.5 V with respectto the reference electrode.

f) Note the current from the digital multimeter and calculate the currentdensity.

g) The desirable value of calculated current density should be less than 70micro ampere per square meter of drilled pipe surface in contact withthe soil.

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3.6.4 If Contractor again fails to establish the integrity of coating of the boredpipeline string and the same is not acceptable to Owner, the above works shallnot be continued further until the cause analysed and rectified by theContractor to the entire satisfaction of Owner.

3.7 Final Hydrostatic Test

3.5.1 The complete crossing section shall be tested after installation. The testpressure shall be as stipulated in the Special Conditions of Contract. Aftertemperature stabilisation, pressure shall be retained in the pipeline for aperiod of 6 hours and recorded by manothermograph. The hydrostatic testingshall be carried out in accordance with approved procedures and specificationdetailed elsewhere in the document.

3.8 Final Clean up

3.8.1 After completion of construction, Contractor shall clear the site of all balancematerial and debris and bentonite slurry. All balance pipe lengths shall bereturned to Owner’s designated stock yard(s). Site/ ROW shall be cleared tothe complete satisfaction of the land owner’s and authorities havingjurisdiction. All such works shall be done at no extra cost to Owner. The Ownershall be indemnified against any/ all claims arising as a result thereof.

4.0 DOCUMENTATION

4.1 In additional to the documents specified elsewhere in this specification.Contractor shall submit to the Owner the following documents/ records.

• Copies of the permits obtained from authorities having jurisdiction.• Records of pre and post installation hydrostatic testing.• Record of non-destructive testing of welds.• Clearance certificate from the land owners and authorities having

jurisdiction regarding satisfactory clean-up and restoration of the pipelineROW and work sites.

4.2 After completion of construction, Contractor shall prepare and furnish six setsof copies and two sets of reproducible of `As-built’ for the crossings. As builtdrawings shall , as a minimum include the following information

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• True profile of the crossing along the pipeline.• True profile of the pipeline as installed and the depth of cover to top of

pipe at regular intervals.• Location of entry and exit point and angles of entry and exit alongwith

lateral offset of exit point from the original pipeline alignment.• Location and angle of field bends• Location of pipeline markers.

4.3 All documents shall be in English language.

D:\TS\Ball Valves - 002 - TS-R2.doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI – 110 092


BALL VALVES

SPECIFICATION NO. : MEC/TS/05/62/002, Rev-2

MECON LIMITEDDelhi



BALL VALVES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/002 REV-2 Page 1 of 16


C O N T E N T S


1.0 SCOPE 2

2.0 REFERENCE DOCUMENTS 2

3.0 MATERIALS 3

4.0 DESIGN AND CONSTRUCTION 4

5.0 INSPECTION AND TESTS 9

6.0 EXTENT OF INSPECTION & TESTING 12

7.0 TEST CERTIFICATES 13

8.0 PAINTING, MARKING AND SHIPMENT 13

9.0 SPARES AND ACCESSORIES 14

10.0 DOCUMENTATION 14

11.0 GUARANTEE 16

Revision No. Date Revised by Checked by Approved by

2 08.08.2002 K.P. Singh A.K. Johri Niraj GuptaPREPARED BY :

K.P. SINGH

CHECKED BY :

A.K. JOHRI

APPROVED BY :

NIRAJ GUPTA

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BALL VALVES



1.0 SCOPE

This specification covers the minimum requirements for design, manufactureand supply of carbon steel ball valves of size DN 50mm (2”) and above andANSI class 150 to 900 to be used in on-shore pipeline systems handling non-sour hydrocarbons in liquid or gaseous phase, including Liquid Petroleum Gas(LPG).

This specification does not cover ball valves for sour hydrocarbon (liquid/ gas)service as defined in NACE standard MR-01-75.


2.1 All valves shall be manufactured and supplied in accordance with the TwentySecond Edition, January,2002, or the latest edition of American PetroleumInstitute (API) Specification 6D, with additions and modifications as indicatedin the following sections of this specification.

2.2 Reference has also been made in this specification to the latest edition of thefollowing Codes, Standards and Specifications :

ASME B 16.5 : Pipe flanges and flanged fittings

ASME B 16.25 : Buttwelding ends

ASME B 16.34 : Valves – Flanged, threaded and welding end

ASME B16.47 : Large diameter steel flanges

ASME B 31.3 : Chemical & process plant piping system

ASME B 31.4 : Liquid transportation systems for hydrocarbons andother liquids

ASME B 31.8 : Gas transmission and distribution piping systems

ASME Sec.VIII/IX : Boiler and pressure vessel code

ASTM A 370 : Standard test methods and definitions formechanical testing of steel products

ASTM B 733 : Autocatalytic nickel phosphorous coating on metals

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API 6FA : Fire test for valves

API 607 : Fire test for soft-seated quarter-turn valves

API 1104 : Welding of pipelines and related facilities

BS:6755 (Part-II) : Testing of valves – Specification for fire type -testing requirements

MSS-SP-6 : Standard finishes for contact faces of pipe flangesand connecting-end flanges of valves and fittings

MSS-SP-44 : Steel pipeline flanges

SSPC-VIS-1 : Steel structures painting council-visual standard

2.3 In case of conflict between the requirements of this specification, API 6Dand the Codes, Standards and Specifications referred in clause 2.2 above, therequirements of this specification shall govern. Order of precedence shall beas follows :• Data Sheets• This Specification• API 6D Specification• Other Referred Codes & Standards• Manufacturer’s Standard

3.0 MATERIALS

3.1 Material for major components of the valves shall be as indicated in Valve DataSheet. Other components shall be as per Manufacturer’s standard which willbe subject to approval by Purchaser.

3.2 Carbon steel used for the manufacture of valves shall be fully killed.

3.3 The Carbon Equivalent (CE) of valve end connections which are subject tofurther field welding by Purchaser, shall not exceed 0.45% (as calculated bythe following formula) on check analysis for each heat of steel used:

Mn Cr + Mo + V Ni + CuCE = C + -------- + ---------------------- + ---------------

6 5 15

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3.4 Charpy V-Notch test on each heat of base material shall be conducted as perAPI 6D, for all pressure containing parts such as body, end flanges and weldingends as well as bolting material for pressure containing parts. Unless specifiedotherwise, the Charpy impact test shall be conducted at 0°C. The Charpyimpact test specimen shall be taken in the direction of principal grain flow andnotched perpendicular to the original surface of plate or forging.

The minimum average absorbed energy per set of three specimens shallbe 27 J with an individual minimum per specimen of 22 J. No specimen shallexhibit less than 80 percent shear area.

3.5 For all such valves where carbon steel is used as ball material, the ball shallhave 75 micrometer (0.003 inch) thick Electroless Nickel Plating (ENP) as perASTM B733 with following classification : SC2, Type II, Class 2. The hardnessof plating shall be minimum 50 RC.

3.6 When specified in Valve Data Sheet, hardness test shall be carried out on eachheat of base material for all pressure containing parts of the valve. A fullthickness cross-section shall be taken for this purpose and the maximumhardness shall not exceed 248 HV10 based on minimum four measurementsrepresenting the entire thickness.

3.7 All process-wetted parts, metallic and non-metallic, shall be suitable for the fluidsand service specified by the Purchaser. The service gas composition shall be asgiven in Annexure-I.

4.0 DESIGN AND CONSTRUCTION

4.1 Valve design shall meet the requirements of API 6D and other referred codesand shall be suitable for the service conditions indicated in Valve Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, shall beused to design the valve body. Allowable stress requirements shall comply theprovisions of ASME B31.3. In addition, corrosion allowance indicated in ValveData Sheet shall be considered in valve design. However, the minimum wallthickness shall not be less than the minimum requirement of ASME B16.34.The Manufacturer shall have a valid license to use API 6D monogram formanufacture of ball valves.

4.2 Valve body shall be either fully welded or bolted. Valve body joints withthreads are not permitted.

4.3 Valves shall be Full Bore (FB) or Reduced Bore (RB) as indicated in Valve DataSheet. Full bore valves shall be suitable for the passage of all types of pipelinescraper and inspection pigs on regular basis without causing damage to either

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the valve component or the pig. The full bore valve shall provide anunobstructed profile for pigging operations in either direction. Full bore valvesshall be designed to minimize accumulation of debris in the seat ring region toensure that valve movement is not impeded. In case of reduced bore valves,the nominal valve size indicated in Valve Data Sheet corresponds to the endconnection. Nominal valve size of reduced bore shall be as per Table below:

Nominal Valve Nominal Valve Nominal Valve Nominal ValveSize (inches)* Size for Reduced Size (inches)* Size for Reduced

Bore (inches)** Bore (inches)**

2 2 24 203 2 26 224 3 28 246 4 30 248 6 32 2610 8 34 2812 10 36 3014 10 38 3216 12 40 3418 14 42 3620 16 48 4222 18

* Nominal valve size corresponds to end connection.

** Nominal valve size corresponds to the minimum bore as listed inTable-1, API 6D.

4.4 Ball mounting shall be trunnion/ pivot type or as indicated in Valve Data Sheet.Valve design shall minimize the possibility of debris ingress into the trunnion asfar as practicable.

4.5 Valve seats shall be with primary metal to metal contact. O-rings or otherseals, if used for drip tight sealing, shall be encased in a suitable groove insuch a manner that it can not be removed from seat ring and there is noextrusion during opening or closing operation at maximum differentialpressure. The seat rings shall be so designed as to ensure sealing at low aswell as high differential pressures. Seat design with PTFE insert is notacceptable.

4.6 Valves shall have double block and bleed feature to facilitate completeflushing, draining and venting of the valve body cavity.

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For valves to be used in liquid service, the body cavity over-pressure shall beprevented by self relieving seat rings/assemblies. A pressure relief hole in theball is not permitted. Self relieving seat rings shall relieve at a body cavitydifferential pressure not exceeding 50% of the valve class rating pressure.

4.7 When specified in Valve Data Sheet, valves shall be designed to withstand asustained internal vacuum of at least 1 (one) milli-bar in both open and closedpositions.

