Technical 1

PMC Services for capacity augmnetation of Jamnagar-Loni LPG
Pipeline Project
PIPELINE LAYING TENDER, COMPOSITE CIVIL TENDER
(Document No : A922-020-83-41-MK-T-9510)
Page 1 of 1963
Click on the Document Title to go to that section of the document
Table of Contents
Document Number Rev. Document Title Page
Number
A922-020-83-41-MK- 0 PIPELINE LAYING TENDER, COMPOSITE CIVIL TENDER 9
T-9510
A922-020-83-41- A SCOPE OF WORK FOR PIPELINE & ASSOCIATED FACILITIES 10
SOW-9510
A922-020-16-51- 0 SCOPE OF WORKS 46
SOW-01
A922-020-81-41- A SCOPE OF WORK & SUPPLY (U/G CIVIL) 55
SOW-9510
A922-020-83-41-LL- 0 LIST OF ATTACHMENTS FOR PIPELINE LAYING (Pipeline 59
0001 Engineering Department)
A922-020-16-51-LL- 0 LIST OF CONTENT 70
0001
A922-020-81-41-LL- A LIST OF ATTACHMENT (U/G CIVIL) 76
9510
A922-000-83-41-SP- 3 PIPING MATERIAL SPECIFICATION (WITH ATTACHMENTS) - 81
0010 IPMCS
A922-000-83-41- D PIPELINE SCHEMATIC ARRANGEMENT FOR CAPACITY 128
30011 AUGMENTATION OF JAMNAGAR LONI PIPELINE
A922-000-83-41-SP- 0 PIPING MATERIAL SPECIFICATION GENERAL NOTES 129
0010-A1
A922-000-83-41-SP- 0 PIPING MATERIAL SPECIFICATION ¿ ANNEXURE-II (DATA 136
0010-A2 SHEETS & LIST OF SPECIFICATIONS)
A922-020-2-42- 2 WELDING SPECIFICATION 141
WSP-0001
A922-020-2-42- 2 WELDING SPECIFICATION CHART 184
WSC-0001
A922-020-02-42- 0 PROTECTIVE COATING SPECIFICATION 194
PCS-0001
A922-020-02-42- 0 ELECTRONIC GEOMETRY PIGGING 196
EGP-0001
A922-000-83-41-AD- 0 ADDENDUM TO STANDARD SPECIFICATIONS HFW LINEPIPE 208
0005 6-71-0005
A922-000-83-41-AD- A ADDENDUM TO STANDARD SPECIFICATIONS FOR 3LPE OF 210
0041 LINEPIPES
A922-000-16-54-DD- 0 ADDENDUM TO BOLT TENSIONING AND BOLT TIGHTENING 214
0001 REQUIREMENTS
A922-000-83-41-SP- 0 SPECIFICATION FOR GEO-TEXTILE BAGS FOR ANTI- 219
0007 BUOYANCY
A922-000-83-41-SP- 0 JOB STANDARD FOR DIMENSIONS OF STUD BOLTS 224
0006
A922-000-83-41-ST- A Typical Right Of Use For Pipelines. 229
0002
A922-000-83-41-ST- 0 PROCESS_VENT_&_DRAIN CONNECTION_DETAILS 230
0011
A922-000-83-41-ST- 0 PRESSURE_GAUGE_INSTRUMENTS CONNECTIONS DETAILS 232
0012
6-71-0005 4 Standard specification for high frequency welded (HFW) line pipe 233
(onshore).
6-71-0014 4 Standard specification for pipeline ball valves (onshore). 264
6-71-0021 5 Standard specification for long radius bends for onshore pipelines. 279
6-71-0024 4 Standard specification for seamless fittings and flanges (size upto 290
DN 400 mm (16") ).
6-71-0035 4 Standard specification for casing insulators and end seals. 297
6-71-0041 3 Standard specification for 3 layer polyethylene coating of linepipes. 307
6-71-0044 3 Standard specification for field joint coating (onshore pipelines). 336
Page 2 of 1963
Table of Contents
Number
6-71-0046 4 Standard specification for concrete weight coating of onshore 348
pipelines.
6-71-0048 1 Standard specification for repair of polyethylene coating 360
6-71-0051 4 Standard specification for pipeline construction (onshore). 366
6-71-0052 3 Standard specification for construction of pipelines crossing roads, 404
rail roads & minor water crossings
6-71-0054 3 Standard specification for major river / water crossings using 415
directional drilling method
6-71-0055 3 Standard specification for hydrostatic testing of onshore pipelines. 429
6-71-0057 4 Standard specification for pipeline markers. 449
6-71-0059 4 Standard specification for documentation for pipeline construction. 455
6-71-0062 4 Standard specification for hot tapping. 464
6-71-0071 3 Standard specification for pipeline surveys (onshore). 471
6-44-0012 4 Standard specification for fabrication and erection of piping 495
6-44-0013 4 Standard specification for inspection, flushing and testing of piping 510
systems.
6-44-0016 7 Standard specification for non destructive examination 519
requirements of piping
6-44-0051 6 Technical notes for pipes. 540
6-44-0052 6 Technical notes for valves. 550
6-44-0056 4 Technical notes for gaskets. 570
6-44-0057 4 Technical notes for bolts and nuts. 575
6-79-0020 0 Standard specification for surface preparation and protective 580
coating (new construction)
6-76-0002 2 Standard specification for application of torque and hydraulic bolt 639
tension for flange joints
6-78-0001 1 Specification for quality management system requirements from 672
bidders
6-78-0002 1 Specification for documentation requirement from contractors 679
6-78-0003 1 Specification for documentation requirement from suppliers 688
7-71-0005 4 Typical trench dimensions for pipeline. 697
7-71-0006 4 Pipeline symbols. 698
7-71-0007 4 Topographical symbols. 699
7-71-0008 4 K.M. Post. 700
7-71-0009 4 Typical ROU boundary marker. 701
7-71-0010 4 Aerial marker. 702
7-71-0011 4 Direction marker. 703
7-71-0012 4 Pipeline warning sign. 704
7-71-0013 4 Existing pipeline on sleeper crossing. 705
7-71-0014 4 Navigable waterway pipeline crossing warning sign. 706
7-71-0015 4 Pipeline-road/highway uncased crossing. 707
7-71-0016 4 Pipeline road/highway cased crossing. 708
7-71-0018 4 Typical stream crossing. 709
7-71-0019 4 Details of casing-vent and drain off. 710
7-71-0020 4 Casing pipe details. 711
7-71-0021 4 Existing underground pipe crossing (type-I). 712
7-71-0022 4 Existing underground pipe crossing (type-II). 713
7-71-0024 4 Underground cable crossing. 714
7-71-0025 4 Overhead power line crossing. 715
7-71-0027 2 Typical slope breaker details 716
7-71-0028 1 Bank Protection details for water crossing 717
Page 3 of 1963
Table of Contents
Number
7-71-0029 2 Typical details of railway crossings 718
7-71-0031 0 Typical warning mat details for pipeline 719
7-44-0002 4 Abbreviations. 720
7-44-0003 4 Symbols of piping elements on drawings. 722
7-44-0252 4 Jack screw for spectacle blind fig.8 and spacer & blind (150CL, 726
300CL, 600CL RF).
7-44-0352 4 Orientation of orifice taps (class 600 & below. 727
7-44-0353 4 Wells installation 1 1/2" dia taps (up to class 600). 729
7-44-0601 4 Pipe shoe for hot-insulated CS pipe, size 2" thru 8", Type-S1 (for 731
temp. upto 343 deg.C)
7-44-0606 4 Pipe saddle for bare pipe size 2" thru 48" type-S6A (for temp. upto 732
343 deg. C)
7-44-0621 5 Low support sliding for bare & insulated pipe size 2" thru 36" type 733
L1 & L1A
7-44-0623 5 Low support fixed for bare and insulated pipe size 2" thru. 36" type 734
L3 and L3A.
7-44-0626 5 Low support sliding for bare and insulated pipe size 2" thru. 36" 735
type L6.
7-44-0628 5 Restrained low support for bare & insulated pipe size 2" thru 36" 736
type L8 & 8A
7-44-0630 5 Adjustable low support sliding for bare and insulated pipe size 2" 737
thru. 6" type -L10 & L10A.
7-44-0635 5 Low support sliding and fixed for bare & insulated pipe size 3/4" 738
thru 1-1/2" type-L15.
7-44-0636 5 Low support stanchion for bare & insulated CS/AS/SS pipe type 739
L16 and L16A.
7-44-0637 5 Adjustable low support with four bolts for pipe size 8" thru 24" 740
type-L17 & 17A
7-44-0638 5 Adjustable low support for bare & insulated pipe size 2" thru 24" 741
type L-18 & L18A.
7-44-0639 5 Adjustable low support with guide and cross-guide for bare & 742
insulated pipe size 2" thru 24" type- L19 & L19A.
7-44-0641 4 Pipe clamp for bare CS / AS / SS pipe size ½" thru 24" type- C1 743
7-44-0644 4 U-bolt for bare C.S. pipe size ½¿ thru 24" type-C4 (for operating 744
temp. Upto 232oC)
7-44-0731 0 Low Frication Low Support (Sliding) for Bare and Insulated Pipe 745
Size 2" Through 36" Type L31 & L31A
7-44-0739 5 Dummy pipe support for bare pipe size 2" thru. 24" type B-39. 746
7-44-0742 4 Pipe support brackets type B-42. 747
7-44-0751 4 Guide support for bare pipe size 1/2" thru 24" type G1. 748
7-44-0752 4 Guide support for bare pipe size 1/2" thru 24" Type- G2 & G2A. 749
(for temp. upto 343 deg.C)
7-44-0753 4 Cross guide for bare pipe, size 2" thru 24" Type-G3. (upto 343¿C) 750
7-44-0754 4 Cross-guide for bare pipe on sleeper / rcc beam size 2" thru 24" 751
Type-G4 (for temp. upto 343¿C).
7-44-0755 4 Anchor for bare pipe on sleeper/RCC beam, size 2" thru 24" Type- 752
G5 (upto 343¿C).
7-44-0792 4 Supporting arrangement for angle & relief valves type SP2. 753
A922-000-83-41-DS- A DATA SHEET FOR BALL VALVE (BELOW 2INCH 800#) 754
1001
A922-000-83-41-DS- A DATA SHEET FOR BALL VALVE (BELOW 2 INCH 1500#) 756
1002
A922-000-83-41-DS- A DATA SHEET FOR PLUG VALVE (BELOW 2INCH 800#) 758
1003
Page 4 of 1963
Table of Contents
Number
A922-000-83-41-DS- A DATA SHEET FOR PLUG VALVE (BELOW 2 INCH 1500#) 760
1004
A922-000-83-41-DS- A DATA SHEET FOR GLOBE VALVE (BELOW 2 INCH 800#) 762
1005
A922-000-83-41-DS- A DATA SHEET FOR GLOBE VALVE (BELOW 2 INCH 1500#) 764
1006
A922-000-83-41-DS- A DATA SHEET FOR CHECK VALVE (BELOW 2 INCH 800#) 766
1007
A922-000-83-41-DS- A DATA SHEET FOR CHECK VALVE (BELOW 2 INCH 1500#) 767
1008
A922-000-83-41-DS- A DATA SHEET FOR GATE VALVE (BELOW 2 INCH 800#) 768
1009
A922-000-83-41-DS- A DATA SHEET FOR GATE VALVE (BELOW 2 INCH 800#) 770
1010
VMS Tag No. 51001 6 Datasheet for Gate Valve -0.25¿-1.5¿ 800#,SW 772
VMS Tag No. 52001 6 DataSheet for Globe Valve -0.25¿-1.5¿ 800#,SW 773
VMS Tag No. 53001 6 Datasheet for Check Valve -0.25¿-1.5¿ 800#,SW 774
VMS Tag No. 54321 6 Datasheet for Ball Valve -0.5¿-16¿ 150#,FL,AA3A 775
A922-021-83-41- B EQUIPMENT LAYOUT FOR EOL DT 776
10821
A922-022-83-41- B EQUIPMENT LAYOUT AT SAPAR RT 777
10822
A922-020-83-41- B EQUIPMENT LAYOUT FOR SV STATION-71 778
10820
A922-020-83-41- B EQYUIPMENT LAYOUT FOR SV INSIDE EOL DT 779
10828
A922-020-83-41-1- A GENERAL ARRANGEMENT DRAWING 780
0921
A922-020-83-41- A ALIGNMENT SHEET FROM CH 0 KM TO 1.750 KM 781
12001
A922-020-83-41- A ALIGNMENT SHEET FROM CH 1.750 KM TO 3.5 KM 782
12002
A922-020-83-41- A ALIGNMENT SHEET FROM CH 3.5 KM TO 5.25 KM 783
12003
A922-020-83-41- A ALIGNMENT SHEET FROM CH 5.25 KM to 7 KM 784
12004
A922-020-83-41- A ALIGNMENT SHEET FROM CH 7 KM TO CH. 8.75 KM 785
12005
A922-020-83-41- A ALIGNMENT SHEET FROM CH. 8.75 KM TO CH 10.5 KM 786
12006
A922-020-83-41- A ALIGNMENT SHEET FROM CH. 10.5 KM TO CH 12.25KM 787
12007
A922-020-83-41- A ALIGNMENT SHEET FROM CH. 12.25 KM TO CH 14 KM 788
12008
A922-020-83-41- A ALIGNMENT SHEET FROM CH. 14KM TO CH 15.75 KM 789
12009
A922-020-83-41- A ALIGNMENT SHEET FROM CH.15.75 KM TO CH. 16.569 KM 790
12010
A922-020-83-41- A CROSSING DRAWING FOR PHULZAR RIVER 791
12011
A922-000-02-42-PID- 0 PIPING &INSTRUMENTATION DIAGRAMS (P&IDS); 792
1101
GAIL-ERPL-S03- B Detailed Survey Report 802
J00-001-0B
GAIL-ERPL-S04- A Soil Stratification Report 864
J00-001-0A
Page 5 of 1963
Table of Contents
Number
All Survey Crossing A All Survey Crossing Drawings 876
Drawings
GAIL-ERPL-RM-01 C GAIL-ERPL-RM-01 917
A922-00-000--ITP- 0 INSPECTION AND TEST PLAN (JOB SPECIFIC) 918
ICR-9510
A922-000-16-50-OD- A ANY OTHER DOCUMENT 920
9510
A922-000-16-51-SP- 0 JOB SPECIFICATIONS 1088
80
81
82
A922-020-16-51-IS- 0 JOB STANDARDS 1127
9510
A922-000-16-51- A DRAWING 1130
4701
A922-000-16-51- A DRAWING 1131
4702
A922-000-16-51- A DRAWING 1132
4703
A922-000-16-51- A DRAWING 1133
4704
A922-000-16-51- A DRAWING 1134
4705
A922-020-16-51-CF- 0 COMPLIANCE FORMAT 1135
0001
A922-020-16-51-ID- A DATASHEET INDEX 1137
9510
A922-020-16-51-MD- 0 VENDOR LIST 1165
0001
A922-020-16-51- 0 VENDOR DATA REQUIREMENTS 1171
VDR-0001
6-52-0016 4 Standard specification for pressure, differential pressure and 1174
vaccum gauges
6-52-0021 4 Standard specification for temperature gauges and thermowells. 1183
6-52-0026 4 Standard specification for pressure relief valves. 1190
6-52-0032 4 Standard specification for electronic / pneumatic instruments. 1198
6-52-0042 3 Standard specification for thermocouples, RTDs and thermowells. 1214
6-52-0046 6 Standard specification for signal cables. 1223
6-52-0048 4 Standard specification for junction boxes and cable glands. 1231
6-52-0049 3 Standard specification for main control panel and accessories. 1238
6-52-0067 5 Standard specification for instrument tube fittings. 1251
6-52-0069 5 Standard specification for instrument valves and manifolds. 1257
6-52-0068 4 Standard specification for instrument tubing. 1265
6-52-0060 2 Standard specification for erection tender. 1272
6-52-0080 3 Standard specification for gas detection system. 1298
7-52-0001 4 Instrument connection on vessel, standpipes and tanks. 1322
7-52-0101 2 Instrument support single instrument 1326
7-52-0002 4 Instrument connection on pipes. 1329
7-52-0035 3 Thermowell. 1332
7-52-0036 3 Thermocouple / RTD assembly with thermowell. 1335
7-52-0102 2 Instrument support two instruments 1336
7-52-0104 2 Support details for junction boxes 1339
Page 6 of 1963
Table of Contents
Number
7-52-0105 2 Fabricated canopy for instruments 1340
7-52-0107 2 Perforated tray supports & cables clamping details 1341
7-52-0400 4 List of items for installation standards. 1342
7-52-0432 4 Pressure gauge liquid/gas service. 1351
7-52-0446 4 Pressure instrument gas service meter above. 1352
6-81-2016 3 ITP for receiver & pressure gauges 1353
6-81-2021 3 ITP for temperature gauges & thermo wells. 1357
6-81-2026 3 ITP for pressure relief valves. 1362
6-81-2032 3 ITP for electronic/pneumatic instruments 1367
6-81-2042 3 ITP for thermocouples, RTDs & thermo wells 1374
6-81-2046 3 ITP for signal cables 1379
6-81-2048 3 ITP for junction boxes & cable glands. 1385
6-81-2049 3 ITP for main control panel & accessories 1390
6-81-2067 3 ITP for instrument tube fittings 1395
6-81-2068 3 ITP for instrument tubing 1400
6-81-2069 3 ITP for instrument valves and manifolds 1405
6-81-2080 3 ITP for gas detection system (LEL/H2S) 1410
A922-020-81-41- A DETAILS OF CHAIN LINK FENCING 1416
34701
A922-020-81-41- A DTAILS OF FOOTPATH (PCC INTERLOCKING BLOCKS) 1417
44702
A922-020-81-41- A CROSS-SECTIONAL DETAILS OF ROAD (WBM) 1418
44703
LL-16-48-0402 3 APPROVED VENDOR LIST 1419
6-65-0013 3 Standard specification for chain link fencing. 1424
6-65-0016 3 Standard specification for classification of soil for Earth Work in 1431
site grading
6-65-0017 5 Standard specification for site grading and rock cutting for site 1437
grading
6-65-0018 7 Standard specification for road & flexible pavements. (upto WBM 1449
layer).
6-65-0019 3 Standard specification for concrete pavement. 1460
6-65-0020 3 Standard specification for flexible pavements with bitumen premix 1470
carpet.
7-65-0001 3 Abbreviations, legends and equipment symbols. 1479
7-65-0010 4 Road curves and Crossing. 1483
7-65-0272 4 Unit drainage details (rectangular ditch details). 1484
7-65-0404 3 RCC pavement details. 1485
6-68-0001 4 Standard specification civil and structural works - general scope. 1486
6-68-0002 5 Standard specification civil & structural works materials. 1490
6-68-0003 5 Standard specification civil & structural works earthwork. 1506
6-68-0004 7 Standard specification civil & structural works plain & reinforced 1519
cement concrete
6-68-0006 6 Standard specification civil & structural works structural steel 1549
works.
6-68-0008 6 Standard specification civil & structural works miscellaneous steel 1573
works
6-68-0009 4 Standard specification - civil & structural works - brick masonary. 1585
6-68-0013 4 Standard specification - civil & structural works - miscellaneous 1594
items.
7-68-0056 6 Metal insert plates. 1603
7-68-0101 5 Standard re-bar shapes & cut length computation. 1610
Page 7 of 1963
Table of Contents
Number
7-75-0054 4 Steel gate (for entrances upto 6.0m width). 1617
A922-020-82-41-SP- A JOB SPECIFICATION 1619
9510
A922-020-2-42-CMS- 0 CORROSION MONITORING SYSTEM 1622
0001
A922-00-020-19-41- 0 TECHNICAL COMPLIANCE FORMAT - CONSTRUCTION 1634
TC01
A922-00-020-19-41- 0 CONSTRUCTION SUPERVISION AND MANAGEMENT 1636
0001
6-82-0001 6 Standard specification for health, safety & environment (HSE) 1783
management at construction sites
6-82-6100 2 Standard QA plan construction division (item rate contracts) 1870
6-82-3100 0 Inspection & test plan (ITP) for civil, structural & architectural 1883
works (item rate contracts ¿ with categorization)
6-82-1010 1 ITP for incoming material checking for contractor's supplied 1947
materials
7-82-0001 1 Conditions for Issue and Reconciliation of Materials 1955
Page 8 of 1963
DOCUMENT No.
TENDER FOR PIPELINE LAYING
WORKS FOR JLPL CAPACITY A922-020-83-41-MK-T-9510
AUGMENTATION PROJECT REV.0
Page 1 of 1
GAIL (INDIA) LIMITED
TENDER FOR PIPELINE LAYING WORKS FOR JLPL

CAPACITY AUGMENTATION PROJECT
CLIENT PIPELINE CODE NO : 22101500

CLIENT PIPELINE SECTION CODE : 22101501
OWNER : GAIL (INDIA) LIMITED
CONSULTANT : ENGINEERS INDIA LIMITED
JOB NO. : A922
0 06.01.17 Issued For Bids

VS AR NR
Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 9 of 1963
SCOPE OF WORK FOR DOCUMENT No.
PIPELINE & ASSOCIATED A922-020-83-41-SOW-9510 Rev. A
FACILITIES
(PIPELINE ENGINEERING) Page 1 of 36

गेल (इडं िया) डलडिटे ि
CAPACITY AUGMENTATION OF JAMNAGAR-LONI
PIPELINE PROJECT (LPG PIPELINE)
जािनगर-लोनी पाइपलाइन क्षिता डिस्तार पररयोजना (एल पी जी पाइपलाइन)
SCOPE OF WORK
FOR
PIPELINE & ASSOCIATED FACILITIES
(PIPELINE ENGINEERING)
PIPELINE CODE NO : 22101500
PIPELINE SECTION CODE : 22101501
A 16.12.16 DRAFT RB AR/NR MSG

Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 10 of 1963
FACILITIES
CONTENTS
1.0 INTRODUCTION ...................................................................................................................... 3
2.0 WORK TENDERED ................................................................................................................. 3
3.0 SCOPE OF WORK .................................................................................................................. 4
4.0 SCOPE OF SUPPLY ............................................................................................................. 15
5.0 SCOPE OF WORK AND SCOPE OF SUPPLY FOR OTHER DISCIPLINES .............. 24
6.0 OTHER CONDITIONS OF BID ............................................................................................ 24
7.0 AS-BUILT DOCUMENT/ DRAWINGS ................................................................................ 34
8.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING ................................. 35
9.0 GENERAL ............................................................................................................................... 35
Page 11 of 1963
FACILITIES
1.0 INTRODUCTION
1.1 GAIL is operating and maintaining Jamnagar - Loni LPG pipeline (JLPL) for
transporting LPG from Western part of India to the Northern part of India. The JLPL
LPG pipeline system has three supply sources RIL Jamnagar, Essar Oil (EOL)
Vadinar and Kandla. The pipeline from Kandla and Jamnagar joins at Samakhiali
from where it continues up to Loni passing through Abu road, Nasirabad,
Mansarampura, Piyala and Madanpur Khadar. Loni is the terminating point for JLPL
LPG pipeline. The JLPL LPG pipeline has pumping stations en-route at Samakhiali,
Abu Road, Nasirabad (Ajmer) and Mansarampura (Jaipur). The existing capacity of
JLPL is 2.5 MMTPA. GAIL has planned for capacity augmentation of JLPL from 2.5
MMTPA to 3.25 MMTPA.
1.2 Following facilities envisaged as a part of the capacity augmentation shall be
executed through this tender:
a. Pipeline of size 8.625 inch Approx. 17 km long from EOL to SV1 (at Sapar).
b. The pipeline associated facilities such as Despatch Facilities at EOL DT,
Sectionalizing Valve and associated facilities at pipeline approx. Chainage
1.0 km inside the EOL, Sectionalizing Valve and associated facilities at
pipeline approx. Chainage 12.7 km, Receipt Facilities at SV1 (at Sapar).
c. Shifting of the Sectionalizing Valve station (SV) of the existing size 14 inch
pipeline to new Receipt terminal of proposed size 8.625 inch pipeline. The
proposed RT of 8.625 inch pipeline is in the downstream of the existing SV
of the size 14 inch existing pipeline. Hook-up of size 8.625 inch
pipeline/piping with size 14 inch pipeline at RT of size 8.625 inch pipeline.
The shifting of the SV & Hook-Up shall be carried out without interrupting
the LPG flow in the 14 inch pipeline by using Hot tapping, double stoppling
& temporary By-pass. The shifting of SV also includes new tentatively 200 m
long section of size 14 inch pipeline between stoppling points.
d. Removal of old SV of existing size 14 inch pipeline & tentatively 200 m long
isolated section of existing size 14 inch pipeline between stoppling points.
1.3 This document covers details of Work Tendered, Scope of Work, Scope of Supply
and other requirements for the works envisaged in this tender.
1.4 Details of associated Civil, Structural, Electrical, Mechanical Equipments,
Instrumentation, Telecom, SCADA, Geo-technical, Cathodic Protection works, etc.
are covered elsewhere in the Tender document.
1.5 This document shall be read in conjunction with Schedule of Rates, List of
Attachments, Specifications, Standards, Drawings, P & IDs, Line Schedule, and
other Documents/ Drawings forming part of Tender Document.
2.0 WORK TENDERED
2.1 The work tendered shall consist of the following:
a) Transportation of Company supplied free issue materials from designated
place of issue to Contractor’s Store/ Fabrication Site/ Work Site. Storage
of Company supplied materials till installation.
b) Procurement & Supply of Contractor supplied materials (as per Scope of
Supply).
c) Fabrication, Installation & Testing, Painting & Coating.
d) Hot Tapping & Double Stopling on existing pipeline facilities, Tie-in/ hook-
up with existing facilities.
e) Pre-testing, cleaning, flushing, hydrostatic testing, dewatering, drying, etc.
Page 12 of 1963
FACILITIES
f) Idle time preservation of the pipeline system for the specified period (if
required).
g) Pre-commissioning & Overall Commissioning.
h) Removal of Part of Existing Pipeline/ Piping/ Sectionalizing Valve.
i) All associated Civil, Structural, Electrical, Mechanical Equipment,
Instrumentation, Telecom, SCADA, Geo-technical works, etc.
j) All such works that are not indicated herein but are required to complete
the work in all respects shall form part of the work tendered.
2.2 Refer “Schematic Arrangement of Pipeline Facilities” drawing no. A922-000-83-41-
30011. The Pipeline Schematic indicates the overall project details in brief and is
for reference purpose only. Contractor’s quotation shall be based on complete
scope of work & all documents/ drawings forming part of the Tender Document.
2.3 The piping/ pipeline installation shall be carried out in the Existing EOL terminal
which is in operation/ in the New RT of size 8.625 inch pipeline RT & in SV of 14
inch pipeline which is in close proximity to the existing operational size 14 inch
pipeline/ in the pipeline ROU parallel to existing Operational pipeline. While carrying
out the piping/ Pipeline installation works following safety/ precautionary measures
shall be taken care of by the contractor.
All safety measures and precautions shall be taken during execution of the works.
All works shall be carried out to ensure no damage to the existing facilities.
Contractor is required to perform the works under working space constraints.
Contractor may be required to mobilize lifting equipment/ cranes of higher capacity
& boom length to enable safe lifting/ handling of components /spools etc for the
construction work. All such equipment shall be approved by Engineer in-Charge
before mobilization.
2.4 Contractor shall mobilize and provide all equipments, manpower (skilled and semi-
skilled), consumables and other resources etc. as required.
2.5 Contractor shall be responsible for the successful & timely execution of the
complete job defined in the Tender Document.
3.0 SCOPE OF WORK
3.1 The scope of work detailed herein shall be read in conjunction with the
specifications, standards, drawings, P & IDs, Line Schedule, List of Attachments,
attachments & other documents and Schedule of Rates (A922-020-83-41-MK-SOR-
9510-0) enclosed with the Tender Document. The detailed scope of work for the
pipeline and associated works are as described below.
3.2 The Contractor’s Scope of Work for the work tendered shall consist of, but not
limited to, Mobilization/ demobilization, Physically Locating existing pipeline(s) &
other facilities as proposed pipeline shall be installed parallel to the existing
operational pipeline, providing of all requisite manpower & machinery,
transportation of Company supplied free issue materials including storage,
installation, testing, painting, coating, procurement and supply of all materials (as
per scope of supply), tie-in/ hook-up with existing facilities, pre-commissioning &
overall commissioning, all associated works and all works though not indicated
specifically herein but otherwise required to be performed to complete the work in
all respects.
3.3 All such works that are not indicated herein below but are required for the work to
be completed in all respects shall form part of Contractor's Scope of Work.
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3.4 Scopes of work and details for Civil, Structural, Electrical, Mechanical Equipment,
Instrumentation, Telecom, SCADA, Geo-technical works, etc are covered
elsewhere in the Tender Document.
3.5 The facilities under the project are to be installed in existing operational stations &
terminals/ Pipeline ROU of Jamnagar-Loni Pipeline System. Contractor shall ensure
that existing facilities shall be safeguarded while execution of the work. All works
shall be carried out to ensure no damage to the existing facilities. All safety
measures and precautions shall be taken during execution of the works. Contractor
shall exercise extreme care and ensure complete safety to all facilities, man and
machine and shall fully abide by and comply with the restrictions and conditions
imposed on Contractor from time to time. Contractor shall ensure that there shall be
no movement of heavy machineries over the existing buried pipelines/ piping. While
carrying out trenching/ ditching activities it shall be ensured that there shall not be
any existing underground facilities. Contractor shall locate and mark all
underground facilities before carrying out work using GPRS, pipe locators, cable
locators, etc. In no case there shall be any damage to the existing facilities.
Contractor to comply with the safety permits and shall follow all safety instructions
of the Company. As the works are to be carried out in existing operational stations/
terminals, Contractor to deploy only anti-sparking tools sets, Cold Cutting
Equipments and suitable equipments & machinery. Contractor shall carryout
assessment of safety concerns and shall provide all safety measures, appliances,
equipments, accessories, gas detectors, fire screens, oxygen mask, etc. as
required. Contractor shall provide necessary supervision through adequately
trained/ qualified personnel to ensure safety.
3.6 Contractor to take utmost care and all precautions, all safety measures, application
of safety equipments/ devices, for execution of the works in the stations/ terminals.
In no case there shall be any possibility of hazard due to the works performed by
the contractor. Contractor to develop safety procedure for works to be performed in
all stations. The safety procedure shall be subject to review & approval by the
Company.
3.7 Contractor shall locate all existing underground cables, pipelines, piping, structures,
etc, before start of any excavation work inside Existing pipeline ROU/ operating
terminals/ stations using GPRS, pipe & pipeline locators, cable locators, manual slit
trenching/ trial pits & other suitable methods and as per the instructions of
Engineer-In-Charge.
3.8 Supply and installation of windsocks, safety signboards at all stations/ terminals.
3.9 All construction works shall be carried out based on actual site conditions, drawings
& documents, procedures, specifications, standards and applicable regulations,
PNGRB & OISD regulations, codes & standards and maintaining safety of the
existing facilities.
3.10 Piping Equipment Layouts have been included in the Tender Document to enable
the Contractor to understand the nature of work involved. Piping General
Arrangement & Supports Drawings and Piping Support Indices shall be provided by
Company to the Contractor at appropriate times during Project execution stage.
Contractor shall carryout all works strictly in accordance with the Issued for
Construction (IFC) drawings and specifications/ standards, documents, data sheets
etc. enclosed with the CONTRACT, instructions of Company/ Engineer In-charge
and other provisions of the CONTRACT.
3.11 "Receiving and Taking-over" of Company supplied externally corrosion coated
(3LPE) and bare free-issue line pipes from Line Pipe Manufacturer/ COMPANY in
presence of Company’s representative at Line Pipe Manufacturer’s Storage Yard/
COMPANY designated Storage Yard as detailed subsequently in this document,
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transportation including unloading, handling, stacking, hauling and stringing of line

pipes from dump site to Contractor's own stock yard(s)/ work site(s)/ workshop(s)/
pipeline right-of-use, including arranging all pipe trailers, cranes etc., arranging all
necessary intermediate storage area(s) thereof till the pipes are installed
permanently. Installation Contractor shall supply the truck/trailer for transportation
of coated/ bare pipes from dumpsite. However, Line Pipe Manufacturer shall load
the coated and bare pipe on truck / trailer at the dumpsite.
3.12 Carrying out inspection of Company supplied free-issue coated and bare line pipes
at the time of receiving and taking-over and recording of defects, etc. noticed in the
presence of Company's representative and accepting defect free pipes only. Repair
of damaged pipe, beveled end defects and damaged coating (including supply of
repair materials) noticed at the time of handing over of coated linepipes shall be
carried by Line Pipe Manufacturer.
3.13 Carrying out repairs of pipe and pipe coating defects not attributable to the
Company (after taking over) including defects/damages occurring during
transportation and/or handling after receiving and taking-over including supply of all
materials required for repairs.
3.14 Rebuffing for dents in bevels less than 1 mm in depth shall be carried out by
Contractor prior of welding in the field at no cost to Company.
3.15 For pipes where cutting out involves more than 25 mm from pipe ends, ultrasonic
inspection shall be carried out at pipe ends as per relevant clause of the linepipe
specification, including supply of all equipments. Contractor shall take prior
approval from Company for the agency engaged for carrying out ultrasonic
inspection.
3.16 Loading, unloading, handling, stacking, storing and transportation to workshop(s)/
work site(s) of all materials (other than corrosion coated and bare line pipes) that
may be used for the construction of pipeline system either supplied by Company at
their designated storage yard and/or procured by Contractor as the case may be.
All Company supplied materials (other than line pipe) shall be issued to Contractor
from Company’s designated store indicated elsewhere in the bid document.
3.17 Company has got carried out detailed route survey for the entire pipeline route.
However, carrying out all additional topographical survey and/or geotechnical
surveys required for local detours, detours at crossing locations and elsewhere
during execution and for additional crossings, if any, (applicable for HDD / Boring)
for which details are not available in the bid document including preparation of plan
and profile drawings as directed by Engineer-in-Charge. The survey data included
in the Tender Document is for information and reference purpose only. Contractor
shall prepare and submit drawings, documents and calculations including
calculations for scour level for Company’s review and approval.
3.18 Carrying out thorough internal cleaning of all pipes to remove debris, shots, grit etc.
to the satisfaction of Company/ Engineer-in-Charge.
3.19 Mobilizing and providing all equipments, manpower (skilled and unskilled),
consumables and other resources etc., as required for the execution of complete
work and thereafter demobilizing the same upon completion of work.
3.20 The detailed scope of work pertaining to the pipeline & piping works and associated
works shall be in general but not limited to the following.
3.20.1 Providing all equipments, manpower, machinery, consumables for fabrication,
installation, inspection, testing, pre-commissioning and commissioning; all types of
safety tools, tackles, devices and apparatus, equipment etc. including ladders and
scaffolding etc. complete as required including providing all types of consumables,
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tools, tackles and facilities for inspection and interpretation of testing results by
Company/ Company's Representative personnel.
3.20.2 Mobilization of requisite manpower, machinery, equipments, Cold Cutting
Equipments, Specialized Equipments and other resources, etc and demobilization
after completion of work. Furnishing and mobilizing at site(s) of all construction
equipments, tools and tackles, fully equipped and fully manned with other required
support facilities etc. needed for successful execution of the works.
3.20.3 “Receiving and taking over” of all Company supplied free issue materials from the
Company’s designated place(s) of issue, transportation including loading,
unloading, handling from Company’s designated place(s) of issue to Contractor’s
store/ work site(s)/ workshop(s) including arranging all necessary intermediate
storage area(s) thereof as required till the permanent installation of materials.
3.20.4 Procurement and supply of all materials, equipments that are included in the scope
of supply of Contractor, transportation of all materials from manufacturer’s works
including loading, unloading, handling, storing and transportation to Contractor’s
store/ work site(s)/ workshop(s) including arranging all necessary intermediate
storage area(s) thereof, as required. Contractor shall procure and supply all
materials (as per scope of supply) other than free issue materials, in sequence and
at appropriate time for successful completion of the work. All equipments, materials,
consumables, components, etc. shall be new and suitable for the intended service.
Approved vendor list has been enclosed with the Tender Document for various
items. Contractor shall strictly follow the approved vendor list enclosed with the
tender. For items, which are not covered in the vendor list, Contractor shall obtain
Company’s prior approval for the vendor. Necessary details i.e. data sheets &
specifications, as required, are enclosed with the Tender Document. Contractor
shall also procure and supply mandatory spares and spares required for pre-
commissioning and commissioning/ start-up as recommended by the vendor for all
items supplied by the Contractor and as per specifications & details provided in the
Tender Document.
3.20.5 All procurement shall be strictly as per Specifications & Data Sheets enclosed with
the Tender Document. Preparation of Material Take Off (MTO), Purchase
Requisition, review of Vendor drawings, documents and calculations, approval of
manufacturing procedures wherever necessary, and third party inspection at
manufacturer’s works of the materials by internationally reputed agencies. Third
party inspection agency shall be engaged by the Contractor. Third party inspection
shall be to Contractor’s account and the agency shall be subject to Company’s
approval. Quality control and expediting of all procured items at Vendor’s shop or at
fabrication yard. Company Representative shall be provided with access to all
manufacturing works.
3.20.6 Loading, unloading, handling, stacking, storing and transportation to workshop/
work site of all materials that shall be used for the construction.
3.20.7 Company may ask for transportation of any other materials, piping items,
equipments, machinery etc. from any location to any location, as required.
Contractor shall carryout transportation, including lifting, loading and unloading.
Contractor shall quote the rate for all transportation at the applicable item(s).
3.20.8 Contractor to ensure compliance with Vendor’s and supplier’s instructions,
procedures and recommendations for transportation, handling, installation, testing
and commissioning.
3.20.9 Maintaining and operating an adequate material control procedure at worksite.
3.20.10 Submission of proposed work execution plan along with detailed schedule of
activities for Company’s approval and carrying out all works as per approved
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procedures and within stipulated time period for all proposed works to be executed
including of all modifications & hook-ups.
3.20.11 Preparation of detailed procedures for fabrication, installation, testing and pre-
commissioning & commissioning. Such procedures shall be submitted to Company/
Engineer In-Charge for review and approval.
3.20.12 Obtaining all clearances, approvals, permissions and work permit, hot work permit
for the works as required. Contractor to obtain the hot work permits from Company/
concerned authorities having jurisdiction thereof to work within existing and
operating stations/ terminals and shall strictly comply with all requirements/
stipulations/ conditions/ recommendations of the Company/ concerned authorities.
The requirements of “OISD Std 105” shall be complied with for Railway Crossing of
Pipeline. After completion of work, Contractor shall obtain a certificate from the
Company/ concerned authorities that the job has been completed as per their
requirement and the area/ land has been restored to their satisfaction. All
necessary coordination and compliances as per general permission from the
authorities having jurisdiction during actual execution of work. Company shall
provide general permission from the authorities for the construction of piping works.
3.20.13 Contractor to obtain specific permissions from Company/ concerned authorities for
carrying out hook-up works.
3.20.14 Staking, clearing, grading of Pipeline Right of Use (ROU) as required, trenching to
all depths in all types of soils including soft and hard rock, chiselling, or otherwise
cutting etc. to a width to also accommodate the OFC/ cable conduit as per relevant
standards, drawings, specifications etc., stringing, aligning, bending, welding, NDT
including AUT, radiography, field weld joint coating including supply of all materials,
corrosion coating of long radius bends and buried fittings/ valves including supply of
materials, providing sand/ soft soil padding including supply of sand/ soft soil
wherever required, laying and lowering of the pipeline including locating existing
pipeline using pipe locator and maintaining the minimum spacing from existing
pipeline(s), backfilling including supply of select backfill material wherever required,
carrying out all types of crossings such as rail, road, river, canal, drain, utility, minor
& major water course crossings including supply & installation of casing pipes and
carrier pipe inside casing pipes, providing two component epoxy coating on inner
surface of casing pipe wherever required by statutory authority, providing suitable
anti-corrosive paints on both sides of CS conduit for OFC wherever required by
statutory authority, bank stabilization of water course crossings as required,
arranging all additional temporary land/ area required for construction purposes.
Supply and installation of anti-buoyancy measures viz. continuous concrete
coating, geo-textile gravel filled bags, extra cover, select backfill etc. on pipeline,
installation of supports wherever required, tie-in/ hook-up with Existing pipeline/
piping including cutting of temporary test headers if any, tie-in/ hook-up with
existing piping/ pipeline, re-bevelling, NDT, fit-up, welding, radiography etc.; clean-
up, ROU restoration, pigging, flushing, gauging, hydrostatic testing with the quantity
of corrosion inhibitor as required, dewatering with the addition of approved
chemicals to neutralize the effect of inhibitor added during hydrostatic test at
required dosage, swabbing, drying, Magnetic Cleaning, EGP, pre-commissioning &
Overall commissioning of the pipelines system including supply of all materials such
as required type and quantity of pigs, manpower, equipment, consumables and
carrying out all associated works as per relevant specifications, standards and
approved drawings enclosed with the Tender Document.
3.20.15 Preparation of bevel and coating cut back of linepipes. The requirements indicated
in welding specification and charts shall be complied with.
3.20.16 Carrying out thorough inspection of the Linepipes and Coatings.
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3.20.17 Carrying out radiographic inspection and interpretation of radiograph of welds.