4.8 Full Bore Valves of nominal size 200mm(8”) & above and Reduced Bore Valvesof nominal size 250mm(10”) & above shall have provision for secondarysealant injection under full line pressure for seat and stem seals. Sealantinjection points shall be provided with a needle valve accommodating a greasefitting. Location and arrangement of sealant points shall be as per Figure-1(Annexure-II).

4.9 Valves shall be provided with vent and drain connections. Location andarrangement of vents and drains alongwith provision of valves shall be as perFigure-1 (Annexure-II).

4.10 Valve design shall ensure repair of gland packing under full line pressure.

4.11 a) Valve ends shall be either flanged or butt welded or one end flanged and oneend butt welded as indicated in Valve Data Sheet. Flanges of the flanged endcast/ forged body valves shall be integrally cast/forged with the body of valve.Face-to-face/ end-to-end dimensions shall conform to API 6D.

b) Flanged end shall have dimensions as per ASME B16.5 for valve sizes upto DN600mm (24 inches) excluding DN 550mm (22 inches) and as per MSS-SP-44for valve sizes DN 550mm (22 inches) & for DN 650mm (26 inches) and above.Flange face shall be either raised face or ring joint type as indicated in ValveData Sheet. Flange face finish shall be serrated or smooth as indicated in ValveData Sheet. Smooth finish when specified shall be 125 to 200 AARH.

c) Butt weld end preparation shall be as per ASME B16.25. The thickness of thepipe to which the valve has to be welded shall be as indicated in Valve DataSheet. Valves shall be without transition pups. In case significant differenceexists between thickness of welding ends of valve and connecting pipe, thewelding ends of valve shall have bevel preparation as per ASME B31.4 or ASMEB31.8, as applicable.

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4.12 Design of weld end valves shall be such that during field welding operation,the soft seals are not liable to be damaged.

4.13 Valves shall be provided with ball position indicator and stops of ruggedconstruction at the fully open and fully closed positions.

4.14 Full Bore Valves of nominal size ≥ 200mm(8”) and Reduced Bore Valves ofnominal size ≥ 250mm(10”) shall be equipped with support foot and liftinglugs. Tapped holes and eye bolts shall not be used for lifting lugs. Height ofsupport foot shall be kept minimum.

4.15 When indicated in Material Requisition, valves shall have locking devices tolock the valve either in full open (LO) or full close (LC) positions. Lockingdevices shall be permanently attached to the valve operator and shall notinterfere with operation of the valve.

4.16 Valves shall be of fire resistant design as per API 607/BS:6755 (Part-II)/API6FA, as indicated in Valve Data Sheet.

4.17 Valves shall be provided with anti-static devices to ensure electrical continuitybetween stem / ball and valve body. Valve design shall be such as to avoidbimetallic corrosion between carbon steel and high alloy steel components.Suitable insulation shall be provided as required.

4.18 Valves shall be suitable for either buried or above ground installation asindicated in Valve Data Sheet.

4.19 When stem extension requirement is indicated in Valve Data Sheet, the valvesshall have the following provisions :

a) Valves provided with stem extension shall have water proof outer casing.Length of stem extension shall be as indicated in Valve Data Sheet. The lengthindicated corresponds to the distance between centreline of the valve openingand centreline of the rim of the hand wheel on a vertical shaft or centreline ofthe hand wheel on a horizontal shaft.

b) Vent and drain connections and sealant injection lines shall be terminatedadjacent to the valve operator by means of suitable piping anchored to thevalve body. Pipe used shall be API 5L Gr. B/ ASTM A 106 Gr. B, with Sch. 160.Fittings shall be ASTM A 105/ ASTM 234 Gr. WPB, Socket Welded, ANSI class6000.

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BALL VALVES



c) Stem extension and stem housing design shall be such that the completeassembly will form a rigid unit giving a positive drive under all conditions withno possibility of free movement between valve body, stem extension or itsoperator.

d) Outer casing of stem extension shall have 3/8” or ½” NPT plugs at the top andbottom, for draining and filling with oil to prevent internal corrosion.

4.20 Operating Devices

a) Valves shall have a power actuator or manual operator as indicated in ValveData Sheet. In case of manual operator, valve sizes < DN 100mm (4 inches)shall be wrench operated and valve sizes ≥ DN 150mm (6 inches) shall be gearoperated. Valve design shall be such that damage due to malfunctioning ofthe operator or its controls will only occur in the operator gear train or powercylinder and that damaged parts can be replaced without the valve cover beingremoved.

b) The power actuator shall be in accordance with the Purchaser specificationissued for the purpose and as indicated in Valve and Actuator Data Sheet.Operating time shall be as indicated in Valve Data Sheet. Valve operating timeshall correspond to full close to full open/full open to full close under maximumdifferential pressure corresponding to the valve rating. For actuated valves, theactuator torque output shall be 1.50 times the break torque required tooperate the ball valve under the maximum differential pressure correspondingto the valve class rating.

c) For manual operator of all valves, the diameter of the hand wheel or thelength of operating wrench shall conform to API 6D requirements and be suchthat under maximum differential pressure, the total force required to operatethe valve does not exceed 350 N. Manufacturer shall also indicate the numberof turns of hand wheel (in case of gear operators) required for operating thevalve from full open to full close position.

d) Direction of operation of hand wheel or wrench shall be in clock-wise directionwhile closing the valve. Hand wheels shall not have protruding spokes.

e) Gear operators, when provided, shall have a self locking provision and shall befully encased, in water proof/ splash proof/ dust proof/ weather proofenclosure and shall be filled with suitable grease.

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f) Operating devices shall be designed for easy operation of the valve undermaximum differential pressure corresponding to the valve rating.

4.21 All welds shall be made by welders and welding procedures qualified inaccordance with the provisions of ASME Section IX. The procedure qualificationshall include impact test and hardness test and shall meet the requirements ofclauses 3.4 and 3.6 of this specification, respectively.

4.22 All welds shall be stress relieved in accordance with ASME Section VIII.

4.23 Repair by welding is not permitted for fabricated and forged body valves.However repair by welding as per ASME B16.34 is permitted for cast bodyvalves. Repair shall be carried out before any heat treatment of casting isdone. Repair welding procedure qualification shall include impact test andhardness test and shall meet the requirements of clauses 3.4 & 3.6 of thisspecification, respectively.

4.24 The tolerance on internal diameter and out of roundness at the ends forwelded end valves shall be as per applicable connected pipe specification asindicated in Valve Data Sheet.

4.25 Valve stem shall be capable of withstanding the maximum operating torquerequired to operate the valve against the maximum differential pressurecorresponding to applicable class rating. The combined stress shall not exceedthe maximum allowable stresses specified in ASME Section VIII, Division I. Incase of power actuated valves, the valve stem shall be capable of withstandingmaximum output of the power actuator.

5.0 INSPECTION AND TESTS

5.1 The Manufacturer shall perform all inspection and tests as per therequirements of this specification and the relevant codes, prior to shipment, athis works. Such inspection and tests shall be, but not limited to, the following:

5.1.1 All valves shall be visually inspected.

5.1.2 Dimensional check on all valves shall be carried out as per the Purchaserapproved drawings.

5.1.3 Chemical composition and mechanical properties shall be checked as perrelevant material standards and this specification, for each heat of steel used.

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5.1.4 a) Non-destructive examination of individual valve material and componentsconsisting of, but not limited to castings, forgings, plate and assembly weldsshall be carried out by the Manufacturer.

b) Body castings of all valve shall be radiographically examined on 100% of thesurface of critical areas as per ASME B16.34. Procedure and acceptancecriteria shall be as per ASME B16.34. The extent of radiography shall be asfollows:

ANSI class 150 - All sizes - Nil

ANSI class 300 - < DN 400mm (16”) - Nil> DN 450mm (18”) - 100%

ANSI class 600 - All sizes - 100%and above

All castings shall be wet magnetic particle inspected 100% of the internalsurfaces. Method and acceptance shall comply with ASME B.16.34.

c) All valves, with body fabricated from plates made or by forgings, shall beultrasonically examined in accordance with the procedure and acceptancestandard of Annexure E of ASME B16.34. All forgings shall be wet magneticparticle inspected 100% of the internal surfaces. Method and acceptance shallcomply with ASME B 16.34

d) Bodies and bonnets made by welded assembly of segments of castings,forgings, plates or combinations thereof shall be examined, as applicable, bymethods of clause 5.1.4 b) for cast components or clause 5.1.4 c) for forgedcomponents and plates.

5.1.5 Full inspection by radiography shall be carried out on all welds of pressurecontaining parts. Acceptance criteria shall be as per ASME B 31.4 or ASMEB31.8, as applicable, and API 1104.

5.1.6 Welds which in Purchaser’s opinion cannot be inspected by radiographicmethods, shall be checked by ultrasonic or magnetic particle methods andacceptance criteria shall be as per ASME Section VIII, Division 1, Appendix 12and Appendix 6, respectively.

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BALL VALVES



5.1.7 a) All finished wrought weld ends subject to welding in field shall be 100%ultrasonically tested for lamination type defects for a distance of 50mm fromthe end. Laminations shall not be acceptable.

b) Weld ends of all cast valves subject to welding in field shall be 100%radiographically examined and acceptance criteria shall be as per ASMEB16.34.

c) After final machining, all bevel surfaces shall be inspected by dye penetrant orwet magnetic particle methods. All defects longer than 6.35 mm are rejected,as are defects between 6.35 mm and 1.59mm that are separated by a distanceless than 50 times their greatest length. Rejectable defects must be removed.Weld repair of bevel surface is not permitted.

5.1.8 All valves shall be tested in compliance with the requirements of API 6D.During pressure testing, valves shall not have sealant lines and other cavitiesfilled with sealant, grease or other foreign material. The drain, vent andsealant lines shall be either included in the hydrostatic shell test or testedindependently. No leakage is permissible during hydrostatic testing. The bodycavity self relieving feature meeting the requirements of clause 5.6 of thisspecification shall also be checked.

5.1.9 A supplementary air seat test as per API 6D shall be carried out for all valves.A bubble tight seal is required without the use of any sealant. No leakage isallowed. Test pressure shall be held for at least 15 minutes.