3.20.18 All welding and NDT shall be carried out as per welding specification and charts
enclosed with the Tender Document.
3.20.19 Carrying out welding including cutting, edge preparation (inclusive of grinding the
edges of pipe, fittings, flanges, etc. to match with the matching edges of different
thickness wherever required), fit-up, bending, pre-heating wherever required, NDT
including radiography and other non-destructive tests, destructive tests, as
specified. NDT requirements for process and other piping shall be in accordance
with relevant specifications enclosed with the Tender Document.
3.20.20 Welding of all tie-in joints including tie-in joints and bends on either side of major
river/ canal/ road/ rail crossings/ other facilities as required including adjoining
pipeline sections, cutting of test header, re-bevelling and tie-in with adjacent
pipeline segments.
3.20.21 Field weld joint coating and corrosion coating of Long Radius (LR) bends by cold
applied tapes/ heat shrink sleeves (HSS) complying relevant specification enclosed
with Tender Document. 100% solid high build epoxy (minimum 800 micron thick)
(Duracoat/ Epigen or equivalent) or PU Coating of thickness DFT 1.5 mm (min.)
shall be applied for underground piping & valves.
3.20.22 Installation of all insulating joints, valves, appurtenances, instruments etc.
3.20.23 Providing slope breakers in steep slope areas (slope more than 1 in 10) including
supply of all materials. Contractor shall carry out slope breaker survey and slope
breaker shall be installed (before backfilling) as per standard no. 7-71-0027
enclosed with the Tender Document, after approval of Engineer-In-charge. Slope
breakers shall also be installed in locations wherever there are possibilities of
erosion of soil as per instructions of Engineer In-charge at site.
3.20.24 Supply & installation of bank-protection measures as per the standard no.7-71-
0028 for river crossings & at location as per the instruction of Engineer In-charge.
3.20.25 Sand/ soft soil padding of minimum 150 mm thickness around pipeline wherever
required in areas where trenching has been done in rock or gravel or hard soil
including supply of sand/ soft soil. The pipeline trench shall not be filled with gravel
and large stones or boulders.
3.20.26 Select backfilling of the pipeline trench at station pipeline approaches. The extent of
the select backfill of the pipeline trench shall be upto 100 m from the Above
Ground/ Buried transition point of the pipeline. The Select backfilling shall be as per
the standard enclosed with the tender package.
3.20.27 Installation of pipeline by Horizontal directional drilling method (HDD). Carrying out
topographic, geo-technical investigation and hydrological survey for the crossing
and its interpretation including calculation of scour level, preparing plan and profile
drawings, installation & testing procedures as directed by Company. Contractor
shall also carryout soil investigation for crossing design. Carrying out all design,
detailed engineering and engineering for construction including preparation of all
construction drawings and procedures/ documents as per the requirements of
applicable specifications for installation of pipeline segments by using Horizontal
Directional Drilling (HDD) method. Contractor shall submit the scour level
calculations, crossing drawings and design calculations to Company for review and
approval. Contractor shall also indicate the name of HDD agency and approval for
the same shall be obtained from Company before placement of the order. Work
shall start only after approval of the above. Acquisition of land for HDD activities
including land required for HDD equipments, pipe string, pits etc. shall be to
contractor’s account. HDDs shall be carried out for crossings keeping HDD lengths
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limited to the extent required for the purpose of crossing i.e. without drilling
additional lengths. The HDD lengths shall also be subjected to approval by
Company.
3.20.28 Installation of pipeline for crossings by open-cut/ boring-jacking methods. In case
the Contractor proposes to install the crossings by HDD or any other equivalent
method complying tender requirement, the Contractor may do so at his own risk,
time and cost but subject to Company’s approval. The rates quoted by the
Contractor shall remain firm irrespective of the method of installation (HDD/ any
other equivalent method/ Open cut method/ Boring-Jacking) adopted.
3.20.29 Carrying out National Highway/ State Highway, Expressway, Railways, Canals and
major road crossings by conventional/ boring/ Jacking/ HDD method with casing
pipe.
3.20.30 Supply (as per the scope of Supply) and installation of casing pipes (by open cut/
jacking/ boring/ any other trenchless technique) assembly, including supply of all
materials, viz. casing pipe, casing insulators and end seals, vents and drains etc.
complete, at cased crossings.
3.20.31 Supply and installation of OD 168.3 mm CS conduit for Optical Fibre Cable
including end seals for all bored crossings, HDD crossings & all river crossings.
3.20.32 Cased crossings shall be installed at locations indicated in Issued for Construction
alignment sheets. The number of crossings indicated in the alignment sheets is
subject to change based on engineering, construction and statutory requirements or
the requirements of the Authority having jurisdiction over a utility crossing.
3.20.33 Carrying out pipeline installation at Overhead power cable crossing, existing above
ground/ buried pipeline crossing including supply of concrete slab as per the
standards enclosed with the tender package.
3.20.34 Supply and installation of 0.5 mm thickness & width (Pipeline outside Dia. in
mm+300 mm) warning tape over entire pipeline as per the Job standard enclosed
with the Tender. Warning tape shall be laid 200 mm above the top of pipeline. The
material of warning tape shall be of high density polyethylene and non
biodegradable type. It shall have non-toxic and anti-rodent properties.
3.20.35 Providing all necessary barricading material, safety signboards, warning lights etc
to safeguard the pipeline & public against accidents during construction of pipeline
in densely populated areas.
3.20.36 Contractor shall ensure that no damage is done to the irrigation water pipes (MS/
Hume/ PVC/ HDPE pipes, Concrete channel) during pipeline installation. In case,
the damage is done to these utilities, it shall be sole responsibility of the contractor
to restore these utilities. Any claim arising due to damage and delay in restoration
of utilities shall be settled by the contactor at his own expense.
3.20.37 Repair of leak/ burst by replacement of pipe etc. found during hydrotest shall be
carried out by the Contractor. Contractor shall submit a report for failure to
Company. Repair of leaks/ burst, not attributable to Contractor, occurring in
Company supplied material shall be carried out by the Contractor and the
Contractor shall be compensated as per provisions of the contract. However repair
of such defects attributable to Contractor shall be carried out by Contractor at no
extra cost to Company.
3.20.38 Contractor shall carryout topographical, geo-technical investigation and
hydrological survey for water crossings & other crossings in line with the details
enclosed elsewhere in the Tender Document.
3.20.39 Carrying out Magnetic Cleaning (pigging with the help of magnetic pig to remove
steel debris) and Electronic Geometric Pigging (EGP) of size 8.625 inch pipeline.
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3.20.40 Magnetic Cleaning & Gauge Plate run of size 14 inch pipeline of tentatively 200 m
long section before tie-in on either side with the existing pipeline.
3.20.41 Carrying out repair of all defects found during Gauge Plate Run, Electronic
Geometric Pigging including locating, digging, cutting, welding, NDT, etc.
3.20.42 Pre-commissioning, drying & commissioning of pipeline & associated facilities
including supply of required quantity of Nitrogen. Providing all equipments,
manpower, machinery, consumables including required number of pigs, for the
pipeline system and associated facilities including stations viz. Despatch Terminal,
Sectionalizing Valve Stations, Tap-Off/ Tap-in Stations and Receipt Terminal.
3.20.43 Final clean-up and restoration of ROU and other conveniences like temporary
approach roads/ temporary works, barren land, road, rail, canals, water crossings,
cultivable land etc. to original condition as per specification and drawings to the
entire satisfaction of Company and authorities having jurisdiction over the same,
including disposal of surplus construction materials. Stones laid to mark the
boundaries of adjoining fields shall be restored by Contractor to original conditions.
Contractor shall arrange necessary clearance from all concerned authorities/ land
owners to the effect that ROU has been restored back to the original condition.
Claims if any thereafter, shall be settled/ borne by the contractor.
3.20.44 Disposal of surplus excavated soil from trench and disposal of Bentonite used for
carrying out HDD crossings. The material should be disposed off in proper manner
with the approval/ consent from local authorities/ villagers.
3.20.45 If required, Idle time preservation of pipeline by filling Nitrogen at a positive
pressure of 2 bar(g) as per specification including supply of Nitrogen, as per the
COMPANY instructions.
3.20.46 Preparation of as-built drawings & documents, pipe-books, documents,
photographs, video records and project records as per specification and
instructions of the Company including furnishing of all Test Certificates/ Inspection
Reports for all materials used for permanent installation.
3.20.47 Supply and installation of anti-buoyancy measures viz. continuous concrete
coating, extra cover, select backfill, geo-textile bags etc. on pipeline as directed by
Engineer In-charge for water crossing, marshy areas, all other areas prone to
flooding, etc.
Minimum thickness for continuous concrete weight coating (CCWC) shall be as
given below:
Pipe Size, inch (mm) CCWC Thickness, mm
8.625 (219.1) 40
Contractor shall also provide anti-buoyancy measures based on site specific

conditions. Contractor shall implement the anti-buoyancy measures as per the
instructions of Engineer In-charge at site.
3.20.48 Supply and installation of all types of pipeline markers including their painting for
the entire route as per specification 6-79-0020 (irrespective of paint system shown
on respective standards) and all associated civil works. Location of markers shall
be as per Issued for Construction Alignment Sheets, specification and standards
enclosed with the Tender Document and as directed by Engineer-in-Charge.
3.20.49 Hot Tapping & Double Stoppling works on existing size 14 inch pipeline at new RT
of size 8 inch Pipeline at Sapar including deployment of required man-power,
supply of Equipments & consumables (as per scope of supply), Excavation,
installation of Slipt-Tee, pressure balance tappings, installation of sandwich valves,
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Hot tapping, Stoppling, Temporary by-pass piping for isolated pipeline section, Vent
& drain tapping for isolated pipeline section and further connection of tappings to
company supplied mobile flare, purging of isolated pipeline section with nitrogen to
completely evacuate the LPG. Excavation to expose isolated pipeline section.
Removal of Condensate & Wax/ Deposit of the Isolated section of pipeline if
required, making the section completely hydrocarbon free. Contractor shall provide
all equipments, material as required for carrying out the works. Removal of the
isolated pipeline section in the lengths of 12 m including cold cutting. Transportation
of removed section of pipeline to designated storage yard of GAIL & stacking of the
pipes including handling, Loading, Unloading, intermediate Storing, etc.
3.20.50 Providing schedules, progress reporting, organization chart at construction site,
quality assurance plan and developing quality control procedures, as per
requirements indicated elsewhere in the Tender Document.
3.20.51 Coordination and supervising the work of sub-contractors.
3.20.52 Transportation of appropriate materials to worksite, intermediate storage points,
maintaining and operating an adequate material control procedure at worksite.
3.20.53 Fabrication of all piping, structural components as per approved drawings.
3.20.54 Hook up/ tie-in of pipeline and piping system with Existing terminal/ station facilities,
as required. All works pertaining to hook-up, purging, obtaining specific permissions
for carrying out hook-up including supply of all items for hook-up, obtaining details
of existing facilities for hook-up, carrying out all engineering works for hook-ups etc.
3.20.55 All works related to testing, dewatering, swabbing, drying, pre-commissioning and
overall commissioning.
3.20.56 Any other works not specifically listed herein but are required to be carried out to
complete entire work related to pipelines, stations/ terminals and the associated
facilities. All incidental and associated works and any other works not specifically
listed herein but are required to be carried out to complete entire work related to
pipelines, stations/terminals and the associated facilities and making the entire
pipeline system ready for operation.
3.20.57 All associated civil, structural, architectural, mechanical Equipment, electrical,
instrumentation, OFC laying, telecom, SCADA works, etc. shall be performed in
accordance with relevant documents enclosed elsewhere in the Tender Document.
3.20.58 Contractor shall carryout inertization of the piping sections that were evacuated in
before carrying out any cutting works. Contractor shall provide all equipments,
material as required for the inertization including supply of inert gas. Contractor
shall also carry out condensate removal & wax/ deposit removal if required, of the
piping section and shall ensure that the complete piping section is hydrocarbon
free. Contractor shall provide all equipments, material as required for carrying out
the works.
3.20.59 Fabrication, erection, installation, testing, painting & coating of the whole piping
system consisting of Scraper Launcher, Scraper Receiver, pipes, valves (manual
and actuated), flanges, fittings, etc; providing hydrostatic vents & drains; carrying
out all piping works as per P & IDs, Piping General Arrangement & Supports
Drawings, Support Indices, other drawings, documents & instructions of Engineer
In-Charge, carrying out welding, NDT including radiography; weld repairs/ retesting,
cleaning/ flushing, hydrotesting, pneumatic testing, dewatering, functional testing,
cutting of pipes and beveling, pre-commissioning, Overall commissioning including
supply of all materials and manpower that are required during pre-commissioning
and commissioning and all associated works.
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3.20.60 Installation of all types of valves (manual/ actuated), inline and online instruments
viz. pressure gauges, temperature instruments, Other Instruments, safety valves
etc. for all sizes, ratings and materials, pertaining to entire station piping.
3.20.61 Carrying out installation of inline Valves, as and when shutdown is given by
Company, by cutting and hook-up with existing pipeline/ piping subsequent to
evacuation & inertization of that section of pipeline/ piping, including all the required
piping and support works.
3.20.62 Preparation of isometrics and/ or fabrication drawings required for the purpose of
fabrication during execution of work & marking them up with the field changes (if
any).
3.20.63 Shop fabrication activities shall be carried out at an appropriate place suitably
located by the Contractor for the purpose preferably in the near vicinity of the
stations. Pre-fabricated spool pieces shall be transported to Station area for
erection and installation at work site pursuant to obtaining clearance of such spools
by Engineer In-charge.
3.20.64 As the works are to be carried out in existing operational stations/ terminals,
Contractor to deploy only anti-sparking tools sets and suitable equipments &
machinery.
3.20.65 Contractor to ensure that while making flanged hook-ups with existing facilities the
existing isolation valve shall be in closed position. Contractor may have to provide
additional temporary supports to the existing piping for hook-up & testing works.
3.20.66 Carrying out thorough internal cleaning of all pipes, fittings, flanges, valves etc, to
remove debris, shots, grit etc. to the satisfaction of Engineer In-Charge prior to
welding.
3.20.67 Carrying out welding including cutting, edge preparation (inclusive of grinding the
edges of pipe, fittings, flanges, etc. to match with the matching edges of different
thickness wherever required), fit-up, bending, pre-heating wherever required, NDT
including radiography and other non-destructive tests, as specified. NDT
requirements for process and other piping shall be in accordance with applicable
Piping Class requirements as stipulated in PMS (Piping Material Specification) &
WSC (Welding Specification Chart) relevant enclosed with the Tender document.
3.20.68 Carrying out inspection of Company supplied free-issue materials at the time of
receiving and taking-over and recording of defects, etc. noticed in the material, in
the presence of Company's representative.
3.20.69 Repair of leaks/ burst, occurring in Company/ Contractor supplied material shall be
carried out by the Contractor.
3.20.70 Carrying out repairs (including supply of all materials) on Company supplied
materials for defects not attributable to Company which will include repair of all
defects/ damages occurring during transportation and/ or handling after receiving
and taking over, without any cost and time implication to Company. Any repair work
on Company supplied materials shall only be carried out after specific approval
from the Company/ Engineer In-Charge.
3.20.71 Supply, fabrication and erection of pipe/ equipment supports (for all sizes/
thickness) including plates, shoes, clamps, pipes, cradles, turn buckles, T-posts,
brackets, other steel members, for all types of supports such as sliding supports,
guides, cross-guides, anchors etc, all necessary equipments, consumables, labour
etc. for completing all works including supply of bolts, nuts, washers, U-clamps,
wooden blocks etc. as required for supporting.
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3.20.72 Fabrication and erection of piping supports for modification of existing supports
and/ or additional supports in existing Piping as per drawings, documents and as
directed by Engineer In-Charge.
3.20.73 Providing brackets from existing structure/ other structures for pipe support;
modifications/ extension of platforms/ extension of walkways, providing additional
platforms/ ladders for improving/ providing accessibility.
3.20.74 All associated mechanical works including supply of all materials required, unless
covered separately elsewhere in the bid document.
3.20.75 Hook-up of piping with equipments and with the existing piping.
3.20.76 NDT including Radiography, fit-up, welding, etc. Radiography inside existing
operational areas shall be carried out by close proximity radiography technique &
with necessary applicable work permits from competent authority.
3.20.77 Painting of above ground piping corresponding entire station piping, structural steel
elements, for pipe supports, all equipment, all related miscellaneous items as
required and as directed by Engineer In-Charge. Paint shall be suitable for design
temperature indicated in Line schedule document. The painting shall be in
accordance with Specification No. 6-79-0020 & as per the requirements specifically
given in the tender documents.
Wherever touch up/ repair of primer is required, high built epoxy zinc phosphate
primer shall be used.
3.20.78 Buried piping & valves shall be provided with 100% solid high build epoxy
(minimum 800 micron thick) coating or 1.5 mm Polyurethane (PU) coating.
3.20.79 Contractor shall perform low pressure pneumatic leak test at 7 kg/cm2g for the
flanged joints & piping system corresponding to individual piping systems/
subsystems & station piping as per approved pre-commissioning procedure & shall
maintain a record in specified formats.
3.20.80 Repair of leaks/ burst, not attributable to Contractor, occurring in Company supplied
material shall be carried out by the Contractor and the Contractor shall be
compensated as per provisions of the Contract. However repair of such defects
attributable to Contractor shall be carried out by Contractor at no cost to Company.
Contractor shall submit a report for failure to Company.
3.20.81 If required, Idle time preservation of piping at Despatch Facilities, SV and
associated Facilities & Receipt Facilities by filling Nitrogen at a positive pressure of
2 bar(g) as per specification including supply of Nitrogen, as per the COMPANY
instructions.
3.20.82 Final clean up and restoration of site, facilities etc. as per the requirement of
Company/ Engineer In-Charge including filling (wherever required) and grading of
areas around stations for avoiding any local flooding of area. Contractor shall
carryout clearing, grading & filling of the area/ land, if any, required at site on
completion of works to get all areas to required levels.
3.20.83 Transportation and stacking of all surplus Company supplied free issue material to
Company’s designated store after completion of works or as directed by Engineer
In-Charge.
3.20.84 Provide, maintain and operate all temporary facilities required for the construction
related works and remove the same after completion of work.
3.20.85 Preparation of as-built drawings, documents, site inspection documents prepared
during execution stage and project records including furnishing of all Test
Page 23 of 1963
FACILITIES
Certificates/ Inspection Reports as per specifications and as per the instructions of

Engineer In-Charge.
3.20.86 Co-ordination as required with other Agencies & other Contractors. Coordination
and supervising the work of sub-contractors.
3.20.87 Providing schedules, progress reporting, organization chart at construction site,
quality assurance plan and developing quality control procedures, as per
requirements indicated elsewhere in the Tender Document.
3.20.88 All associated Civil, Structural, Electrical, Mechanical Equipment, Instrumentation,
Telecom, SCADA, Geo-technical works, etc as per details, documents, drawings
covered elsewhere in the Tender Document.
3.20.89 Any other works not specifically listed herein but required for completion of the
works in all respects. All incidental and associated works and any other works not
specifically listed herein but are required to be carried out to complete the entire
work related to the system, making the entire system ready for operation.
3.20.90 In case any activity, though not specifically indicated in Schedule of Rates (SORs)
description but the same is covered under Scope of Work/ Specification/ Drawings/
Documents etc, it is understood that the Contractor shall do such performance &
provisions so mentioned without any time & cost implication to Company.
3.20.91 It is Contractor’s sole responsibility to carry out all works in safe and efficient
manner and in strict compliance to the Contractual requirements.
3.20.92 No extra claims or variations related payments shall be allowed for items or
activities which are required to complete the pipeline system and make it fully
operational as per the scope of work defined in the Tender document.
4.0 SCOPE OF SUPPLY
4.1 Materials to be supplied by Company
Company shall supply the following materials required for permanent installation in
the system, to the Contractor at appropriate times during the execution stage as
free issue materials.
4.1.1 Company shall make available to the contractor the required quantities of 3LPE
externally coated and bare linepipes for pipeline installation as per the following
details as free issue material:
Pipe OD, Wall

S. Material
mm Thickness Coating Storage Yard Purpose
No. details
(inch) (mm)
For size 8.625 inch pipeline of approx. 17 km long
Designated
API 5L Gr. Storage Yard of
219.1 Buried
1 X-65 PSL2, 7.4 3LPE Linepipe/ Coating
(8.625”) Pipeline
HFW Vendor near to
Pipeline ROU
Page 24 of 1963
FACILITIES
Pipe OD, Wall

S. Material
No. details
(inch) (mm)
Storage Yard at LR Bends &

API 5L Gr.
219.1 Peravali, KG Above
2 X-56 PSL2, 11.1 Bare
(8.625”) Basin, Andhra Ground
HFW
Pradesh Pipeline
For size 14 inch pipeline section of approx. 200 m long
Buried
API 5L Gr. GAIL Storage Yard Pipeline &
355.6
1 X-70 PSL2, 9.5 3LPE at Vijaypur, LR Bends
(14”)
HFW Madhya Pradesh (after
decoating)
For size 14 inch Temporary By-pass piping of Hot-Tapping & Double Stoppling
Temporary
By-Pass for
API 5L Gr. GAIL Storage Yard Hot Tapping
355.6
1 X-70 PSL2, 9.5 3LPE at Vijaypur, & Double
(14”)
HFW Madhya Pradesh Stoppling at
14 inch
pipeline
Legend:
HFW : High Frequency Welded Lineipe
3LPE : 3 Layer Polyethylene External Coating of Pipe
LR Bends : Long Radius Bends
Note:
1 Contractor shall finalize the linepipe quantities with suitable escalations so that
at no point of time during execution of the pipeline construction activities there
shall be any shortage of Linepipes.
2 The contractor shall be paid for the actual quantity of linepipes installed.
Contractor to return the surplus linepipes to Company as per instructions of
Engineer In-Charge after completion of installation works.
3 At Designated Storage Yard (near to Pipeline ROU), The Linepipe/Coating
Vendor shall load the Coated linepipes onto the truck/ Trailers arranged by the
installation contractor.
4 Bevel Protectors of the linepipes shall be the property of the pipeline
installation Contractor. Contractor has to collect and dispose-off the bevel
protectors. Contractor shall quote accordingly.
5 At Storage Yard (Peravali, Andhra Pradesh & Vijaypur, Madhya Pradesh), The
pipeline installation contractor shall arrange all Cranes, Equipments,
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FACILITIES
Manpower, etc for Inspection, lifting & loading of linepipes on to the trailers
arranged by him for transportation of the free issue linepipes to Fabrication
mill, intermediate Storage, Fabrication Yard and Work Site(s).
4.1.2 Company shall make available to the contractor the required quantities of Coated/
bare Casing pipes for pipeline crossings as per the following details as free issue
material:
Pipe OD, Wall

S. Material
No. details
(inch) (mm)
Casing pipe for 8.625 inch pipeline crossing
API 5L Gr. Railway

1 16” 11.1 Bare GAIL Hazira
X-70 PSL2 Crossings
Highway &
API 5L Gr. Bare/
2 16” 6.4 Other
X-65 PSL2 3LPE
Crossings
M/s KPTL
API 5L Gr. Bare/ Railway
3 16” 7.5 Mandana Kota
X-65 PSL2 3LPE Crossings

4 16” 8.7
Highway &
API 5L Gr. Bare/
5 16” 6.4 Other
X-65 PSL2 3LPE
Crossings
M/s B&R Kanda
6 16” 7.5 Kota

7 16” 12.7
Note:
1 Contractor shall finalize the Casing pipe quantities with suitable escalations so
that at no point of time during execution of the pipeline construction activities
there shall be any shortage of Casing pipe.
2 Contractor to return the surplus as per Casing pipe to Company instructions of
Engineer In-Charge after completion of installation works.
3 At Storage Yard (GAIL Hazira/ M/s KPTL Mandana Kota/ M/s B&R Kanda
Kota), The pipeline installation contractor shall arrange all Cranes,
Equipments, Manpower, etc for Inspection, lifting & loading of Casing pipe on
to the trailers arranged by him for transportation of the free issue pipes to
Fabrication mill, intermediate Storage, Fabrication Yard and Work Site(s).
4.1.3 All Manual Valves & MOV tagged valves (Ball, Plug, Gate, Globe & Check) of Size
NPS 2 inch & Above. The designed place issue is SV-71/ RT- Sapar.
4.1.4 All Station Pipes of Size NPS 2 inch & Above. The designed place issue is SV-71/
RT-Sapar.
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FACILITIES
4.1.5 All Flanges (Flange, Blind Flange, Figure 8, etc.) of Size NPS 2 inch & Above. The
designed place issue is SV-71/ RT- Sapar.
4.1.6 All Fittings (Elbow, Tee, Reducers, O’lets, etc.) of Size NPS 2 inch & Above. The
designed place issue is SV-71/ RT- Sapar.
4.1.7 All Scraper Launcher, Scraper Receiver & Pig Signallers. The designed place issue
is SV-71/ RT- Sapar.
4.1.8 All Flow Tees. The designed place issue is SV-71/ RT- Sapar.
4.1.9 All Insulating Joints. The designed place issue is SV-71/ RT- Sapar.
4.1.10 Company shall arrange following items/ Equipments which shall be used for Hot
Tapping & Double Stoppling works. All other materials/ Equipments/ Consumables
required for carrying out Hot Tapping & Double Stoppling works using following
items/ Equipments shall be deployed/ Supplied by the installation contractor.
S.No. Machine Detail Place of Issue
1 1 no. of Hot Tapping Machine, IP- IPS-Abu Road
101, Range Is 0.5” to 2.5”,
2 1 no. of Hot Tapping Machine, IP- IPS-Mansarampura
406, Range is 3” to 16”
3 2 nos. of IPSCO-Jackscrews IPS-Abu Road
Hydraulic Actuator (Stopple
Machine), Range is 14” to 20”
4 1 no. of Hydraulic Power Unit IPS-Mansarampura
along with additional new TR-2
Engine, used for IP-406 & Stopple
Machines
5 2 nos. of IPSCO-Pivoting Style IPS-Abu Road
Plugging Head, 14”
6 1 no. of IPSCO-Hot Tapping CGS-Bhiwari
Adapter, 6”-600#
7 2 nos. of IPSCO-Hot Tapping IPS-Abu Road
Adapter, 14”-600#
8 2 nos. of IPSCO-STOPPLE-Line IPS-Abu Road
Stop Housing (Adapter), 14”-600#
9 4 nos. Full Bore Ball Valves, 600# 2 nos. at IPS-Mansarampura
(Both End Threaded), 2”
10 Hose Connector, 2.875”
11 Hose Connector, 1.125”
12 Hose Connector, 12G (Gauge
Pitch)
4.1.11 For items covered under 4.1.3 thru 4.1.10, The pipeline installation contractor shall
arrange all Cranes, Equipments, Manpower, etc for Inspection, lifting & loading of
Free Issue Materials on to the trailers arranged by him for transportation of the free
issue materials to Fabrication mill, intermediate Storage, Fabrication Yard and Work
Site(s).
4.1.12 Company shall arrange Fire Tender & Equipments during Hot Tapping/ Double
Stoppling Works and during commissioning Stage.
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FACILITIES
4.1.13 Company shall arrange Mobile Flare at SV Sapar for LPG flaring during Hot
Tapping/ Double Stoppling Works & Removal of isolated section of size 14 inch
pipeline and Commissioning.
4.2 Conditions for Company Supplied Materials
4.2.1 The Contractor shall be responsible for taking over of the materials and subsequent
handling, hauling, transportation to the actual work site(s)/ fabrication yard(s) and
storage & safe keeping of the materials. Contractor shall arrange all equipment/
cranes etc. for loading of these materials on their truck/ trailers for transportation.
4.2.2 The Contractor shall inspect all Company supplied free issue materials at the time
of taking over from the Company and defects noticed, if any, shall be brought to the
notice of Company/ Company representative and jointly recorded. Once the
material has been taken over by the Contractor, all the responsibility for safe
keeping of the materials shall rest with the Contractor.
4.2.3 Contractor shall be fully responsible for proper storage of all materials.
4.2.4 Every month the Contractor shall submit to the Company an account for the
material issued to the Contractor in the Performa prescribed by Engineer In-
Charge.
4.2.5 On completion of the works Contractor shall submit a “Material Appropriation
Statement” for all materials supplied by the Company as free issue materials.
4.2.6 All unused and scraps material shall be the property of the Company and shall be
returned by Contractor to Company at Company’s designated storage point(s)
including transportation of the same from Contractor’s stock yard(s)/ worksite(s)/
work shop(s) to the Company’s designated storage point(s). Contractor shall be
responsible for the proper measurements of the unused/ scrap materials to be
returned to the Company.
4.2.7 If any kind of damage/ defect in Company’s supplied materials shall occur during
handling, storage, loading, unloading, construction by the Contractor, Company
reserves the right to recover the amount from the Contractor.
4.3 Materials to be supplied by Contractor
All materials (other than Company supplied free issue materials as specified in
clause no. 4.1 of this document) required for successful execution of the project
shall be provided by the Contactor, including any additional materials required for
completion of the work. The materials supplied shall meet the requirements of the
Tender Document. The procurement and supply, in sequence and at appropriate
time and place, including inspection and expediting, of all materials and
consumables required for completion of the work as defined in the Tender
Document shall be entirely the Contractor’s responsibility. All materials supplied by
the Contractor shall be strictly in accordance with the requirements of relevant
material specifications, data sheets & other relevant documents enclosed with the
Contract document. All equipments, materials, components, etc. shall be new and
specifically purchased for this project from Company approved vendors, duly
inspected by third party inspection agency as per the list of approved Third Party
Inspection Agencies like CEIL, Lloyds, Bureau Veritas, etc (Only manufacturer
certificate shall not be adequate).
As a minimum, the materials to be supplied by the Contractor shall include, but not
limited to, the following:
4.3.1 All piping Manual valves (Ball, Plug, Gate, Globe & Check) of Size NPS 0.75 inch to
1.5 inch.
4.3.2 All Station Pipes of Size NPS 0.75 inch to 1.5 inch.
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FACILITIES
4.3.3 All Flanges (Flange, Blind Flange, Figure 8, etc.) of Size NPS 0.75 inch to 1.5 inch.
4.3.4 All Fittings (Elbow, Tee, Reducers, O’lets, Couplings, etc.) of Size NPS 0.75 inch to
1.5 inch.
4.3.5 All stud bolts, nuts, jack screws for all sizes.
4.3.6 All gaskets of all sizes.
4.3.7 All equipments & consumable such as welding electrodes, oxygen, acetylene, inert
gases, all types of welding electrodes, filler wires, solder wires, brazing rods, flux
etc. for welding/ cutting and soldering purposes.
4.3.8 All materials including consumables required for hook-up with existing piping
facilities/equipments.
4.3.9 All supporting materials such as plates, shoes, clamps, clips, pipes, cradles, turn
buckles, T-posts, brackets, other steel members, packing plates (machined
wherever required), pipe saddles/ shoes, bolts, nuts, washers, U-clamps, wooden
blocks, etc.
4.3.10 All pipes, fittings, flanges, blind flanges, gaskets, nuts, bolts, clamps, strainers,
equipments/ consumables, metallic blinds, temporary gaskets as required for
cleaning, filling, pressurizing, hydrostatic testing and dewatering, etc. All materials,
equipments and consumables required for hydrostatic testing like pumps, pressure
gauges, test water, etc.
4.3.11 All equipment and consumables required for all types of test and NDT (such as
radiography, including close proximity radiography technique, Ultrasonic testing,
magnetic particle examination, dye penetration testing, etc.) including radiographic
film, X-ray/ gamma ray machines, developing equipments and consumables,
Ultrasonic equipments), etc.
4.3.12 All materials for pneumatic leak testing of station piping including arranging all
required equipments, etc.
4.3.13 All types and painting & coating materials including primer and paints for above
ground piping as per the details/ specification furnished in the tender package and
100% solid high build epoxy (minimum 800 micron thick) coating or 1.5 mm
Polyurethane (PU) for coating buried piping, including solvents, Grit Shot blasting
materials & cleaning agents, compressed air etc. High built epoxy zinc phosphate
primer for touch up/ repair of primer.
4.3.14 All materials & consumables for pre-commissioning and Overall commissioning of
the system.
4.3.15 All materials i.e. fittings, flanges, valves, blind flange etc. required for isolation, if
required.
4.3.16 All materials, equipments, tools/ tackles and specialized manpower, etc for
Hydraulic Bolt Tensioning & Controlled Torque Tightening.
4.3.17 All materials for making hook-ups with existing piping including additional temporary
supports to the existing piping as required.
4.3.18 All materials shall be supplied with commissioning and start up spares wherever
required as per specifications & as per the requirements stated by the
manufacturers.
4.3.19 All materials required for cased crossing other than casing pipe shall include, but
not limited to, Painting material as indicated in the standards, as instructed by the
Engineer In-Charge & as per the requirements of Statutory Authority for Casing
Pipes, Insulators including Galvanized Fasteners, Zinc Ribbon as required, end
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FACILITIES
Seals and Casing Vent & Drain, etc. The Casing Pipe shall be free issued by
company.
The arrangement of insulator shall be made in segments duly held together with
Galvanized bolts and nuts, to be supplied with casing insulators. The number of
segments shall be two for pipe diameters up to DN 300 mm (12"). For larger
diameter, the number of segments may be more than two, but their number shall be
kept minimum. As an alternate design the casing insulator element shall be a
flexible section containing a toothed male butt strap at one end and an
appropriately toothed female slot on the other end. The same shall be wrapped
over the outer surface of the carrier pipe and locked positively. The insulator rings
should be fastened onto the carrier pipe with the appropriate tool to be provided by
the casing insulator manufacturer. No metallic parts or attachments should be
considered in the casing insulator element assembly. The design of casing insulator
should allow for onsite adjustments for any variances within the allowable O.D.
range of pipeline and should grip the pipe firmly without any chances of horizontal
movement or breakage of the insulator rings during installation. Refer fig. nos. 3.0 &
3.1 of specification no. 6-71-0035 enclosed with the Tender Document.
All materials required for carrying out two component epoxy coating for internal
surface of casing pipe, wherever required by statutory authorities. All materials
required for carrying out painting of the inside & outside surfaces of CS conduits,
wherever required by the statutory Authority.
4.3.20 Supply of API 5L Gr. B, 168.3 mm OD, 6.4 mm wall thickness CS conduit for OFC
for all cased/ bored crossings and wherever pipeline is installed by HDD method
including supply of end seals, etc. CS conduit of 168.3 mm dia. for OFC shall also
be used in open cut river crossing by strapping with concrete coated linepipe.
4.3.21 All safety tools, tackles, devices, appliances, apparatus, accessories, gas
detectors, fire screens, equipments, fire fighting equipments, shielding materials,
etc. including ladders and scaffolding complete as required.
4.3.22 All materials for installation of windsock and safety signboard.
4.3.23 All temporary material as required.
4.3.24 All materials for all types of pipeline markers including cement, sand,
reinforcements, structural steel, etc.
4.3.25 Supply of 0.5 mm thick & width (OD+300) warning tape (OD: Outside Diameter).
The material of warning tape shall be of high density polyethylene and non-
biodegradable type. It shall have non-toxic and anti-rodent properties. The color of
warning tape shall be bright yellow with letters printed in Black of indelible type with
high abrasion resistant. The danger symbol shall be in red color.
4.3.26 All materials required for continuous concrete coating/ gravel filled geo-textile bags
for providing negative buoyancy to the pipeline wherever required. Contractor shall
take prior approval of Company and furnish all details including design calculations
in case of use of purpose built geo-textile bags. For river crossings, only continuous
concrete coating shall be provided for negative buoyancy.
4.3.27 All materials and consumables required for external corrosion coating of field weld
joints for size 8 inch pipeline & size 14 inch section of pipeline. All materials and
consumables required for field joint coating, corrosion coating of LR bends of size
8.625 inch pipeline & size 14 inch section of pipeline. Contractor shall confirm that
proposed field joint coating material is suitable for type of terrain encountered along
pipeline route. Contractor shall take prior approval from Company for field joint
coating material to be used.
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FACILITIES
4.3.28 All materials and consumables required for concrete coating (where required) of
field weld joints.
4.3.29 All materials required for repair of damaged corrosion coating of linepipe.
4.3.30 All material, equipments & consumables for HDD works including Raychem “Dirax”
or equivalent field joint coating material required for HDD crossings for size 8.625
inch pipelines and size 14 inch section of pipeine.
4.3.31 All materials required for sand/ soft soil padding around pipeline and optical fibre
cable, HDPE warning mats, select backfill of approved quality, slope breakers, bank
stabilization of water crossings, etc.
4.3.32 All materials, Equipments, consumables, deployment skilled manpower, etc. for Hot
Tapping & Double Stoppling works using company supplied equipments including
but not limited to, Split Tee, lock-O-Ring, Blind Flange, Auxiliary components,
Stopple Sealing Elements compatible to hot tapping machine(s), materials for
ballooning {if required, along with all required valves, flanges, pipe, weldolet/ reducing
tee, gaskets, stud bolts, nuts} etc. all equipments/ consumables/ tools other than
company supplied Equipments/ Tools/ Consumables.
Bidder with his hot tapping/stopple plugging operator shall visit the location
of the machine and get conversant with the machine. Bidder shall verify and
enlist the machine parts and its accessories. Bidder shall inform the balance
component /parts required for hot tapping(s) & Double Stoppling to the
company and submit the same with his bid.
All balance components/parts of the machines, as required, to carry out the
works shall be arranged by the contractor and mobilize immediately after
award of work. Only machine(s) compatible parts /components shall be
provided by the contractor.
Bidder shall contact the COMPANY, before planning for visit for hot tapping
machine. The exact location of the machines for the pre-bid machine location
visit shall be informed by the above stated company person.
4.3.33 All materials & equipments including consumables, nitrogen etc. required for
inertization, hook-up with existing facilities and equipments, as applicable.
4.3.34 All pipes, fittings, flanges, blind flanges, gaskets, nuts, bolts, clamps, strainers,
equipment/ consumable, metallic blinds, temporary gaskets as required for filling,
pressurising, hydrostatic testing and dewatering, swabbing etc. including test
headers for pigging and hydrostatic testing.
4.3.35 Rock shield.
4.3.36 All materials, equipments, consumables etc. required for Magnetic Cleaning &
Electronic Geometric Pigging (EGP) of pipeline.
4.3.37 All materials and equipments for excavating trench, grading of ROU, pipeline & pipe
laying/ installation and other works.
4.3.38 Corrosion inhibitor, oxygen scavengers and bactericides for water used for
hydrostatic testing including water for testing.
4.3.39 Pumps, water and corrosion inhibitors for water for hydrostatic testing.
4.3.40 Mobilization of all construction equipments.
4.3.41 Mobilization of HDD rig of adequate capacity and associated facilities including
tools & tackles required for execution of HDD works.
4.3.42 Required quantities of nitrogen for idle time preservation and pre-commissioning of
Pipeline and associated facilities, if required.
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FACILITIES
4.3.43 Required quantities of nitrogen for pneumatic leak testing of station piping including
all associated material and including arranging all required equipments, etc.
4.3.44 Required quantities materials for making the existing pipeline & piping hydrocarbon
free including nitrogen for inertization of the existing pipelines & piping.
4.3.45 All pigs for cleaning, gauging, filling, dewatering, swabbing, drying, EGP, pre-
commissioning of the pipeline.
4.3.46 All materials for commissioning of the pipeline including required quantities of
nitrogen for commissioning of Pipeline and associated facilities, as applicable, as
per the requirements enclosed with the Tender Document.
4.3.47 Deployment of all Construction Equipments. Deployment of all Lifting Equipments /
Cranes of suitable lifting capacity & adequate boom length, as required.
4.3.48 All materials required for repair/ restoration of pavements, roads, walls, other
structures affected/ damaged by Contractor’s construction activities. Materials shall
be equivalent/ superior to those used for original construction of the facility.
4.3.49 All materials for cutting, dismantling and removal of existing pipelines.
4.3.50 All materials not specified above but required for successful completion of the entire
work whether temporary or permanent in nature.
4.4 Contractor shall be fully responsible for proper upkeep and storage of all materials.
4.5 As the works are to be carried out in existing operational stations/ terminals,
Contractor to deploy only anti-sparking tools sets and suitable equipments &
machinery.
4.6 The rates quoted for the execution of the work shall be inclusive of supply of all
materials mentioned at clause no. 4.3 of this document, unless specifically covered
otherwise under Schedule of Rates (SORs).
4.7 The quantities indicated in Schedule of Rates under Contractor’s scope of supply
are approximate. Contractor shall carryout Material Take-Off (MTO) of all materials
required based on Issued for Construction (IFC) drawings, P & IDs and firm up the
actual requirement of materials. All escalation/ extra materials procured by
Contractor for contingencies shall be Contractor’s property and no payments shall
be made for such materials. Payment shall be made for actual materials installed
by the Contractor as a part of permanent installation.
4.8 Storage of Materials:
4.8.1 All piping/ pipeline materials shall be stored in a covered storage shed to prevent
them from direct exposure to sun, rain, wind and dust and preserved against
deterioration and corrosion due to poor or improper storage while under the custody
of the Contractor.
4.8.2 On completion of the works Contractor shall submit a “Material Appropriation
Statement” for all materials supplied by the COMPANY as free issue materials.
4.8.3 The scrap allowances shall be permissible as per the provision of Bid document.
The percentage allowance shall be accounted on the basis of actual consumption
as incorporated in the work.
4.8.4 The Contractor shall check that valves, fittings, specials, etc. are not subjected to
corrosion from hydrostatic test water remaining in the packing.
4.8.5 All machined surfaces shall be properly greased and should be maintained and
protected from damages.
4.8.6 Openings of equipment, machinery, valves, etc. shall be kept blocked/ covered with
blinds to prevent entry of foreign matter.
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FACILITIES
4.8.7 As far as possible materials shall be transported to the site of erection only just prior
to the actual erection and shall not be left lying around indefinitely on ground but
kept on packing/ sleepers etc. to maintain the minimum distance from the ground as
specified and/ or as per directions of Engineer In-charge.
5.0 SCOPE OF WORK AND SCOPE OF SUPPLY FOR OTHER DISCIPLINES
Detailed scope of work and scope of supply covered in this document is pertaining
to pipeline laying and associated pipeline terminal/ station piping works only.
Detailed scope of work related to other disciplines, Civil, Structural, Electrical,
Mechanical Equipment, Instrumentation, Geo-technical works, Telecommunication,
SCADA, Cathodic Protection, etc. are covered in separate documents and the
same are enclosed elsewhere in the Tender Document. All these documents shall
be read in conjunction with this document and shall form an integral part of the
overall Scope of Work of the Contractor. Contractor shall be responsible for supply
of all items and carrying out all works related to Corrosion Monitoring system as per
relevant documents & drawings enclosed elsewhere in the bid document.
6.0 OTHER CONDITIONS OF BID
6.1 Site Visit
6.1.1 Bidders as a part of bid requirement shall make site visits along the pipeline route
prior to quoting to familiarize themselves with all the salient features of terrain,
construction difficulties, availability of ROU and infrastructure along the pipeline
route. Contractor shall be deemed to have considered all constraints and
eventualities on account of site conditions along pipeline routes while formulating
his bid. Contractor shall not be eligible for any compensation in terms of cost and/ or
time, on account of site conditions along pipeline routes varying to any extent from
whatever is described in the Tender Document and the drawings/ data furnished
along with the Tender Document.
6.1.2 The Contractor must ensure that during construction activities no damage and
disturbance occurs to the existing facilities. All construction activities shall be
performed by experienced & competent persons.
6.1.3 Equipment layouts and “Sample” Piping General Arrangement & Supports drawing
are included in the Tender document for the purpose of Contractor’s understanding
of the nature of work involved. These drawings are indicative only. Company shall
provide Issued for Construction (IFC) drawings for all terminals progressively during
construction.
6.2 Pipeline Right of use (ROU)
6.2.1 For pipeline construction purposes, ROU of varying width shall be made available
depending upon site conditions. In Forest areas and congested areas such as built-
up areas etc., reduced corridor width shall be available. All these eventualities shall
be taken into account. It shall be Contractor’s responsibility to make arrangement
for any additional land required for fabrication, construction, storage and all other
work areas. Contractor shall carry out construction work within the width as made
available to him. Where the pipeline route passes through forest/ plantation areas,
contractor shall clear only the minimum width required for laying the pipeline as per
approved procedure for pipeline construction. Felling of trees/ plants shall be
minimized. Damage to any obstruction, temporary/ permanent structure, etc. within
ROU shall be repaired and restored and shall be to Contractor’s account. The width
of the ROU made available to the contractor is in general 20 m. The ROU has other
operating pipelines also. Contractor shall arrange for additional temporary ROU, as
required, for the purpose of pipeline construction at his own cost & time.
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6.2.2 The Contractor must ensure that during installation of the pipeline minimum
damage/ disturbance occurs to the land. The land has to be restored to original
condition. All construction activities shall be in accordance with the local
Government regulations and shall be performed by the competent and qualified
persons for providing adequate protection to the general public, livestock, wild life,
forest, power lines, buildings etc. in the vicinity of the pipeline.
6.2.3 During pipeline construction, measures shall be adopted in order to minimize the
impact of pipeline construction activities on the environment. During ROU
clearance, the vegetation shall be cut off at ground level leaving the roots intact.
Only stumps and roots directly over the trench shall be removed for pipeline
installation.
6.2.4 Company has acquired the ROU free of any encroachments/ temporary/ permanent
structures. However, in case any such encroachments or structures are
encountered during execution, the same shall be got removed by the contractor or
local detouring of pipeline shall be carried out.
6.2.5 ROU shall be opened in stretches and may not be continuous. In such an event
contractor shall skip the section and jump over to next stretch where ROU is
available, without any cost & time implication to the Company.
6.3 Environmental Restrictions
The following measures shall be adopted during pipeline construction in order to
minimise the impact of pipeline construction activities on the environment:
6.3.1 While working in plantation areas, Contractor shall take due care to minimise the
damage of trees. The number of trees felled shall be restricted to minimum based
on working requirement for pipeline installation. Necessary afforestation for trees fell
in ROU shall be done in consultation with the statutory authority. In the paddy field
area, Contractor shall exercise maximum care not to damage the crop outside the
ROU. The compensation of damage of crop outside ROU, if any, shall be to
Contractor’s account. Damage to any obstruction, temporary/ permanent structure,
boundary walls etc. shall be repaired, restored and shall be to Contractor’s account.
6.3.2 Intake and discharge of water required/ used for line flushing and testing should not
cause unacceptable environmental disturbance. During dewatering process, proper
drainage arrangement shall be made to discharge the hydro-test water to avoid
flooding of the nearby area.
6.3.3 As far as possible, the contractor shall ensure that river and stream crossings are
done during dry season to avoid disturbance of breeding grounds and soil erosion.
The river bed, embankments and dykes shall be restored adequately at the sole
satisfaction of the concerned authority after installation of crossings.
6.4 Crossings
For all rails, road, canal, river & other water crossings, Contractor shall liaison with
relevant authorities and intimate them well in advance about the schedule and
methodology of crossing. It shall be obligatory on the part of the Contractor to
ensure that Authorized Representative of the authority under whose jurisdiction the
crossing falls should be made available at site by the Contractor at the time of
making crossing. After completion of works and complete restoration of ROU,
Contractor shall provide NOC from the relevant official pertaining to complete
restoration to their satisfaction and certification in respect of no other damage
caused to their property outside the earmarked ROU. The boring / jacking of carrier
pipe shall not be done.
6.4.1 Railway Crossings
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Pipeline at railway crossings shall be provided with casing pipe. The casing pipe
shall be three nominal pipe sizes larger than carrier pipe. In case as per statutory
authority requirements, higher size of casing pipe is required, the same shall be
complied with by the Contractor. Casing Pipe shall be installed by boring/ jacking.
Casing pipe shall be internally coated with two component epoxy coating wherever
required by statutory authorities. CS conduit for OFC shall be provided with suitable
anti-corrosive paint on inside & outside surfaces wherever required by the statutory
authority. If required by Railway authorities, carrier pipe shall be protected with zinc
ribbon anodes, the same shall be carried out by Cathodic Protection Contractor
through separate Contract, all coordination for the same shall be carried out by the
contractor under this Contract. ROU limit shall be defined by Railway authorities.
Higher thickness of Linepipes (Linepipe of location class “class-4”) shall be
provided for the crossing alongwith Casing pipe. Casing pipe length shall be
extending minimum 0.6 m beyond either side of the ROW. Additionally, the casing
pipe shall extend to 5m plus depth of pipe below the natural ground level beyond
the toe of slope of embankment subject to minimum of 14 m from the centre of
outside track. Casing pipe shall be installed extending equally in either side of the
Railway crossing. All railway crossings shall be cased crossings installed by boring
method. The railway crossing shall comply with the requirements of API RP 1102
and Indian Railways regulations and standards. The crossing angle shall be as
close to 90° as possible. Cover of casing pipe for railway crossings shall be
minimum 1.7 m. The casing pipe shall be provided with minimum 50 mm diameter
vent pipe. The Contractor shall also take due care to identify and take due
precautions so as not to disturb or damage the utilities like cables, water lines and
other structures.
Casing vent pipe shall be at least 1.2 m away vertically from aerial electrical wires
and shall be suitably insulated from underground conduits carrying electrical wires
on railway land. Casing pipe should be so placed and oriented so as to prevent any
leakage inside railway boundary except through the vent pipes. The casing pipes
shall be installed with even bearing throughout the length.
6.4.2 Road Crossings
a) Open cut/ boring/ trenchless technology/ HDD method shall be adopted for
crossings. The method of crossing shall be firmed up by Contractor based on
site conditions, in consultation with concerned authorities and Engineer In-
charge. The final decision of the crossing method shall be with Company/
Engineer In-charge. All requirements of statutory authorities shall be complied
with. The Contractor shall also take due care to identify and take due
precautions so as not to disturb or damage the utilities like cables, water lines
and other structures.
b) After laying the pipeline in a road crossing by open cut method, the Contractor
shall completely restore the road to its original condition.
c) While laying the pipeline in road crossings by open cut method the Contractor
should ensure that the traffic is not stopped during the execution of work. This
may be done by cutting half of the road at a time so as to enable the traffic to
pass on the remaining half of the road. Alternatively, the Contractor can
provide diversion roads to maintain the flow of traffic.
d) The Contractor shall provide proper caution boards during daytime and
danger lights during night time when the cutting operation of the road is going
on.
e) For cased crossings, the pipeline should be taken through the casing pipe, the
top of which shall be at least 1.2 metres below the road top as specified or as
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per the requirements of the authorities, whichever is deeper. All National

Highways shall be cased crossing installed by boring method.
f) For NH crossings, casing pipe length shall be extending minimum 0.6 m
beyond either side of the ROW. Casing pipe shall be installed extending
equally in either side of the National Highway crossing.
g) For SH crossings, casing pipe length shall be extending minimum 0.6 m
beyond either side of the ROW. Casing pipe shall be installed extending
equally in either side of the State Highway crossing.
h) For National Highways/ state highways, crossing shall not be too near the
existing structure on the NH/ SH maintaining a minimum distance of 15
metres or as specified by Highway Authority.
i) The National Highway crust shall be built to the same strength as the existing
crust on either side of the trench or to thickness and specification stipulated
by Highway Authority. Care shall be taken to avoid the formation of a dip at
the trench.
6.4.3 River, Canal, Drain, Other Water Crossings
a) Open cut/ boring/ trenchless technology/ HDD method shall be adopted for
crossings. The method of crossing shall be firmed up by Contractor based on
site conditions, in consultation with concerned authorities and Engineer In-
charge. The final decision of the crossing method shall be with Company/
Engineer In-charge. All requirements of statutory authorities shall be complied
with. The Contractor shall also take due care to identify and take due
precautions so as not to disturb or damage the utilities like cables, water lines
and other structures.
b) As a minimum following requirements shall be complied with for river
crossings with open cut method:
i. The water crossings shall be installed in accordance with the
requirement of the specification no. 6-71-0052.
ii. Geo-technical investigation and hydrological survey of various river
crossings shall be carried out by the Contractor.
iii. The limit of crossing shall be considered as 30 meter on either side of
river banks (i.e. Bank width + 60 meters). Continuous Concrete
Coating (CCW) pipeline shall be provided for entire limit of crossing.
iv. The CCW pipeline cover shall be maintained throughout the bed width.
v. Pipeline shall preferably be straight within the bed width.
vi. Elastic/ cold field bend shall be provided for tie-in with the pipeline.
vii. Only continuous concrete coating shall be provided as anti buoyancy
measure for all river crossings. The concrete coating shall be for the
entire limit of crossing.
viii. CS conduit of 168.3 mm dia. API 5L Gr. B, 6.4 mm thickness for OFC
shall be strapped with concrete coated pipe during installation.
ix. Contractor shall prepare the crossing drawing and submit for
Company’s review and shall be approved by Engineer In-charge.
x. The scour level shall be maintained for the full width of river &
thereafter scour should follow a path parallel to the natural profile of
the bank slope in case the bank slope is less than 5H : 1V. In case the
bank slope is steeper than 5H : 1V follow slope not more than 5H : 1V.
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The above stated requirements are minimum requirements for river

crossings. All requirements of 6-71-0052 shall be complied with.
c) No damage should be caused to any irrigation sources, while laying the
pipeline through canal crossings.
d) The flood banks of the River/ Canal should be brought to the original
condition, if they are damaged by the installation of the pipeline. Stabilisation
of banks shall be carried out as per requirements of concerned authorities.
e) HDD method shall be adopted for river/ water/ canal/ social forestry crossings
as decided at site by Engineer In-charge during execution of work or
concerned authority.
6.4.4 Requirements for Pipeline crossings by HDD
As a minimum following requirements shall be complied with for the HDD crossings:
a) The crossings shall be installed in accordance with the requirement of the
specification 6-71-0054.
b) Contractor shall necessarily perform all topographic surveys, geo-technical
investigation for design and engineering. Contractor shall submit survey data,
scour level calculation, installation design calculations and crossing drawings
for Company’s approval. Work shall start only after Company’s approval.
c) The top of pipeline for HDD crossings shall be taken at least 8 m below the
bed of river or 2.5 m below scour level whichever is deeper.
d) The top of pipeline for HDD crossings shall be taken at least 5 m below the
bed of drain, nala, stream & other water bodies or 2.5 m below scour level
whichever is deeper.
e) The top of pipeline for HDD crossings shall be taken at least 5 m below bed
level of lined/ unlined canals.
f) The top of pipeline for HDD crossings shall be taken at least 5 m below roads,
highways, water logged areas, etc.
g) The cover indicated above at point nos. “c), d), e) & f)” are minimum and the
same shall be increased wherever it is requirement of design or requirement
of authority having jurisdiction. Due consideration shall be given on following
factors, while deciding cover:
 Possibility of bentonite leakage
 Design & calculations
 HDD profile
h) The detailed construction methodology/ plan and time etc shall be finalized by
Contractor in consultation with concerned authorities having jurisdiction over
the river/ canal/ drain/ nala etc. Supply and installation of 168.3 mm OD, 6.4
mm thick CS conduit in a separate HDD shall be installed for OFC along the
pipeline in the entire HDD crossing by the Contractor.
i) Contractor shall take prior approval from Company and submit all design
calculations, procedures & drawings for Company’s approval.
6.5 Installation of Conduits for Optical Fibre Cable at Crossings
6.5.1 Optical Fibre Cable shall be installed as per Scope of Work (Telecom & SCADA)
enclosed elsewhere in the Tender Document.
6.5.2 Installation of separate CS conduit pipe for OFC (inside HDPE duct) at all
crossings where the carrier pipe is installed by HDD method and where casing
pipe is installed by boring/ HDD. The centre-to-centre distance between pipeline
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and CS conduit shall be 4 m based on as installed dimension. In no case OFC

conduit shall be installed in casing of carrier pipe.
6.5.3 At river crossings by open cut, CS conduit pipe containing HDPE duct shall be
strapped to the concrete coated carrier pipe at 5m interval using high strength PE
straps.
6.6 Hydrostatic Testing
6.6.1 Hydrostatic testing of pipelines shall exclude valves at terminals, SVs and facilities
that are to be installed as a part of the Despatch & Receipt Terminals. Temporary
test headers shall be provided and the pipelines shall be hydrostatically tested
between the temporary test headers only. The pipeline shall be hydrostatically
tested to the minimum test pressure of 1.25 times the Design Pressure (i.e. 1.25 x
90 = 112.5 kg/cm2).
6.6.2 The highest point of the test section shall be subjected to the minimum test
pressure as specified above.
6.6.3 However the maximum hydrostatic test pressure at any location in the pipeline
during testing shall not exceed the pressure required to produce hoop stress equal
to 95% of SMYS or mill test pressure whichever is lower for pipe material based on
the minimum wall thickness in the test section. The test duration shall be 24 hours
after stabilization. Hydrostatic test shall be done with corrosion inhibitor dosed
water only.
6.6.4 Subsequent to separate hydrostatic testing of pipeline and associated facilities, tie-
in/ hook up shall be carried out by the Contractor. Pipes/ prefabricated assembly
used for such tie-in shall be pre-tested to a test pressure specified for the pipeline.
All materials required for the fabrication of the test headers shall be provided by
the Contractor at no extra cost to Company. After successful completion of
hydrostatic testing, the Contractor shall de-water the pipeline as per the directions
of Engineer In-charge.
6.6.5 All test headers shall be fabricated from highest wall thickness pipes of respective
sizes of the project.
6.6.6 Piping facilities between the insulating joint and hook up point/ battery limit,
sectionalizing valve stations and all above ground facilities installed by Contractor
shall be hydrostatically tested to a test pressure equivalent to 1.25 times design
pressure as indicated in line schedule document, in accordance with “Standard
specification for Inspection, Flushing and Testing of Piping System” enclosed with
the Tender Document. All valves in the piping network being hydro tested shall be
kept in the crack open position. Holding time shall be six hours.
All piping upto the hook-up points shall be hydrostatically tested to a minimum test
pressure equivalent to 1.25 times design pressure. The design pressure is
indicated in the Line Schedule document. The hydrostatic testing shall be in
accordance with “Standard specification for Inspection, Flushing and Testing of
Piping System” (Specification No. 6-44-0013) enclosed with the tender document.
All valves in the piping network being hydrostatically tested shall be kept in the
crack-open position. Holding time shall be six hours. All temporary flanges, blind
flanges, studs, bolts, nuts, gaskets etc. required for making the test section ready
for carrying out hydrostatic testing piping loops shall be supplied by Contractor
without any cost & time implication to Company.
Water required for hydrotesting and construction purposes is in the scope of the
Contractor with no additional cost to Company. Only fresh water with 0.1 % of
Glutaraldehyde (Aqucar IG 50 Water Treatment Microbiocide of DOW) or
equivalent shall be used for hydrotesting.
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6.7 Dewatering and Swabbing

6.7.1 Dewatering of pipeline after hydrostatic testing shall be taken up by Contractor, only
when Contractor is ready for swabbing operations. The pipeline/ section of pipeline
after hydrostatic testing shall be left filled with inhibited water. In case, dewatering of
any test section is proposed by Contractor for any reason depending upon site
conditions (e.g. using test water for adjoining section due to non availability of
water), the Contractor shall swab such sections as per applicable requirements of
Contract and fill the section with dry air (<0 degrees DPT) at a pressure of 2 bar
(g).Transfer of test water from one test section to another section may be
considered, however dosing additional quantity of corrosion inhibitor, as required,
shall be done.
6.7.2 Disposal of water (hydro-testing) shall be done by Contractor after obtaining
necessary permission from concerned authority/ land Company so that no liability
on this account comes on Company. Disposal of inhibitor dozed water shall be
carried out after neutralization of water by approved procedure. Neutralization
procedure shall be prepared by the contractor and reviewed by Company.
6.8 Corrosion Inhibitor
6.8.1 The products to be used for corrosion inhibition of the water used for hydrostatic
testing and their dosage shall be as specified in Hydrostatic test specification.
6.8.2 Contractor (not the inhibitor manufacturer) shall get the inhibitor tested for corrosion
inhibition and microbiological control efficiency from competent Govt. / PSU
Laboratory. The test report shall be submitted to Company for approval prior to
undertaking hydrostatic testing works.
6.8.3 The dosage as recommended by Company shall only be adopted.
6.8.4 Necessary records for dosing of inhibitor should be maintained by the laying
Contractor and such records should be handed over to Company.
6.9 Preservation
6.9.1 After hydrostatic testing, the line shall be dewatered followed by swabbing, drying,
all online permanent instruments, SVs, etc. shall be installed and subsequently the
pipeline shall be filled with Nitrogen.
6.9.2 The positive pressure shall be maintained at 2 bar (g) in the pipeline during
preservation. The necessary arrangements like valves, fittings, manpower, etc.
shall be kept for maintenance of pressure in the pipeline during idle time.
6.10 Leak Detection
6.10.1 Contractor shall submit a detailed procedure for leak detection during hydro test.
Such method of detection shall consume minimum possible time to complete the
hydro test activity within contractual completion schedule. This procedure needs
prior approval of the Engineer In-charge.
6.10.2 All works for locating and repair of major leak/ burst (occurred during hydrostatic
testing) including necessary repairing/ replacing/ cutting and removing out
defective pipe length as defined in the specification.
6.10.3 All works for locating and repair of minor leak (occurred during hydrostatic testing)
which require sectionalizing of pipeline.
6.10.4 Contractor shall carry out repairing/ replacing of defective pipe length including
cutting and removing of defective pipes, pre-testing of replacement pipe for 24
hours and welding into the pipeline, NDT of the welds, coating of the weld joints,
clean up, retesting of pipeline including providing all equipments, manpower &
consumables.
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6.11 Magnetic Cleaning & EGP

The Contractor shall carry out magnetic cleaning and EGP of the size 8.625 inch
pipeline. The Contractor shall engage a specialised agency who has previously
carried out such operations (magnetic cleaning, EGP) and shall develop
procedures, supervise and monitor the entire operations, coordinate with other
Contractor(s). Rectification of defects observed during EGP run, shall be carried out
by Contractor including digging, cutting, replacement, repair, welding, NDT etc. All
works shall be carried out as per relevant specifications enclosed with the Tender
Document.
6.12 Pre-Commissioning & Overall Commissioning of Pipeline & Associated Facilities
6.12.1 Contractor shall be responsible for pre-commissioning of the pipeline system being
installed by him. The above shall include P & ID checks (with respect to
requirement of design/ operation/ safety and interlocks of latest revision of P&ID's),
flushing, tightness test, de-watering, as required and supply of consumables
required during pre-commissioning. Contractor shall supply manpower, materials,
equipment including nitrogen along with necessary piping and instrumentation
connections for monitoring flow rate, pressure, temperature etc temporary venting
along with necessary piping, valves and instrumentation as well as consumables.
All works shall be carried out as per relevant specifications enclosed with the
Tender Document.
6.12.2 Contractor shall carrying out Overall Commissioning of the complete pipeline
system covered under the Tender Document and also of the pipelines installed by
the HDD contractor(s) through separate contract.
6.12.3 Contractor shall mobilize all equipments, consumables, nitrogen and manpower for
carrying out pigging, drying, inertization and commissioning activities.
6.12.4 Contractor shall engage a specialized agency (if Contractor does not have specific
manpower), who have previously carried out such operations. Contractor shall
propose the name of the commissioning agency for approval from Company.
Contractor shall develop procedures, supervise and monitor the entire operations,
coordinate with other Contractor(s) as required till the time commissioning
operations are completed. Contractor shall mobilise all equipment, materials,
consumables including pigs, nitrogen and manpower etc for commissioning
activities. All necessary piping connection as required shall be carried out.
6.12.5 All works for Overall Commissioning shall be carried out as per relevant
specifications enclosed with the Tender Document.
6.13 Priorities
Company may, at its sole option, assign priority of construction to any part or
segment of the work area. Contractor shall comply with such priority of execution
without any cost and time implication to the Company.
6.14 Tie-in with pipeline
After the pipeline works have been mechanically completed and ready for tie-in,
Contractor shall carry out tie-in of terminal piping with the pipeline at despatch/
receipt terminals, SV, IP, TOP stations. Tie-in work shall be carried out as per the
instruction of Engineer In-charge.
6.15 Non-Destructive Testing (NDT)
NDT requirements for process and other piping shall be in accordance with Piping
Material Specification. Repeat Radiography due to defective radiograph on repaired
joints due to Contractor’s fault and/ or additional radiography necessitated due to
poor performance of Contractor’s welders shall be done at Contractor’s cost.
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Radiography of the weld joints shall be carried out by Safe-rad or equivalent close
proximity radiography technique only.
6.16 Isometrics/ Fabrication Drawings
The Contractor shall prepare fabrication drawings and isometrics and get them
approved from Engineer In-Charge at site, before execution.
6.17 Contractor to ensure adequate resource mobilization during the period of execution
& strictly adhere to the Scheduled completion period. Since the execution of works
shall be carried out in the area under operational control of asset operator, it shall
be mandatory for the Contractor to ascertain full time supervision through
competent HSE Officers during entire period of work execution.
6.18 Contractor to carry out all works required for successful completion of the entire
system. It is the responsibility of the Contractor to execute the project in full
compliance to the “Contract”.
6.19 The Contractor is cautioned to exercise extreme care and take necessary
precautions to prevent damage to the existing pipeline(s), facilities, electrical and
other cables during execution of the entire works. Restoration/ reconstruction of all
structures/ facilities affected during pipeline construction shall be carried out by
Contractor.
6.20 Wherever Contractor comes across HDPE or other material water lines/ open
channels/ drains in the fields used for cultivation/ irrigation, suitable arrangements
similar to the existing type shall be made by the Contractor for ensuring water
supplies across the fields and maintain the same till construction is completed in
that stretch and shall restore the same after construction activities. Any claims
arising out of non compliance to the above requirements, as granted by competent
authorities shall be to Contractor’s account.
6.21 Contractor shall carry out all testing and inspection of materials; equipment etc. in
independent NABL approved testing institutions, laboratories, if so desired by
Company.
6.22 Disposal and treatment of treated hydro-testing water, excavated materials, and
surplus materials etc. as per local authority’s requirements.
6.23 Any other work not specifically listed but required for successful completion of
entire pipeline system. It is the responsibility of the Contractor to execute the
project in full compliance to the “Contract”.
6.24 Special Requirements for Hydraulic Bolt Tensioning and Bolt Torques
Hydraulic bolt tensioning shall be carried out as per standard specification for
application of torque and hydraulic bolt tension for flange joints, document no. 6-76-
0002 & its Addendum as applicable. For all other bolts not falling in the range of
Hydraulic Bolt Tensioning & fulfilling criteria for controlled bolt torque, Torque
wrenches shall be used with specified torque values. For all piping classes the
following are to be ensured by the contractor.
6.24.1 Flange connections with bolting of nominal diameter 25 mm (1 inch) and over shall
have sufficient clearance and access to allow the use of hydraulic tensioning
equipment. The equipment supplier, tensioning procedure and supporting
calculations shall be subject to approval by Company.
6.24.2 Stud bolts shall be longer by one diameter to facilitate the bolt tensioning. Excess
thread shall be protected by a threaded cap. On bolts at ambient temperature duty
the cap should have a grease nipple.
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6.24.3 Contractor shall include quality checks during terminal work construction and
proper records/ documents should be maintained. Special attention is needed for
high-pressure system.
6.24.4 Mechanical integrity of flange joints shall be ensured by the Contractor. A standard
check list for this activity along with post box-up checks should be developed and
practiced. The following guidelines shall be used besides other relevant codes like
ASME etc. This checklist should include following points.
a) Ensuring right type of Gasket, fasteners etc., conforming to the
specifications as per design and drawing.
b) Alignment of flanges and inspection of threads in case of tapped holes in
flanges.
c) Inspection of gasket surface.
d) Ensuring that gasket is properly seated.
e) Checking that fasteners are tightened upto required depth in tapped hole, if
applicable.
f) Ensuring that fasteners are tightened as per tightening procedure and using
specific torque value with well-maintained tools and torque wrenches.
g) All critical joints should be boxed up under the supervision of the Engineer
In-Charge.
h) Each joint shall be boxed up and tightened only by skilled Technician duly
approved by competent authority.
i) Checking the individual joint for any leak during system pressure testing by
using special tapes, soap solution or as per relevant code.
j) Inter-face joints should be system pressure tested as per relevant code to
ensure their integrity.
k) All the points in the checklist, including the names of the persons involved in
the execution/ inspection of the boxing up of critical and high-pressure joints
should be recorded. Company reserves the right to review these records at
site.
l) Box-up of interface flange joints (FJNHT) which are not subjected to hydro
test, need extra attention. Separate records shall be maintained for such
joints.
6.24.5 After Mechanical completion, the piping system shall be handed over to the
commissioning team. Pre-commissioning & Commissioning activities shall be
carried out by the Contractor. At this stage, interface joints and inline instrument
joints (like Control valves, Safety valves, Ultrasonic flow meters etc.) are not
hydrotested. Therefore, contractor shall identify & mark these joints on Isometric
Drawings/ Piping General Arrangement Drawings and on the vendor drawings for
review by Company and hand over the same to the Company for their information
during handing over of the piping system. Contractor shall take care of these joints
during leak test prior to start-up & shall undergo preventive leak checks at all
phases of start up.
6.24.6 Contractor shall take special care for flanged joints within packaged units (like
pumps etc.), equipment flanges like instrument nozzles, etc. which are not covered
in testing loops. All such flange joints shall be listed separately. Contractor shall
also submit a procedure for tightening of such flanged joints using Hydraulic
tensioners/ Torque wrenches for Company’s review. The requirements are already
specified above.
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6.24.7 Following documents shall be furnished in the procedure for each such flanged
joint, along with support design calculations considering the more stringent of
design/ hydrotest conditions.
a) For each joint, the Torque value, where torque wrenches are to be used.
b) Bolt tensioning when Tensioners are used.
6.25 Contractor’s Responsibilities
6.25.1 Appraisal and taking cognizance of site-conditions, Central Government, Gujarat
State Government rules & regulations/ bye-laws, applicable Indian Standards and
Codes, applicable International standards & codes, authorities having jurisdiction
over the work site(s), environmental and pollution rules and regulations including
conditions/ stipulations laid down by the concerned authorities etc. The Contractor
is deemed to have recognized any restrictive features and constraints of the site(s),
and /or specific requirements of the work and made due allowance for it in the work
to be performed by him. Furnishing and mobilizing at site(s) of all construction
equipments, manpower, tools and tackles, construction spreads, fully equipped and
fully manned with all required support facilities etc.
6.25.2 It shall be Contractor’s responsibility to obtain all NOCs, regulations, stipulations,
bye-laws of concerned authorities/ state PCBs and carry out the work in
accordance with the same.
6.25.3 Contractor shall restore all facilities and other conveniences like temporary
approach roads/ temporary works, structures, road, etc to original condition to the
entire satisfaction of Company and/ or authorities having jurisdiction over the same.
Contractor shall arrange necessary clearance from the concerned authorities/ land
owners, as applicable.
6.25.4 Contractor shall be responsible for the successful & timely execution of the
complete job defined in the Tender Document.
6.25.5 It is the responsibility of the Contractor to execute the project in full compliance to
the “Contract”.
7.0 AS-BUILT DOCUMENT/ DRAWINGS
7.1 Contractor shall develop and submit as-built Alignment Sheets indicating
planimetry, profile, topographic features, linepipe details, crossing details, soil
details, Location Class, location of existing pipelines, re-routes/ detours and all
changes during execution. The sample alignment sheet has been included in the
Tender Document. Contractor shall develop the as-built alignment sheets based on
the sample alignment sheet drawing. Contractor shall provide as-built drawings in
electronic form (native and pdf format) as well as in hard copies.
7.2 Contractor shall develop and submit as-built crossing drawings indicating
planimetry, crossing profile, topographic features, linepipe details, soil details,
location of existing pipelines. The sample crossing drawing has been included in
the Tender Document. Contractor shall develop the as-built crossing drawing based
on the sample crossing drawing. Contractor shall provide as-built drawings in
electronic form (native and pdf format) as well as in hard copies.
7.3 Contractor shall develop and submit as-built Piping General Arrangement Drawings
& Support Drawings and other documents/ drawings.
7.4 Contractor shall prepare all documents as per the requirements indicated in
Specification for Documentation for Pipeline Construction No. 6-71-0059 enclosed
with the Tender Document. In addition to the hard copy, three copies of final
documents shall also be submitted in electronic media i.e. CD ROM/ DVD ROM
Page 43 of 1963
FACILITIES
diskettes (in native and pdf formats) and all as built documents shall be uploaded in
PIMS database.
7.5 Software used for the presentation of these documents shall be as follows:
Type of document Software (Authorized and licensed software)
Reports MS Office 2007/ (Word / Excel)
Drawings AutoCAD-2008
7.6 The following documents and drawings shall be submitted as as-built, as a