5.1.10 Manufacturer who intends bidding, must submit at bid stage, certificate andreport for successful fire type-tests for valves in accordance with API-607/BS:6755 (Part-II)/ API 6FA, as applicable in Valve Data Sheet.

Failure to comply with this requirement shall be a cause of rejection of theoffer.

5.1.11 Valves shall be subjected to Operational Torque Test as per supplementarytest requirement of API 6D under hydraulic pressure equal to maximumdifferential pressure corresponding to the valve rating.

For manually operated valves, it shall be established that the force required tooperate the valve does not exceed the requirements stated in clause 4.20(c) ofthis specification.

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BALL VALVES



5.1.12 Power actuated valves shall be tested after assembly of the valve and actuator atthe valve Manufacturer’s works. At least five open-close-open cycles withoutinternal pressure and five open-close-open cycles with maximum differentialpressure shall be performed on the valve actuator assembly. The time for fullopen to full close shall be recorded during testing.

If required, the actuator shall be adjusted to ensure that the opening and closingtimes are within the limits stated in Actuator Data Sheet issued for the purpose.

Hand operator provided on the actuator shall also be checked after the cyclictesting, for satisfactory manual over-ride performance.

These tests shall be conducted on minimum one valve out of a lot of five(5)valves of the same size, rating and the actuator model/ type. In case the tests donot meet the requirements, retesting / rejection of the lot shall be decided byPurchaser’s Inspector.

5.1.13 When indicated in Valve Data Sheet, valves shall be subjected to anti-statictesting as per supplementary test requirement of API 6D.

5.2 Purchaser reserves the right to perform stage-wise inspection and witness testsas indicated in clause 5.1 above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection tothe Purchaser’s Inspector.

Purchaser reserves the right to require additional testing at any time to confirm orfurther investigate a suspected fault. The cost incurred shall be to Manufacturer’saccount.

In no case shall any action of Purchaser or his Inspector relieve the Manufacturerof his responsibility for material, design, quality or operation of valves.

Inspection and tests performed/ witnessed by the Purchaser’s Inspector shall inno way relieve the Manufacturer’s obligation to perform the required inspectionand tests.

6.0 EXTENT OF INSPECTION & TESTING

6.1 Purchaser’s Inspector shall perform inspection and witness tests on all valves oras indicated in the Quality Assurance Plan (QAP) attached with this specification.

6.2 The hydrostatic testing and cyclic opening and closing of the valves with theoperator shall be witnessed by Purchaser’s Inspector.

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7.0 TEST CERTIFICATES

7.1 Manufacturer shall submit the following certificates :

a) Mill test certificates relevant to the chemical analysis and mechanicalproperties of the materials used for valve construction as per the relevantstandards.

b) Test certificates on hydrostatic and pneumatic tests complete with records oftiming and pressure of each test.

c) Test reports on radiograph and ultrasonic inspection.

d) Test report on operation of valves conforming to clause 5.1.11 and 5.1.12 ofthis specification.

e) All other test reports and certificates as required by API 6D and thisspecification.

The certificates shall be valid only when signed by Purchaser’s Inspector. Onlythose valves which have been certified by Purchaser’s Inspector shall bedespatched from Manufacturer’s works.

8.0 PAINTING, MARKING & SHIPMENT

8.1 Valve surface shall be thoroughly cleaned, freed from rust and grease andapplied with sufficient coats of corrosion resistant paint. Surface preparationshall be carried out by shot blasting to SP-6 in accordance with “SteelStructures Painting Council – Visual Standard SSPC-VIS-1”. For valves to beinstalled underground, when indicated in Valve Data Sheet, the externalsurfaces of the buried portion of valves shall be painted with three coats ofsuitable coal tar epoxy resin with a minimum dry film thickness of 300 microns.

8.2 Manufacturer shall indicate the type of corrosion resistant paint used, in thedrawings submitted for approval.

8.3 All valves shall be marked as per API 6D. The units of marking shall be metricexcept Nominal Diameter which shall be in inches. Marking shall be done bydie-stamping on the bonnet or on the housing. However, for buried valves themarking shall be done on the above ground portion of the stem housing only.

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8.4 Valve ends shall be suitably protected to avoid any damage during transit. Allthreaded and machined surfaces subject to corrosion shall be well protected bya coat of grease or other suitable material. All valves shall be provided withsuitable protectors, for flange faces, securely attached to the valves. Bevelends shall be protected with metallic or high impact plastic bevel protectors.

8.5 All sealant lines and other cavities of the valve shall be filled with sealantbefore shipment.

8.6 Packaging and shipping instructions shall be as per API 6D.

8.7 On packages, following shall be marked legibly with suitable marking ink :

a) Order Number

b) Manufacturer’s Name

c) Valve Size and Rating

d) Tag Number

e) Serial Number

9.0 SPARES & ACCESSORIES

9.1 Manufacturer shall furnish list of recommended spares and accessories forvalves required during start-up and commissioning.

9.2 Manufacturer shall furnish list of recommended spares and accessoriesrequired for two years of normal operation and maintenance of valves.

9.3 Manufacturer shall quote for spares & accessories as per Material Requisition.

10.0 DOCUMENTATION

10.1 At the time of bidding, Manufacturer shall submit the following documents :

a) General arrangement/assembly drawings showing all features and relativepositions and sizes of vents, drains, gear operator / actuator, painting, coatingand other external parts together with overall dimensions.

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b) Sectional drawing showing major parts with reference numbers and materialspecification. In particular, a blow-up drawing of ball-seat assembly shall befurnished complying the requirement of clause 4.5 of this specification.

c) Reference list of similar ball valves manufactured and supplied in last fiveyears indicating all relevant details including project, year, client, location, size,rating, service etc.

d) Torque curves for the power actuated valves along with the break torque andmaximum allowable stem torque. In addition, sizing criteria and torquecalculations shall also be submitted for power actuated valves.

e) Descriptive technical catalogues of the Manufacturer.f) Installation, Operational and Maintenance Manual.g) Copy of valid API 6D certificate, wherever applicable.h) Details of support foot, including dimensions and distance from valve centre

line to bottom of support foot.i) Quality Assurance Plan enclosed with this tender duly signed, stamped and

accepted.

IMPORTANT

The drawings to be submitted alongwith the bid shall be in totalcompliance with the requirement of technical specification and datasheets of the valves with no exception & deviation.

10.2 Within two weeks of placement of order, the Manufacturer shall submit sixcopies of, but not limited to, the following drawings, documents andspecifications for Purchaser’s final approval :

a) Detailed sectional arrangement drawings showing all parts with referencenumbers and material specifications as referred to in clause 10.1 above.

b) Assembly drawings with overall dimensions and features. Drawing shall alsoindicate the number of turns of hand wheel (in case of gear operators)required for operating the valve from full open to full close position and thepainting scheme. Complete dimensional details of support foot (whereapplicable) shall be indicated in these drawings as referred to in clause 10.1above.

c) Welding, heat treatment and testing procedures.

d) Details of corrosion resistant paint to be applied on the valves.

MECON LIMITEDDelhi



BALL VALVES



Manufacture of valves shall commence only after approval of the abovedocuments. Once the approval has been given by Purchaser, any changes indesign, material and method of Manufacture shall be notified to Purchaserwhose approval in writing of all changes shall be obtained before the valve ismanufactured.

10.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaserone reproducible and six copies of the approved drawings, documents andspecifications as listed in clause 10.2 above.

10.4 Prior to shipment, Manufacturer shall submit one reproducible and six copies ofthe following:

a) Test certificates as per clause 7.0 of this specification.b) Manual for installation, erection, maintenance and operation instructions,

including a list of recommended spares for the valves.


11.0 GUARANTEE

11.1 Manufacturer shall guarantee that the materials and machining of valves andfittings comply with the requirements in this specification and in the PurchaseOrder.

11.2 Manufacturer is bound to replace or repair all valve parts which should resultdefective due to inadequate engineering or to the quality of materials andmachining.

11.3 If valve defect or malfunctioning cannot be eliminated, Manufacturer shallreplace the valve without delay,

11.4 Any defect occurring during the period of Guarantee shall be attended to bymaking all necessary modifications and repair of defective parts free of chargeto the Purchaser as per the relevant clause of the bid document.

11.5 All expenses shall be to Manufacturer’s account.

D:\old data\FATEH\MP Region\Kailaras\Tender RFQ\Check Valve\Check Valves - 004 - TS-R2.doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI – 110 092


CHECK VALVES


MECON LIMITEDDelhi



CHECK VALVES



C O N T E N T S


1.0 SCOPE 2

2.0 REFERENCE DOCUMENTS 2

3.0 MATERIALS 2

4.0 DESIGN AND CONSTRUCTION 3

5.0 INSPECTION AND TESTS 4

6.0 TEST CERTIFICATES 5

7.0 PAINTING, MARKING AND SHIPMENT 6

8.0 SPARES AND ACCESSORIES 6

9.0 DOCUMENTATION 6

10.0 GUARANTEE 7


MECON LIMITEDDelhi



CHECK VALVES



1.0 SCOPE

This specification covers the minimum requirements for design, manufactureand supply of carbon steel check valves of size DN 50mm (2”) and above andANSI class 150, 300 and 600 , for use in onshore pipeline systems handlingnon-sour hydrocarbons in liquid phase or gaseous phase including LiquefiedPetroleum Gas (LPG).


2.1 All valves shall be manufactured and supplied in accordance with the latestedition of American Petroleum Institute (API) Specification 6D or 594 or BritishStandard BS:1868, with additions and modifications as indicated in thefollowing sections of this specification.

For Contractual purpose, the edition in force at the time of floating of theenquiry shall be termed as “latest edition”.

3.0 MATERIALS

3.1 Material for major components of the valves shall be as indicated in Valve DataSheet. Other components shall be as per Manufacturer’s standards which willbe subject to approval by Purchaser.

3.2 Carbon steel used for the manufacture of valves shall be fully killed.

3.3 The Carbon Equivalent (CE) of valve end connections which are subject tofurther field welding by Purchaser, shall not exceed 0.45% (as calculated bythe following formula) on check analysis for each heat of steel used :

Mn Cr + Mo + V Ni + CuCE = C + -------- + ---------------------- + ---------------

6 5 15

3.4 Charpy V-Notch test on each heat of base material shall be conducted as perAPI 6D, clause 7.5, for all pressure containing parts such as body, end flangesand welding ends as well as bolting material for pressure containing parts.Unless specified otherwise, the Charpy impact test shall be conducted at 0°C.The Charpy impact test specimen shall be taken in the direction of principalgrain flow and notched perpendicular to the original surface of plate or forging.