minimum:
a) All Inspection, Testing and NDT records. Radiographs/ UT of all weld joints
packed in separate card board boxes in one set.
b) Pipe and calculation books/ records.
c) All inspection & testing documents.
d) All purchase specification & procurement documents.
e) All piping GA drawings and supports at terminals.
7.7 For the purpose of preparation of as-built Piping General Arrangement & supports
Drawings, Contractor shall update the latest "Issued for Construction" drawings
provided by the Company.
8.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING
No technical documents are required to be submitted at the time of bidding
except where specifically has been asked for such as List of balance
component /parts required for hot tapping(s) & Double Stoppling, etc. Bidder
shall comply with all the requirements of Tender Document without any
deviations. Company reserves the right to reject any bid with deviations
without making any reference to bidder. Bidder shall furnish signed &
stamped copy of technical compliance format & no deviation certificate.
9.0 GENERAL
9.1 In case of conflict between the requirements given in this document and the
requirements of other specifications and documents enclosed with the Tender
document, the requirements specified in the this document shall govern.
9.2 Should there be conflict, discrepancy, inconsistency or dispute between the various
documents, they shall be specifically brought in to the notice of Company and shall
be referred in order of priority as given below:
 Scope of Work & Schedule of Rates
 P & IDs / Line Schedule
 Piping Material Specification/ Data Sheets
 Job specifications
 Job Standards
 Drawings
 Standards
 Standard Specifications
 Other documents not covered above
Page 44 of 1963
FACILITIES
9.3 If any dispute arises with regards to the interpretation of any of the clauses/ detail of
the Tender Document, the decision of the Company shall be final.
9.4 All drawings, documents etc. pertaining to Pipeline Engineering such as Standard
Specifications, Job Specifications, Standards, Job Standards, Data Sheets, etc are
included in the List of Attachment (Document No. A922-000-83-41-LL-9510).
Page 45 of 1963
DOCUMENT No.
SCOPE OF WORK FOR COMPOSITE
WORKS A922-020-16-51-SOW- 01
(INSTRUMENTATION & TELECOM) Rev. 0
Page 1 of 9
SCOPE OF WORK
FOR
COMPOSITE WORKS
(INSTRUMENTATION & TELECOM)
PROJECT : JAMNAGAR LONI LPG PIPELINE

PROJECT
OWNER : M/s GAIL
0 03/11/16 Issued with Tender BO SK SM

Rev Prepared Checked Approved
Date Purpose
No by by by
Page 46 of 1963
DOCUMENT No.
SCOPE OF WORK FOR PIPELINE
LAYING AND TERMINAL WORKS A922-020-16-51-SOW- 01
Page 2 of 9
1. INTRODUCTION
M/s GAIL proposes to lay a new cross-country pipeline for augmentation of its
existing capacity of its Jamnagar-Loni LPG pipeline. The new pipeline is between
EOL DT to SV-1 RT with a distance of approx. 17 km.
2.0 GENERAL
2.1 The description and requirements contained in this specification are concise by
necessity and cannot include all details. However, it is the responsibility of the
contractor to execute the job on a turnkey basis in accordance with the
specifications and internationally recognized good engineering practices for
smooth and successful operation of various stations and facilities of pipeline.
2.2 Any activity specifically not listed in this document, does not absolve the contractor
of their responsibility to include such activities in their scope of work and supply,
which otherwise is necessary, to complete instrumentation work for the project. All
such activities shall be carried out by the contractor without any implication.
2.3 The contractor’s scope of work shall include:
Complete instrumentation and control installation works and supply of materials

as per the details listed in “Schedule of rates” (Instrumentation), scope of work
detailed in Standard Specification for Erection Tender (6-52-0060) and in this
document. Contractor’s scope of supply shall also include supply of instrument
items specifically listed in the “Schedule of rates” with data sheets, specifications
attached elsewhere in the tender document.
2.3.1.1 Scope of work shall be read in conjunction with the Schedule of Rates, drawings,
specifications and data sheets and other documents forming a part of the contract
document. Wherever there is a contradiction between the above, Schedule of
Rates and this document shall take precedence.
2.3.1.2 Contractor shall quote unit rates for all items covered in the “Schedule of Rates”
(SOR).
2.3.1.3 Every month, the contractor shall submit an account for all the materials issued to
him by the Owner (as applicable) in the Standard Performa prescribed for this
purposes by the Engineer-in-Charge.
2.3.1.4 On completion of the work, the contractor shall submit `Material Appropriation'
statements for all materials issued by the Owner in the Performa prescribed by the
Engineer-in-Charge.
2.3.1.5 Contractor shall be responsible for supply of items, installation, field testing,
calibration and providing assistance for pre-commissioning and commissioning of
all instrumentation items.
2.3.1.6 Contractor shall be responsible for all kind of works inside the control room i.e.
panel (TIC) installation, cable laying, tray/conduit erection/installation and for
proper cable terminations and loop checking, pre commissioning and
commissioning.
Page 47 of 1963
DOCUMENT No.
Page 3 of 9
2.3.1.7 Drawings and Installation Standards enclosed with the tender are only for
reference and indicative of general nature for scope of work. Actual installation
shall be carried out based on final installation standards, Bill of Material and
vendor’s drawings / documents issued to site and as per instructions of Engineer-
in-Charge.
2.3.1.8 Instrument items such as pipe and pipe fittings, valves and manifold, junction
boxes, Signal/Control/Power cables, cable glands, instruments like TE,TT,PG,PT,
Gas detectors PSV/TSV etc., as required, shall be supplied from EIL approved
vendor’s only. Contractor shall take prior approval of make and specification of
such items before placement of order.
2.3.1.9 Contractor’s scope shall also include dropping/shifting of the PSV/TSV from the
installed position to laboratory for calibration/re-calibration/rechecking, etc., and
reinstall back to original location including parts replacement, gasket, stud/bolts
etc., re-fixing of the PSV/TSV including lapping if required to be done. The unit
rate in the Schedule of Rates shall also include the same.
2.3.1.10 During trial run/start up/commissioning, the contractor shall provide skilled
personnel and supervision round the clock at contractor’s cost. Any defect or
changes of setting, recalibration, etc., if any during the above activity shall be
rectified/done immediately to the satisfaction of engineer-in-charge or his
representative. The number and category of the personnel shall be as decided by
the engineer-in-charge. The cost of the above is deemed to be included by the
contractor in the rate quoted.
2.3.1.11 Contractor's scope shall include making holes in the RCC for fixing up of
supports for instrumentation items, trays etc.
2.3.1.12 The methodology of cable supports shall be as follows: -
a. Perforated/Angle/Ladder Trays (Contractor’s supply) for all the cables from the
individual instruments to the respective junction boxes.
b. Trenches (Prepared by contractor) as per the layout drawings (and any

subsequent site adjustments as deemed necessary by the engineer-in-
charge).
2.3.1.14 The fieldwork shall be carried out under strict safety regulations and work permits
as laid down by the client. The contractor shall take extreme care regarding
safety and all safety gear like helmets; hand gloves, safety belts, spectacles etc.
shall have to be provided by the contractor.
2.3.1.15 Refer 6-52-0060, clause 3.2, All work as applicable is included in contractors
scope.
2.3.1.16 The ferruling for cables shall be done with tag number of instruments for
individual pair. Cross ferruling shall be done for cable ferruling in field and in the
control room as per instruction of the Engineer in charge.
2.3.1.17 The contractor shall have to assess the actual site conditions/requirements
before placement of order for cable/trays as per the actual site condition.
Contractor has to prepare a cable routing layout as per actual site requirements
from field to control room and get the approval from the engineer-in-charge,
before placement of procurement.
Page 48 of 1963
DOCUMENT No.
Page 4 of 9
2.3.1.18 Wherever trenches are of longer/ smaller dimension than the maximum
dimension identified in the SOR, the rate shall be considered as pro-rata basis for
increase/ decrease in floor area change.
2.3.1.19 Welding/NDT, Charpy V-notch, QA/QC requirement etc. shall be as per Piping
Material Specification (PMS), EIL standards and specifications and other
requirement attached / mentioned elsewhere in the tender document. Contractor
to also note that 100% PMI shall be carried out in the entire socket weld joints in
the installation of instruments. The SOR price shall include all the above in the
installation of respective instrument/item.
2.3.1.20 Welding shall be as per welding standard attached elsewhere in the tender
document.
3.0 Scope of Work & Supply
3.1 Scope of Work (Instrumentation)
The instrumentation works shall include, but not limited to the following to complete
the works:
a. Installation, Commissioning off all field instruments.
b. Calibration of all field instruments.
c. Installation, Commissioning of junction boxes.
d. Fabrication, erection, laying of cable trays.
e. Preparation of cable trenches (buried).
f. Laying including termination of all interconnection cabling (single pair and multi
pair signal, alarm, control, power cables, system cables, etc.) between
instruments and junction boxes, instrument / junction boxes to control room
Control panels/ TIC Cabinet, electrical panels to Control panels/ TIC
Cabinets.
g. Installation of canopies for instruments
h. Supply, Installation of instrument valves and manifolds, mounting accessories,

impulse piping/ tubing, pipe/tube fittings, cable glands, identification tags,
conduits, structural material required for instrument and junction box supports,
trays and painting etc.
i. Laying of earthing cables/ strips for instrument cases and junction boxes to
earth grid, GI/ copper strips for grounding of racks/ Cabin/ panels in the control
room with construction of earth pit.
j. Excavation of trenches for burial of the cable, filling with sand, laying of bricks,
back filling and compacting of the excavated earth. Removal of pre-cast
concrete slabs (if required) and sand on the existing concrete trench, and re-
filling of RCC cable trenches with sand and re-fixing back the concrete slabs
after laying of new cables.
Page 49 of 1963
DOCUMENT No.
Page 5 of 9
k. Complete loop checking and megger testing of cables.
l. Hydraulic testing of instrument impulse lines (piping/tubing).
m. Pre-commissioning and Commissioning.
n. Documentation.
o. As built drawings.
3.1.1 Contractor shall be responsible for transportation of the identified RTUs from store
location of Client at Bangalore (Karnataka) to various work sites at Jamnagar Area,
the base location for the pipeline.
3.1.2 Scope of work shall be read in conjunction with the Schedule of Rates, drawings,
specifications and data sheets and other documents forming part of the Contract
document. Wherever there is a contradiction between the above, Schedule of Rates
and this document shall take precedence.
3.1.3 All civil work & steel works related to installation of RTU cabinets including
construction of base frame shall be under the scope of the contractor.
3.1.4 The contractor’s scope of work & supply and responsibilities includes, transportation of
RTU from GAIL Store at Bangalore & carrying out complete works related to
SCADA/RTU including providing assistance to RTU OEM (M/s Synergy ) for
powering up, testing & commissioning , at the various works location JLPL network
as per the SOR.
3.1.5 In the control room/ porta cabins, the contractor's scope shall include installation of
RTU panels/ cabinets ( along with necessary civil & structural works), including ,
laying and identification of all cables connected between the field and the control
room , supply, installation & termination of inter-panel cables between TIC-RTU
inside control room & RTU panel, supply ,installation & commission of wall mounted
TIC-RTU cabinet along with analog barriers, & relays and termination of field signal
cables, loop checking ,supply of double compression cable gland and glanding of
cables, system cables etc, dressing of the above cables inside the control room,
ferruling/tagging and termination of cables in the cabinets.
3.2 Scope of Supply (Instrumentation)
3.2.1 The scope of contractor for supply of instrumentation items shall include, but
not limited to the following to complete the Instrumentation works:
a) Supply of all field instrumentation & TIC Panels a per datasheets

b) Supply of cable trays, perforated/ angle trays including clamping, identifying tags.
c) Supply of junction boxes, cable glands, plugs and adapters.
d) Supply of all interconnecting cables (single pair & multi-pair signal, alarm, RTD and
control cables etc.) between instruments and junction boxes and up to control room
mounted cabinets/ panels.
e) Supply of ferrules and identifying tags for cables at field and panels.
Page 50 of 1963
DOCUMENT No.
Page 6 of 9
f) Supply of all installation and erection materials (pipe fittings shall be as per the
PMS and tube/ tube fittings shall be of SS316) including instrument valves &
manifolds, mounting accessories, impulse piping/ SS tubing, pipe/ tube fittings,
cable glands, plugs, adapters, identification tags, conduits, structural material
required for instrument supports and trays and painting etc.
g) Supply of earthing cables/ strips for connecting instrument cases to earth grid, GI/
copper strips/ shielded cables for grounding of panels in control room with earth pit.
h) Supply of yoke supports for instruments and junction boxes.
i) Supply of canopies fabricated out of 2 mm thick MS sheet for instruments.
j) Supply of pipe sleeves for instrumentation cable entry to the control room.
k) Supply of skin type temperature elements as per datasheet.
l) Supply of skin type temperature elements (RTD) with thermowell as per datasheet.
m) Supply of temperature elements (RTD) with thermowell as per datasheet.
3.2.2 The junction boxes, cable glands, cables, pipes, pipe fittings, tubes, tube
fittings, instrument valves & manifolds instruments like TE,TT,PG,PT, Gas
detectors PSV/TSV etc. shall be from EIL approved vendors.
3.2.3 Contractor to note that wherever stainless steel is specified, it refers to
austenitic and/ or ferrite steel.
3.2.4 All cable glands shall be double compression type and shall be provided with
PVC hood. Cable glands shall be suitable for the cable dimensions with ± 2
mm tolerance.
3.2.5 For all electrical items supplied by the contractor including junction boxes,
cable glands and accessories supplied for projects in India, certification from
CMRS for explosion proof to IS 2148 suitable for IEC Zone 1, Group IIA & IIB
and Weatherproof to IP 65 as per IS 13947 and approval from PESO
(Petroleum Explosive and Safety Organisation) / CCE (Chief Controller of
Explosives, India) shall be furnished irrespective of place of manufacture.
3.2.6 Refer 6-52-0060 Clause 7.1.1. This clause stands deleted as these materials
(Impulse pipe and pipe fittings) are in Contractor’s scope of supply as per
SOR.
3.2.7 Refer 6-52-0060 Clause 7.1.2; this clause stands deleted as these materials
(tubes, tube fittings, instrument valves manifolds) are in Contractor’s scope of
supply as per SOR.
3.2.8 Refer 6-52-0060 Clause 7.1.4 & 7.1.7. This clause stands deleted as these
materials (Junction Boxes, cable glands, plugs, gland adaptors etc.) are to be
supplied by contractor as per SOR.
3.2.9 For instrument material supplied by Contractor such as cables, junction boxes,
pipe, pipe-fittings, tube, tube-fittings, Instrument valves and Manifolds;
drawings, data from vendor shall be furnished as required as per the
respective standard specification. Also vendor shall furnish:
a) Inspection and test procedures.
b) Complete catalogues with part list for all contractor supplied instruments.
c) Certificates from statutory body for hazardous area for junction boxes,
cable glands, plugs, adaptors.
d) Material test certificates.
Page 51 of 1963
DOCUMENT No.
Page 7 of 9
e) Vendor List for all items.

Note: This list indicates the minimum drawings and document
requirements. However, vendor shall submit a complete list of document
and drawing schedule listing all the drawings and documents to be
submitted by them during the course of execution of the job. The
schedule shall list all drawings and documents along with their number
and expected date of submission.
4. SCOPE OF WORK (Telecommunication- OFC & its associated items Installation
4.1 General
4.1.1 Contractor shall be responsible for complete activities involving all sub-contractors
including OFC laying sub-contractor (as applicable) working under him for the
complete OFC laying works, as part of his scope.
4.1.2 Scope of work shall be read in conjunction with the Schedule of Rates for OFC
and its associated items, drawings, specifications and other documents forming
part of the Contract document. Wherever there is a contradiction between the
above, Schedule of Rates and this document shall take precedence.
4.1.3 Every month, the contractor shall submit an account for all the materials issued to
him by the Owner (as applicable) in the standard Performa prescribed for this
purpose by the Engineer-in-Charge.
4.1.4 On completion of the work, the contractor shall submit `Material Appropriation'
statements for all materials issued by the Owner in the Performa prescribed by the
Engineer-in-Charge.
4.1.5 The fieldwork shall be carried out under strict safety regulations and work permits
as laid down by the Client. The contractor shall take extreme care regarding
safety and all safety gear like helmets; hand gloves, safety belts, spectacles etc
shall have to be provided by the contractor.
4.2 Scope of Work (Telecommunication- OFC & its associated items Installation)
Contractor’s scope shall include all supply and works related to OFC installation
read in conjunction with the Schedule of Rates & Job Specification: OFC
Installation And Associated Works (Doc. No. A922-000-16-51-SP-80), OFC
Specification (A922-000-16-51-SP-81) all associated drawings, specifications and
other requirements forming part of the Tender document)
The scope shall include the following as a minimum:
4.1.1 Collection of data, Liaison with all statutory /public bodies for obtaining permission
for OFC installation in pipeline trench or separately, if applicable. Owner will issue
the necessary request letters seeking permission and pay/reimburse any fees
Page 52 of 1963
DOCUMENT No.
Page 8 of 9
payable to statutory /public bodies for according permission of OFC laying, as

required.
4.1.2 Supply, storage, and transportation to site, loading, unloading, etc to and from
designated stores and use of any equipment, materials including consumables
required for laying, jointing, testing, termination of Optical Fiber Cable.
4.1.3 Excavation in pipeline trench or separate trench, as depicted with diagrams, as

per the requirement.
4.1.4 Installation & laying of OFC through permanently lubricated HDPE conduit in
Pipeline trench & Separate trench directly and through CS conduit as required,
excavation as required, padding, backfilling including supply and use of all
materials required like push fit couplers, end plugs etc all complete as per
specification and as per the site requirement.
4.1.5 Bed preparation, laying (through Blowing technique) of One (1) no. of Optical
Fibre Cable through (40 mm OD, 6kg/cm2) permanently lubricated HDPE conduits
in the same trench of the pipeline (refer drawing. No. A922-000-16-51-4701_
Arrangement of OFC w.r.t to pipeline), installation of jointing closures at jointing
locations as required, jointing pits, metallic marker, electronic markers, back-filling
etc. shall be done. Where service crossing exists, in addition to the general
guidelines stated in the OFC laying specification, the Contractor shall follow all the
particular requirements asked for by the Engineer-In-Charge including supply of
any materials required.
4.1.6 Sub-ducting of HDPE conduit in casing conduit, at crossings, as defined in the

specifications and tender document. End sealing of HDPE conduits, use of
Couplers, end plugs, etc as required to be procured & supplied by contractor.
4.1.7 Jointing, testing, Termination (in the FTC) & handing over of the laid OFC.
4.1.8 Laying of earthing cables/ strips for OFC to earth grid and Copper strips for
grounding of FTC in the control room & other consumer location with earth pit.
4.1.9 Arrange necessary power-supply, all equipment / instruments, manpower, test-

gear, accessories, etc., necessary for installation/ jointing/ testing/ termination of
OFC.
4.1.10 Contractor to supply and install conduiting/casing of OFC cable inside the building
till FTC.
4.1.11 Contactor to ensure that there shall be provisioning of jointing chamber on the
both side on crossing (rail, road, nallah, river).
4.1.12 At all stations, Contactor shall place the OFC in the loop box (specification of loop
box is attached elsewhere in tender) which shall be located in Control room.
Page 53 of 1963
DOCUMENT No.
Page 9 of 9
4.1.13 Drawings enclosed with the contract are only for reference and indicative of
general nature for scope of work. Actual installation shall be carried out based on
actual site conditions and Contractor’s drawings / documents issued to site and as
per instructions of Engineer-in-Charge.
.
4 SCOPE OF SUPPLY
4.1 Scope of Supply (Optical Fibre Cable & its associated items installation)
The scope of contractor for supply of OFC cables and related items for OFC
laying & termination shall include but not limited to the following:
a) Supply of Optical Fiber Cable as per specification.

b) Supply of Permanently lubricated HDPE Conduits as per specification.
c) Supply of Jointing Closures, OFC distance markers, Electronic Marker System
with Marker and Locator, FTC & Loop Box as per specification.
d) Supply of all materials including consumables required for installation/laying,
jointing, testing of Optical Fiber Cable including supply of Jointing Pits,
Blowing pits, Push fit couplers, end plugs, metallic markers, Locators, sand,
soft soil, Warning mats, cable tags, ties, pulling wire for OFC/Duct Pulling
(rugged and durable) etc. all complete.
e) Supply of complete technical literature, alignment sheets, as-built documents
and other documentation.
Page 54 of 1963
DOCUMENT No.
SCOPE OF WORK
PIPELINE LAYING WORKS A922-020-81-41-SOW-9510
Rev. A
Page 1 of 4
SCOPE OF WORK AND SUPPLY

(U/G CIVIL)
PIPELINE LAYING WORKS
(Tender No. A922-020-83-41-MK-T-9510)
PROJECT : CAPACITY AUGMENTATION OF JLPL
JOB NO. : A922
A 28.10.16 ISSUED FOR BIDS PR RS VG

Date Purpose
No by by by
Page 55 of 1963
DOCUMENT No.
SCOPE OF WORK
A922-020-81-41-SOW-9510
PIPELINE LAYING TENDER
Rev. A
Page 2 of 4
CONTENTS
1.0 SCOPE ................................................................................................................................. 3
1.1 GENERAL ............................................................................................................................ 3
1.2 DETAILED SCOPE OF WORK ........................................................................................ 3
2.0 SCOPE OF SUPPLY.......................................................................................................... 4
3.0 LIST OF ATTACHMENTS ................................................................................................. 4
4.0 USE OF FOLLOWING CEMENT SHALL BE CONSIDERED ..................................... 4
5.0 SPECIFIC REQUIREMENTS ........................................................................................... 4
6.0 SCHEDULE OF RATES: ................................................................................................... 4
Page 56 of 1963
DOCUMENT No.
SCOPE OF WORK
A922-020-81-41-SOW-9510
Rev. A
Page 3 of 4
1.0 SCOPE
1.1 GENERAL
Tender scope of Work & Supply for U/G Civil works for capacity augmentation of JLPL
shall include supply of all materials, consumables, tools, tackles, machinery,
equipment, manpower etc. required for construction, fabrication, erection, installation,
painting, testing and commissioning (wherever required) supervision of all civil
structural works.
All Civil work shall be executed as per Scope of work mentioned below, Schedule of
Rates, approved Drawings/ Documents, EIL Specifications and Standards, relevant
BIS Codes and direction of Engineer-in-Charge.
Any other work not listed above but required to be executed for completion of the work
shall deemed to be included in CONTRACTOR’s scope of work.
1.2 DETAILED SCOPE OF WORK

CIVIL WORKS
 Site grading by earthwork in cutting/filling with approved/selected non-expansive
earth from borrow areas including cutting of trees, stripping and clearing of
borrowed area, loading, transportation, unloading and spreading of borrowed earth
in layers, watering, rolling, clearing and stripping at filling areas, uprooting of
vegetation, roots and disposal of the shrubs, bushes, roots etc., all complete as per
standards, specifications, drawings, documents and direction of Engineer-in-
Charge. (Borrow areas shall be arranged by CONTRACTOR on his own without
additional cost to OWNER).
 Construction of RCC pavement including providing catchments drains (RCC) with

MS grating cover at edge of the pavement including earth work in cutting/ filling as
required for grade preparation, compaction including providing WBM base,
reinforcement bars, reinforced cement concrete, providing joints and sealing
material etc. including supply of all materials and consumable required all complete.
 Providing Chain link fencing along with steel gate including supply of all material,
consumable, earthworks in excavation, backfilling, disposal of surplus earth as per
drawings, standards, specifications and direction of Engineer-in-Charge.
 Borrow areas with all leads shall be arranged by CONTRACTOR on his own
including taking approval from statutory and local authority, paid royalty and
services taxes to local authority.
 Collection of debris, surplus/ unserviceable earth and disposal of same outside the
plant boundary limit including transportation, loading, unloading, clearing of site etc.
all complete as per specifications and direction of Engineer-in-charge.
 Construction of inter locking Paver block footpath including providing sand base
course, watering for compaction etc., supply of all other materials as required all
Page 57 of 1963
DOCUMENT No.
SCOPE OF WORK
A922-020-81-41-SOW-9510
Rev. A
Page 4 of 4
complete as per standards, specifications, drawings, and direction of Engineer-in-

charge.
 Any other work not listed above but required for satisfactory and successful
commissioning of the work shall be deemed to be included in CONTRACTOR’s
scope of work.
2.0 SCOPE OF SUPPLY

CIVIL AND STRUCTURAL WORKS
OWNER’s SCOPE OF SUPPLY
NIL
CONTRACTOR’s SCOPE OF SUPPLY
Procurement and supply of all materials and consumables required for the job including
arranging of all tools, tackles, equipment, machinery and labor required for satisfactory
completion of the job shall be the responsibility of the CONTRACTOR within the quoted
rates.
3.0 LIST OF ATTACHMENTS

For list of Std. Specifications, Standards, Job Specification, documents and drawings
attached with bids Refer Doc. No. A922-020-81-41-LL-9510.
4.0 USE OF FOLLOWING CEMENT SHALL BE CONSIDERED

i) 43 Grade Ordinary Portland cement conforming to IS:8112
ii) Portland Pozzolona cement (PPC, Fly ash based) conforming to IS:1489 Part-1
5.0 SPECIFIC REQUIREMENTS
5.1 Brick Class Civil Works/ Items shall be of minimum Class 5 conforming to IS: 1077.
6.0 SCHEDULE OF RATES:

For schedule of rates of U/G Civil works refer Document Number
- A922-020-81-41-MK-SOR-9510
Page 58 of 1963
LIST OF ATTACHMENTS FOR DOCUMENT No.
PIPELINE LAYING A922-020-83-41-LL-0001 REV.0
LIST OF ATTACHMENTS FOR PIPELINE LAYING

(Pipeline Engineering Department)


JOB NO. : A922
0 06.01.17 Issued For Bids

VS AR NR
Date Purpose
No by by by
Page 59 of 1963
Page 2 of 11
CONTENTS
1.0 LIST OF ATTACHMENTS.............................................................................. 3
2.0 JOB SPECIFICATIONS ................................................................................. 3
3.0 JOB STANDARDS ......................................................................................... 4
4.0 STANDARD SPECIFICATIONS .................................................................... 4
5.0 PIPELINE STANDARDS ................................................................................ 6
6.0 PIPING STANDARDS .................................................................................... 7
7.0 DATA SHEET FOR CONTRACTOR SUPPLIED ITEMS ............................... 9
8.0 DRAWINGS ................................................................................................... 9
9.0 P & IDs ......................................................................................................... 10
10.0 MISCELLANEOUS ...................................................................................... 10
11.0 INSPECTION DOCUMENT ......................................................................... 11
Page 60 of 1963
Page 3 of 11
CONTRACTOR shall carry out all works strictly in accordance with the drawings/
documents/ specifications indicated in subsequent paragraphs.
2.0 JOB SPECIFICATIONS
Sl No. Specification No. No. of Rev. Title

Sheets
A922-000-83-41-SP-0010 47 3 Piping Material

1
Specification
A922-000-83-41-30011 1 D Schematic Arrangement for

2 Capacity Augmentation
Jamnagar -Loni Pipeline
Standard for dimension of
5 0
3 A922-000-83-41-SP-0006 Stud bolts
Specification for Geo Textile
5 0
4 A922-000-83-41-SP-0007 Bags for Anti-Buoyancy
Addendum to bolt
5 0 tensioning & bolt tightening
5 A922-000-16-54-DD-001
requirements
A922-000-83-41-SP- 7 0 Annexure-1 to Piping

6
0010-A1 Material Specification
A922-000-83-41-SP- 5 0 Annexure-2 to Piping

7
0001-A2 Material Specification
3 0 Addendum to Standard
8 A922-000-83-41-AD-0005
Specification no. 6-71-0005.
3 0 Addendum to Standard
9 A922-000-83-41-AD-0041
Specification no. 6-71-0041.
A922-000-02-42-WSP- 43 2 Welding Specification for

10
0001 Onshore Pipeline
A922-020-02-42-WSC- 10 2 Welding Specification

11
0001 Charts
Addendum To Standard
A922-020-2-42-PCS- 2 0 Specification To Surface
12
0001 Preparation And Protective
Coating (6-79-0020 Rev.0)
Specification for Magnetic

A922-020-02-42-EGP- 12 0
13 Cleaning & Electronic
0001
Geometric Pigging
- -
14 - Line Schedule
- -
15 - Technical Specification for
Page 61 of 1963
Page 4 of 11

Sheets
Pre-Commissioning &
Commissioning
3.0 JOB STANDARDS

Sheets
Typical Right Of Use For
A922-000-83-41-ST-0002 1 0
1 Pipelines.
Process Vent & Drain
A922-000-83-41-ST-0011 2 0
2 Connection Details
Pressure Gauge
A922-000-83-41-ST-0012 1 0 Instruments Connection
3
Details
4.0 STANDARD SPECIFICATIONS

Sheets
Standard specification for
6-71-0005 31 4 high frequency welded
1
(HFW) line pipe (onshore).
6-71-0014 15 4 pipeline ball valves
2
(onshore).
Standard Specification for
6-71-0021 11 5 Long Radius Bends for
3
Onshore Pipelines.
seamless fittings and
6-71-0024 7 4
4 flanges (size up to DN 400
mm (16"))
6-71-0035 10 4 casing insulators and end
5
seals.
Standard specification for 3
6-71-0041 29 3 layer polyethylene coating
6
of line pipes.
6-71-0044 12 3 Field Joint Coating
7
(Onshore Pipelines)
6-71-0046 12 4 Concrete Weight Coating of
8
Onshore Pipelines.
6-71-0048 6 1 Repair of Polyethylene
9
Coating
6-71-0051 38 4 pipeline construction
10
(onshore)
Page 62 of 1963
Page 5 of 11

Sheets
Specification for
Construction of Pipelines
6-71-0052 11 3
11 Crossing Roads, Railroad
and Minor Water Crossings
Standard Specification For
Pipeline River Crossings
6-71-0054 14 3
12 Using Directional Drilling
Method.
6-71-0055 20 3 hydrostatic testing of
13
onshore pipelines.
6-71-0057 6 4
14 Pipeline markers
6-71-0059 9 4 documentation for pipeline
15
construction
6-71-0062 7 4
16 hot tapping
Specification For Detailed
6-71-0071 24 3 Pipeline Route Survey
17
(Onshore)
6-44-0012 15 4 Fabrication and Erection of
18
Piping
6-44-0013 9 4 Inspection, Flushing and
19
Testing of Piping Systems
Non Destructive
6-44-0016 21 7
20 Examination Requirement
of Piping
6-44-0051 10 6 Technical Notes for Pipes
21
6-44-0052 20 6 Technical Notes for Valves
22
Technical Notes for
6-44-0056 5 4
23 Gaskets
Technical Notes for Bolts &
6-44-0057 5 4
24 Nuts.
surface preparation and
6-79-0020 59 0
25 protective coating (new
construction)
application of torque and
6-76-0002 33 2
26 hydraulic bolt tension for
flange joints
Specification for quality
6-78-0001 7 1 management system
27
requirements from bidders
Page 63 of 1963
Page 6 of 11

Sheets
Specification for
documentation
6-78-0002 8+1 1
28 requirements from
contractors
Specification for
6-78-0003 8+1 1 documentation
29
requirements from suppliers
5.0 PIPELINE STANDARDS
No. of
Sl No. Document No. Rev Title
Sheets
Typical trench dimensions
7-71-0005 1 4
1 for pipeline.
7-71-0006 1 4 Pipelines symbols.

2
7-71-0007 1 4 Topographical Symbols

3
7-71-0008 1 4 K.M. Post
4
Typical ROU boundary
7-71-0009 1 4
5 marker
7-71-0010 1 4 Aerial marker
6
7-71-0011 1 4 Direction marker
7
7-71-0012 1 4 Pipeline Warning Sign
8
Existing pipeline on
7-71-0013 1 4 sleeper crossing.
9
Navigable Waterway
7-71-0014 1 4 Pipeline Crossing Warning
10
Sign
Pipeline-road/highway
7-71-0015 1 4
11 uncased crossing.
Pipeline road/highway cased
7-71-0016 1 4
12 crossing.
7-71-0018 1 4 Typical Stream Crossings
13
Details of Casing Vent and
7-71-0019 1 4
14 Drain off
7-71-0020 1 4 Casing pipe details.
15
7-71-0021 Existing Under Ground Pipe
1 4
16 Crossing (Type - I)
Existing Under Ground Pipe
7-71-0022 1 4
17 Crossing (Type - II)
Under Ground Cable
7-71-0024 1 4
18 Crossing
Page 64 of 1963
Page 7 of 11
Over Head Power Line

7-71-0025 1 4
19 Crossing
7-71-0027 1 2 Typical slope breaker details
20
Bank Protection details for
7-71-0028 1 1
21 water crossing
Typical details of railway
7-71-0029 1 2
22 crossings
Typical warning mat details
7-71-0031 1 0
23 for pipeline
6.0 PIPING STANDARDS
No. of
Sheets
7-44-0002 2 4 Abbreviations
24
Symbols of piping elements
7-44-0003 4 4
25 on drawings
Jack screw for spectacle
7-44-0252 1 4 blind fig.8 and spacer & blind
26
(150CL, 300CL, 600CL RF).
7-44-0352 2 4 Orientation of Orifice Taps
27
Wells installation 1½” dia
7-44-0353 2 4 taps (up to class 600)
28
Pipe shoe for hot - insulated
C.S. pipe, size 2" thru 8",
7-44-0601 1 4
29 Type-S1 (for temp. upto
343C)
Pipe saddle for bare pipe
7-44-0606 1 4 size 2” thru 48” type-S6A (for
30
temp. upto 343C)
Low support sliding for bare
7-44-0621 1 5 and insulated pipe size 2"
31
thru. 36" type-L1 & L1A
Low support fixed for bare &
7-44-0623 1 5 insulated pipe size 2" thru.
32
36" type-L3 & L3A.
Low support sliding for bare
7-44-0626 1 5 and insulated pipe size 2”
33
thru. 36” Type-L6
Restrained Low support for
7-44-0628 1 5 bare and insulated pipe size
34
2" thru. 36", type-L8 & L8A
Adjustable low support
sliding for bare and insulated
7-44-0630 1 5
35 pipe size 2" thru. 6" type-L10
& L10A.
Page 65 of 1963
Page 8 of 11
Low support sliding & fixed

7-44-0635 1 5 for bare & insulated pipe size
36
3/4" thru 11/2"type-L15.
Low support stanchion for
7-44-0636 1 5 bare & insulated CS/AS/SS
37
pipe type – L16 and L16A.
Adjustable low support with
7-44-0637 1 5 4 bolts for pipe size 8"
38
thru 24" type-L17 & L17A.
Adjustable low support for
bare and insulated pipe size
7-44-0638 1 5
39 2" thru 24". Type-L18 &
L18A
Adjustable low support with
guide & cross guide for bare
7-44-0639 1 5
40 and insulated pipe size 2"
thru 24" type-L19 & L19A.
Low friction Low support
(Sliding) for bare and
7-44-0731 1 0 insulated pipe size 2”
41
through 36” Type L31 &
L31A
Pipe clamp for bare CS/ AS/
7-44-0641 1 4 SS pipe size 1/2" thru 24”
42
Type C-1
U-bolt for bare CS pipe size
7-44-0644 1 4 1/2" thru 24" type-C4 (for
43
operating temp. Upto 2320C)
Dummy pipe support for
7-44-0739 1 5 bare pipe size 2" thru 24"
44
type B-39
Pipe support brackets type-
7-44-0742 1 4
45 B42
Guide support for bare pipe
7-44-0751 1 4
46 size 1/2" thru 24" type-G1
Guide support for bare pipe
7-44-0752 1 4 size 1/2" thru 24" type G2 &
47
G2A. (for temp. Up to 3430C)
Cross guide for bare pipe
7-44-0753 1 4 Size 2" thru 24" type-G3 (for
48
temp up to 3430C)
Cross Guide For Bare Pipe
On Sleeper/ Rcc Beam,
7-44-0754 1 4
49 Size 2" Thru 24" Type-G4
(For Temp Up To 3430c)
Anchor for bare pipe on
sleeper/ RCC beam, size 2"
7-44-0755 1 4
50 thru 24" type-G5(for temp up
to 3430C)
Supporting arrangement for
7-44-0792 1 4 angle & relief valves type-
51
SP2.
Page 66 of 1963
Page 9 of 11
Conditions for issue and

7-82-0001 9 1
52 reconciliation of materials
In addition to the above listed support standards, other job specific special supports
may also be required. This shall be provided to the contractor during detailed
engineering/ Installation stage.
7.0 DATA SHEET FOR CONTRACTOR SUPPLIED ITEMS
No. of
Sl No. Data Sheet No. Rev Title
Sheets
A922-000-83-41-DS-1001 Ball Valve- 0.5”-1.5”-
2 0
1 800#_SW
Ball Valve- 0.5”-1.5”-
A922-000-83-41-DS-1002 2 0
2 1500#_BW
Plug Valve- 0.5”-1.5”-
A922-000-83-41-DS-1003 2 0
3 800#_SW
Plug Valve- 0.5”-1.5”-
A922-000-83-41-DS-1004 2 0
4 1500#_BW
Globe Valve-0.5”-1.5”-
A922-000-83-41-DS-1005 2 A
5 800#_SW
Globe Valve-0.5”-1.5”-
A922-000-83-41-DS-1006 2 A
6 1500#_BW
Check Valve-0.5”-1.5”-
A922-000-83-41-DS-1007 1 A
7 800#_SW
Check Valve-0.5”-1.5”-
A922-000-83-41-DS-1008 1 A
8 1500#_BW
Gate Valve-0.5”-1.5”-
A922-000-83-41-DS-1009 2 A
9 800#_SW
Gate Valve-0.5”-1.5”-
A922-000-83-41-DS-1010 2 A
10 1500#_BW
Gate Valve -0.25”-1.5”
VMS Tag No. 51001 1 6
11 800#,SW
Globe Valve -0.25”-1.5”
VMS Tag No. 52001 1 6
12 800#,SW
Check Valve -0.25”-1.5”

VMS Tag No. 53001 1 6
13 800#,SW
Ball Valve -0.5”-16”

VMS Tag No. 54321 1 6
14 150#,FL,AA3A
8.0 DRAWINGS
Sl No. Drawing No. No. of

Rev Title
Sheets
Equipment layout for EOL-
A922-021-83-41-10821 1 B
1 DT
Page 67 of 1963
Page 10 of 11
Sl No. Drawing No. No. of

Rev Title
Sheets
Equipment layout for SV-1
A922-022-83-41-10822 1 B
2 RT
A922-020-83-41-10820 1 B Equipment layout for SV-71
3
Equipment layout for SV
A922-020-83-41-10828 1 B
4 Inside EOL
A922-020-83-41-10921 1 A Sample GAD
5
Alignment Sheet From CH 0
A922-020-83-41-12001 1 A
6 KM TO 1.750 KM
Alignment Sheet From CH
A922-020-83-41-12002 1 A
7 1.750 KM TO 3.5 KM
A922-020-83-41-12003 1 A
8 3.5 KM TO 5.25 KM
A922-020-83-41-12004 1 A
9 5.25 KM to 7 KM
Alignment Sheet From CH 7
A922-020-83-41-12005 1 A
10 KM TO CH. 8.75 KM
Alignment Sheet From CH.
A922-020-83-41-12006 1 A
11 8.75 KM TO CH 10.5 KM
A922-020-83-41-12007 1 A
12 10.5 KM TO CH 12.25KM
A922-020-83-41-12008 1 A
13 12.25 KM TO CH 14 KM
A922-020-83-41-12009 1 A
14 14KM TO CH 15.75 KM
Alignment Sheet From
A922-020-83-41-12010 1 A CH.15.75 KM TO CH. 16.56
15
KM
Crossing Drawing For
A922-020-83-41-12011 1 A
16 Phuljhar River
9.0 P & IDs
Sl No. P&ID No. No. of

Rev Title
Sheets
A922-02-42-000-1100 1 1 Legends and General Notes
1
A922-02-42-000-1101 1 1 Legends and General Notes
2
A922-02-42-021-1112 Main line Pumps at EOL
1 2
3 (sheet 2 of 2) Despatch Terminal
A922-02-42-022-1111 1 2 Reciept terminal at SV-1
4 .
Filtration and Metering
A922-02-42-022-1112 1 2
5 System at SV-1 Terminal
10.0 MISCELLANEOUS
No. of
Sl No. ITP No. Rev Title
Sheets
GAIL-ERPL-S03-J00-001-
62 B Detailed Survey Report
1 0B
Page 68 of 1963
Page 11 of 11
No. of
Sl No. ITP No. Rev Title
Sheets
GAIL-ERPL-S04-J00-001-
12 A Soil Stratification Report
2 0A
All Survey Crossing
41 B All Survey Crossing Drawing
3 Drawings
GAIL-ERPL-RM-01 1 C Route Map

4
11.0 INSPECTION DOCUMENT
No. of
Sheets
Inspection Certificate type
A922-000-18-42-ICR- 3.2 requirements for tender
2 0
1 9510 no. A922-020-83-41-MK-T-
9510.
Page 69 of 1963
PIPELINE LAYING AND A922-020-16-51-LL-0001
ASSOCIATED FACILITIES Rev 0
(Instrumentation & Telecom) Page 1 of 6
GAIL (India) LIMITED
PROJECT : JAMNAGAR LONI LPG PIPELINE PROJECT
OWNER : M/s GAIL
LIST OF ATTACHMENT
FOR
PIPELINE LAYING AND ASSOCIATED FACILITIES
(Instrumentation & Telecom)
0 03/11/16 ISSUED FOR BIDS SS SK PKS
Rev.
Date Purpose Prepared by Checked by Approved by
No
Page 70 of 1963
ASSOCIATED FACILITIES Rev. 0
(Instrumentation & Telecom)
Page 2 of 6
CONTENTS
2.0 DOCUMENTS
4.0 STANDARDS
5.0 DRAWINGS
Format No. EIL 1641-1924 Rev. 1 0900020083012d7d_A4 Copyright EIL – All rights reserved
Page 71 of 1963
(Instrumentation) Page 3 of 6
CONTRACTOR shall carry out all works strictly in accordance with the
drawings/documents/specifications indicated in subsequent paragraphs.
2.0 DOCUMENTS
No. of
S.No Document No. Rev. Title
Sheets
Scope of Work for Composite
1. A922-020-16-51-SOW-01 9 0
Works
Vendor Data requirement for
2. A922-020-16-51-VDR-0001 3 1
Instrumentation
Technical Confirmation for
3. A922-020-16-51-CF-0001 1 0
Instrumentation.
Job Specification–OFC Installation
4. 18 0
A922-000-16-51-SP-80 and Associated works
Optical Fibre Cable Specification
5. A922-000-16-51-SP-81 11 0
Procedure for Optical Fibre Cable
6. A922-000-16-51-SP-82 10 0 testing
7. A922-020-YP-DS-1111 1 0 Data sheet Pressure Gauge
A922-020-YP-DS-3001 Data sheet Pressure Transmitter
8. 1 0
Datasheet for Pressure Relief

9. A922-020-YR-DS-3101 1 0
valves
Data Sheets For Telemetry
10. A922-000-YE-DS-5100 1 0
Interface Panels and Accessories
Data sheet RTD /Temperature
11. A922-020-YT-DS-1002 1 0
Transmitter / Thermowell
Data sheet Skin thermocouple
12. A922-020-16-51-DS-1001 1 A
/Temperature Transmitter
13. A922-020-YD-DS-2640 4 0 Data sheet for Gas detector
Datasheet for Cables
14. A922-020-16-51-DS-1004 8 0
A922-020-16-51-DS-1001 Datasheet for Junction Box
15. 1 0
Vendor List
16. A922-020-16-51-MD-0001 6 0
Page 72 of 1963
No. of Re
S.No Specification No. Title
Sheets v.
1. Standard specification for receiver
6-52-0016 9 4
and pressure gauges
2. Standard specification for
6-52-0032 16 4
electronic/pneumatic instruments
3. 6-52-0042 9 3 Standard specification for
thermocouples, RTDs and
thermowells.
4. 6-52-0046 8 6 Standard specifications for signal
cables.
5. 6-52-0048 7 4 Standard specifications for Junction
Boxes and cable Glands.
6. 6-52-0049 13 3 Standard specification for Main
control panel and accessories
7. 6-52-0060 26 2 Standard Specification for erection
tender.
8. 6-52-0067 6 5 Standard specifications for
instrument tube fittings
instrument tubing
instrument Valves and manifolds
11. 6-52-0026 8 4 Standard specification for Pressure
Relief valves
12. 6-52-0080 24 3 Standard Specification for Gas
detectors
temperature gauges and
thermowells.
14. 6-81-2016 3 4 Inspection Test plan for receiver and
pressure gauges.
15. 6-81-2032 7 3 Inspection & test plan for
electronic/pneumatic instruments
16. 6-81-2042 5 3 Inspection Test plan for
thermocouples, RTDs and
thermowells
17. 6-81-2046 6 3 Inspection Test plan for Signal
cables
18. 6-81-2049 5 3 Inspection Test plan for Control
Panel & accessories
19. 6-81-2048 5 3 Inspection test plan for Junction
Boxes and Cable glands
20. 6-81-2067 5 3 Inspection test plan for Instrument
tube fittings
tubing
Page 73 of 1963
No. of Re
S.No Specification No. Title
Sheets v.
valves and manifolds
23. 6-81-2026 5 3 Inspection Test plan for Pressure
Relief valves
24. 6-81-2080 6 3 Inspection test plan for Gas
detectors.
temperature gauges and
thermowells.
4.0 STANDARDS
No. of
S.No Drawing No. Rev. Title
Sheets
7-52-0001 4 4 Instrument connection on
1.
vessel, standpipes and tanks.
7-52-0002 3 3 Instrument connections on
2.
pipes
3. 7-52-0035 3 3 Thermowell
7-52-0036 1 3 Thermocouple/RTD Assembly
4.
with Thermocouple
7-52-0101 3 2 Instrument support for Single
5.
Instrument
7-52-0102 3 2 Instrument support for Double
6.
Instrument
7. 7- 52-0104 1 2 Junction Box mounting
8. 7-52-0105 1 2 Canopy for instruments

7-52-0107 1 2 Perforated Tray support and
9.
clamping details
7-52-0400 9 4 List of items for installation
10.
material
7-52-0432 1 4 Pressure gauge Liquid / Gas
11.
Service
7-52-0446 1 4 Pressure Instrument Gas
12.
Service
5.0 DRAWINGS
A922-000-16-51-IS01 1 0 Pressure Instrument Liquid &

1.
Vapor Service Meter below
A922-000-16-51-IS03 1 0 Schematic diagram for skin
2. temperature measurement
system
Page 74 of 1963
A922-000-16-51-IS05 1 0 Pressure Gauge Liquid/Gas

3.
Service
Arrangement of OFC with
4. 1 A
A922-000-16-51-4701 respect to Pipeline
1 A OFC installation (Inside
5.
A922-000-16-51-4702 Terminals)
OFC installation (Cased
6. 1 A
A922-000-16-51-4703 Crossing)
OFC Joint Identification
7. 1 A
A922-000-16-51-4704 Marker
8. A922-000-16-51-4705 1 A OFC Jointing Pit
Page 75 of 1963
SCOPE OF WORK DOCUMENT No.
PIPELINE LAYING WORKS A922-020-81-41-LL-9510
Rev. A
Page 1 of 5
LIST OF ATTACHEMENTS
(U/G CIVIL)
(Tender No. A922-020-83-41-MK-T-9510)
PROJECT : CAPACITY AUGMENTATION OF JLPL
JOB NO. : A922
A 26.10.2016 ISSUED FOR BIDS PR RS VG

Rev. Prepared Checked
Date Purpose Approved by
No by by
Page 76 of 1963
DOCUMENT No.
SCOPE OF WORK A922-020-81-41-LL-9510
Rev. A
Page 2 of 5
CONTENTS
1.0 LIST OF ATTACHMENTS .......................................................................................... 3
1.1 DOCUMENTS ............................................................................................................ 3
1.2 VENDOR LIST FOR GRATING .................................................................................. 3
1.3 JOB STANDARDS ..................................................................................................... 3
1.4 STANDARD SPECIFICATIONS ................................................................................. 3
1.5 STANDARDS ............................................................................................................. 5
Page 77 of 1963
DOCUMENT No.
SCOPE OF WORK A922-020-81-41-LL-9510
Rev. A
Page 3 of 5
CONTRACTOR shall carry out all works strictly in accordance with the drawings/ standards/
documents/ specifications indicated in subsequent paragraphs.
1.1 DOCUMENTS
No. of
S. No Document No. Rev. Title
Sheets
1. A922-020-81-41-LL-9510 A 5 List of Attachments (U/G Civil)
2. A922-020-81-41-SOW-9510 A 4 Scope of work (U/G Civil)
1.2 VENDOR LIST FOR GRATING
No. of
S. No. Document No. Rev. Title
Sheets
List of approved products for use in Civil-
1. LL-1648-0402 3 5
Structural works
1.3 JOB STANDARDS

S.
Drawing No. Rev. Title
No
1. A922-020-81-41-34701 A Details of Chain link Fencing
2. A922-020-81-41-44702 A Details of footpath (PCC interlocking blocks)
3. A922-020-81-41-44703 A Cross-Sectional Details of Road (WBM)
S. No Specification Rev. No. of Title

No. Sheets
U/G CIVIL
6-65-0013 3 7 Standard specification for chain link fencing.

1.
Standard Specification for Classification of Soil
6-65-0016 3 6
2. for Earthwork in Site Grading.
Standard specification for site grading & rock
6-65-0017 5 12
3. cutting for site grading
Standard Specification for Road & Flexible
6-65-0018 7 11
4. Pavements (up to WBM layer).
6-65-0019 3 10 Standard Specification for Concrete Pavements.
5.
Standard Specification for Flexible Pavements
6. 6-65-0020 3 9
with Bitumen Premix Carpet.
Page 78 of 1963
DOCUMENT No.
SCOPE OF WORK A922-020-81-41-LL-9510
Rev. A
Page 4 of 5
S. No Specification Rev. No. of Title

No. Sheets
STRUCTURAL
Standard specification civil and structural works
7. 6-68-0001 4 4
- General scope
8. 6-68-0002 5 16
- Materials
9. 6-68-0003 5 13
- Earthwork
Standard specification civil & structural works
10. 6-68-0004 7 30
Plain and Reinforced Cement Concrete
Standard specification civil & structural works
11. 6-68-0006 6 24
structural steel works.
Standard specification: civil & structural works -
12. 6-68-0008 6 12
miscellaneous steel works
Standard specification - civil & structural works -
13. 6-68-0009 4 9
brick masonry.
Standard specification - civil & structural works -
14. 6-68-0013 4 9
miscellaneous items.
QUALITY MANAGEMENT SYSTEM
Quality management system requirements from
6-78-0001 1 7
15. bidders
6-78-0002 1 8+1 Documentation requirements from contractors
16.
Specification for documentation requirements
17. 6-78-0003 1 8+1
from suppliers.
CONSTRUCTION
Std. Specification for HSE Management at
6-82-0001 6 87
18. Construction Site
Inspection & Test Plan (ITP) for incoming
19. 6-82-1010 1 8 material checking for contractor’s supplied
materials
Inspection & test plan (ITP) for civil, structural &
20. 6-82-3100 0 64 architectural works (item rate contracts – with
categorization)
Standard Quality Assurance Plan Construction
6-82-6100 2 13
21. Division (Item Rate Contracts)
Page 79 of 1963
DOCUMENT No.
SCOPE OF WORK A922-020-81-41-LL-9510
Rev. A
Page 5 of 5
1.5 STANDARDS
Rev. No. of
S. No Standard No. Title
Sheets
U/G CIVIL
1. 7-65-0001 3 4 Abbreviations, Legends & Eqpt. Symbols
2. 7-65-0010 4 1 Road curves and crossings.

3. 7-65-0272 4 1 Unit drainage details (rectangular ditch details).
4. 7-65-0404 3 1 RCC pavement details.
STRUCTURAL
5. 7-68-0056 6 7 Metal Insert Plate
Standard re-bar shapes & cut length
6. 7-68-0101 5 7
computation.
ARCHITECTURAL
7. 7-75-0054 4 2 Steel gate (for entrances up to 6.0m width)
NOTE:
Standards and specifications shall be read in conjunction with “Addendum to EIL
Standards & Specifications [Refer Document Scope of work for Civil, Structural &
Enabling works at Stations”, Doc. No. A922-020-81-41-SOW-8001 for Part-A & Part-B]
Page 80 of 1963
JOB SPECIFICATION No.
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 1 of 47
PIPING MATERIAL SPECIFICATION
Spec Name : A922-000-83-41-SP-0010_3

Spec Desc. : PIPING MATERIAL SPECIFICATION
Client : GAIL INDIA LIMITED
Project : JLPL STATIONS
Location : GUJRAT & RAJASTHAN
Job No. : A922
Dept/Sec. : 83/41
3 27/12/2016 REVISED & RE-ISSUED AS JOB RB AR/NR MSG

SPECIFICATION

SPECIFICATION

SPECIFICATION
0 07/11/2016 ISSUED AS JOB SPECIFICATION RB AR/NR MSG
Rev. No Date Purpose Prepared by Checked by Approved by

Template No. 5-0000-0001-T1 Rev. 1 Copyright EIL- All rights reserved
Page 81 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 2 of 47
Abbreviations:
Template No. 5-0000-0001-T2 Rev. Copyright EIL- All rights reserved

Page 82 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 3 of 47
CONTENTS
Sl. No. Description Pages
1 Piping Material Specifications A922-000-83-41-SP-0010 Rev 3
2 Annex.-I, Piping Material Specification General Notes, (A922-000-83-41-SP-0010-A1) Rev 0.
3 Annex. -II, List of Specs. and Stds. & Valve Data Sheets (<2"), (A922-000-83-41-SP-0010-
A2) Rev. 0.

Page 83 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 4 of 47
Client : GAIL INDIA LIMITED Dept./Sect. : 83/41

Location : GUJRAT & RAJASTHAN
PIPING MATERIAL SPECIFICATION INDEX

Piping Spl. Basic
Sl. No Class Rating C.A Service Remarks
Reqt. Material
1 AA3A 150 1.5 CARBON STEEL NON CORROSIVE UTILITIES (ABOVE

GROUND) CATEGORY "D" FLUID - COOLING
WATER, INSTRUMENT AIR(2" & ABOVE),
PLANT AIR, INERT GAS, CARBON DI OXIDE
(DRY), NITROGEN, CONDENSATE & BOILER
FEED SUCTION (NON IBR). THIS CLASS DOES
NOT COVER UNDERGROUND PIPING AND
THE FIRE WATER SERVICE. FOR SIZES
ABOVE 30", TEMPERATURE AND PRESSURE
RATINGS SHALL BE 70 DEG.C & 7.0 KG/CM2G
RESPECTIVELY.
2 AA9A 150 3 CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG)
3 AL9A 150 3 LOW CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG), LOW
TEMPER TEMPERATURE SERVICE
ATURE
SERVICE
4 BA9A 300 3 CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG)
5 BL9A 300 3 LOW CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG), LOW
ATURE
SERVICE
6 DA9A 600 3 CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG)
7 DL9A 600 3 LOW CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG), LOW
ATURE
SERVICE
8 EA9A 900 3 CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG)
9 EL9A 900 3 LOW CARBON STEEL LIQUIFIED PETROLEUM GAS (LPG), LOW
ATURE
SERVICE
Notes : 1. For PMS General notes refer Annexure-I of this document.
2. For List of Specs. and Stds. & Valve Data Sheets (<2") refer Annexure-II
of this document.
Package : IPMCS
Report No. : 50

Page 84 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 5 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : AA3A Sheet 1 of 7
PIPE CLASS : AA3A

RATING : 150
BASE MATERIAL : CARBON STEEL
CORROSION ALLOWANCE : 1.5 MM
SPECIAL REQUIREMENT :
TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS
TEMP 0 38 50 65 100 150 186
PRESS 10.55 10.55 10.55 10.55 10.55 10.55 10.55
SERVICE
NON CORROSIVE UTILITIES (ABOVE GROUND) CATEGORY "D" FLUID - COOLING WATER, INSTRUMENT AIR(2" & ABOVE),
PLANT AIR, INERT GAS, CARBON DI OXIDE (DRY), NITROGEN, CONDENSATE & BOILER FEED SUCTION (NON IBR). THIS
CLASS DOES NOT COVER UNDERGROUND PIPING AND THE FIRE WATER SERVICE. FOR SIZES ABOVE 30",
TEMPERATURE AND PRESSURE RATINGS SHALL BE 70 DEG.C & 7.0 KG/CM2G RESPECTIVELY.
NOTES
1 NDT REQUIREMENTS AS PER EIL STANDARD 6-44-0016.
6 FOR FABRICATED REDUCERS,REFER EIL'STD 7-44-0485 & 7-44-0487. FOR MITRES, REFER EIL'STD 7-44-0033.
31 USE BUTTERFLY VALVES INSTEAD OF GATE VALVES FROM 10" ONWARDS IN WATER SERVICE AND UPTO 70 DEG C.
DESIGN PRESSURE FOR BUTTERFLY VALVES IS LIMITED UPTO 10 BAR.
64 AWWA C207 CL.D FLANGES SHALL BE OF HUB TYPE.
65 FORGINGS ARE ACCEPTABLE IN LIEU OF PLATE MATERIAL FOR BLIND FLANGES AND SPACER & BLINDS.
76 FOR PERMANENT BW STRAINERS,REFER EIL'STD 7-44-0303 & 7-44-0304; AND FOR TEMPORARY STRAINERS,REFER
EIL'STD 7-44-0300.
77 FOR SIZES > 24", SPACER & BLIND SHALL BE DESIGNED BY THE MANUFACTURER AS PER ASME B31.3.
86 BUTTERFLY VALVES FOR THE SPEC ARE PN10 RATED WITH A MAXIMUM PRESSURE OF 10.2 KG/CM2G.
97 USE 5-PIECE 90 DEG. MITRE FOR SIZES FROM 16" TO 44", 6-PIECE 90 DEG. MITRE FOR SIZES 48" TO 68" & 7-PIECE
MITRE FOR SIZES 72" TO 80". 45 DEG. MITRE SHALL REQUIRE ONE PIECE LESS.
98 FOR SIZES ABOVE 30", TEMPERATURE AND PRESSURE RATINGS SHALL BE 70 DEG.C & 7.0 KG/CM2G RESPECTIVELY.
99 BLIND FLANGES AND SPACER & BLINDS SPECIFIED TO MANUFACTURER'S STANDARD SHALL BE DESIGNED FOR 70
DEG.C AND 7.0 KG/CM2G TO SUIT 150#, FF, 125AARH, AWWA C207 CL.D FLANGES.
SPECIAL NOTES
ITEM SIZE DESCRIPTION A.CODE

MAINTAINENCE ALL FLANGED, TO BE KEPT MINIMUM
JOINTS
PIPE JOINTS 1.5" & BELOW SW COUPLING 3000 LBS.
2.0" & ABOVE BUTTWELDED
DRAINS ON LINES <= 1.5" REFER EILSTD 7-44-350, DF3
ON LINES >= 2.0" 0.75" OR AS PER P&ID. REFER EIL STD. 7-44-351, D4
VENTS ON LINES <= 1.5" REFER EIL STD. 7-44-350, VC1
ON LINES >= 2.0" 0.75" OR AS PER P&ID. REFER EIL STD 7-44-351, V1
TEMP.CONN 1.5" FLANGED. REFER EIL STD 7-44-353
PRESS.CONN 0.75" SW, SH HVY NIPPLE WITH GATE VALVE TO SPEC AS PER EIL STD
7-44-354
Package : IPMCS
Report No. : 50 AA3A
Page 85 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 6 of 47

72.
70.
68.
66. R
64. R R
62. R R R
60. R R R R
58. R R R R R
56. R R R R R R
54. R R R R R R R
52. R R R R R R R R
50. R R R R R R R R R
48. T R R R R R R R R R
46. T R R R R R R R R R R
44. T R R R R R R R R R R R
BRANCH PIPE ( SIZE IN INCHES)
42. T R R R R R R R R R R R R
40. T R R R R R R R R R R R R R
38. T R R R R R R R R R R R R R R
36. T R R R R R R R R R R R R R R R
34. T R R R R R R R R R R R R R R R R
32. T R R R R R R R R R R R R R R R R R
30. T R R R R R R R R R R R R R R R R R R
28. T R R R R R R R R R R R R R R R R R R R
26. T R R R R R R R R R R R R R R R R R R R R
24. T R R R R R R R R R R R R R R R R R R R R R
22.
20. T R R R R R R R R R R R R R R R R R R R R R R
18. T P R R R R R R R R R R R R R R R R R R R R R R
16. T R P R R R R R R R R R R R R R R R R R R R R R R
14. T P R P R R R R R R R R R R R R R R R R R R R R R R
12. T P P R P R R R R R R R R R R R R R R R R R R R R R R
10. T R P P R P R R R R R R R R R R R R R R R R R R R R R R
8.0 T P R P P R P R R R R R R R R R R R R R R R R R R R R R R
6.0 T P P R P P R P R R R R R R R R R R R R R R R R R R R R R R
5.0
4.0 T P P P P P P P P R R R R R R R R R R R R R R R R R R R R R R
3.5
3.0 T P P P P P P P P P R R R R R R R R R R R R R R R R R R R R R R
2.5
2.0 T P P P P P P P P P P P R R R R R R R R R R R R R R R R R R R R R
1.5 T T H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
1.25
1.0 T T H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
0.75 T T T H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
0.5 T T T T H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
10.000
12.000
14.000
16.000
18.000
20.000
22.000
24.000
26.000
28.000
30.000
32.000
34.000
36.000
38.000
40.000
42.000
44.000
46.000
48.000
50.000
52.000
54.000
56.000
58.000
60.000
62.000
64.000
66.000
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
.500
.750
RUN PIPE (SIZE IN INCHES)
CODE DESCRIPTION
F SADDLE FUSED JT T TEES J THREADOLET
H H. COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X Refer Notes
S SOCKOLETS L SWEEPOLET
Package : IPMCS
Page 86 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 7 of 47

R 72.
R R 70.
R R R 68.
R R R 66.
R R R 64.
R R R 62.
R R R 60.
R R R 58.
R R R 56.
R R R 54.
R R R 52.
R R R 50.
R R R 48.
R R R 46.
R R R 44.
BRANCH PIPE (SIZE IN INCHES)
R R R 42.
R R R 40.
R R R 38.
R R R 36.
R R R 34.
R R R 32.
R R R 30.
R R R 28.
R R R 26.
R R R 24.
22.
R R R 20.
R R R 18.
R R R 16.
R R R 14.
R R R 12.
R R R 10.
R R R 8.0
R R R 6.0
5.0
R R R 4.0
3.5
R R R 3.0
2.5
R R R 2.0
H H H 1.5
1.25
H H H 1.0
H H H 0.75
H H H 0.5
68.000
70.000
72.000
Package : IPMCS
Page 87 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 8 of 47

Note :(The shaded portion of PMS body shows Field Fabricated Items)
Item Lower Upper Sch/ Commodity Note

Input Dmn. STD Material
Type Size Size Thk Description Code No
Id. (Inch) (Inch) (mm)
Pipe Group
PIP PIPE .5 1.5 HVY IS-1239-I IS-1239 (BLACK) PE, C.WELDED PI6D471Z0
PIP PIPE 2 6 HVY IS-1239-I IS-1239 (BLACK) BE, C.WELDED PI6D411Z0
PIP PIPE 8 14 6.0 IS-3589 IS-3589 GR.330 BE, WELDED PI7D919Z0
NIP NIPPLE .5 1.5 HVY IS-1239-I IS-1239 (BLACK) PBE, C.WELDED PN6D461Z0
Flange Group
FLG FLNG.SW .5 1.5 M B-16.5 ASTM A 105 150, RF/125AARH FSC0127Z0
FLG FLNG.SO 2 24 B-16.5 ASTM A 105 150, RF/125AARH FNC0127Z0
FLG FLNG.SO 26 80 AWWA-C207 ASTM A 105 150, FF/125AARH FN40121Z0

CL.D
FLB FLNG.BLIND .5 24 B-16.5 ASTM A 105 150, RF/125AARH FBC0127Z0
FLB FLNG.BLIND 26 48 AWWA-C207 ASTM A 285 GR.C 150, FF/125AARH FB45321Z0

CL.D
FEF FLNG.FIG.8 .5 8 ASME- ASTM A 105 150, FF/125AARH FGK0121Z0
B16.48
FEF SPCR&BLND 10 24 ASME- ASTM A 105 150, FF/125AARH FCK0121Z0
B16.48
FEF SPCR&BLND 26 80 MNF'STD ASTM A 285 GR.C 150, FF/125AARH FCG5321Z0
Fitting Group
ELB90 ELBOW.90 .5 1.5 B-16.11 ASTM A 105 SW, 3000 WA602D2Z0
ELB90 ELBOW.90 2 6 STD B-16.9 ASTM A 234 BW, 1.5D WAG684Z10

GR.WPB
ELB90 ELBOW.90 8 14 M B-16.9 ASTM A 234 BW, 1.5D WAG754Z10
GR.WPB-W
ELB45 ELBOW.45 .5 1.5 B-16.11 ASTM A 105 SW, 3000 WB602D2Z0
Package
Report No.
: IPMCS
: 50 AA3A
Page 88 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 9 of 47


Fitting Group
ELB45 ELBOW.45 2 6 STD B-16.9 ASTM A 234 BW, 1.5D WBG684Z10
GR.WPB
ELB45 ELBOW.45 8 14 M B-16.9 ASTM A 234 BW, 1.5D WBG754Z10
GR.WPB-W
MIT90 MITRE.90 16 80 M EIL'STD IS-3589 GR.330 BW, 1.5D WDKF141Z0
MIT45 MITRE.45 16 80 M EIL'STD IS-3589 GR.330 BW, 1.5D WGKF141Z0
TEQ T.EQUAL .5 1.5 B-16.11 ASTM A 105 SW, 3000 WE602D2Z0
TEQ T.EQUAL 2 6 STD B-16.9 ASTM A 234 BW WEG684ZZ0

GR.WPB
TEQ T.EQUAL 8 48 M B-16.9 ASTM A 234 BW WEG754ZZ0
GR.WPB-W
TRED T.RED .5 1.5 B-16.11 ASTM A 105 SW, 3000 WR602D2Z0
TRED T.RED 2 6 STD, B-16.9 ASTM A 234 BW WRG684ZZ0

STD GR.WPB
TRED T.RED 8 48 M, M B-16.9 ASTM A 234 BW WRG754ZZ0
GR.WPB-W
REDC REDUC.CONC 2 6 STD, B-16.9 ASTM A 234 BW WUG684ZZ0
STD GR.WPB
REDC REDUC.CONC 8 14 M, M B-16.9 ASTM A 234 BW WUG754ZZ0
GR.WPB-W
REDC REDUC.CONC 16 80 M, M EIL'STD IS-3589 GR.330 BW WUKF14ZZ0
REDE REDUC.ECC 2 6 STD, B-16.9 ASTM A 234 BW WVG684ZZ0