The minimum average absorbed energy per set of three specimens shallbe 27 J with an individual minimum per specimen of 22 J. No specimen shallexhibit less than 80 percent shear area.

MECON LIMITEDDelhi



CHECK VALVES



3.5 All process – wetted parts, metallic and non-metallic, shall be suitable for thefluids and service specified by the Purchaser.


4.1 Following types of check valves, meeting the requirements of applicablestandards (refer clause 2.1 of this specification) are acceptable :

a) Swing check valveb) Dual plate check valvec) Axial flow (Nozzle) check valve

Valve design shall be suitable for the service conditions indicated in Valve DataSheet. Corrosion allowance indicated in Valve Data Sheet shall be considered invalve design.

4.2 In case of swing check valves, the disc hinge shall be mounted on the valvebody and shall not be attached to the valve body cover. Valve body cover jointshall be of bolted design. Screwed covers shall not be used.

4.3 Valves shall be provided with non-renewable integral type seats as indicated inValve Data Sheet. Non-renewable seats shall be of a design which does notrequired renewal over the design life of the valve.

4.4 Valves shall be provided with drain connection as per the Manufacturer’sstandard. Drain tapping shall be provided in a position suitable to completelydrain the valve with valve in horizontal position.

4.5 Valve ends shall be either flanged or butt welded or one end flanged and oneend butt welded as indicated in Valve Data Sheet. Flanged end shall havedimensions as per ASME B16.5 for sizes upto DN 400mm (16”). Flanges of theflanged end cast body valves shall be integrally cast with the body of thevalve.

4.6 Butt weld end preparation shall be as per ANSI B16.25. The thickness of thepipe to which the valve has to be welded shall be as indicated in Valve DataSheet. Valves shall be without transition pups. In case difference existsbetween thickness of valve neck end and connecting pipe, the bevel end ofvalve shall be prepared as per ANSI B31.8 or ANSI B31.4, as applicable.

4.7 Valves of size DN 200mm (8”) and above shall be equipped with lifting lugs. Tapped holes and eye bolts shall not be used for lifting lugs.

MECON LIMITEDDelhi



CHECK VALVES



4.8 An arrow indicating the direction of flow shall be embossed or cast on the bodyof all valves.

4.9 All welds shall be made by welders and welding procedures qualified inaccordance with the provisions of ASME Section IX. The welding and repairwelding procedure qualification shall include impact test and shall meet therequirements of clause 3.4 of this specification.

4.10 Repair by welding is permitted for cast body valves subject to written approvalby Purchaser and shall be carried out as per ANSI B16.34. Repair shall becarried out before any heat treatment of casting is done.


5.1 The Manufacturer shall perform all inspection and tests as per the requirementsof this specification and the relevant codes, prior to shipment at his works. Suchinspection and tests shall be, but not limited to, the following :

5.1.1 All valves shall be visually inspected.

5.1.2 Dimensional check on all valves shall be carried out as per the Purchaserapproved drawings.

5.1.3 Chemical compositions and mechanical properties shall be checked as perrelevant material standards and this specification, for each heat of steel used.

5.1.4 a) Where applicable, the body castings of valves shall be radiographicallyexamined on 100% of the surface of critical areas as per ANSI B16.34. Procedure and acceptance criteria shall be as per ANSI B16.34.

b) Where applicable, valve body made by forging and plate componentsshall be ultrasonically examined in accordance with procedure andacceptance standard of Annexure E of ANSI B16.34.

c) The extent of radiography/ ultrasonic examination shall be as follows :

ANSI class 150 - All sizes - Nil

ANSI class 300 - < DN 400mm (16”) - Nil> DN 450mm (18”) - 100%

ANSI class 600 - All sizes - 100%

MECON LIMITEDDelhi



CHECK VALVES



5.1.5 All valves shall be tested in compliance with the requirements of applicablestandard (refer clause 2.0).

5.2 Purchaser reserves the right to perform stage-wise inspection and witness testsas indicated in clause 5.1 above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection tothe Purchaser’s Inspector.

Purchaser reserves the right to require additional testing at any time to confirmor further investigate a suspected fault. The cost incurred shall be toManufacturer’s account.

In no case shall any action of Purchaser or its Inspector relieve the Manufacturerof his responsibility for material, design, quality or operation of valves.

Inspection and tests performed/ witnessed by the Purchaser’s Inspector shall inno way relieve the Manufacturer’s obligation to perform the required inspectionand tests.


Manufacturer shall submit the following certificates :

a) Mill test certificates relevant to the chemical analysis and mechanicalproperties of the materials used for the valve construction as per therelevant standards.

b) Hydrostatic test certificates complete with records of timing and pressureof each test.

c) Test reports of radiograph and ultrasonic inspection, as applicable.

d) All other test reports and certificates as required by applicable standardand this specification.

The certificates shall be valid only when signed by Purchaser’s Inspector. Onlythose valves which have been certified by Purchaser’s Inspector shall bedespatched from Manufacturer’s works.

MECON LIMITEDDelhi



CHECK VALVES



7.0 PAINTING, MARKING AND SHIPMENT

7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease andapplied with sufficient coats of corrosion resistant paint. Surface preparationshall be carried out by shot blasting to SP-6 in accordance with “Steel StructuresPainting Council – Visual Standard SSPC-VIS-1”.

7.2 All valves shall be marked as per applicable standard. The units of marking shallbe metric except nominal diameter which shall be in inches.

7.3 Valve ends shall be suitably protected to avoid any damage during transit. Allthreaded and machined surfaces subject to corrosion shall be well protected bya coat of grease or other suitable material. All valves shall be provided withsuitable protectors for flange faces, securely attached to the valves.

7.4 Packaging and shipping instructions shall be as per applicable standard.

7.5 On packages, the following shall be marked legibly with suitable marking ink:

a) Order Number

b) Manufacturer’s Name

c) Valve Size and Rating

d) Tag Number

8.0 SPARES AND ACCESSORIES

8.1 Manufacturer shall recommend and quote separately the spares for valvesrequired for commissioning and two years of normal operation.

9.0 DOCUMENTATION

9.1 At the time of bidding, Manufacturer shall submit the following documents :

a) General arrangement drawings showing all features together with overalldimensions and actual valve bore size.

b) Sectional drawing showing major parts with reference numbers andmaterial specification.

MECON LIMITEDDelhi



CHECK VALVES



c) Details of corrosion resistant paint proposed to be applied.

d) Reference list of similar supplies of check valves, including project, year,client, location, size, rating, services, etc. shall be furnished by theManufacturer for the last three years. (The valves shall be provenfor service indicated in Valve Data Sheet).

9.2 Within three weeks of placement of order, the Manufacturer shall submit fourcopies of, but not limited to, the following drawings, documents andspecifications for Purchaser’s approval.

a) Detailed sectional drawings showing all parts with reference numbers andmaterial specification.

b) Assembly drawings indicating overall dimensions, features and paintingscheme.

Once the approval has been given by Purchaser, any changes in design, materialand method of manufacture shall be notified to Purchaser whose approval inwriting of all changes shall be obtained before the valve is manufactured.

9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaserone reproducible and six copies of all approved drawings, documents andspecifications as listed in clause 9.2 above.

9.4 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible andsix copies of the following :

a) Test certificates as listed in clause 6.0 of this specification.

b) Manual for installation, erection, maintenance and operation instructions,including a list of recommended spares for the valves.


10.0 GUARANTEE

10.1 Manufacturer shall guarantee that the materials and machining of valves andfittings comply with the requirements in this specification and in the PurchaseOrder.

MECON LIMITEDDelhi



CHECK VALVES



10.2 Manufacturer is bound to replace or repair all valve parts which should resultdefective due to inadequate engineering or to the quality of materials andmachining.

10.3 If valve defect or malfunctioning cannot be eliminated, Manufacturer shallreplace the valve without delay,

10.4 Any defect occurring during the period of Guarantee shall be attended to bymaking all necessary modifications and repair of defective parts free of chargeto the Purchaser as per the relevant clause of the bid document.

10.5 All expenses shall be to Manufacturer’s account.

D:\old data\FATEH\MP Region\Kailaras\Tender RFQ\Globe Valve\TS - Globe Valve.doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI - 110 092


GLOBE VALVES



MECON LIMITEDDELHI


TECHNICAL SPECIFICATION

TITLE GLOBE VALVE SPECIFICATION NO. PAGE 1 OF 11

MEC/TS/05/62/005 REVISION 0

C O N T E N T S


1.0 GENERAL 2

2.0 DOCUMENTATION 3

3.0 DESIGN & CONSTRUCTION 4

4.0 OPERATION 6

5.0 INSPECTION & TESTING 7

6.0 RADIOGRAPHY OF CAST VALVES 8

7.0 IBR CERTIFICATION 9

8.0 QUALITY ASSURANCE PLAN (QAP) 9

9.0 MARKING 10

10.0 DESPATCH 11

PREPARED BY :

GURDEEP SINGH

CHECKED BY :

A.K. SARKAR

APPROVED BY :

A.K. JOHRI


MECON LIMITEDDELHI



TITLE GLOBE VALVES SPECIFICATION NO. PAGE 2 OF 11


1.0 GENERAL

1.1 Vendor shall supply valves along with auxiliaries, if any, such as gear operator,bypasses, drains, etc., specified in the valve specification sheets and thisspecification.

1.2 Vendor shall quote in strict accordance with the valve Data / Specificationsheets, technical specification and enclosures to this specification. Deviationsto the Specification / Data sheets, if any, shall be indicated as per clause 2.0.

1.3 All codes and standards for manufacturing, testing, inspection etc., shall be oflatest editions.

1.4 Associated Gas Composition

As per Annexure-I

1.5 Materials

1.5.1 Material for major components of the valves shall be as indicated in Valve DataSheet. However, Manufacturer shall confirm that valve trim material is suitablefor Natural Gas with composition/ quality as given in clause 1.4. Othercomponents shall be as per Manufacturer's standards which will be subject toapproval by Purchaser.

1.5.2 Carbon steel used for the manufacture of valves shall be fully killed.

Carbon equivalent (CE) of valve end connections which are subject to furtherfield welding , as calculated by the following formula, shall not exceed 0.45 oncheck analysis for each heat of steel used.

Mn Cr + Mo + V Ni + CuCE = C + -------- + ---------------------- + ---------------

6 5 15


MECON LIMITEDDELHI





2.0 DOCUMENTATION

2.1 Vendor shall submit with the offer the following :

2.1.1 Manufacturer’s complete descriptive and illustrative Catalogue/ Literature.

2.1.2 Detailed dimensioned general arrangement and cross-sectional drawings withParts/ material lists, weight etc., for valves to manufacturer’s standard.

2.1.3 Drawings for valves with accessories like gear operator, extension bonnet,extended stems with stands bypass, etc., giving major salient dimensions.

2.1.4 One copy of the valve technical specification and data sheets signed as“ACCEPTED” by the manufacturer with all deviations marked clearly.

2.1.5 If the valve is regretted or has no deviation, the manufacturer shall writeclearly on valve specification sheets as “REGRET” or “NO DEVIATION”.

2.1.6 If there is any deviation in the specification, the same shall be listed clausewise. Even clauses which are acceptable shall be categorically confirmed as“ACCEPTED”.

2.1.7 On failure to submit document as specified in clauses 2.1.1 to 2.1.6 above, theoffer is likely to be rejected.

2.2 Vendor shall submit for approval the drawings mentioned in item no 2.1.2 &2.1.3 after placement of order and before start of manufacture. No otherdrawing shall be submitted for approval.

2.2.1 Test reports shall be supplied for all mandatory tests as per the applicablecode. Test reports shall also be furnished for any supplementary tests asspecified in clause 3.11 to 3.16.

2.2.2 Material test certificates (Physical property, chemical composition & heattreatment report) of the pressure containing parts shall be furnished for thevalves supplied. Material test certificates for the other parts shall also befurnished for verification during inspection.


MECON LIMITEDDELHI






3.1 Valves shall be designed, manufactured, tested, inspected and marked as perthe manufacturing standards design codes and standards (Latest editions)indicated in the respective valve specification sheets. Any conflict between thethe technical specifiction, specification sheets and referred standard codes shallbe brought to the notice of the purchaser for clarifications, but generallytechnical specification, data sheets shall govern. No deviation to specification/standard shall be permitted through vendor drawings approval. Approval ofdrawings shall be valid only for design features.

3.2 Bonnet extension wherever specification the valve sheet to BS : 6364 shall befor “Non Cold Box Application” unless otherwise specified in the requisition.Even if not called for in valve sheet, valves indicated as ‘CRYO’ shall besupplied with bonnet extension.

3.3 For heavy valves provisions shall be available for lifting by way of lugs, eyebolts and such standard devices.

3.4 All flanged valves shall have flanges integral (except forged valves) with thevalve body. Flange finish shall be as per valve specification sheet.

3.5 For all weld end valves with bevel end as per ANSI B16. 25.

The contour of bevel shall be as follows :

Material Wall Thickness Weld Contour

Carbon steel upto 22 mm figure 2 type A(Except low temp. > 22 mm figure 3 type Acarbon steel )Alloy steel, upto 10 mm figure 4Stainless steel & > 10 mm to 25 mm figure 5 type Alow temp. carbon steel > 25 mm figure 6 type A

3.6 If an overlay weld-deposit is used for the body seat ring and seating surface,the seat ring base material shall be at least equal to the corrosion resistance ofthe material of the shell.


MECON LIMITEDDELHI





3.7 Valve body/ bonnet shall be forged/ cast as specified. Forging is acceptable inplace of casting but not vice-versa.

3.8 Material of construction of yoke shall be minimum equivalent to body/ bonnetmaterial.

3.9 Stem shall be forged or machined from forged / rolled bar. No casting ispermitted, .

3.10 Stelliting / hard facing by deposition shall be minimum 1.6 mm. Renewableseat ring may be seal welded.

3.11 As a pre qualification low temperature carbon steel, (LTCS), 3 ½ Ni steel(CRYO) & austenitic stainless (CRYO) valves shall be subjected to cryogenictest as per BS 6364 and test shall be witnessed and certified by third partyinspection agency like Lloyds, B.V., DNV or EIL. For INDIAN vendors,inspection agency shall be MECON only. The vendor has to submit testcertificate for prototype valves along with the offer. Prototype test carried on aparticular size, rating and design will qualify valves of sizes equal to and belowthe particular size of the same rating and design.

Cryogenic testing as per BS 6364 shall be carried out at temperature (-45 °C),(-100 °C) & (-196 °C ) for “LTCS”, 3 ½ Ni steel (CRYO) & austenitic stainlesssteel “CRYO” valves respectively.

3.12 Repair welding procedure for austenitic stainless steel valves in ‘CRYO’ serviceshall have to be qualified for impact test as per ANSI B31.3. Minimumacceptable impact energy shall be 20J or lateral expansion of 0.38 mm at tempof -196 Deg C

3.13 Wherever impact test of SS studs/ nuts is called for in the data sheet, theimpact value shall be 27J at the intended service temperature specified in thedata sheets.

3.14 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shallhave to be conducted as per following :

- ASTM A 262 practice “B” with acceptance criteria of “60 Mills/ Year (Max.)” –For all materials forged, rolled, wrought and casting.


MECON LIMITEDDELHI





OR

- ASTM A 262 practice “E” with acceptance criteria of “No cracks as observedform 20X magnification” – For all materials other than castings. “Microscopicstructure to be observed form 250X magnification” in addition.

3.15 When specifically asked for in MR for high temperature application of somegrades of austenitic stainless steel (eg. SS309, 310, 316, 316H etc.) ASTM A262 practice “C” with acceptance criteria of “15 Mils/ Year – (Max.)” shall haveto be conducted.

3.16 For the IGC test as described in 3.14 & 3.15 two sets of samples shall bedrawn from each solution annealing lot, one set corresponding to highestcarbon content and other set corresponding to highest pressure rating

3.17 Spiral wound bonnet gasket are to be provided with inner/ outer ring exceptwhen encapsulated gaskets type body- bonnet joints are employed. Outer ringmay be avoided in case of Non- circular spiral wound gasket used in 150#valve provided the outermost layer of spiral touches the bolts ascertaining thecentering.

4.0 OPERATION

4.1 Generally the valves are hand wheel of lever operated. Gear operation shall beprovided as under :

Class Size RequiringGear Operator

900 # 6” and Larger1500 # 3” and Larger2500 # 3” and Larger

For sizes lower than these ranges, hand wheel shall be provided.

4.2 Gear operator shall be totally enclosed bevel gear in grease case with greasenipples/ plugs with position indicators for open / close position.


MECON LIMITEDDELHI





4.3 Where gear operator is not called for as per clause 4.1 but vendorrecommends a gear operator, he shall highlight such case/s and quoteseparate prices for the valve and gear operator.

4.4 Gear operator shall be so designed to operate effectively with the differentialpressure across the closed vale equal to the cold non-shock pressure rating.

4.5 Hand wheel diameter shall not exceed 750 mm and lever length shall notexceed 500 mm. on both sides. Effort to operate shall not exceed 35 kgs athand wheel periphery. However failing to meet the above requirements vendorshall offer gear operated valve and quote as per clause 4.3.

5.0 INSPECTION AND TESTING

5.1 Every valve shall be subjected to all the mandatory tests and checks called inthe respective codes/ data sheet.

5.2 Every valve, its components and auxiliaries be subjected to all the mandatorytests and checks called in the respective codes, data sheets etc. by themanufacturer.

5.3 Though the extent of inspection by purchaser or his authorised representativeshall be as under, however exact extent with hold points shall be decided byMECON and recorded in the form of inspection plan.

FORGED VALVES :

1) Visual and dimensional inspection.

2) Review of material test certificates.

3) Any mandatory or supplementary test.

4) Hydrostatic test on 10% valves selected on random basis.

5) Strip check as applicable for valves


MECON LIMITEDDELHI





CAST STEEL VALVES :

1) Visual and dimensional inspection.2) Review of material test certificates.3) Review of radiographs/ radiographic reports of any other NDT

tests wherever applicable as per data sheet.4) Any mandatory or supplementary test.5) Hydrostatic test. 100% for body, 10% other test.6) Strip check as applicable for valves.

5.4 In case of motor operated or actuator operated valves, functional/operationalchecks as per the requirements of the specifications shall be made on eachvalve.

6.0 RADIOGRAPHY OF CAST VALVES

6.1 Valves under critical, very highly critical, lethal and toxic services shall beradiographed as specified in respective data sheets When specifically notmentioned in individual data sheet, valve casting shall undergo radiographicexamination as specified hereunder :

...........................................................................................................Material Rating Size Range Radiography...........................................................................................................All 150 # 24” And Below Nil

150 # 26” And Above 100%300 # 16” And Below Nil300 # 18” And Above 100%600 # All Sizes 100%& Above

...........................................................................................................

6.2 Radiography procedure, areas of casting to be radiographed shall be a per ANSIB-16.34 and acceptance criteria shall be as per ANSI B-16.34 Annexure-B.However for areas of casting to be radio-graphed for types of valve not coveredin ANSI B-16.34, vendor shall enclose details of areas to be radiographed in linewith ANSI B-16.34.

6.3 Random radiography wherever specified in individual data sheets, the samplingshall be per size of the quantity ordered for each foundry.


MECON LIMITEDDELHI





6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall bedone by X-Ray/ Gamma-Ray to get the required sensitivity.

6.5 Over and above the stipulation laid down in clauses 6.1, 6.2, 6.3 & 6.4, all valvecastings shall only be procured among the foundries after obtaining approvalfrom Client / Consultant.

7.0 IBR CERTIFICATION

7.1 For valves described “IBR” valves shall be in accordance with the latest IBR(Indian Boiler Regulation) including the requirements specified in thespecification.