STD GR.WPB
REDE REDUC.ECC 8 14 M, M B-16.9 ASTM A 234 BW WVG754ZZ0
GR.WPB-W
REDE REDUC.ECC 16 80 M, M EIL'STD IS-3589 GR.330 BW WVKF14ZZ0
SWGC SWAGE.CONC .5 3 STD, BS-3799 ASTM A 105 PBE WNH026ZZ0

STD
SWGE SWAGE.ECC .5 3 STD, BS-3799 ASTM A 105 PBE WPH026ZZ0
STD
CAP CAP .5 1.5 B-16.11 ASTM A 105 SCRF, 3000 WF60282Z0
CAP CAP 2 6 STD B-16.9 ASTM A 234 BW WFG684ZZ0

GR.WPB
CAP CAP 8 48 M B-16.9 ASTM A 234 BW WFG684ZZ0
GR.WPB
CAP CAP 50 80 CALC ASME-VIII ASTM A 285 GR.C BW WF3J54ZZ0
CPLF CPLNG.FULL .5 1.5 B-16.11 ASTM A 105 SW, 3000 WJ602D2Z0
Package
Report No.
: IPMCS
: 50 AA3A
Page 89 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 10 of 47


Fitting Group
CPLH CPLNG.HALF .5 1.5 B-16.11 ASTM A 105 SW, 3000 WK602D2Z0
CPLL CPLNG.LH .5 1.5 B-16.11 ASTM A 105 SW, 3000 WL602D2Z0
CPLR CPLNG.RED .5 1.5 B-16.11 ASTM A 105 SW, 3000 WM602D2Z0
UNN UNION .5 1.5 BS-3799 ASTM A 105 SW, 3000 WQH02D2Z0
Valves Group
GAV VLV.GATE .25 1.5 API 602/ ISO BODY-ASTM A SW, 800, 3000, B- 51001ZZZ0
15761 105,TRIM- 16.11, SHT NO.- 51001
STELLITED,STEM-
13%CR.STEEL
GAV VLV.GATE 2 24 API 600/ ISO BODY-ASTM A 216 FLGD, 150, B-16.5, 51321ZZZ0
10434 GR.WCB,TRIM- RF/125AARH, SHT
13% CR.STEEL NO.- 51321
GLV VLV.GLOBE .25 1.5 BS EN ISO BODY-ASTM A SW, 800, 3000, B- 52001ZZZ0
15761 105,TRIM- 16.11, SHT NO.- 52001
STELLITED,STEM-
13%CR STEEL
GLV VLV.GLOBE 2 16 BS-1873 BODY-ASTM A 216 FLGD, 150, B-16.5, 52321ZZZ0
GR.WCB,TRIM- RF/125AARH, SHT
13% CR.STEEL NO.- 52321
CHV VLV.CHECK .25 1.5 BS EN ISO BODY-ASTM A SW, 800, 3000, B- 53001ZZZ0
15761 105,TRIM- 16.11, SHT NO.- 53001
STELLITED
CHV VLV.CHECK 2 24 BS 1868 BODY-ASTM A 216 FLGD, 150, B-16.5, 53321ZZZ0
GR.WCB,TRIM- RF/125AARH, SHT
13% CR.STEEL NO.- 53321
CHV VLV.CHECK 26 48 API-594 BODY-ASTM A 105 FLGD, 150, 53316ZZZ0
/A AWWAC207,
216GR.WCB,TRIM- FF/125AARH, SHT
13% CR.STEEL NO.- 53316
BLV VLV.BALL .5 16 BS EN ISO BODY-ASTM A 105 FLGD, 150, B-16.5, 54321ZZZ0
17292 /A RF/125AARH, SHT
216GR.WCB,TRIM- NO.- 54321
BODY SEAT-
RPTFE
BFV VLV.BTRFLY 3 24 BS EN 593 BODY-ASTM A 216 WAFL, 150, B-16.5, 56321ZZZ0
GR.WCB,TRIM- WAF/125AARH, SHT
13% CR.STEEL NO.- 56321
BFV VLV.BTRFLY 26 48 BS EN 593 BODY-ASTM A 216 FLGD, 150, 56316ZZZ0
GR.WCB,TRIM- AWWAC207,
13% CR.STEEL FF/125AARH, SHT
NO.- 56316
Bolt Group
BOS BOLT.STUD 18 80 B-18.2 BOLT:A193 GR.B7, BS40404Z0
NUT:A194 GR.2H
Package
Report No.
: IPMCS
: 50 AA3A
Page 90 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 11 of 47


Bolt Group
BOM BOLT.M/C .5 16 B-18.2 BOLT:A307 GR.B, BM41418Z0
NUT:A563 GR.B
Gasket Group
GAS GASKET .5 24 B-16.21- NONASBESTOS RING, 150, 2 MM GKBAX52Z0
ANSI B16.5 BS7531 GR X
GAS GASKET 26 80 AWWA-C207 NONASBESTOS FULLFACE, 150, 2 MM GK2AX22Z0
CL.D BS7531 GR X
Trap/Strainer Group
TRP TRAP.STEAM .5 1.5 MNF'STD B:A105;T:13%CR;S: FLGD, THRMDNMC, TR3065530
SS304 150,RF/125AARH
TSR STRNR.TEMP 1.5 24 EIL'STD B:A285GR.C;INT:S CONETYPE, ST14431Z0
S304 150,FF/125AARH
PSR STRNR.PERM .5 1.5 MNF'STD B:A105;INT:SS304 SW, Y-TYPE, 800 SP303D510
PSR STRNR.PERM 2 6 M EIL'STD B:A234GR.WPB;IN BW, T-TYPE SP13344Z0

T:SS304
PSR STRNR.PERM 8 24 M EIL'STD B:A234GR.WPBW;I BW, T-TYPE SP13644Z0
NT:SS304
Package
Report No.
: IPMCS
: 50 AA3A
Page 91 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 12 of 47

PIPE CLASS : AA9A

RATING : 150
CORROSION ALLOWANCE : 3 MM
TEMP -29 38 50 65 100 150
PRESS 19.98 19.98 19.57 19.11 18.04 16.11
SERVICE
LIQUIFIED PETROLEUM GAS (LPG)
NOTES
101 PIPING DESIGN SHALL BE AS PER ASME B31.4, PNGRB REGULATIONS & OISD 214.
102 FITTINGS OF SIZE 2 INCH TO 16 INCH SHALL BE OF SEAMLESS TYPE.
103 ALL VENTS & DRAINS, INCLUDING HYDROTEST VENTS & DRAINS, SHALL BE PROVIDED WITH BALL VALVE & BLIND
FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN THE PIPING & INSTRUMENTATION DIAGRAM (P&ID).
104 ALL ABOVE GROUND PIPING BRANCH CONNECTIONS SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON
THE NEXT PAGE. IN BURIED PIPING O'LETS SHALL NOT BE USED, BRANCH CONNECTION SHALL BE DONE BY USING
'TEES'.
105 NDT OF WELDS WITHIN THE TERMINALS/ STATIONS SHALL BE AS FOLLOWS,
RADIOGRAPHY: 100% FOR ALL BUTT WELDS
MPI: 100% FOR ALL SOCKET WELDS
ALL OTHER REQUIREMENTS SHALL BE AS PER RELEVANT WELDING SPECIFICATION & WELDING CHART.
106 FOR MATERIAL DESCRIPTION OF VALVES & STRAINERS APPLICABLE DATA SHEETS SHALL BE REFERED.
107 ALL STUD BOLTS & NUTS SHALL BE HOT DIPPED GALVANIZED AS PER ASTM A153.
SPECIAL NOTES

JOINTS
PIPE JOINTS 1.5" & BELOW SW COUPLING
2.0" & ABOVE BUTT WELDED
DRAINS 0.75" AS PER A922-000-83-41-ST-0011.
VENTS 0.75" AS PER A922-000-83-41-ST-0011.
TEMP. CON. 1.5" 'FLANGED TYPE' AS PER 7-44-0353. 'WELDED TYPE' & 'SKIN TYPE'
AS PER INSTRUMENTATION STANDARD.
PR. CON. ON 0.75" (PI, PT, PG & PDT ON PIPING) AS PER A922-000-83-41-ST-0012.
PIPING
PR. CON. ON 2.0" (PI, PT, PG & PDT ON EQUIP., VESSELS) FLANGED WITH BALL
EQUIP. VALVE UNLESS OTHERWISE INDICATED
IN P & ID
Package : IPMCS
Page 92 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 13 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. T 16.
14. T T 14.
12. T T T 12.
10. T T T T 10.
8.0 T T T T T 8.0
6.0 T T T T T T 6.0
5.0 5.0
4.0 T T T T W W W 4.0
3.5 3.5
3.0 T T T W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W 2.0
1.5 T T T T S S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S S S S 1.0
0.75 T T T S S S S S S S S S 0.75
0.5 T T T T S S S S S S S S S 0.5
10.000
12.000
14.000
16.000
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Page 93 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 14 of 47


Pipe Group
PIP PIPE .5 1.5 S160 B-36.10 ASTM A 333 GR.6 PE, SEAMLESS PI24677Z0
PIP PIPE 2 3 S160 B-36.10 ASTM A 333 GR.6 BE, SEAMLESS PI24617Z0
PIP PIPE 6 6 12.7 B-36.10 ASTM A 333 GR.6 BE, SEAMLESS PI24617Z0
PIP PIPE 8 8 S80 API 5L API 5L GR.X-52 BE, SEAMLESS PIAG517Z0

PSL2
PIP PIPE 10 10 14.3 API 5L API 5L GR.X-52 BE, SEAMLESS PIAG517Z0
PSL2
PSL2
PIP PIPE 16 16 17.5 API 5L API 5L GR.X-52 BE, SAW PIAG516Z0
PSL2
Flange Group
FLG FLNG.SW .5 1.5 M B-16.5 ASTM A 350 300, RF/125AARH FSCD747Z0
GR.LF2 CL.1
FLG FLNG.WN 2 6 M B-16.5 ASTM A 350 300, RF/125AARH FWCD747Z0
GR.LF2 CL.1
FLG FLNG.WN 8 16 M B-16.5 ASTM A 694 GR.F- 300, RF/125AARH FWCA247Z0
52 (CHARPY)
FLB FLNG.BLIND .5 6 B-16.5 ASTM A 350 300, RF/125AARH FBCD747Z0
GR.LF2 CL.1
FLB FLNG.BLIND 8 16 B-16.5 ASTM A 105 300, RF/125AARH FBC9847Z0
(CHARPY)
FEF FLNG.FIG.8 .5 6 ASME- ASTM A 350 300, FF/125AARH FGKD741Z0
B16.48 GR.LF2 CL.1
FEF FLNG.FIG.8 8 8 ASME- ASTM A 105 300, FF/125AARH FGK9841Z0
B16.48 (CHARPY)
B16.48 (CHARPY)
Fitting Group
ELB90 ELBOW.90 .5 .75 B-16.11 ASTM A 350 SW, 6000 WA6T7D3Z0
GR.LF2 CL.1
ELB90 ELBOW.90 1 1.5 B-16.11 ASTM A 350 SW, 3000 WA6T7D2Z0
GR.LF2 CL.1
ELB90 ELBOW.90 2 6 M B-16.9 ASTM A 420 BW, 1.5D WAGB44Z10 102
GR.WPL6
ELB90 ELBOW.90 8 16 M B-16.9 MSS SP-75 BW, 1.5D WAGBH4Z10 102
GR.WPHY-52
(CHARPY)
ELB45 ELBOW.45 .5 .75 B-16.11 ASTM A 350 SW, 6000 WB6T7D3Z0
GR.LF2 CL.1
Package
Report No.
: IPMCS
: 50 AA9A
Page 94 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 15 of 47


Fitting Group
ELB45 ELBOW.45 1 1.5 B-16.11 ASTM A 350 SW, 3000 WB6T7D2Z0
GR.LF2 CL.1
ELB45 ELBOW.45 2 6 M B-16.9 ASTM A 420 BW, 1.5D WBGB44Z10 102
GR.WPL6
ELB45 ELBOW.45 8 16 M B-16.9 MSS SP-75 BW, 1.5D WBGBH4Z10 102
GR.WPHY-52
(CHARPY)
TEQ T.EQUAL .5 .75 B-16.11 ASTM A 350 SW, 6000 WE6T7D3Z0
GR.LF2 CL.1
TEQ T.EQUAL 1 1.5 B-16.11 ASTM A 350 SW, 3000 WE6T7D2Z0
GR.LF2 CL.1
TEQ T.EQUAL 2 6 M B-16.9 ASTM A 420 BW WEGB44ZZ0 102
GR.WPL6
TEQ T.EQUAL 8 16 M B-16.9 MSS SP-75 BW WEGBH4ZZ0 102
GR.WPHY-52
(CHARPY)
TRED T.RED .5 .75 B-16.11 ASTM A 350 SW, 6000 WR6T7D3Z0
GR.LF2 CL.1
TRED T.RED 1 1.5 B-16.11 ASTM A 350 SW, 3000 WR6T7D2Z0
GR.LF2 CL.1
TRED T.RED 2 6 M, M B-16.9 ASTM A 420 BW WRGB44ZZ0 102
GR.WPL6
TRED T.RED 8 16 M, M B-16.9 MSS SP-75 BW WRGBH4ZZ0 102
GR.WPHY-52
(CHARPY)
REDC REDUC.CONC 2 6 M, M B-16.9 ASTM A 420 BW WUGB44ZZ0 102
GR.WPL6
REDC REDUC.CONC 8 16 M, M B-16.9 MSS SP-75 BW WUGBH4ZZ0 102
GR.WPHY-52
(CHARPY)
REDE REDUC.ECC 2 6 M, M B-16.9 ASTM A 420 BW WVGB44ZZ0 102
GR.WPL6
REDE REDUC.ECC 8 16 M, M B-16.9 MSS SP-75 BW WVGBH4ZZ0 102
GR.WPHY-52
(CHARPY)
SWGC SWAGE.CONC .5 3 M, M BS-3799 ASTM A 350 PBE WNHT76ZZ0
GR.LF2 CL.1
SWGE SWAGE.ECC .5 3 M, M BS-3799 ASTM A 350 PBE WPHT76ZZ0
GR.LF2 CL.1
CAP CAP .5 .75 B-16.11 ASTM A 350 SCRF, 6000 WF6T783Z0
GR.LF2 CL.1
CAP CAP 1 1.5 B-16.11 ASTM A 350 SCRF, 3000 WF6T782Z0
GR.LF2 CL.1
CAP CAP 2 6 M B-16.9 ASTM A 420 BW WFGB44ZZ0 102
GR.WPL6
Package
Report No.
: IPMCS
: 50 AA9A
Page 95 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 16 of 47


Fitting Group
CAP CAP 8 16 M B-16.9 MSS SP-75 BW WFGBH4ZZ0 102
GR.WPHY-52
(CHARPY)
CPLF CPLNG.FULL .5 .75 B-16.11 ASTM A 350 SW, 6000 WJ6T7D3Z0
GR.LF2 CL.1
CPLF CPLNG.FULL 1 1.5 B-16.11 ASTM A 350 SW, 3000 WJ6T7D2Z0
GR.LF2 CL.1
CPLH CPLNG.HALF .5 .75 B-16.11 ASTM A 350 SW, 6000 WK6T7D3Z0
GR.LF2 CL.1
CPLH CPLNG.HALF 1 1.5 B-16.11 ASTM A 350 SW, 3000 WK6T7D2Z0
GR.LF2 CL.1
CPLL CPLNG.LH .5 .75 B-16.11 ASTM A 350 SW, 6000 WL6T7D3Z0
GR.LF2 CL.1
CPLL CPLNG.LH 1 1.5 B-16.11 ASTM A 350 SW, 3000 WL6T7D2Z0
GR.LF2 CL.1
CPLR CPLNG.RED .5 .75 B-16.11 ASTM A 350 SW, 6000 WM6T7D3Z0
GR.LF2 CL.1
CPLR CPLNG.RED 1 1.5 B-16.11 ASTM A 350 SW, 3000 WM6T7D2Z0
GR.LF2 CL.1
O'let Group
SLT SOCKOLET .5 .75 MSS-SP97 ASTM A 350 SW, 6000 YSST7D3Z0
GR.LF2 CL.1
SLT SOCKOLET 1 1.5 MSS-SP97 ASTM A 350 SW, 3000 YSST7D2Z0
GR.LF2 CL.1
WLT WELDOLET 2 3 M, MSS-SP97 ASTM A 350 BW YWSX44ZZ0
XXS GR.LF6 CL.1
S160 GR.LF6 CL.1
Bolt Group
BOS BOLT.STUD .5 6 B-18.2 BOLT:A320 GR.L7 BS44231Z0 107
(HDG), NUT:A194
GR.4 (HDG)
BOS BOLT.STUD 8 16 B-18.2 BOLT:A193 BS43927Z0 107
GR.B7(HDG),
NUT:A194
GR.2H(HDG)
Gasket Group
GAS GASKET .5 16 B-16.20- SP.WND SPIRAL, 300 GK65074Z0
ANSI B16.5 SS316+GRAFIL
Package
Report No.
: IPMCS
: 50 AA9A
Page 96 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 17 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : AL9A Sheet 1 of 4
PIPE CLASS : AL9A

RATING : 150
SPECIAL REQUIREMENT : LOW TEMPERATURE SERVICE

TEMP -45 38 50 65 100 150
PRESS 19.98 19.98 19.57 19.11 18.04 16.11
SERVICE
LIQUIFIED PETROLEUM GAS (LPG), LOW TEMPERATURE SERVICE
NOTES
'TEES'.
SPECIAL NOTES

JOINTS
DRAINS 0.75" AS PER A922-000-83-41-ST-0011.
VENTS 0.75" AS PER A922-000-83-41-ST-0011.
PIPING
EQUIP. VALVE UNLESS OTHERWISE INDICATED IN P & ID
Package : IPMCS
Report No. : 50 AL9A
Page 97 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 18 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. 16.
14. 14.
12. 12.
10. 10.
8.0 8.0
6.0 T 6.0
5.0 5.0
4.0 T T 4.0
3.5 3.5
3.0 T T T 3.0
2.5 2.5
2.0 T T T W 2.0
1.5 T T T T S 1.5
1.25 1.25
1.0 T T S S S S 1.0
0.75 T T T S S S S 0.75
0.5 T T T T S S S S 0.5
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 AL9A
Page 98 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 19 of 47


Pipe Group
Flange Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
B16.48 GR.LF2 CL.1
Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPL6
GR.WPL6
Package
Report No.
: IPMCS
: 50 AL9A
Page 99 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 20 of 47


Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
O'let Group
GR.LF2 CL.1
GR.LF2 CL.1
XXS GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
Gasket Group
Package
Report No.
: IPMCS
: 50 AL9A
Page 100 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 21 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : BA9A Sheet 1 of 5
PIPE CLASS : BA9A

RATING : 300
TEMP -29 38 50 65 100 150
PRESS 52.1 52.1 51.08 50 47.51 45.98
SERVICE
NOTES
'TEES'.
SPECIAL NOTES

JOINTS
DRAINS 0.75" AS PER A922-000-83-41-ST-0011.
VENTS 0.75" AS PER A922-000-83-41-ST-0011.
PIPING
Package : IPMCS
Report No. : 50 BA9A
Page 101 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 22 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. T 16.
14. T T 14.
12. T T T 12.
10. T T T T 10.
8.0 T T T T T 8.0
6.0 T T T T T T 6.0
5.0 5.0
4.0 T T T T W W W 4.0
3.5 3.5
3.0 T T T W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W 2.0
1.5 T T T T S S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S S S S 1.0
0.75 T T T S S S S S S S S S 0.75
0.5 T T T T S S S S S S S S S 0.5
10.000
12.000
14.000
16.000
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 BA9A
Page 102 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 23 of 47


Pipe Group

PSL2
PSL2
PSL2
PSL2
Flange Group
GR.LF2 CL.1
GR.LF2 CL.1
52 (CHARPY)
GR.LF2 CL.1
(CHARPY)
B16.48 GR.LF2 CL.1
B16.48 (CHARPY)
B16.48 (CHARPY)
Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
Package
Report No.
: IPMCS
: 50 BA9A
Page 103 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 24 of 47


Fitting Group
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
Package
Report No.
: IPMCS
: 50 BA9A
Page 104 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 25 of 47


Fitting Group
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
O'let Group
GR.LF2 CL.1
GR.LF2 CL.1
XXS GR.LF6 CL.1
S160 GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
GR.B7(HDG),
NUT:A194
GR.2H(HDG)
Gasket Group
Package
Report No.
: IPMCS
: 50 BA9A
Page 105 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 26 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : BL9A Sheet 1 of 4
PIPE CLASS : BL9A

RATING : 300

TEMP -45 38 50 65 100 150
PRESS 52.1 52.1 51.08 50 47.51 45.98
SERVICE
NOTES
'TEES'.
SPECIAL NOTES

JOINTS
DRAINS 0.75" AS PER A922-000-83-41-ST-0011.
VENTS 0.75" AS PER A922-000-83-41-ST-0011.
PIPING
Package : IPMCS
Report No. : 50 BL9A
Page 106 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 27 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. 16.
14. 14.
12. 12.
10. 10.
8.0 8.0
6.0 T 6.0
5.0 5.0
4.0 T T 4.0
3.5 3.5
3.0 T T T 3.0
2.5 2.5
2.0 T T T W 2.0
1.5 T T T T S 1.5
1.25 1.25
1.0 T T S S S S 1.0
0.75 T T T S S S S 0.75
0.5 T T T T S S S S 0.5
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 BL9A
Page 107 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 28 of 47


Pipe Group
Flange Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
B16.48 GR.LF2 CL.1
Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPL6
GR.WPL6
Package
Report No.
: IPMCS
: 50 BL9A
Page 108 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 29 of 47


Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
O'let Group
GR.LF2 CL.1
GR.LF2 CL.1
XXS GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
Gasket Group
Package
Report No.
: IPMCS
: 50 BL9A
Page 109 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 30 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : DA9A Sheet 1 of 5
PIPE CLASS : DA9A

RATING : 600
TEMP -29 38 50 65 100 150
PRESS 104.11 104.11 102.17 100.02 95.03 91.97
SERVICE
NOTES
'TEES'.
109 FOR MATERIAL DESCRIPTION OF PIPELINE SPECIALITY ITEMS VIZ. SCRAPER TRAPS, INSULATING JOINTS, FLOW
TEES, PIG SIGNALERS REFER APPLICABLE DATA SHEETS.
110 THESE ARE LINEPIPES. THIS LINEPIPES SHALL BE USED IN ABOVE GROUND SECTION FROM PIPELINE ABOVE
GROUND/ BURIED TRANSITION LOCATION TO SCRAPER TRAP ONLY. THIS LINEPIPE SHALL NOT BE USED FOR
STATION/ TERMINAL PIPING.
111 THIS FLANGE SHALL BE USED FOR SCRAPER TRAP'S PIPELINE NOZZLE MATING FLANGE. THE SAME SHALL NOT BE
USED ANY WHERE IN THE STATION/ TERMINAL PIPING.
SPECIAL NOTES

JOINTS
DRAINS 0.75" AS PER A922-000-83-41-ST-0011.
VENTS 0.75" AS PER A922-000-83-41-ST-0011.
PIPING
Package : IPMCS
Report No. : 50 DA9A
Page 110 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 31 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. T 16.
14. T T 14.
12. T T T 12.
10. T T T T 10.
8.0 T T T T T 8.0
6.0 T T T T T T 6.0
5.0 5.0
4.0 T T T T W W W 4.0
3.5 3.5
3.0 T T T W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W 2.0
1.5 T T T T S S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S S S S 1.0
0.75 T T T S S S S S S S S S 0.75
0.5 T T T T S S S S S S S S S 0.5
10.000
12.000
14.000
16.000
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 DA9A
Page 111 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 32 of 47


Pipe Group

PSL2
PIP PIPE 8 8 11.1 API 5L API 5L GR.X-56 BE, E.R.W PIAG714Z0 110
PSL2
PSL2
PSL2
PSL2
Flange Group
GR.LF2 CL.1
GR.LF2 CL.1
52 (CHARPY)
FLG/60 FLNG.WN 8 8 11.1 B-16.5 ASTM A 694 GR.F- 600, RF/125AARH FWCA367Z0 111
0 56 (CHARPY)
GR.LF2 CL.1
(CHARPY)
B16.48 GR.LF2 CL.1
B16.48 (CHARPY)
B16.48 (CHARPY)
Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
Package
Report No.
: IPMCS
: 50 DA9A
Page 112 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 33 of 47


Fitting Group
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
Package
Report No.
: IPMCS
: 50 DA9A
Page 113 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 34 of 47


Fitting Group
GR.LF2 CL.1
GR.WPL6
GR.WPHY-52
(CHARPY)
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
O'let Group
GR.LF2 CL.1
GR.LF2 CL.1
XXS GR.LF6 CL.1
S160 GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
GR.B7(HDG),
NUT:A194
GR.2H(HDG)
Gasket Group
Package
Report No.
: IPMCS
: 50 DA9A
Page 114 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 35 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : DL9A Sheet 1 of 4
PIPE CLASS : DL9A

RATING : 600

TEMP -45 38 50 65 100 150
PRESS 104.11 104.11 102.17 100.02 95.03 91.97
SERVICE
NOTES
'TEES'.
SPECIAL NOTES

JOINTS
DRAINS 0.75" AS PER A922-000-83-41-ST-0011.
VENTS 0.75" AS PER A922-000-83-41-ST-0011.
PIPING
Package : IPMCS
Report No. : 50 DL9A
Page 115 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 36 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. 16.
14. 14.
12. 12.
10. 10.
8.0 8.0
6.0 T 6.0
5.0 5.0
4.0 T T 4.0
3.5 3.5
3.0 T T T 3.0
2.5 2.5
2.0 T T T W 2.0
1.5 T T T T S 1.5
1.25 1.25
1.0 T T S S S S 1.0
0.75 T T T S S S S 0.75
0.5 T T T T S S S S 0.5
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 DL9A
Page 116 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 37 of 47


Pipe Group
Flange Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
B16.48 GR.LF2 CL.1
Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.WPL6
GR.WPL6
GR.WPL6
Package
Report No.
: IPMCS
: 50 DL9A
Page 117 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 38 of 47


Fitting Group
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
CAP CAP 2 6 M B-16.9 ASTM A 420 BW WFGB44ZZ5
GR.WPL6
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
GR.LF2 CL.1
O'let Group
GR.LF2 CL.1
GR.LF2 CL.1
XXS GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
Gasket Group
Package
Report No.
: IPMCS
: 50 DL9A
Page 118 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 39 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : EA9A Sheet 1 of 5
PIPE CLASS : EA9A

RATING : 900
TEMP -29 38 50 65 100 150
PRESS 156.22 156.22 153.36 150.11 142.55 137.86
SERVICE
NOTES
'TEES'.
113 FITTINGS OF SIZE UPTO 16 INCH SHALL BE OF SEAMLESS TYPE.
SPECIAL NOTES

JOINTS
PIPE JOINTS ALL BUTT WELDED
DRAINS 0.75" AS PER A922-000-83-41-ST-0011
VENTS 0.75" AS PER A922-000-83-41-ST-0011
PIPING
PR. CON. ON 2.0" (PI, PT, PG & PDT ON EQUIP., VESS.) FLNG WITH 2 NOS. BALL
Package : IPMCS
Report No. : 50 EA9A
Page 119 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 40 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. T 16.
14. T T 14.
12. T T T 12.
10. T T T T 10.
8.0 T T T T T 8.0
6.0 T T T T T T 6.0
5.0 5.0
4.0 T T T T W W W 4.0
3.5 3.5
3.0 T T T W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W 2.0
1.5 T T T T W W W W W W 1.5
1.25 1.25
1.0 T T W W W W W W W W W 1.0
0.75 T T T W W W W W W W W W 0.75
0.5 T T T T W W W W W W W W W 0.5
10.000
12.000
14.000
16.000
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 EA9A
Page 120 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 41 of 47


Pipe Group
PIP PIPE .5 3 S160 B-36.10 ASTM A 333 GR.6 BE, SEAMLESS PI24617Z0

PSL2
PSL2
PSL2
PSL2
PIP PIPE 16 16 S100 API 5L API 5L GR.X-52 BE, SAW PIAG516Z0
PSL2
Flange Group
FLG FLNG.WN .5 2 M B-16.5 ASTM A 350 1500, RTJ/63AARH FWCD789Z0
GR.LF2 CL.1
FLG FLNG.WN 3 3 M B-16.5 ASTM A 350 900, RTJ/63AARH FWCD779Z0
GR.LF2 CL.1
FLG FLNG.WN 4 6 M B-16.5 ASTM A 694 GR.F- 900, RTJ/63AARH FWC9979Z0
42 (CHARPY)
FLG FLNG.WN 8 16 M B-16.5 ASTM A 694 GR.F- 900, RTJ/63AARH FWCA279Z0
52 (CHARPY)
FLB FLNG.BLIND .5 2 B-16.5 ASTM A 350 1500, RTJ/63AARH FBCD789Z0
GR.LF2 CL.1
FLB FLNG.BLIND 3 3 B-16.5 ASTM A 350 900, RTJ/63AARH FBCD779Z0
GR.LF2 CL.1
FLB FLNG.BLIND 4 16 B-16.5 ASTM A 105 900, RTJ/63AARH FBC9879Z0
(CHARPY)
FEF FLNG.FIG.8 .5 3 ASME- ASTM A 350 900, RTJ/63AARH FGKD779Z0
B16.48 GR.LF2 CL.1
FEF FLNG.FIG.8 4 4 ASME- ASTM A 105 900, RTJ/63AARH FGK9879Z0
B16.48 (CHARPY)
FEF SPCR&BLND 6 16 ASME- ASTM A 105 900, RTJ/63AARH FCK9879Z0
B16.48 (CHARPY)
Fitting Group
ELB90 ELBOW.90 .5 3 M B-16.9 ASTM A 420 BW, 1.5D WAGB44Z10 113
GR.WPL6
ELB90 ELBOW.90 4 6 M B-16.9 MSS SP-75 BW, 1.5D WAGF94Z10 113
GR.WPHY-42
GR.WPHY-52
(CHARPY)
ELB45 ELBOW.45 .5 3 M B-16.9 ASTM A 420 BW, 1.5D WBGB44Z10 113
GR.WPL6
ELB45 ELBOW.45 4 6 M B-16.9 MSS SP-75 BW, 1.5D WBGF94Z10 113
GR.WPHY-42
Package
Report No.
: IPMCS
: 50 EA9A
Page 121 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 42 of 47


Fitting Group
GR.WPHY-52
(CHARPY)
TEQ T.EQUAL .5 3 M B-16.9 ASTM A 420 BW WEGB44ZZ0 113
GR.WPL6
TEQ T.EQUAL 4 6 M B-16.9 MSS SP-75 BW WEGF94ZZ0 113
GR.WPHY-42
GR.WPHY-52
(CHARPY)
TRED T.RED .5 3 M, M B-16.9 ASTM A 420 BW WRGB44ZZ0 113
GR.WPL6
TRED T.RED 4 6 M, M B-16.9 MSS SP-75 BW WRGF94ZZ0 113
GR.WPHY-42
GR.WPHY-52
(CHARPY)
REDC REDUC.CONC .5 3 M, M B-16.9 ASTM A 420 BW WUGB44ZZ0 113
GR.WPL6
REDC REDUC.CONC 4 6 M, M B-16.9 MSS SP-75 BW WUGF94ZZ0 113
GR.WPHY-42
REDC REDUC.CONC 8 16 M, M B-16.9 MSS SP-75 BW WUGG24ZZ0 113
GR.WPHY-52
REDE REDUC.ECC .5 3 M, M B-16.9 ASTM A 420 BW WVGB44ZZ0 113
GR.WPL6
REDE REDUC.ECC 4 6 M, M B-16.9 MSS SP-75 BW WVGF94ZZ0 113
GR.WPHY-42
REDE REDUC.ECC 8 16 M, M B-16.9 MSS SP-75 BW WVGG24ZZ0 113
GR.WPHY-52
CAP CAP .5 3 M B-16.9 ASTM A 420 BW WFGB44ZZ0 113
GR.WPL6
CAP CAP 4 6 M B-16.9 MSS SP-75 BW WFGF94ZZ0 113
GR.WPHY-42
GR.WPHY-52
(CHARPY)
O'let Group
WLT WELDOLET .5 3 M, MSS-SP97 ASTM A 350 BW YWSX44ZZ0
XXS GR.LF6 CL.1
S160 GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
Package
Report No.
: IPMCS
: 50 EA9A
Page 122 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 43 of 47


Bolt Group
GR.B7(HDG),
NUT:A194
GR.2H(HDG)
Gasket Group
GAS GASKET .5 2 B-16.20- SOFT IRON OCT-RING, 1500 GK67238Z0
ANSI B16.5
GAS GASKET 3 16 B-16.20- SOFT IRON OCT-RING, 900 GK67237Z0
ANSI B16.5
Package
Report No.
: IPMCS
: 50 EA9A
Page 123 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 44 of 47

Location : GUJRAT & RAJASTHAN Pipe Class : EL9A Sheet 1 of 4
PIPE CLASS : EL9A

RATING : 900

TEMP -45 38 50 65 100 150
PRESS 156.22 156.22 153.36 150.11 142.55 137.86
SERVICE
NOTES
'TEES'.
113 FITTINGS OF SIZE UPTO 16 INCH SHALL BE OF SEAMLESS TYPE.
SPECIAL NOTES

JOINTS
PIPE JOINTS ALL BUTT WELDED
DRAINS 0.75" AS PER A922-000-83-41-ST-0011
VENTS 0.75" AS PER A922-000-83-41-ST-0011
PIPING
PR. CON. ON 2.0" (PI, PT, PG & PDT ON EQUIP., VESS.) FLNG WITH 2 NOS. BALL
Package : IPMCS
Report No. : 50 EL9A
Page 124 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 45 of 47

72. 72.
70. 70.
68. 68.
66. 66.
64. 64.
62. 62.
60. 60.
58. 58.
56. 56.
54. 54.
52. 52.
50. 50.
48. 48.
46. 46.
44. 44.
42. 42.
40. 40.
38. 38.
36. 36.
34. 34.
32. 32.
30. 30.
28. 28.
26. 26.
24. 24.
22. 22.
20. 20.
18. 18.
16. 16.
14. 14.
12. 12.
10. 10.
8.0 8.0
6.0 T 6.0
5.0 5.0
4.0 T T 4.0
3.5 3.5
3.0 T T T 3.0
2.5 2.5
2.0 T T T W 2.0
1.5 T T T T W 1.5
1.25 1.25
1.0 T T W W W W 1.0
0.75 T T T W W W W 0.75
0.5 T T T T W W W W 0.5
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
.500
.750
CODE DESCRIPTION
Package : IPMCS
Report No. : 50 EL9A
Page 125 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 46 of 47


Pipe Group
PIP PIPE .5 3 S160 B-36.10 ASTM A 333 GR.6 BE, SEAMLESS PI24617Z5

PSL2
Flange Group
FLG FLNG.WN .5 2 M B-16.5 ASTM A 350 1500, RTJ/63AARH FWCD789Z5
GR.LF2 CL.1
FLG FLNG.WN 3 3 M B-16.5 ASTM A 350 900, RTJ/63AARH FWCD779Z5
GR.LF2 CL.1
FLG FLNG.WN 4 6 M B-16.5 ASTM A 694 GR.F- 900, RTJ/63AARH FWC9979Z5
42 (CHARPY)
FLB FLNG.BLIND .5 2 B-16.5 ASTM A 350 1500, RTJ/63AARH FBCD789Z5
GR.LF2 CL.1
FLB FLNG.BLIND 3 3 B-16.5 ASTM A 350 900, RTJ/63AARH FBCD779Z5
GR.LF2 CL.1
FLB FLNG.BLIND 4 6 B-16.5 ASTM A 105 900, RTJ/63AARH FBC9879Z5
(CHARPY)
FEF FLNG.FIG.8 .5 3 ASME- ASTM A 350 900, RTJ/63AARH FGKD779Z5
B16.48 GR.LF2 CL.1
FEF FLNG.FIG.8 4 4 ASME- ASTM A 105 900, RTJ/63AARH FGK9879Z5
B16.48 (CHARPY)
FEF SPCR&BLND 6 6 ASME- ASTM A 105 900, RTJ/63AARH FCK9879Z5
B16.48 (CHARPY)
Fitting Group
ELB90 ELBOW.90 .5 3 M B-16.9 ASTM A 420 BW, 1.5D WAGB44Z15 113
GR.WPL6
ELB90 ELBOW.90 4 6 M B-16.9 MSS SP-75 BW, 1.5D WAGF94Z15 113
GR.WPHY-42
ELB45 ELBOW.45 .5 3 M B-16.9 ASTM A 420 BW, 1.5D WBGB44Z15 113
GR.WPL6
ELB45 ELBOW.45 4 6 M B-16.9 MSS SP-75 BW, 1.5D WBGF94Z15 113
GR.WPHY-42
TEQ T.EQUAL .5 3 M B-16.9 ASTM A 420 BW WEGB44ZZ5 113
GR.WPL6
TEQ T.EQUAL 4 6 M B-16.9 MSS SP-75 BW WEGF94ZZ5 113
GR.WPHY-42
TRED T.RED .5 3 M, M B-16.9 ASTM A 420 BW WRGB44ZZ5 113
GR.WPL6
TRED T.RED 4 6 M, M B-16.9 MSS SP-75 BW WRGF94ZZ5 113
GR.WPHY-42
REDC REDUC.CONC .5 3 M, M B-16.9 ASTM A 420 BW WUGB44ZZ5 113
GR.WPL6
REDC REDUC.CONC 4 6 M, M B-16.9 MSS SP-75 BW WUGF94ZZ5 113
GR.WPHY-42
Package
Report No.
: IPMCS
: 50 EL9A
Page 126 of 1963
PIPING MATERIAL
A922-000-83-41-SP-0010_3
SPECIFICATION
Page 47 of 47


Fitting Group
REDE REDUC.ECC .5 3 M, M B-16.9 ASTM A 420 BW WVGB44ZZ5 113
GR.WPL6
REDE REDUC.ECC 4 6 M, M B-16.9 MSS SP-75 BW WVGF94ZZ5 113
GR.WPHY-42
CAP CAP .5 3 M B-16.9 ASTM A 420 BW WFGB44ZZ5 113
GR.WPL6
CAP CAP 4 6 M B-16.9 MSS SP-75 BW WFGF94ZZ5 113
GR.WPHY-42
O'let Group
WLT WELDOLET .5 2 M, MSS-SP97 ASTM A 350 BW YWSX44ZZ5
XXS GR.LF6 CL.1
Bolt Group
(HDG), NUT:A194
GR.4 (HDG)
BOS BOLT.STUD 4 6 B-18.2 BOLT:A320 GR.L7 BS44231Z5 107
(HDG), NUT:A194
GR.4 (HDG)
Gasket Group
GAS GASKET .5 2 B-16.20- SOFT IRON OCT-RING, 1500 GK67238Z5
ANSI B16.5
GAS GASKET 3 6 B-16.20- SOFT IRON OCT-RING, 900 GK67237Z5
ANSI B16.5
Package
Report No.
: IPMCS
: 50 EL9A
Page 127 of 1963
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
JAMNAGAR - LONI PIPELINE CAPACITY AUGMENTATION PROJECT
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
PIPELINE FROM DT AT EOL TO RT AT SV-1, SAPAR D

D
NOTES:
1. THIS DRAWING IS INDICATIVE & FOR INFORMATION PURPOSE ONLY.
2. CHAINAGES INDICATED ARE IN KM AND ARE TENTATIVE. THE FACILITIES & CHAINAGES INDICATED HEREIN ARE BASED
ON SURVEY DATA & DATA AVAILABLE FOR THE EXISTING PIPELINE.
3. FACILITIES INDICATED INSIDE TERMINALS ARE FOR REFERENCE. DETAILS OF FACILTIES & ARRANGEMENT SHALL
BE AS PER P&IDs ONLY.
4. THERE IS COMMON ROU OF 6.625" EOL TO R/L PIPELINE UP TO EXISTING SV-1 AND NEW ROU FROM EXISTING
SV-1 TO RT CUM SV-1 SAPAR . D
5. CHAINAGES INDICATED HEREIN MAY CHANGE BASED ON VARIATION IN LENGTH OF PIPELINE ROUTE DUE TO
REROUTINGS, IF ANY.
6. HOT TAPPING & DOUBLE STOPPLING WITH BY PASS ARRANGEMENT SHALL BE CARRIED OUT AT SV-1 SAPAR FOR
REMOVAL OF EXISTING SECTIONALISING VALVE AND INSTALLATION OF NEW SECTIONALISING VALVE AT RT D
CUM SV-1 SAPAR.
7. CHAINAGE & LOCATION OF NEW SV INSIDE THE EOL REFINERY IS AWAITED FROM THE CLIENT.
D
SCHEMATIC ARRANGEMENT FOR DRAWING NO. REV.