7.2 SW/ BW end carbon steel valves under IBR< the chemical composition shallconform to the following :

Carbon (Max) : 0.25%Others (S,P, Mn) : As per IBR regulations

7.3 For valves described “IBR” test certificate in form III-C shall be furnished,signed by IBR inspection authority or an approved representative.

7.4 All “IBR” valves shall be painted red in body-bonnet/ body cover joint.

8.0 QUALITY ASSURANCE PLAN (QAP)

8.1 Procurement of Bought out Materials

All critical materials such as casting, forging, pressure holding parts, electricaland instrument accessories, etc. shall be purchased by the Vendor from GAIL/MECON approved suppliers meeting Qualification Criteria stipulated if any.Vendor shall submit a list of bought out materials and sub-vendors for thesebought out materials for MECON approval within 2 weeks from Telefax/ Letterof Intent.

8.2 Calibration Records

Vendor shall use only calibrated measuring and test instruments and maintaincalibration records. Vendor shall furnish records of calibration of measuring andtest instruments including re calibration records to concerned InspectionAuthority.


MECON LIMITEDDELHI





8.3 Quality Records

Vendor shall maintain quality records as per approved procedures. InspectionReports & Test Record. Copies shall be furnished to Inspection Authority.

8.4 Final Documentation

8.4.1 Final drawings/ documents consisting of technical data manual/ mechanicalcatalogue is a compilation of “as built” certified, drawings and data,manufacturing and test records, installation, operating and maintenanceinstructions. For drawings where Purchaser’s approval is required, the final certified drawings shall be included. Final documents shall be legiblephotocopies in A4, A3 or A2 size only. The purchase requisition shall also forma part of the final documentation.

8.4.2 Final documentation shall be bound in Hard board folder(s) of size 265 mm x315 mm (10½” x 12½”) and shall not be more than 90 mm thickness.

9.0 MARKING

9.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard referred in specification sheet as applicable. Vendorsname, valve rating, material designation, nominal size, direction of flow (if any)etc. shall be integral on the body.

9.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no,securely attached on the valve body.

9.3 Paint or Ink for marking shall not contain any harmful metal or metal saltssuch as zinc, lead or copper which causes corrosive attack on heating.

9.4 Carbon steel valves shall be painted with coats of red oxide zinc chromateprimer or single coat of aluminum paint. Forged valves supplied chemicallyblackened (phosphated) is also acceptable.

9.5 All alloy steel high temp valves shall be painted with heat resistant siliconepaint suitable for intended temperature.


MECON LIMITEDDELHI





9.6 All 3 ½ Ni Steel / LTCS valves shall be painted with one coat of inorganic zincsilicate coating.

10.0 DESPATCH

10.1 Valves shall be dry, clean and free from moisture, dirt and loose foreignmaterials of any kind.

10.2 Valves shall be protected from rust, corrosion and any mechanical damageduring transportation, shipment and storage.

10.3 Rust preventive on machined surfaces to be welded shall be easily removablewith a petroleum solvent or not harmful to welding.

10.4 Each end of valves shall be protected with the following materials :

Flange face : Wood, Metal or Plastic coverBevelled end : Wood, Metal or Plastic coverSW & Scrd. End : Plastic cap

10.5 End protectors to be used on flange faces shall be attached by at least threebolts or wiring through bolt holes and shall not be smaller than the outsidediameter of the flange. However plastic caps for SW & SCRD. End valves shallbe press fit type.

10.6 End protectors to be used on beveled end shall be securely and tightlyattached.

10.7 For special service valves additional requirement of despatch shall beprescribed in data sheet.

D:\Technical Specifications & Standards\007 - Scrapper Trap - TS.doc

SPECIFICATIONFOR

SCRAPPER TRAP

SPECIFICATION NO. : MEC/S/05/62/007, Rev-1


MECON LIMITEDREGD. OFF RANCHI


NEW DELHI

STANDARD SPECIFICATIONSCRAPPER TRAP



C O N T E N T S

Sl.No. Description

1.0 SCOPE


3.0 MATERIALS





8.0 GUARANTEE

9.0 SPARES

10.0 DOCUMENTATION




NEW DELHI




1.0 SCOPE

This specification covers the basic requirements for design, manufacture, inspection,testing & supply of scrapper launching & receiving traps to be installed in pipelinesystem transporting non-sour hydrocarbons in liquid or gaseous phase includingLiquefied Petroleum Gas (LPG). This specification does not cover scraper launching &receiving trap for sour hydrocarbons (liquid/ gas) services as defined in NACE Std. MR-01-75.


2.1 Reference has also been made in this specification to the latest edition of the followingcodes, standards and specifications :

a) ASME B 31.4 : Pipeline Transportation System for LiquidHydrocarbons and Other Liquids

b) ASME B 31.8 : Gas Transmission and Distribution Piping System

c) ASME B 16.5 : Steel Pipe Flanges and Flanges Fittings

d) ASME B16.9 : Factory made Wrought Steel Butt Welding Fittings

e) ASME B 16.11 : Forged Steel Fittings, Socket-Welding andThreaded

f) ASME B 16.25 : Butt-Welding Ends

g) ASTM A370 : Mechanical testing of steel products

h) ASME Sec-VIII and IX : Boiler and Pressure Vessels Codes.

i) API 1104 : Specification for Welding Pipeline andRelated Facilities

j) MSS-SP-44 : Specification for High Test Wrought WeldingFittings.

k) MSS-SP-75 : Specification for High Test Wrought WeldingFittings

l) MSS-SP-97 : Integrally Reinforced Forged Branch Outlet FittingsSocket Welding Threaded and Butt Welding Ends



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m) SSPC-VIS-1 : Steel Structure Painting Council

In case of conflict between the requirements of this specification and the requirementsof above referred documents, the requirements of this specification shall govern.

3.0 MATERIALS

3.1 Materials and thicknesses of main components used in manufacture of traps shall beindicated by Manufacturer and shall be suitable for service conditions indicated in thedata sheets and annexures. These shall be subject to approval by purchaser. The steelused shall have a minimum SMYS of 35,000 psi.

3.2 Fully killed carbon steel shall be used.

3.3 Material of the ends to be field welded by purchaser shall have carbon equivalent lessthan or equal to 0.45 based on check analysis, for each heat of steel, calculatedaccording to the following formula.

Mn Cr + Mo + V Ni + CuCE = C + -------- + --------------------- + ---------------

6 5 15

3.4 For Scraper Traps, specified to be used for Gas service or High Vapour Pressure (HVP)liquid service, Charpy V-notch test shall be conducted at 0°C for each heat of steel usedin the manufacture of pressure containing parts of the traps. Test procedure shallconform to ASTM A-370. The Charpy V-notch test specimens shall be taken in thedirection of principal grain flow and notched perpendicular to the original surface of theplate or forging. The minimum average absorbed impact energy values of three full sizedspecimens shall be as under, unless otherwise indicated in the Data sheets :-

Diameter Base Metal Weld Metal and HAZ(inches) (Joules) (Joules)

For all size 27 27

The minimum impact energy value of any one specimen of the three specimensanalysed as above, shall not be less than 80% of the above mentioned average values.

For scrapper Traps, specified to be used for other hydrocarbon service, the Charpy V-notch test requirements as stated above are not applicable.



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3.5 For Scraper Traps, specified to be used for Gas service or High Vapour Pressure (HVP)liquid service, hardness test shall be carried out as per ASTM A370 for each heat of steelused. A full thickness cross section shall be taken for this purpose and the maximumhardness of the base material, weld metal and heat affected zone (HAZ) of all thepressure containing parts shall not exceed 248 HV10. The maximum difference inhardness of Base metal, Weld metal and Heat affected zone (HAZ) of pressurecontaining parts of the traps shall be less than 80 points Vicker’s HV10.

For scrapper Traps, specified to be used for other hydrocarbon service, the hardness testrequirements as stated above are not applicable.


4.1 The cylindrical portion of the trap shall be designed as per design code and design factorindicated in the data sheets. Quick end closure shall be designed as per sec. ASME Sec.VIII, Div. 1 for design conditions indicated in data sheets. A corrosion allowance of 3mm shall be considered in design of the traps. Quality of welding shall be such that weldefficiency factor of 1.0 is achieved.

4.2 The trap shall be capable of handling instrumented pigs, model like Linalog 360 of AMFTuboscope or British gas magnetic inspection vehicle or equivalent and scraper pigs asspecified in scraper Trap data sheet.

4.3 The trap body and neck, diameter has been indicated in the data sheet. Trap length tosuit the purpose and thickness to meet the class rating shall be suggested by themanufacturer and approved by the purchaser. Circumferential weld on scraper tarpbody and neck shall not be permitted.

4.4 Concentric or eccentric reducer, as indicated in data sheets, used in the manufacture oftraps shall conform to MSS-SP-75.

4.5 Vents and drains shall be provided on each trap. The trap shall be provided with asuitable slope and the drain location shall be such that complete drainage of the trap ispossible. Sizes for vent and drain shall be as indicated in data sheet.

4.6 All branch connections shall be made by weldolets/ nippolet or by extrusions as indicatedin the data sheet. All weldolets shall confirm to MSS-SP-97 and nippolets shall bemanufacturer’s standard. The extruded opening shall be adequately heat treated andstress relieved.

4.7 End connections of traps shall be flanged or butt welded as indicated in data sheet.a) Flanged ends, if specified shall have dimension as per ASME B16.5 for sizes upto

24" NB (excluding 22 NB) and as per ASME B16.47 / MSS-SP-44 for sizes 22 NBand 26 NB and above. Flanges shall be as indicated in data sheets.



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b) Butt weld ends if specified shall have ends prepared as per ASME B16.25.However, end preparation for butt welding ends having unequal thicknesses withrespect, to connecting pipe shall be as per ASME B31.4/ ASME B31.8 asapplicable.

c) The location & orientation of all nozzle connections shall be submitted forpurchaser's approval before manufacturing.

4.8 The quick opening end closure shall be of clamp ring or band lock type or equivalentdesign. The closure shall also consist of a safety relief system allowing the opening onlywhen there is no pressure in the trap. Screwed type or plug-in type of end closures arenot acceptable. End closure shall be hand operated and operable by one operator. Endclosures of size 24" and above shall be fitted with worm gear operator for the opening ofthe closure.

Hinge of the closure shall be so designed that the weight of the end closure is fullysupported with out sagging.

4.9 Receiving traps shall be provided with a pig indicator in the middle of the neck and theindicator shall conform to the specification issued for the purpose. Pig indicator shall besuitable for bi-directional operation and shall have visual flag and manual reset. Thesame shall also have provision for remote indication. REFER SPECIFICATION No.MEC/S/05/62/48 and Pig Signaller Data Sheet.

4.10 Suitable handling system for inserting and retracting the scraper and instrumented pigsfrom the trap shall be provided with each trap. Handling system shall consist of afabricated structural steel framework comprising a bench fitted with a purpose-designedcradle for the pig. A pusher/ puller mechanism operated by a cable system employing ahand cranked winch shall be mounted on the bench framework for inserting/ retractingthe pig from the trap. The bench frame should be suitable for bolting to the floor. Allparts of the handling system in contact with each other shall be of the anti spark type.

4.11 Fabricated steel supports, minimum two numbers at suitable spacing shall be providedwith traps for mounting on concrete blocks. These supports will not be subjected topipeline achorage forces. The material of support shall be compatible with trap materialfor welding purposes. All welds shall be examined by magnetic particle method.

4.12 Completed assembly shall be stress relieved as per the provisions of the design codes.

4.13 All welds shall be made by welders and welding procedures qualified in accordance withthe provisions of ASME Sec. IX. The procedure qualification shall include impact test andhardness test when required as per clause 3.4 & 3.5 of this specification and shall meetthe requirements as specified therein.



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4.14 Repair by welding on parent metal is not allowed. Repair of welds shall be carried outonly after specific approval by purchaser's representative for each repair. The repairwelding shall be carried out by the welders and welding procedures duly qualified as perASME Section IX and records for each repair shall be maintained. The repair weldingprocedure qualification shall include impact test and hardness test when required as perclause 3.4 & 3.5 of this specification and shall meet the requirements as specifiedtherein.

4.15 The traps shall be equipped with a half internal removable filtering basket consisting of apunched plate with a least five rows of drain holes.

4.16 The filtering basket shall slide on guides on wheels and in all cases the material of theparts being in contact with each other shall be of the anti spark type.

4.17 The tolerance on internal diameter and out of roundness at the ends for the weldingend of the neck (at the end where connecting pipeline will be welded) shall be as perapplicable connected pipe specification as indicated in the data sheet.


5.1 The manufacturer shall perform all inspections and test as per the requirements of thisspecification and the relevant codes prior to shipment at his works. Such inspections andtests shall be, but not limited to the following :-

5.1.1 All trap shall be visually inspected.

5.1.2 Chemical composition and mechanical properties including hardness shall be checked foreach heat of steel used.

5.1.3 Dimensional check shall be carried out as per the approved drawings.

5.1.4 Hydrostatic test shall be conducted for all scraper traps complete in all respects includingmounting of pig indicators at a pressure equal to 1.5 times the design pressure. The testpressure shall be held for a minimum period of one hour.

5.1.5 All butt welds shall be 100% radiographically inspected. Procedure and acceptancecriteria shall be as per API 1104.

5.1.6 Ultrasonic or magnetic particle inspection shall be carried out on all welds which inPurchaser's Representative's opinion can not be radiographically inspected. Procedureand acceptance criteria shall be as per ASME Sec. VIII, Appendix-U and VI respectively.



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5.1.7 All finished wrought weld shall be 100% ultrasonically inspected for lamination typedefects for a distance of 50mm from the end. Any lamination larger than 6.35 mm shallnot be acceptable.

5.1.8 All forgings shall be wet magnetic particle examined on 100% of the forged surfaces.Method and acceptance shall comply with MSS-SP-53.

5.1.9 A minimum of two closing and opening cycles shall be performed and correct operationof both quick opening closure and safety system shall be ascertained.

5.2 Purchaser's Representative reserves the right to perform stage wise inspection andwitness tests including hydrostatic test, as indicated in specification at manufacturer’sworks prior to shipment. Manufacturer shall give reasonable notice of time & shallprovide without charge reasonable access and facilities required for inspection, to thepurchaser's representative.

Inspection and tests performed / witnessed by Purchaser's Representative shall in noway relieve the Manufacturer's obligation of specific integrity of the scraper traps.

Manufacturer's equipment shall be subject to examination and approval by purchaser toensure proper fabrication and testing of traps.


Manufacturer shall furnish the following certificates

a) Test certificates relevant to the chemical and Mechanical properties includingHardness of the materials used for manufacture of trap as per relevant standardsand this specification.

b) Hydrostatic test certificates.

c) Test reports on radiography, ultrasonic inspection and magnetic particleexamination.

d) Test reports on heat treatment carried out, if any.

The certificate shall be considered valid only when signed by purchaser’s representative.



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7.1 After all inspection and test required have been carried out, all external surfaces shall bethoroughly cleaned to remove grease, dust and rust. Surface preparation shall be carriedout by shot blasting to SP-6 in accordance with "Steel Structures Painting Council VisualStandard - SSPC-VIS-1". Machined parts shall be coated with anti-rust removable paintand non machined parts shall be applied with two coats of protective paint.Manufactures shall indicate the type of paint used in the drawings submitted forapproval.

7.2 Marking shall be done on a stainless steel plate and affixed to the body by means ofcorrosion resistant fasteners. Marking shall include the following :-

a) Manufacturer's Nameb) Trap/ Neck Diameter, Thicknessc) Materiald) ASME Class Ratinge) Tag Numberf) Design Pressureg) Design Temperatureh) Test Pressurei) Design Factorj) Year of Manufacturek) Empty weight of the trap assembly.

7.3 Before shipment, traps shall be properly packed against damage duringtransportation. All machined surface subject to corrosion during transit shall be wellprotected by coat of grease or other suitable material. All traps shall be provided withsuitable protectors, for flange faces, securely attached to the traps. Bevel ends shallbe protected with metallic or high impact plastic bevel protectors.

7.4 Only those traps, which have been inspected and certified by the purchaser’sinspector shall be supplied.

8.0 GUARANTEE

8.1 Manufacturer shall guarantee that the trap alongwith accessories is in compliance withthe requirements of this specification for materials and workmanship. Manufacturer shallreplace or repair all parts which should result defective due to inadequate design or theworkmanship. In case the defect can not be eliminated, Manufacturer shall replace thetrap without any delay. Any defect occurring within the time period specified elsewhereshall be repaired making all necessary modifications and repair of defective parts free ofcharge to the purchaser.



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9.0 SPARES

9.1 Manufacturer shall furnish list of recommended spares and accessories for ScrapperTraps required during start up and commissioning. As a minimum, the commissioningspares shall include 200% extra consumable spares viz. gaskets/ o-rings/ seals etc. foreach trap. Cost of such spares shall be included by the Manufacturer in the item ratesindicated in Purchase Requisition.

9.2 Manufacturer shall furnish separately a list of recommended spares and accessoriesrequired for two years of normal operation and maintenance of Scraper Traps.

10.0 DOCUMENTATION

10.1 Manufacturer shall furnish at the time of bidding, the following documents:-

a) General arrangement drawing of scraper trap, pig signallers, quick opening endclosure with overall dimensions.

b) Clause wise list of deviations from this specification, if any listed at one place inthe document.

c) Reference list of similar supplies for the past five years including project, clientyear of supply & contact person.

d) Quality Assurance Plan (QAP) enclosed with this tender duly signed, stampedand accepted.

10.2 Within two weeks of placement of order, the manufacturer shall submit four copies of,but not limited to, the following drawings, documents and specifications for approval.

a) Calculations according to the relevant codes for the body including branchconnections and quick end closures.

b) Trap assembly and sectional drawings showing all parts with materials anddimensions.

c) Support Assembly Drawing.

d) Arrangement & details of foundation bolts for pig handling and lifting system,where applicable.

e) Welding procedure and method of manufacture.



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Once the above said documents have been approved by the Purchaser, any changes indesign, material and method of manufacturer shall be notified to the Purchaser, whoseapproval in writing of all changes shall be obtained before the traps are manufactured.

10.3 Within four weeks from the approval date Manufacturer shall submit one reproducibleand six copies of all approved drawings, documents and specification as listed in clause10.2 of this specification.

10.4 Prior to shipment, the manufacturer shall submit one reproducible and six copies of thefollowing :

a) Test certificate as listed in clause 6.0 of this specification.

b) Manual for installation, erection instructions, maintenance and operationsinstruction.

10.5 All documents shall be in English Language.

D:\TS\Insulating Joints - 09 - TS.doc

SPECIFICATIONFOR

INSULATING JOINTS





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STANDARD SPECIFICATIONINSULATING JOINTS



C O N T E N T S

Sl.No. Description

1.0 SCOPE


3.0 MATERIALS

4.0 DESIGN & CONSTRUCTION REQUIREMENTS




8.0 GUARANTEE

9.0 DOCUMENTATION




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1.0 SCOPE

This specification cover the basic requirements for design manufacture, testingand supply of carbon steel insulating joints to be installed in onshore pipelinesystems handling hydrocarbons in liquid or gaseous phase including LiquifiedPetroleum Gas (LPG).


2.1 Reference has been made in this specification to the latest edition of, thefollowing Codes, Standards and Specifications.

a) ASME B 31.8 Gas Transmission & Distribution pipingSystem

b) ASME B 31.4 Liquid transportation systems forhydrocarbons, LPG, Anhydrous Ammonia andAlcohols

c) ASTM A 370 Mechanical testing of Steel Product

d) ANSI B 16.25 Butt Welding Ends

e) ASME Section Boiler & pressure Vessel Code viii & ix

f) API 1104 Standard for welding pipelines and Relatedfacilities.

g) SSPC-VIS-1 Steel Structures painting Council VisualStandard.

h) MSS-SP-53 Quality standard for steel castings andforgings for valves flanges and fittings andother piping components - magnetic particleexamination method.

i) MSS-SP-75 Specification for high test wrought weldingfittings.



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j) NACE RP 0286 The electrical isolation of cathodicallyprotected pipelines.