CAPACITY AUGMENTATION OF A922-000-83-41-30011 D
JAM NAGAR - LONI PIPELINE
REV. DATE REVISION BY CHK APPROVED
Page 128 of 1963
A922-000-83-41-30011_D-Schematic.Dwg 1-1641-0503 REV.0 A3-420x297
DOCUMENT No.
ANNEXURE – I (PIPING
MATERIAL SPECIFICATION A922-000-83-41-SP-0010-A1
GENERAL NOTES) Rev. 0
Page 1 of 7

गेल (इडं िया) डलडिटे ि
CAPACITY AUGMENTATION OF JAMNAGAR-LONI
जािनगर-लोनी पाइपलाइन क्षिता डिस्तार पररयोजना (एल पी जी पाइपलाइन)
ANNEXURE-I
PIPING MATERIAL SPECIFICATION

GENERAL NOTES
0 08.11.16 ISSUED FOR ENGINEERING

RB NR MSG
Date Purpose
No by by by
Page 129 of 1963

DOCUMENT No.
Page 2 of 7
CONTENTS
1.0 SCOPE .......................................................................................................... 3
2.0 CODES .......................................................................................................... 3
3.0 MATERIAL SPECIFICATIONS ...................................................................... 3
4.0 CLASS DESIGNATION CODE ...................................................................... 3
5.0 PIPES ............................................................................................................ 4
6.0 FITTINGS ...................................................................................................... 5
7.0 BENDS .......................................................................................................... 5
8.0 FLANGES ...................................................................................................... 5
9.0 GASKETS ...................................................................................................... 6
10.0 BOLTING ....................................................................................................... 6
11.0 THREADS ...................................................................................................... 7
12.0 VALVES ......................................................................................................... 7
13.0 OTHER REQUIREMENT ............................................................................... 7
Page 130 of 1963

DOCUMENT No.
Page 3 of 7
1.0 SCOPE
This specification (PMS) covers various piping classes for process & utility
piping and minimum requirements for various piping materials necessary for
the design of the piping facilities.
This specification shall be read in conjunction with various Codes and
Standards as applicable.
2.0 CODES
Pipeline/ piping terminal facilities envisaged as part of this project shall be
designed and engineered primarily in accordance with the provisions of the
latest edition of the following codes:
 ASME B31.4 - Pipeline Transportation Systems for Liquids and
Slurries
 ASME B31.3 - Process Piping
 OISD 214 - Design and Construction requirements for Cross country
LPG Pipelines
 PNGRB Regulations
All Codes, Standards and Specifications referred herein shall be the latest
edition of such documents.
For sake of brevity the initials of the society to which the codes are referred
may be omitted in the specifications, for example, B16.5 is a code referring to
ASME, A105 is a code referring to ASTM.
In addition, EIL specifications and standards for various piping and pipeline
materials shall also be applicable.
3.0 MATERIAL SPECIFICATIONS
Individual piping class has been generally designed to cover a set of services
operating within pressure-temperature combination as per ASME B16.5/
B16.34 or part of it. Deviations of material from class specifications may occur
due to specific design conditions and/ or availability. These deviations are
permissible if they equal or better the individual class requirements and shall
be subjected to approval on case-to-case basis.
All materials shall conform to detailed specifications, Standards listed in
annexure-II of this specification as applicable.
4.0 CLASS DESIGNATION CODE
The piping class designation shall generally consist of four digits made up of
Alphabet, Alphabet, Numerical & Alphabet e.g.AA1A, AA1K etc. as follows:
First Alphabet Second Alphabet & Fourth Alphabet
Third numerical
A-150 CLASS A3-differences in the A - Carbon steel
specifications within
the same class rating
and material; CA-1.5
mm
Page 131 of 1963

DOCUMENT No.
Page 4 of 7
A-150 CLASS A9-differences in the A - Carbon steel

mm
A-150 CLASS L9-differences in the A - Carbon steel
mm; Low Temperature
Service
B-300 CLASS A9-differences in the A - Carbon steel
mm
B-300 CLASS L9-differences in the A - Carbon steel
mm; Low Temperature
Service
D-600 CLASS A9-differences in the A - Carbon steel
mm
D-600 CLASS L9-differences in the A - Carbon steel
mm; Low Temperature
Service
E-900 CLASS A9-differences in the A - Carbon steel
mm
E-900 CLASS L9-differences in the A - Carbon steel
mm; Low Temperature
Service
5.0 PIPES
5.1 Pipes made by acid-Bessemer process shall not be acceptable. The steel
used shall be fully killed and made with fine grain structure. The grade and
Page 132 of 1963

DOCUMENT No.
Page 5 of 7
wall thickness of various sizes of pipes shall be as per piping material

specification for the applicable class.
5.2 Pipe dimension shall be in accordance with ASME B36.10 for carbon steel
ASTM standard pipes; IS:1239 & IS:3589 for wrought steel & wrought iron
pipe; B36.10/ B36.19 for stainless steel pipe, API 5L for carbon steel API 5L
grade pipes and respective ASTM standard for non-ferrous and non-metallic
pipes.
5.3 All pipe threads shall conform to American Standard Taper as per ASME B
1.20.1 NPT, unless otherwise specified.
5.4 For butt weld end, bevel shall be in accordance with API specification 5L or
ASME B16.25 as applicable. In case of difference in thickness of matching
ends, requirements of ASME B 31.4 shall apply.
5.5 Non-standard pipe sizes viz. 1¼”, 2½”, 3½”, 5”, 22” and 26” shall not be
treated as a part of this specification.
6.0 FITTINGS
6.1 Fully killed carbon steel shall be used in the manufacture of fittings. The
carbon steel fittings shall have carbon equivalent not exceeding 0.43%,
based on check analysis.
6.2 Threaded joints, if used, shall conform to American Standard Taper as per
ASME B1.20.1 NPT.
6.3 Dimensions of socket welded/ screwed fittings shall conform to ASME
B16.11. Swage shall be as per BS 3799
6.4 Dimensions of steel butt welded fittings shall be as per ASME B16.9/ MSS-
SP-75, as applicable.
6.5 Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its
thickness.
6.6 Butt welding ends shall conform to API specification 5L or ASME B 16.25 as
applicable. In case of difference in thickness of matching ends, requirements
of ASME B 31.4 shall apply.
6.7 Integrally reinforced forged branch fittings such as Sockolet, Weldolet etc.
shall be as per MSS-SP-97. Fittings not covered in MSS-SP-97 shall conform
to manufacturer’s standard.
6.8 Fittings thickness tolerances shall match pipe thickness tolerance.
7.0 BENDS
7.1 Unless otherwise specified for process piping, elbow of radius R = 1.5D shall
only be used.
7.2 Miters shall not be used.
8.0 FLANGES
8.1 Pressure Temperature Rating of flanges shall conform to B16.5/ MSS-SP-44/
B16.47 SERIES ‘A’, as applicable.
8.2 Dimensions of flanges shall be in accordance with B16.5/ MSS-SP-44/
B16.47 SERIES ‘A’, as applicable.
Page 133 of 1963

DOCUMENT No.
Page 6 of 7
8.3 Neck of weld neck (WN) flanges shall suit pipe bore and thickness.
8.4 Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness.
8.5 Threads for screwed flanges, if used, shall conform to American Standard
Taper as per ASME B1.20.1 NPT.
8.6 Sizes for blind flanges shall be indicated by nominal pipe size.
8.7 Finish of steel flange faces shall be as follows:
Serrated Finish/ 125 AARH/ Smooth : Serrations with 125-250
Finish µin AARH
63 AARH : 32 TO 63 µin AARH
8.8 Butt welding ends of WN flanges shall conform to ASME B 16.25.
8.9 Brinnel hardness for RTJ groove shall be atleast 20 BHN more than that of
corresponding gasket as specified.
8.10 For Class Rating 150#, 600# & 900#, Spectacle blind/ Spacer & Blind of size
upto 24” shall be in accordance with ASME B16.48. For Class Rating 150# &
600#, Spacer & Blind of size 26” & Above shall be in accordance with EIL
Standard. For Class Rating 900#, Spacer & Blind of size 26” & Above shall be
in accordance with Manufacturer Standard.
8.11 Two Jack screws, 1800 apart shall be provided in Spectacle blind or Spacer &
Blind assemblies as per EIL standard No. 7-44-0252.
9.0 GASKETS
9.1 Spiral wound gaskets shall conform to ASME B 16.20. All spiral wound
gaskets shall be provided with carbon steel centering ring. Spiral wound
gasket shall be self aligning type.
9.2 Octagonal ring joint gasket shall conform to B16.20.
10.0 BOLTING
10.1 Nuts for Bolts and Studs shall be American Standard Hexagon Heavy Series
and double chamfered.
10.2 Dimension and tolerances for stud bolts and nuts shall be as per ASME
B18.2.1 and B18.2.2 with full threading to ASME B1.1 Class 2A thread for
bolts and Class 2B for nuts. Diameter of stud bolts shall be as per ASME B
16.5/ ASME B16.47 with full threading.
10.3 Threads for nuts shall be as per ASME B1.1, as follows:
Nuts for stud bolts dia ¼" to 1" : UNC-2B
Nuts for stud bolts dia 1⅛" to 3¼" : 8UN-2B
10.4 Threads for stud bolts shall be as per ASME B1.1, as follows:
Stud bolts dia ¼" to 1" : UNC-2A
Stud bolts dia 1⅛" to 3¼" : 8UN-2A
10.5 Threads for threaded pipe, fitting, flanges and valve shall be in accordance
with B1.20.1 taper threads, unless specified otherwise.
10.6 Heads of jack screws shall be heavy hexagonal type. Jack screw end shall be
rounded. Stud bolts shall be fully threaded with two hexagonal nuts.
Page 134 of 1963

DOCUMENT No.
Page 7 of 7
11.0 THREADS
11.1 Threaded joints shall be made with 1” wide PTFE joining tape.
12.0 VALVES
12.1 Valves shall be as per Valve Data Sheet & Specifications.
13.0 OTHER REQUIREMENT
13.1 In PMS wherever ‘M’ is indicated as thickness, the end thickness of the item
shall be the thickness of same size pipe within the piping class.
13.2 All piping items 2” & above shall be Charpy V-notch impact tested.
Page 135 of 1963

DOCUMENT No.
PIPING MATERIAL A922-000-83-41-SP-0010
SPECIFICATION – ANNEXURE-II ANNEXURE - II Rev.0
Page 1 of 5
ANNEXURE – II
DATA SHEETS & LIST OF SPECIFICATIONS
0 08.11.16 ISSUED FOR ENGINEERING

RB NR MSG
Date Purpose
No by by by
Page 136 of 1963

DOCUMENT No.
Page 2 of 5
TABLE OF CONTENTS
1.0 LIST OF SPECIFICATIONS & STANDARDS
2.0 LIST OF VALVE DATA SHEETS (<2”)
3.0 VALVE DATA SHEETS (<2”)
Page 137 of 1963

DOCUMENT No.
Page 3 of 5
1.0 LIST OF SPECIFICATIONS & STANDARDS
Following detailed EIL specifications shall be used for procurement of materials

against various piping classes.
S.No. Title Specification No.

Standard Specification for High Frequency welded
1. 6-71-0005
(HFW) linepipe (Onshore)
Addendum to Standard Specification for High
2. A922-000-83-41-AD-0005
Frequency welded (HFW) linepipe (Onshore)
3. Standard Specification for 3 Layer PE Coating 6-71-0041
Addendum to Standard Specification for 3 Layer
4. A922-000-83-41-AD-0041
PE Coating
5. Standard Specification for Pipeline Ball Valves 6-71-0014
Addendum to Standard Specification for Pipeline
6. A922-000-83-41-AD-0014
Ball Valves
7. Standard Specification for Pipeline Plug Valves 6-71-0016
Addendum to Specification for Pipeline Plug
8. A922-000-83-41-AD-0016
Valves
9. Specification for Check Valves 6-71-0017
Addendum to Specification for Pipeline Plug
10. A922-000-83-41-AD-0017
Valves
11. Standard Specification for Long Radius Bends 6-71-0021
Standard Specification for Seamless Fittings and
12. 6-71-0024
Flanges up to 400(16”)NB
Addendum to Standard Specification for Seamless
13. A922-000-83-41-AD-0024
Fittings and Flanges up to 400(16”)NB
14. Specification for Flow Tees 6-71-0025
15. Specification for Insulating Joints (onshore) 6-71-0026
16. Standard Specification for Scraper Traps 6-71-0031
17. Standard Specification for Pig Signaller 6-71-0033
Standard Specification for Surface preparation
18. 6-79-0020
and protective coating (new construction)
Standard Specification for Fabrication and 6-44-0012
19.
Erection of Piping
Standard Specification for Inspection, Flushing
20. 6-44-0013
and Testing of Piping System
Standard Specification for Non Destructive
21. 6-44-0016
Examination Requirements of Piping
22. Technical Notes for Pipes 6-44-0051
23. Technical Notes for Valves 6-44-0052
Technical Notes for Flanges, Spectacle Blinds and
24. 6-44-0053
Drip Rings
Technical Notes for Butt Welded, Socket Welded
25. 6-44-0054
and Screwed Fittings
26. Technical Notes for Gaskets 6-44-0056
Page 138 of 1963

DOCUMENT No.
Page 4 of 5
27. Technical Notes for Bolts & Nuts 6-44-0057

Technical notes for spring support
28. 6-44-0070
assemblies
29. Stub-in standard 7-44-0032
30. Gasket Thickness 7-44-0170
Method of cutting and dimensions of field
31. 744-0485
manufactured concentric reducers.
32. Tolerances for fabrication 7-44-0486
Method of cutting & dimensions of field
33. 7-44-0487
manufactured eccentric reducers.
34. Details of mitered elbow. 7-44-0033
T-strainer type- 1 2"- 4" (150CL RF, 300CL RF &
35. 7-44-0303
RTJ, 600CL RF & RTJ).
‘T’ strainer type-1 6" - 24"(150# RF, 300# RF and
36. 7-44-0304
RTJ, 600# RF and RTJ).
Temporary strainer RF (all ratings), FF 125# -
37. 7-44-0300
300#.
38. Vent & drains (on lines 1 ½” and below) 7-44-0350
39. Vents and drains (on lines 2" and above) 7-44-0351
40. Wells installation 1 ½” dia taps 7-44-0353
41. Pressure tappings (PA, PG, PC, PT, PIC etc) 7-44-0354
42. Welding of pipe with different thickness 7-44-0476
43. Butt welding end preparation 7-44-0477
44. Fillet weld details 7-44-0478
Welding details for branch connections (not
45. 7-44-0479
breaking into)
46. Butt weld details (dimensions) 7-44-0480
Welding detail for branch connections
47. 7-44-0482
(stub in)
48. Branch connection (breaking into) 7-44-0483
49. Branch connection (not breaking into) 7-44-0484
50. Clearances 7-44-0501
51. Accessibility for valves & instruments 7-44-0502
52. Valve accessibility & clearances 7-44-0503
Clearance requirements for orifice flange
53. 7-44-0504
instrument piping
54. Table of basic span 7-44-0506
Maximum spacing of guides for vertical
55. 7-44-0507
and horizontal pipes
2.0 LIST OF VALVE DATA SHEETS (<2”)
Following data sheets shall be used for procurement of piping materials.
Page 139 of 1963

DOCUMENT No.
Page 5 of 5
S.No. Title Data Sheet No.

Data sheet for AA9A, AL9A,
1. BA9A, BL9A, DA9A & DL9A Ball A922-000-83-41-DS-1001
valve (1.5” & below)
Data sheet for EA9A & EL9A Ball
2. A922-000-83-41-DS-1002
Data sheet for Plug valve AA9A,
3. AL9A, BA9A, BL9A, DA9A & A922-000-83-41-DS-1003
DL9A (1.5” & below)
Data sheet for Plug valve EA9A &
4. A922-000-83-41-DS-1004
EL9A (1.5” & below)
5. BA9A, BL9A, DA9A & DL9A Globe A922-000-83-41-DS-1005
Data sheet for EA9A & EL9A
6. A922-000-83-41-DS-1006
Globe valve (1.5” & below)
Data sheet for Check valve AA9A,
7. AL9A, BA9A, BL9A, DA9A & A922-000-83-41-DS-1007
DL9A (1.5” & below)
Data sheet for Check valve EA9A
8. A922-000-83-41-DS-1008
& EL9A (1.5” & below)
9. BA9A, BL9A, DA9A & DL9A Gate A922-000-83-41-DS-1009
Data sheet for EA9A & EL9A Gate
10. A922-000-83-41-DS-1010
Data sheet for AA3A Gate valve (
11. 51001
1.5” & below)
Data sheet for AA3A Globe valve (
12. 52001
1.5” & below)
13. . Data sheet for AA3A Check valve
53001
14. ( 1.5” & below)
Data sheet for AA3A Ball valve (
15. 54321
0.5” to 16”)
3.0 VALVE DATA SHEETS (<2”)
Data Sheets as listed above are enclosed herewith.
Page 140 of 1963

WELDING SPECIFICATION FOR A922-020-02-42-WSP-0001
ONSHORE PIPELINE REV.2
Page 1 of 43
WELDING SPECIFICATION FOR

ONSHORE PIPELINE
PROJECT : CAPACITY AUGMENTATION OF JAMNAGAR-

LONI PIPELINE PROJECT ( LJL/011)
CLIENT : M/s GAIL (INDIA) LIMITED
EPCM : M/s ENGINEERS INDIA LTD.
JOB NO. : A922

PIPELINE CODE : 22101500
2 23.12.2016 Revised & Reissued for Tender S K Mishra P Chowdhary A Roy
1 21.11.2016 Revised & Reissued for Tender S K Mishra P Chowdhary A Roy
0 09.09.2016 Issued for Tender P V Chitti P Chowdhary A Roy
Rev. No Date Purpose Prepared by Checked by Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
Page 141 of 1963

Page 2 of 43
CONTENTS
1.0 SCOPE 3
2.0 APPLICABLE CODE AND STANDARDS 3
3.0 BASE MATERIAL 4
4.0 WELDING CONSUMABLES 4
5.0 EQUIPMENT AND ACCESSORIES 5
6.0 WELDING PROCESSES 6
7.0 BEVEL CLEANING/BEVEL INSPECTION 6
8.0 ALIGNMENT AND SPACING 6
9.0 WEATHER CONDITIONS 8
10.0 WELDING 8
11.0 HEAT TREATMENT 10
12.0 INSPECTION AND TESTING 12
13.0 REPAIRS OF WELDS 15
ANNEXURE – 1: Destructive Testing of Welded joint (Butt welds) 16
ANNEXURE-3: RADIOGRAPHY INSPECTION 23
EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD 28
EXHIBIT-B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION 31
EXHIBIT – C: RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST 32
EXHIBIT – D: RECORD FORM FOR WELDER QUALIFICATION TEST 35
EXHIBIT – E: WELDER’S IDENTIFICATION CARD 36
EXHIBIT – F: RADIOGRAPHIC PROCEDURE FOR PIPE WELDING 37
Page 142 of 1963

Page 3 of 43
1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of welded
joints of carbon steel piping systems connected with the pipeline and related facilities.
The welded pipe joints shall include the following:
a) All line pipe joints of the circumferential butt welded and socket welded types.
b) Attachments of castings, forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded/fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other instrument
tappings.
Any approval granted by the OWNER shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
The Welding Specification Charts specified in this document shall refer to A922-020-02-42-
WSC-0001.
2.0 APPLICABLE CODE AND STANDARDS

All welding work, equipment, equipment for welding, heat treatment, other auxiliary functions
and the welding personnel shall meet the requirements of the latest editions of the codes,
standards and specification listed below:
a) ANSI B 31.4: Code for Transportation System for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and Alcohols.
b) API 1104 (2013): Standard for welding of Pipelines and Related Facilities.
c) ASME Sec. II part C (2015): Specification for welding Electrodes and filler Materials.
d) ASME Sec. V (2015): Non Destructive Examination.
e) A922-020-02-42-WSC-0001: Welding Specification Chart for Pipeline and Hot Tap
Welding.
f) BS EN ISO 6892-1(2009) Metallic materials. Tensile testing. Method of test at
ambient temperature.
g) ASTM E3 (2011): Standard guide for preparation of metallographic specimens.
h) ISO 6507-1 (2005): Metallic Materials-Vicker’s Hardness test-Part 1: Test method.
i) ISO 6507-2 (2005):- Metallic Materials-Vicker’s Hardness test-Part 2: Verification &
Calibration of testing machines.
j) BS EN ISO 148-1(2009): Metallic materials. Charpy pendulum impact test.
k) ASTM A 370 (2012a): Standard Test Methods and Definitions for Mechanical Testing
Of Steel Products
l) ASTM E 1815 (2008): Standard Test Method for Classification of Film for Industrial
Radiography
Page 143 of 1963

Page 4 of 43
2.1 Abbreviations:
ANSI: American National Standards Institute
API: American Petroleum Institute
ASME: American Society of Mechanical Engineers
BS: British Standard
CRT: Cathode Ray Tube
CTOD: Crack Tip Opening Displacement
GMAW: Gas Metal Arc Welding
GTAW: Gas Tungsten Arc Welding
HAZ: Heat Affected Zone
HV: Vickers Hardness
IIW: International Institute of Welding
IQI: Image Quality Indicator
ISO: International Organization for Standardisation
MPI: Magnetic Particle Inspection
PQR: Procedure Qualification Record
SMAW: Shielded Metal Arc Welding
UT: Ultrasonic Testing
UTS: Ultimate Tensile Strength
WPS: Welding Procedure Specification
3.0 BASE MATERIAL

In general carbon steel is used in this specification. The details of material specification are
given in the Welding Specification Charts attached along with other project data sheets.
The CONTRACTOR will arrange and maintain the record of test certificates of all the
materials for the reference of the welding engineer.
4.0 WELDING CONSUMABLES

a) The CONTRACTOR shall provide at his own expense all the welding consumables
necessary for the execution of the job such as electrodes, oxygen, acetylene etc. and
these shall bear the approval of the OWNER.
b) The welding electrodes/filler wires supplied by the CONTRACTOR shall conform to

the class specified in the welding specification chart attached along with other project
data sheets. The materials shall be of the make approved by the OWNER.
c) The electrode shall be suitable for the welding process recommended and base metal
used. Physical properties of the welds produced by an electrode recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal unless otherwise specified in Welding Specification Chart
and shall correspond to the physical properties of the class of electrode adopted. The
Page 144 of 1963

Page 5 of 43
choice of electrode shall be made after conducting the required tests on the electrodes
as per relevant standards, and shall be the sole prerogative of the OWNER.
d) The CONTRACTOR shall submit batch tests certificates from the electrode
manufacturers giving details of physical and chemical tests carried out by them for
each batch of electrodes to be used.
e) Electrode Qualification test records shall be submitted as per the Exhibit-A (attached)
in respect of the electrodes tested by the CONTRACTOR for obtaining the approval of
the OWNER.
f) All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers (except cellulosic
electrodes) shall be kept in holding ovens, at the temperature recommended by the
electrode manufacturer. Ovens shall be used for low hydrogen electrodes only. Out-
of-the oven time of electrodes before they are consumed shall not exceed the limits
recommended by the electrode manufacturer. The electrodes shall be handled with
care to avoid any damage to the flux covering.
Different grades of electrodes shall be stored separately. Cellulosic electrodes used

shall however be used as per specific recommendations of manufacturer.
g) Diffusible hydrogen in any of the weld shall be limited to a maximum of 10 ml per

100 g of weld metal irrespective of the type of consumables or welding method. The
method of determination shall be as per AWS A4.3 as indicated in AWS A5.1 or ISO
3690:2012.
h) The electrodes used shall be free from rust, oil, grease, earth and other foreign matter
which affect the quality of welding.
h) Shielding Gas
The composition and purity of shielding gas when required by the welding processes
other than shielded metal arc welding, when permitted by the OWNER shall bear the
approval of the OWNER. Where appropriate, gases or gas mixture of the following
quality shall be used.
a) argon complying with BS 4365.

b) carbon dioxide complying with type 1 specified in BS 4105.
c) gas mixtures that have been proved to be satisfactory as a result of procedure
approval tests.
When a gas mixture is used which has specified additions, e.g. 2% O2, 5% CO2 the
variation of such addition shall not exceed ±10% of that stated. Moisture content shall
correspond to a dew point of -30˚ C or lower.
5.0 EQUIPMENT AND ACCESSORIES
5.1 The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedules.
5.2 All the equipment for performing the heat treatment, including transformers, thermocouples,
pyro-metres, automatic temperature recorders with suitable calibration arrangements, etc. shall
Page 145 of 1963

Page 6 of 43
be provided by the CONTRACTOR, at his own expense and these shall bear the approval of
the OWNER. Adequate means of measuring current and voltage shall be available.
5.3 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR, will be done at his own expense.
6.0 WELDING PROCESSES
6.1 The welding processes to be employed are given in the welding specification chart attached
along with other project data sheets. Any deviation desired by the CONTRACTOR shall be
obtained through the express consent of the OWNER.
6.2 A combination of different welding processes or a combination of electrodes of different

classes/makes could be employed for a particular joint only after duly qualifying the welding
procedures to be adopted and obtaining the approval of the OWNER.
7.0 BEVEL CLEANING/BEVEL INSPECTION

Before welding, all rust and foreign matter shall be removed from the bevelled ends by power
operated tools. This shall be effected inside and outside and for a minimum distance of 25
mm from the edge of the weld bevel. The bevels shall be thoroughly inspected at this stage.
If any of the ends of the pipe joints are damaged to the extent that, in the opinion of OWNER,
satisfactory weld spacing cannot be obtained and local repair by grinding cannot be
successfully done, the damaged ends shall be cut and bevelled to the satisfaction of the
OWNER, with an approved bevelling machine. Manual cutting and weld repairs of bevels is
not allowed. Should laminations, split ends or inherent manufacturing defects in the pipe be
discovered, the lengths of pipe containing such defects shall be removed from the line to the
satisfaction of OWNER. On pipes which have been cut back, a zone extending 25 mm back
from the new field bevel, shall be ultrasonically tested to the requirement of the line pipe
specification to ensure freedom from laminations. The new bevel shall be 100% visual and
100% dye penetrant/MPI tested . A report shall be written for all testing and records kept.
8.0 ALIGNMENT AND SPACING

8.1 Line pipes
Immediately prior to line-up CONTRACTOR shall inspect the pipe ends inside and outside for
damage, dents, lamination etc. Pipe for welding shall be set up, correctly spaced, allowing for
temperature changes during welding, in correct alignment and shall in no circumstances be
sprung into position. Temporary attachments of any kind shall not be welded to the pipe.
Welds joining the sections of the pipeline, valve installation or similar welds classified as tie-in
welds shall be made in the trench. Otherwise the alignment and welding shall be made along
side the ditch with the pipe supported on skids and pack pads or other suitable means approved
by OWNER, at least 500 mm above the ground unless approved by the OWNER in specific
cases.
Seam orientation of welded pipe shall be selected to ensure that at the circumferential welds, the
longitudinal welds shall be staggered in the top 90" of the pipeline, or 250 mm whichever is the
lesser. A longitudinal joint shall pass an appurtenance of a structural element at a minimum
distance of 50 mm. Should a section of the line containing uncompleted welds fall from the
skids, the CONTRACTOR shall immediately inform OWNER.
Every effort shall be made to reduce misalignment by the use of the clamp and rotation of the
pipes to the best fit. For pipe of same nominal wall thickness the off-set shall not exceed 1.6
Page 146 of 1963

Page 7 of 43
mm. The off set may be checked from outside using dial gauges. Any branch connection
sleeve, etc. shall be at least 150 mm from any other weld. The welds for fittings shall be so
located that the toe of the weld shall not come within 50 mm of any other weld. Cold dressing is
permissible only in cases of slight misalignment and may only be carried out with a bronze
headed hammer. Hot dressing shall not be permitted. When welding pipes of different wall
thickness (as directed by OWNER) a special transition piece shall be used. This shall have a
minimum of 1:4 taper. The welds shall be subject to both ultrasonic and radiographic
inspections.
The root gap shall be accurately checked and shall conform to the qualified welding procedure.
The use of internal line-up clamps is mandatory for pipe diameters 10" and above. However, in
some case (tie-in welds, flanges, fittings, diameter of pipe 10" and below etc.) Where it is
impossible to use internal clamps, an external line-up clamp may be used.
The internal line-up clamp shall not be released before the entire first pass has been completed.
When an external line-up clamp is used, all spaces between bars or at least 60% of the first pass
shall be welded before the clamp is released and the pipe remaining adequately supported on
each side of the joint. segments thus welded shall be equally spaced around the circumference of
the pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
8.2 Station Piping/Terminal Piping
Components to be welded shall be aligned and spaced as per the requirements laid down in
applicable code. Special care must be taken to ensure proper fitting and alignment when the
welding is performed by GTAW process. Flame heating for adjustment and correction of ends is
not permitted unless specifically approved by the Engineer-in-Charge.
A wire spacer of suitable diameter may be used for maintaining the weld root opening while
tacking but it must be removed after tack welding and before laying the root bead.
For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in position
with the aid of couplers, yokes and ‘C’ clamps, to maintain perfect alignment. Yokes shall be
detached after the completion of weld, without causing any surface irregularity. Any
irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the
Engineer-in-Charge.
Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified
welders using approved WPS. Since the tack welds become part of the final weldment they
shall be executed carefully and shall be free from defects. Defective tack welds must be
removed prior to the actual welding of the joints.
Tacks should be equally spaced. Minimum number of tacks shall be:
3 tacks - for 2 1/2" and smaller dia. pipes.