2.2 In case of conflict between the requirements of this specification and any code,Standard or Specification referred to in this Specification, the requirements ofthis specification shall govern.

3.0 MATERIALS

3.1 Material for the pressure containing parts of the insulating joints shall be asindicated in the data sheets. Material for pups shall be equivalent or superior tothe material of connecting pipeline which is indicated in the data sheets. Otherpart shall be as per manufacturer's standard suitable for the service conditionindicated in Insulating Joint Data Sheets and shall be subject to approval bypurchaser.

3.2 Insulating joints which are subject to field welding by purchaser, shall havecarbon equivalent (CE) not exceeding 0.45 based on check analysis for each heatof steel calculated according to the following formula :

CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15

3.3 When specified in the IJ Data Sheet, charpy V-notch test shall be conducted oneach heat of base material, weld metal and heat affected zone of all pressurecontaining parts such as body, welding ends in accordance with the impact testprovisions of ASTM A 370 at a temperature of 0° C. The charpy impact testspecimens shall be taken in the direction of principal grain flow and notchedperpendicular to the original surface of the plate of forging. Average impactenergy value of three full sized specimens shall be 27 joules. Minimum impactenergy value of any one specimen shall not be less than 80% of the averageimpact energy specified. No specimen shall exhibit less than 80% shear area.

3.4 Carbon steel used for the manufacture shall be fully killed

3.5 When specified in data sheet, hardness test shall be carried out as per ASTMA370 for each heat of steel used. The maximum hardness of base metal, weldmetal and heat affected zone of all pressure parts shall be 248 HV10, unlessspecified otherwise.



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3.6 Insulation material shall be minimum 20 mm thick and shall comply section 5,NACE RP 0286.

4.0 DESIGN & CONSTRUCTION REQUIREMENTS

4.1 Mechanical

4.1.1 Insulating joints shall be of integral type fabricated by welding and with pups oneither side as shown in data sheet. A corrosion allowance as indicated in datasheet shall be considered in design. Bolted and threaded joints are notacceptable.

4.1.2 All materials used for the manufacture of the insulating joint shall be inaccordance with clause 3.0 of this Specification.

4.1.3 Insulating joints shall be designed using the design principles of ASME Section-VIII Div. 1. The design shall be checked for the following two cases :

Case-I : Design Pressure (as per Data Sheet) + Axial Force (F)

The Axial force shall be calculated as under :

F = 0.1 x S x A

Where

S = SMYS of connected pipe (refer Data Sheet)A = Metal cross-sectional area of connected pipe.

The allowable stress in this case shall be less than or equal to 0.5 x SMYS ofinsulating joint material.

Case-II : Hydrostatic Test Pressure

The allowable stress in this case shall be less than or equal to 90% of SMYS ofinsulating joint material.

All design parameters shall be as per Insulating Joint Data Sheet. Detailedcalculations shall be submitted for Purchaser approval.



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4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to1 millibar.

4.1.5 The joint between pipe pup pieces and main forging shall be full penetration buttweld type. Weld design shall be such as resulting in a weld joint factor of 1.0.

4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparationfor butt welding ends having unequal thickness with respect to connecting pipe,shall be as per ASME B31.4/ B31.8 as applicable.

4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAWpipes, shall be removed for a distance of at least 50mm from each end.

4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. Theinternal bore shall be same as that of connecting pipe including its tolerances.

4.1.9 The insulating joint shall be formed by sandwiching and locking in positions theinsulating material in a bell and spigot type of joint. The joint shall be assembledin such a way that its various components are firmly locked in position and thecompleted joint is capable of withstanding stresses due to designed operatingconditions and field hydrostatic testing.

4.1.10 Insulating joints shall be suitable for aboveground or underground installationsas indicated in the data sheets.

4.1.11 All welds shall be made by welders and welding procedures qualified inaccordance with the provisions ASME section IX. The procedure qualificationshall include impact test and hardness test and shall meet the requirements ofclause 3.3, 3.5 of this specification.

4.1.12 Repair welding on parent metal is not allowed. Repair of welds shall be carriedout only after specific approval by purchaser's representative for each repair.The repair welding shall be carried out by welders and welding procedures dulyqualified as per ASME section IX and records for each repair shall be maintained.

4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm fromthe nominal internal diameter.



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4.1.14 Out of roundness measured at the root face of the welding ends shall not bemore than 0.5% of the specified inside diameter.

4.2 Electrical

4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kiloVolts.

4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either sideof the insulating joint for connecting 10 mm2 and 50 mm2 cables formeasurement/ shorting purposes. Cleats shall be attached to the insulating jointby welding.


5.1 The manufacture, shall perform all inspection and tests as per the requirementsof this specification and the relevant codes, prior to shipment at his works. Suchinspection and tests shall be, but not limited to the following:

5.1.1 All insulating joints shall be visually inspected.

5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings.

5.1.3 Chemical composition and mechanical properties including hardness shall bechecked as per relevant material standards and this specification, for each heatof steel used.

5.1.4 Non-destructive inspection of insulating joints shall be carried out as givenbelow:

a) 100% radiography shall be carried out on all butt & repair welds ofpressure containing parts. Acceptance limits shall be as per API 1104.

Welds which in purchaser's Representative opinion can not be inspectedby radiographic methods,shall be checked by ultrasonic or magneticparticle methods. Acceptance criteria shall be as per ASME Section VIIIAppendix-12 and Appendix-6 respectively.



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b) All finished weld ends shall be 100% ultrasonically tested for laminationtype defects for a distance of 5Omm from the ends. Any laminationlarger than 6.35 mm shall not be acceptable.

c) All forgings shall be wet magnetic particle inspected on 100% of forgedsurfaces. Method and acceptance shall comply MSS-SP-53.

d) All fillet weld of thickness < 6mm shall be examined 100% by magneticparticle inspection and ≥ 6mm shall be examined 100% by UT.Accetpance criteria for MPI & UT shall be as per ASME Sec.VIII Appendix-6 & Appendix-12 respectively.

5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in datasheet. The test duration shall be of 15 minutes.

5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for10 minutes. The tightness shall be checked by immersion or with a frothingagent. No leakage will be accepted.

5.1.7 Dielectric Test

a) Insulation resistance of each insulating joint shall be atleast 25 mega-ohms when checked with 500-1000 V DC.

b) Insulating joint before and after the hydrostatic test, shall be tested fordielectric integrity for one minute at 5000 V A.C., 50 cycles and theleakage current before and after hydrostatic test shall be equal. Testingtime voltage and leakage shall be recorded and certified. No repair shallbe permitted to the insulating joints failed in the above mentioned tests.

5.2 Purchaser reserves the right to perform stagewise inspection and witness test asindicated in Para 5.1 at Manufacturer's works prior to shipment. Manufacturershall give reasonable notice of time and shall provide without charge reasonableaccess and facilities required for inspection to the purchaser's Representative .

Inspection and tests performed/witnessed by the Purchaser's Representativeshall in no way relieve the Manufacturer's obligation to perform the requiredinspection and test.



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6.1 Manufacturer shall submit following certificates to Purchaser's Representative.

a) Test certificates relevant to the chemical analysis and mechanicalproperties including hardness of the materials used for construction ofinsulating joint as per this specification and relevant standards.

b) Test reports on non-destructive testing.

c) Test certificates for hydrostatic and air tests.

d) Test certificate for electrical test.

e) Test report on vacuum test.

7.0 PAINTING, MARKING AND SHIPMENT.

7.1 Insulating joint surface shall be thoroughly cleaned, freed from rust and greaseand applied with sufficient coats of corrosion resistant paint. Surface preparationshall be carried out by shot blasting to SP-6 in accordance with "steel structurespainting council - Visual standard SSPC-VIS-l.". External surfaces of burriedinsulating joints shall be painted with three coats of suitable coal tar epoxy resinwith a minimum dry film thickness of 300 microns.

Manufacturer shall indicate the type of corrosion resistant paint used, in thedrawings submitted for approval.

7.2 Insulating joints shall be marked with indelible paint with the following data:-

a. Manufacturer's name

b. Suitable for inch nominal diameter pipeline

c. End thickness in mm

d. Material

e. Design Pressure/ Hydrostatic Test Pressure



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f. ANSI Class Ratingg. Tag No.h. Year of Manufacture

7.3 Insulating joints shall be suitably protected to avoid any damage during transit.Metallic bevel protectors shall be provided to weld ends.

7.4 Only those insulating joints which have been inspected and certified byPurchaser shall be shipped.

8.0 GUARANTEE

8.1 The manufacturer shall guarantee that the materials used comply with therequirements of this specification.

8.2 Manufacturer shall replace or repair insulating joints found defective due toinadequate engineering or quality of material.

8.3 Manufacturer shall replace the insulating joint without delay if the defect ormalfunctioning can not be eliminated.

8.4 Any defects occurring within 12 months from the date of installation or within 30months from the date of despatch, whichever is earlier, shall be repaired makingall necessary modifications and repair of defective parts free of charge to thepurchaser.

9.0 DOCUMENTATION

9.1 All documents shall be in English Language.

9.2 At the time of bidding, Bidder shall submit the following documents:-

a) General arrangement drawing along with cross sectional view, overalldimensions and details of insulating meterials recommended.

b) Reference lists of previous supplies of insulating joint of similarspecification.



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c) Clausewise list of deviation from this specification, if any.

9.3 Within three weeks of placement of order, the Manufacturer shall submit fourcopies of but not limited to the following drawings, documents and specificationsfor approval.

a) Fabrication drawings and relevant calculations for pressure containingparts.

b) Welding procedure and method of manufacture for all phases ofmanufacture.

c) Quality Assurance Plan (QAP)

Once the approval has been given by purchaser any changes in design, materialand method of manufacture shall be notified to the Purchaser whose approval inwriting of all changes shall be obtained before the insulting joint aremanufactured.

9.4 Within four weeks from the approval date Manufacturer shall submit onereproducible and six copies of the approved drawings, documents andspecifications as listed in 9.3 of this specification.

9.5 Prior to shipment, the manufacturer shall submit one reproducible and six copiesof the test certificates as listed in Clause 6.0 of this specification.

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