4 tacks - for 3" to 12" dia. pipes.
6 tacks - for 14" and larger dia. pipes.
Welding shall commence only after approval of fit-up by the Engineer-In-Charge.
Page 147 of 1963

Page 8 of 43
9.0 WEATHER CONDITIONS

The parts being welded and the welding personnel shall be adequately protected from rain and
strong winds. In the absence of such a protection no welding shall be carried out. The
completed welds shall be suitably protected in case of bad weather conditions.
10.0 WELDING
10.1 Root Pass for Line Pipe Welding
a) Root pass shall be made with electrodes/filler wires recommended in the welding
specification chart attached along with other project data sheets. The size of the
electrodes used shall be as per the approved welding procedure.
b) Position or roll welding may be permitted. Separate procedures shall be submitted and
qualified for up hill, down hill, vertical down and roll welding. The vertical up method of
welding shall be used for the root pass of the tie-ins, special crossings, fittings and special
parts, fillet welds, repairs and when an external line up clamp is used. The down hill
welding may be used for root run welding of tie-ins and special crossings when (a) the
edges are machined or have equivalent preparation (b) internal line up clamps are used
and the fit up is geometrically and mechanically similar to one of the ordinary line
welding without misalignment or unevenness.
c) The root pass of butt joints shall be executed properly so as to achieve full penetration
with complete fusion of the root edges. Weld projection inside the pipe shall not exceed 3
mm wherever not specified by the applicable code.
d) Any deviations desired from the recommended welding technique and electrodes indicated
in the welding specification chart shall be adopted only after obtaining express approval
of the OWNER.
e) Welding shall be continuous and uninterrupted during a pass.
f) On completion of each run, craters, welding irregularities, slag etc., shall be removed by
grinding and chiselling.
g) While the welding is in progress care shall be taken to avoid any kind of movement of the
components, shocks, vibration and stresses to prevent occurrence of weld cracks.
h) Fillet welds shall be made by shielded metal arc welding process using low hydrogen
electrodes only irrespective of the thickness and class of piping. Electrode size shall not
exceed 3.25 mm diameter for socket joints. At least two passes shall be made on socket
weld joints.
i) Peening shall not be used.
Joint Completion for Line Pipe Welding

a) In case of manual welding, the first pass shall be carried out by a minimum of two
welders, working simultaneously and so placed as to cause minimum distortion of the
pipe.
b) The number of welders and the allowable welding sequences shall be as those laid down
in the qualified welding procedure specification. Once the deposit of the first pass has
been started, it must be completed as rapidly as possible, reducing interruptions to the
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minimum. The welding and wire speed shall be approximately same as that established in
the qualified weeding procedure specification.
c) The pipe shall always be adequately supported and must not be bumped or shaken during
welding. The clamp shall be removed, as indicated in clause 8.0 above. Before starting
the second pass, the first pass shall be cleaned and flattened with rotating grinders.
d) The interruption between completion of the first pass and starting the second pass shall be
as stated in the procedure specification, normally not exceeding four minutes.
e) For crack prevention a top and bottom reinforcement of at least one electrode shall be
applied before lowering the pipe on the skid.
f) The welding speed selected shall enable production of a bead which is sufficiently thick
and which shows no undercutting.
g) The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or
following passes, welding operations may be suspended, so allowing the joint to cool
down, provided that the thickness of the weld metal deposited is equal to at least 50% of
the pipe thickness. Upon restarting, depending on the materials, wall thickness and
welding process, a preheating to atleast 100˚ C shall be carried out. Subsequent passes up
to weld completion shall be protected to avoid rapid cooling, if meteorological conditions
to dictate. Cleaning between passes shall be done carefully so as to reduce the possibility
of inclusions.
h) Electrode starting and finishing points shall be staggered form pass to pass. Arc-strikes
outside the bevel on the pipe surface are not permitted. Arc-strike or arc-burn on the pipe
surface outside the weld, which are caused accidently by electrical arcs between the
electrode, electrode holder, welding cable or welding cable round and the pipe shall be
removed by grinding in accordance with a procedure approved by OWNER and the repair
checked by ultrasonic, radiographic, magnetic particle or dye penetrant tests which the
OWNER feels necessary. The pipe wall thickness after grinding shall not be less than the
minimum thickness limit permitted for the pipe. Repair of arc strikes by welding is
prohibited.
i) The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc. These requirements apply not only to completed welds but also to the
bare strip at least so wide as to allow full skid examination at both ends of the pipe to
allow a good ultrasonic inspection when it is required.
10.2 Root Pass for Station/Terminal piping Welding
(a) Root pass shall be made with electrodes/filler wires recommended in the welding
specification chart. For fillet welding, root welding shall be done with consumables
recommended for filler passes. The preferred size of the electrodes is 2.5 mm diameter
(12 SWG) but in any case not greater than 3.25 mm (10 SWG).
(b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.
(c) The root pass of butt joints should be executed so as to achieve full penetration with
complete fusion of the root edges. Weld projection inside the pipe shall be as per
applicable code. It shall be limited 3mm max. when the applicable code does not place
any restriction.
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(d) Any deviation desired from the recommended welding technique and electrodes indicated
in the welding specification charts should be adopted only after obtaining express
approval of the Engineer-in-Charge.
(e) Welding shall be uninterrupted.
(f) While the welding is in progress care should be taken to avoid any kind of movement of
the components, shocks, vibrations and stresses to prevent occurrence of weld cracks.
(g) Peening shall not be used.
Joint Completion for Station/Terminal piping Welding
(a) Joint shall be completed using the class of electrodes recommended in the Welding
Specification Chart.
(b) Two weld beads shall not be started at the same point in different layers.
(c) Butt joints shall be completed with a cover layer that would affect good fusion at the
joint edges and a gradual notch free surface.
(d) Each weld joint shall have a workmanship like finish. Weld identification work shall
be stamped clearly at each joint, just adjacent to the weld. Metal stamping shall not be
used on thin pipe having wall thickness less than 3.5mm. Suitable paint shall be used
on thin wall pipes for identification.
(e) Rust preventive/protective painting shall be done after the weld joint has been
approved.
11.0 HEAT TREATMENT

11.1 Preheating
a) Preheating requirements for the various materials shall be as per the welding
specification chart attached along with other project data sheets.
b) Preheating shall be performed using resistance or induction/heating methods. Pre-
heating for tie-in welds, repair welds or welds at point spreads may be done using a
propane gas burner ring with prior approval from OWNER. The contractor may be
asked to demonstrate the effectiveness of the arrangement.
c) Preheating shall extend uniformly to atleast three times the thickness of the joint, but
not less than 50mm, on both sides of the weld.
d) Preheating temperature shall be maintained over the whole length of the joint during
welding. Temperature indicating crayons or other temperature indicating devices shall
be provided by the CONTRACTOR to check the temperature.
11.2 Post Weld Heat Treatment
a) Post weld heat treatment, wherever required for joints between pipes and fittings, pipe
body and supports shall be carried out by the CONTRACTOR at his expense as per
the relevant specifications, applicable standards and the instructions of the OWNER.
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b) The heat treatment of welded joints shall be carried out as per the requirements laid
down in ANSI B31.4 and other special requirements mentioned in welding
specification charts.
c) The CONTRACTOR shall submit for the approval of the OWNER, well before
carrying out actual heat treatments the details of the post weld heat treatment
procedure as per Exhibit-B attached, that he proposes to adopt for each of the
materials/assembly/part involved.
d) Post weld heat treatment shall be done in a furnace or by using an electric resistance or
induction heating equipment, as decided by the OWNER.
e) While carrying out local post weld heat treatment, technique of application of heat
must ensure uniform temperature attainment at all points of the portion being heat
treated. Care shall be taken to ensure that width of heated band over which specified
post weld heat treatment temperature is attained is atleast as that specified in the
relevant applicable standards/codes.
The width of the heated band centered on weld shall at least be equal to the width of
weld plus 2" (50mm). The temperature gradient shall be such that the length of the
material on each side of the weld, at a temperature exceeding half the heat treatment
temperature, is atleast 2.5 rt where ‘r’ is the bore radius and ‘t’ is the pipe thickness at
the weld.
f) Throughout the cycle of heat treatment, the portion outside the heat band shall be
suitably wrapped under insulation so as to avoid any harmful temperature gradient at
the exposed surface of pipe. For this purpose temperature at the exposed surface of
the pipe shall not be allowed to exceed 400˚C.
g) The temperature attained by the portion under heat treatment shall be recorded by
means of thermocouple pyrometer. Adequate number of thermocouples shall be
attached to the pipe directly at equally spaced locations along the periphery of the pipe
joint. The minimum number of thermocouples attached per joint shall be 2 upto 10"
dia and 3 for 12" dia and above. However, the OWNER can increase the required
minimum number of thermocouples to be attached if found necessary.
h) Automatic temperature recorders which have been suitably calibrated shall be

employed. The calibration chart of each recorder shall be submitted to the OWNER
prior to starting the heat treatment operation and its approval shall be obtained.
i) Immediately on completion of the heat treatment, the post weld heat treatment
charts/records along with the hardness test results on the weld joints (whenever
required as per the welding specification chart) shall be submitted to OWNER for its
approval.
j) Each joint shall bear an identification number which shall be maintained in the piping
sketch to be prepared by the CONTRACTOR. The joint identification number shall
appear on the corresponding post weld heat treatment charts. The same identification
numbers shall also be followed for identification of corresponding radiographic films.
The chart containing the identification number and piping sketch shall be submitted to
the OWNER in suitable folders.
k) Vickers hardness/Brinell hardness of the heat affected zone as well as of the weld
metal, after heat treatment shall be measured using a suitable hardness tester and shall
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not exceed the maximum hardness specified in the welding specification chart. The
weld joint shall be subjected to reheat treatment, when hardness measured exceeds the
specified limit, at the CONTRACTOR's expense.
l) The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the plant owner's
inspector.
12.0 INSPECTION AND TESTING

12.1 General
a) The OWNER's Inspector shall have free access to all concerned areas, where the
actual work is being performed. The CONTRACTOR shall also afford the OWNER's
inspector all means and facilities necessary to carry out inspection.
b) The OWNER is entitled to depute its own inspector to the shop or field where
prefabrication and erection of pipelines are being done, with (but not limited to) the
following objectives:
i) To check the conformance to relevant standards and suitability of various

welding equipment and the welding performance.
ii) To supervise the welding procedure qualification.
iii) To supervise the welders' performance qualification.
iv) To check whether shop/field welding being executed is in conformity with the
relevant specifications and codes of practice followed in pipe construction.
c) CONTRACTOR shall intimate sufficiently in advance the commencement of
qualification tests, welding works and acceptance tests, to enable the OWNER’s
inspector to be present to supervise them.
12.2 Welding Procedure Qualification
a) Welding procedure qualification shall be carried out in accordance with the relevant
requirements of API 1104 latest edition or other applicable codes and other job
requirements by the CONTRACTOR at his expense. The CONTRACTOR shall
submit the welding procedure specifications in format as per Exhibit-C (attached)
immediately after the receipt of the order.
b) OWNER's inspector will review, check and approve the welding procedure submitted
and shall release the procedure for procedure qualification tests. The procedure
qualification test shall be carried out by the CONTRACTOR under field conditions at
his own expense. A complete set of test results in format as per Exhibit-C (attached)
shall be submitted to the OWNER”s Inspector for approval immediately after
completing the procedure qualification test and atleast 2 weeks before the
commencement of actual work. Standard tests as specified in the code shall be carried
out in all cases. In addition to these tests, other tests like radiography, macro/micro
examination, hardness tests, dye penetrant examination, charpy V-notch etc. shall be
carried out on specimens. It shall be the responsibility of the CONTRACTOR to
carryout all the tests required to the satisfaction of the OWNER's Inspector. The
destructive testing of welded joints shall be as per Annexure-1.
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12.3 Welder's Qualification
a) Welders shall be qualified in accordance with the API 1104 or other applicable
specifications by the CONTRACTOR at his expense. The butt weld test pieces of the
qualification test shall meet the radiographic test requirements specified in clause 12.5
and Annexure-3 of this specification. The OWNER's inspector shall witness the test
and certify the qualification of each welder separately. Only those welders who have
been approved by the OWNER's inspector shall be employed for welding.
CONTRACTOR shall submit the welder qualification test reports in the standard
format as shown in Exhibit-D and obtain express approval, before commencement of
the work. It shall be responsibility of CONTRACTOR to carryout qualification tests
of welders.
b) The welders shall always have in their possession the identification card as shown in
Exhibit-E and shall produce it on demand by the OWNER's Inspector. It shall be the
responsibility of the CONTRACTOR to issue the identity cards after it has been duly
certified by the OWNER.
c) No welder shall be permitted to work without the possession of identify card.
d) If a welder is found to perform a type of welding or in a position for which he is not

qualified, he shall be debarred from doing any further work. All welds performed by
an unqualified welder shall be cut and redone by a qualified welder at the expense of
the CONTRACTOR.
12.4 Visual Inspection

Inspection of all welds shall be carried out by OWNER as per the latest editions of the
applicable codes and specifications. All finished welds shall be visually inspected for parallel
and axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage,
cracks, under-cuts, dimensions of the weld, surface porosity and other surface defects as per
EIL Standard, 6-44-0016. Undercutting adjacent to the completed weld shall not exceed the
limits specified in API 1104-2013.
12.5 Non destructive Examination
12.5.1 Line pipe girth welds:
The non destructive examination shall mainly consist of examination using x-ray radiography
as detailed in Annexure-3.
Radiographic examination of one hundred percent (100%) girth welds will be required by the
OWNER. Welds shall meet the standards of acceptability as set forth in API 1104 and as well
as the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the radiographic examination of
work covered by the specification at his expense.
The OWNER will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the OWNER shall be final and binding in this
regard.
All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, for pipes, ultrasonic inspection is
required in the following cases as per Annexure 2 of this Specification.
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a) When 25 mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 25mm to assure no lamination
exist.
b) When welds are repaired.
c) When in the opinion of OWNER, ultrasonic inspection is required to confirm or

clarify defects indicated by radiography.
d) When automatic procedure is used at least 10 cm on each weld shall be ultrasonically

inspected at OWNER's discretion.
e) Welding of Transition piece of pipe.
Line Pipe - Tie-in weld Joints, welding of valves, flanges, Golden joints etc.
In addition to Radiographic examination, 100% ultrasonic inspection shall be required for
certain critical welding of the pipeline (i.e. tie-ins, welding of valves, flanges etc.) which have
not undergone pressure testing (this is to ensure soundness of the total pipeline). All fillet and
groove welds other than those radiographed shall be subjected to dye penetrant/MP inspection.
The non-destructive test system used for inspecting welds must be approved by the OWNER.
Station/Terminal Piping weld joints:

Radiography: All Butt welds, 100%.
Magnetic Particle Testing: All Socket Welds, 100%.
Dye penetrant test/ Magnetic Particle Testing: All fillet welds.
All butt welded golden joints shall be inspected by Ultrasonic Testing, 100%.
12.5.1 Acceptance Criteria
Weld quality as judged on the basis of the acceptability criteria mentioned below:
i) Any weld, which as a result of radiographic and/or ultrasonic examination in the

opinion of OWNER exhibits imperfections greater than the limits, stated in API 1104
latest edition or as superseded in this article shall be considered defective and shall so
be marked with an identification point marker.
ii) In addition to the API 1104 requirements, the welds containing cracks including crater
cracks regardless of size or location are unacceptable.
Lack of fusion and lack of root penetration may be permitted only up to a maximum individual
length of t, where t is nominal pipe wall thickness. Cumulative length of the defect shall not
exceed 25 mm in any 300 mm length of weld. For welds less than 300 mm length, the
aggregate length shall not exceed 8 percent of the weld length. Defects situated in line and
separated by less than the length of the shortest defect shall be considered as one defect.
However, no Lack of fusion or lack of root penetration is permitted at any intersections of
welds.
Suitable records shall be maintained by the CONTRACTOR as desired by the OWNER on the
day to day work done on welding radiography, ultrasonic testing. The CONTRACTOR shall
present the records to the OWNER on day-to-day basis and whenever demanded, for approval.
The NDT acceptance criteria for Station/Terminal Piping weld joints shall be as per ASME
B31.3 latest edition.
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12.6 Destructive Testing

The OWNER has the authority to order the cutting of up to 1 weld per 500 welds completed
for subjecting to destructive tests at no extra cost to OWNER. The destructive testing of joints
shall be made as per Annexure-I.
In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. The sampling and the re-execution of welds shall be carried out by the
CONTRACTOR at his own expense.
If the results are unsatisfactory, welding operations shall be suspended and may not be
restarted until the causes have been identified and the CONTRACTOR has adopted measures
which guarantee acceptable results. If it is necessary in the OWNER's opinion the procedure
shall be re-qualified. The weld joint represented by unsatisfactory welds shall stand rejected
unless investigation prove otherwise.
13.0 REPAIRS OF WELDS
13.1 With the prior permission of OWNER welds which do not comply with the standards of
acceptability shall be repaired or the joint cut out and re-welded.
A separate welding procedure specification sheet shall be formulated and qualified by

CONTRACTOR for repair welds simulating the proposed repair to be carried out. Separate
procedures are required to be qualified for (a) through thickness repair (b) external repair and
(c) internal repair. Welders shall be qualified in advance for repairs. The root pass, for repairs
opening the root, shall be replaced by the vertical uphill technique. The procedure shall be
proven by satisfactory procedure tests to API 1104 including the special requirements of the
specification, and shall also be subjected to metallographic examination, hardness surveys and
Charpy test to determine the effects of repair welding on the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root defects shall be
ground thoroughly and welded with a minimum of two passes. However, while grinding for
repairs, care shall be taken to ensure that no grinding marks are made on the pipe surface
anywhere.
The repair shall be subjected, as a minimum requirement, to the same testing and inspection
requirements as the original weld. After the repair of the circumferential weld, re-radiography
of the full joint shall be carried out. A 100% ultrasonic test shall be done at the repaired area
externally. Any repaired area that is wide, irregular or rough shall be rejected and a full cut
out shall be done.
Repairs are limited to a maximum 30% of the weld length. Welds containing cracks shall be
cut out and rebevelled to make a joint. OWNER shall authorise all repairs.
13.2 Weld Rejected by Accumulation of Defects

Where a weld is rejected by accumulation of defect clause, as defined by API 1104 and this
specification, repairs within these limitations are permitted. Defects in the filling and capping
passes shall be repaired preferentially.
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ANNEXURE – 1: Destructive Testing of Welded joint (Butt welds)
1.0 Destructive Testing of Welded joint - Butt welds

1.1 Preparation
Having passed the visual and the non-destructive inspection, the test weld shall be subjected to
mechanical test.
After satisfactory completion of all visual and non-destructive testing the procedure test weld
shall be set aside for a period not less than 24 hours. No further work on the test weld and no
cutting of test specimens from the weld shall be performed until a period of at least 24 hours
has expired.
Weld specimens shall be taken from the positions indicated in Figure 1 of this specification
from areas as free from defects as possible; for this reason it is necessary to take the previous
non-destructive tests into account. The minimum number of tests to be carried out is given in
Table - 1 of this specification.
The test shall be carried out at laboratories approved by the OWNER. The specimens shall be
prepared in accordance with the figures given in the paragraphs which refer to the individual
test.
1.2 Tensile Strength

Specimens shall be taken from the position indicated in Figure 1 & 1A of this specification.
Two ISO type specimens and two API-type specimens shall be taken.
The ISO test specimens are shown in Figure 2of this specification.
1.2.1 Method
The test shall be carried out in accordance with BS EN ISO 6892-1:2009.
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TABLE 1
Type and Number of Test Specimens for Procedure Qualification Test and Production Welds
PIPE SIZE, OUT
SIDE DIAMETER NUMBER OF SPECIMENS
INCHES TENSILE TENSILE NICK ROOT FACE SIDE MACRO HARDNESS IMPACT TOTAL
API ISO BREAK BEND BEND BEND
WALL THICKNESS ½ INCH (12.7 mm) AND UNDER
UNDER 2 0 0 2 2 0 0 0 0 0 4
2 TO 4½ 0 0 2 2 0 0 0 0 0 4
INCLUDING
OVER 4½ LESS 2 0 2 2 2 0 2 2 12 24
THAN 12¾
12¾ AND OVER 2 2 4 4 4 0 2 2 24 44
WALL THICKNESS OVER ½ INCH (12.7 mm)
4½ AND 0 2 0 0 0 2 0 0 0 4
SMALLER
OVER 4½ LESS 2 0 2 2 2 0 2 2 12 24
THAN 12¾
12¾ AND OVER 2 2 4 0 0 8 2 2 24 44
1.3 Nick-Break Test

1.3.1 Preparation
Specification for nick-break test with notches thus worked can break in the base metal, instead
of in the fusion zone; therefore an alternative test piece may be used after authorization by the
OWNER with a notch cut in the reinforcement of outside weld bead to a maximum depth of
1.5mm, measured from the surface of the weld bead.
1.4 Macroscopic Inspection
1.4.1 Preparation
Specimens shall be taken from the positions indicated in Figure 1 of this specification and
shall be prepared in accordance with ASTM E3-11.
The width of the macrosection has to be at least three times the width of the weld. The section
is to be prepared by grinding and polishing and etched to clearly reveal the weld metal and
heat effected zone.
1.4.2 Method
Specimens shall be carefully examined under the microscope, with a magnification of atleast
25 times (25:1). The OWNER may ask for a macrograph with 5 times (5:1) magnification, for
DOCUMENTATION purposes.
1.4.3 Requirements
Under macroscopic examination, the welded joints shall show good penetration and fusion,
without any defect exceeding the limits stated in the evaluation criteria of the nick break test.
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1.5 Hardness Test

1.5.1 Preparation
The prepared macro section is to be used for hardness testing using the vickers method with 10
kg load indentations are to be made along tranverse direction each approximately 1 mm below
the surface at both side of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses are to be
made. The HAZ identations are to be made along the traverses for approximately 0.5mm each
into unaffected material, and starting as close to the fusion line as possible.
One indentation at each side of the weld along each traverse has to be made on parent metal.
Reference is made to Figure 3 of this specification. The indentations are to be made in the
adjacent region as well as on the opposite side of the macro section along the specified
traverses.
1.5.2 Method
The test shall be carried out in accordance with recommendation of ISO 6507-1:2005, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO 6507-
2:2005 and using a diamond pyramid penetrator set at 2.37 rad (136") with a load of 10 kg.
1.5.3 Requirements
Hardness value shall not exceed the limit specified in welding specification chart. In case of a
single reading strictly ( +10HV) higher than the specified limit, further indentations shall be
made to check if the high value was an isolated case.
All the hardness values contained from the heat affected zone shall not exceed 100 HV with
respect to the average hardness of the values obtained for the base metal. If these additional
tests give a hardness within the specification limit the slightly higher value may be accepted.
1.6 Charpy-V-Notch Impact Test

1.6.1 Specimens shall be taken from the position indicated in Fig. 1 of this specification. The test
specimens will be prepared in accordance with BS EN ISO 148-1:2009.
Three test specimens shall be taken from each sample and they shall be cut and worked so that
their length is transversal and perpendicular to the weld bead with the notch position as shown
in Figure 4 of this specification. The notch shall be perpendicular to the roller surface. The
test specimen width shall depend upon the pipe wall nominal thickness as following:
Nominal wall thickness in mm Test specimen width in mm

Over 12 10
Over 9.5 and upto 12 7.5
From 7 upto 9.5 5
Less than 7 2.5
1.6.2 Test Method

The test shall be carried out as indicated in BS EN ISO 148-1:2009 or ASTM A 370-12a.
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Test pieces shall be immersed in a thermostatic bath and maintained at the test temperature for
at least 15 minutes. They shall then be placed in the testing machine and broken within 5
seconds of their removal from the batch. The test temperature shall be as per Welding
Specification Chart.
1.6.3 Requirements (Note 1)
The impact energy shall be as per the values given in the Welding Specification Charts, for full-
size test pieces. If subsize test pieces are used, the required minimum average (set of three test
pieces) absorbed energy values shall be the required values for full-size test pieces times the
ratio of the specified width of the subsize test piece to the specified width of the full-size test
piece, with such derived values rounded to the nearest joule.
Note :
(1) These values are specified for resistance to brittle fracture only. Where additional
requirements are specified in project data sheet (Ex. pipeline materials with arrest
properties i.e. a higher upper shelf charpy V energy for resistance against propagating
ductile fractures) the same shall be followed.
(2) Only one value is permitted to be lower than average value upto the value specified.
1.7 Bend Test Requirements
The Bend test Specimens shall be made and tested as per the requirements of API 1104. The
acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API 1104.However, the
dimensions of the Jig for guided bend test in Figure 8 (of API 1104) shall be modified as
specified below:
Radius of the Plunger À' = 2t
Radius of the die. `B' = 3t + 1.6 mm
Width of the die. `C' = 50.8
Where t = thickness of the specimen
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ANNEXURE – 2: ULTRASONIC INSPECTION
1.0 ULTRASONIC INSPECTION

In addition to the radiographic inspection, ultrasonic inspection is required as per conditions
listed in paragraph 12.5 of this specification. This section concerns manual ultrasonic
inspection. However ultrasonic inspection by automatic equipment may be used if approved
by the OWNER.
1.1 General:
The CONTRACTOR who carries out the ultrasonic inspections shall have sufficient no. of
qualified personnel, equipment and instruments at his disposal to be able to affect the tests
without hindering or delaying the pipeline assembly operations.
The CONTRACTOR appointed to carry out ultrasonic inspections shall supply all the
instruments necessary for their execution on site.
1.2 Specification for Ultrasonic Testing Procedure Qualification
Before work begins, the CONTRACTOR shall present a specification describing the proposed
UT procedure qualification.
This specification shall state, all the parameters described in API 1104 and the following
information:
a) Type of UT equipment used;
b) Type and dimensions of transducers;
c) Frequency range;
d) Details for calibration;
e) Coupling medium;
f) Inspection technique;
g) Record details;
h) Reference to the welding procedure where it is intended to adopt the specification;
i) Temperature range of the joints to be inspected.
1.3 Qualification of Ultrasonic Inspection Procedure
The ultrasonic inspection procedure shall be approved by the OWNER. Before inspection
begins, the OWNER may require the qualification test of the ultrasonic inspection procedure.
This specification test consists in testing (under normal operating conditions) some
CONTRACTOR welds made according to the same production procedure, where there are
typical defects the test intends to detect.
This test shall be conducted in the presence of the OWNER.
1.4 Test Procedure
Circumferential welds shall be inspected from both sides using angle probes.
The surface with which the probe comes into contact shall be free of metal spatter, dirt, iron
oxide, and scales of any type; therefore it shall be necessary to clean a strip at least 50 mm
wide on both sides of the weld with steel-wire brushes and anyhow the cleaned strip must be at
least wide enough to allow one and a half skip examination.
If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam transducer in order
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to check whether any manufacturing defects are present which could have interfered with the
ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following:
a) Ultrasonic equipment and coupling medium
b) Sample sections for calibration of instruments
c) Equipment for cleaning of surface to be examined
d) Rules calibrated in centimeters for exact location of the position of defects.
The characteristics of the above listed instruments and equipment shall guarantee:
a) That the required standards of the inspection procedure, as previously established an
approved by the OWNER, are satisfied.
b) Continuous operation
All the instruments and equipment shall be approved by the OWNER before being used. The
OWNER has the authority to reject any item that is considered unsuitable. The decision of the
OWNER is final. The CONTRACTOR appointed to carry out ultrasonic inspections shall also
ensure the operational efficiency and maintenance of the instruments and equipment, and shall
immediately substitute any item rejected by the OWNER.
All the instruments and equipment necessary for carrying out ultrasonic inspection on site shall
satisfy the requirements laid down by the public boards of institutions that regulate `safety at
work`.
1.5 Ultrasonic Instruments
The ultrasonic instrument:
a) shall be pulse echo type, able to generate, receive and display, on the screen a
Cathode Ray Tube (CRT), pulse at frequencies between 1 and 6 MHz. The useful part
of the CRT screen shall be at least 70mm wide and at least 50mm high.
shall have variable amplification, with steps of 1 or 2 dB over a range of a least 60 dB.
b) the regulation control shall be accurate to within ±1 dB and this accuracy shall be
certified by the instrument manufacturer.
c) may be powered by a battery or an electric generator. In the first case, the autonomy
of operation (endurance) of the instrument shall be sufficient to carry on working
without frequent interruptions, and the instrument shall be equipped with an automatic
switch which switches if off when the battery runs down; in the second case, there
must be a voltage stabilising device with a tolerance of ±2 Volts.
1.6 Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to the type
of steel, the diameter, and the thickness of the pipeline and to the joint design.
1.7 Reference Sample Pieces
The efficiency of the equipment used, the effective refraction angle of the probe, and the beam
output point, shall be checked using a V1 and V2 sample block, IIW type or the calibration
block ASTM E-428-08.
For manual ultrasonic testing and automated ultrasonic testing the reference sample pieces
shall be as described in API 1104.
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Page 22 of 43
1.8 Calibration
The calibration, qualification of the testing procedure shall be done as provided in API 1104.
1.9 Regulation of Amplification during Production Testing
Scanning sensitivity shall be as provided in API 1104.
1.10 Qualification of Ultrasonic Testing Operators
Before the inspection begins or during the same inspection, the OWNER may require a
qualification test for the ultrasonic equipment operators.
The operators shall be fully qualified as per a recognized standard (ASME Sec V or
equivalent) and they shall have as minimum level II as described in para 11.4.3, API 1104.
The operators shall be able to:
a) calibrate the equipment;
b) perform an operational test under production conditions;
c) interpret the screen picture;
d) evaluate the size and location of reflectors;
e) interpret the type of defects detected;
The OWNER has the option of checking the ability of personnel employed for ultrasonic
testing by means of qualification tests.
1.11 Evaluation of indications given by Ultrasonic Tests
Each time that echoes from the weld bead appear during production testing, the instrument
amplification shall be altered to coincide with the reference amplifications and the probe shall
be moved until maximum response is obtained, paying attention all the time to the probe-tube
coupling.
If, under these conditions, the height of the defect echo is equal to or greater than that of the
reference echo, the defect shall be evaluated according to clause 12.5 of this specification. If
the defect has also been detected by the radiographic and/or visual examination, the
dimensions shall be judged according to the type of examination which detects the greater
defect. Returns that are less than 50% of the reference echo will not be considered. If returns
are above 50% but lower than 100% of the reference echo, and if the operator has good
reasons to suspect that the returns are caused by unfavorably oriented cracks, he shall inform
the OWNER. Moreover, when there is a defect to be repaired, such defect shall be removed
for a length corresponding to the one where no more return echo is given.
1.12 Other Equipment
The use of rules calibrated in centimetres, attached if possible to the probe, for the precise
location of the position of welding defects, is recommended. Defect location is effected by
measuring the projection distance between the probe output and the reflecting surface.
The operators carrying out the tests shall have, besides the probing instrument, tools for
cleaning the pipe surface (files, brushes, etc.) as well as the coupling liquid or paste appropriate
for the temperature of the section to be examined.
Page 162 of 1963

Page 23 of 43
ANNEXURE-3: RADIOGRAPHY INSPECTION

1.0 SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the main
pipeline.
The welded joints shall include the following:
i) Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii) Welds for installation of block valves, insulating joints and other appurtenances and
tie-ins.
iii) Welds at scraper launching and receiving barrels.
iv) Terminal Piping
2.0 APPLICABLE STANDARDS

This specification shall apply in conjunction with the following (all latest edition):
i) API 1104, Standard for welding Pipelines and Related Facilities
ii) ASME B 31.8, Code for Gas Transmission and Distribution Piping Systems.
iii) ASME B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and Alcohols.
iv) ASTM E94 - 04(2010) Standard Guide for Radiographic Examination
iv) The American Society for Nondestructive Testing. Recommended Practice No. SNT-
TC-1A Supplement A.
v) DIN EN 462-1:1994-03: Non-destructive testing-Image quality of Radiographs-Part 1:
Image quality Indicators (wire type)- Determination of image quality value.
3.0 PROCEDURE
3.1 The radiographic examination procedure to be adopted shall be submitted by the
CONTRACTOR as per Exhibit-F.
3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction of
OWNER prior to use. It shall include but not be limited to the following requirements:
i) Lead foil intensifying screens, at the rear of the film shall be used for all exposures.
ii) Type 2 and 3 films as per ASTM E94-04(2010) shall be used.
iii) A densitometer shall be used to determine film density. The transmitted film density
shall be between 2.0 and 3.5 throughout the weld. The unexposed base density of the
film shall not exceed 0.30.
iv) Radiographic identification system and documentation for radiographic interpretation
reports and their recording system.
3.3 The CONTRACTOR shall qualify each procedure in the presence of the OWNER prior to use.
3.4 The procedure of radiographic examination shall produce radiographs of sufficient density,
clarity and contrast so that defects in the weld or in the pipe adjacent to the weld, are clearly
discernible.
3.5 One Check shot of the full joint on main line welds shall be taken per 100 circumferential welds
or one per day of the production which ever is more for cross checking the correctness of the
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Page 24 of 43
radiographs of weld joints executed by the contractors. For taking check shots on
completed/accepted sections, contractor has to separately mobilize either internal
crawler/external X-ray unit, as appropriate.
3.6 All the girth welds of mainline shall be subjected to 100% radiographic examination. The
CONTRACTOR shall furnish all the radiographs to the OWNER, immediately after
processing them, together with the corresponding interpretation reports on approved format.
The details of the radiographs along with the joint identification number shall be duly entered
in a register and signed by the CONTRACTOR and submitted to the OWNER for approval.
3.7 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each exposure
shall not exceed the values given of API 1104. The minimum film overlap, in such cases,
shall be 40mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch
and smaller provided that the source to film distance used is a minimum of 12 inch.
3.8 Three copies of each acceptable radiographic procedure (as per Exhibit-F) and three copies of
radiographic qualification records, shall be supplied to OWNER. One set of the qualifying
radiographs on the job shall be kept by the CONTRACTOR's authorized representative to be
used as a standard for the quality of production radiographic during the job. The other two
sets shall be retained by OWNER for its permanent record.
3.9 Three copies of the exposure charts relating to material thickness, kilo voltage, source of film
distance and exposure time shall also be made available to OWNER by the CONTRACTOR.
3.10 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds meet the
specified acceptance standards and (4) the nature and approximate location of unacceptable
defects observed. It must be possible to relate back to a particular butt weld and welder on
piping drawing and pipe line alignment drawing.
3.11 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting and
ending progress survey stations and (5) shall include original and three copies of the daily
radiographic record. The package shall be submitted to the OWNER daily when possible, but
in no event later than noon of the following day.
3.12 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room with
controlled temperature, film viewer etc. to enable the OWNER to examine the radiographs.
3.13 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be subject to the
approval of the OWNER.
3.14 OWNER shall have free access to all the CONTRACTOR's work facilities in the field.
3.15 Any approval granted by the OWNER shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0 RADIATION SOURCE
4.1 Radiography examination shall be carried out using X-radiations. Radiography examination by
Gamma rays using slow speed films may be allowed, at the discretion of the
CONSULTANT/OWNER in case of inaccessible joints. Radiography by Gamma ray for tie-
in-joints shall be acceptable provided Type I of ASTM E1815-08 film or equivalent is used
and the required sensitivity obtained.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source inside the
pipe, on the pipeline axis, with a radiation of 6.28 red. (360 ).
Page 164 of 1963

Page 25 of 43
If it is impossible to place the radiation source inside the pipe, the weld will be inspected with
the source on the outside. An overlap of at least 40 mm at the ends of each film shall be
required to ensure that the first and last location increment numbers are common to successive
films and to establish that no part of a weld has been omitted.
5.0 LEVEL OF QUALITY
The quality level of Radiographic sensitivity required for radiographic inspection shall be at
least equivalent to the values in Figure-5.
6.0 PENETRAMETERS
6.1 The Image Quality Indicator (abreviation:IQI) shall be used for the qualification of the
welding procedure and during normal line production. Radiographic sensitivity shall be
measured with the wire image quality indicator (Penetrameter). The Penetrameter shall be
selected according to DIN EN 462-1:1994-03 or ISO 19232-1:2004. For radiographs made
with the source on the outside, a Penetrameter shall be placed on each side of the film with the
smaller wire of the Penetrameter turned towards the end of the film itself. When a complete
weld is radiographed in a single exposure using a source inside the piping, four pentrameters
approximately equally spaced around the circumference shall be used. During the procedure
qualification, IQI shall be placed both on the source side and on the film side. The sensitivity
obtained with IQI on the source side shall not be less than the values shown in Fig. 5 of this
specification.
The sensitivity limit may be considered to have been reached when the outline of the IQI, its
identification number and the wire of the required diameter show up clearly on the radiograph.
The OWNER may authorise use of types of IQI other than those planned, provided that they
conform with recognised standards and only if the CONTRACTOR is able to demonstrate that
the minimum sensitivity level required is obtained. For this demonstration, a test shall be
carried out comparing the IQI specified and the CONTRACTOR's to show up the
identification number and other details of the proposed IQI, which must be visible in the test
radiograph.
7.0 FILM IDENTIFICATION MARKERS
All films shall be clearly identified by lead numbers, letters, and/or markers. The image of the
markers shall appear on the films, without interfering with the interpretation. These markers
positions shall also be marked on the part to be radiographed and shall be maintained during
radiography.
8.0 PROTECTION AND CARE OF FILM
8.1 All unexposed films shall be protected and stored properly as per the requirements of API
1104 standard and ASTM E94-04(2010).
8.2 The exposed and unexposed film shall be protected from heat, light, dust and moisture.
Sufficient shielding shall be supplied to prevent exposure of film to damaging radiation prior
to and following the use of the film for radiographic exposure.
9.0 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the radiographs, at
the expense of the CONTRACTOR.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the OWNER in the
same manner as that followed for the original welds. In addition, the repaired weld areas shall
be identified with the original identification number plus the letter R to indicate the repair.
9.3 When evaluating repair film, radiographers shall compare each section (exposure) of the weld
with the original film to assure repair was correctly marked and original defect removed.
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Page 26 of 43
9.4 The OWNER will review prior to any repair of welds, all the radiographs of welds which
contain, according to the CONTRACTOR's interpretation, unacceptable defects. The final
disposition of all unacceptable welds shall be decided by the OWNER.
10.0 QUALIFICATION OF RADIOGRAPHERS
10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and
to the full satisfaction of OWNER.
10.2 Certification of all the radiographers, qualified as per 10.1 above, shall be furnished by the
CONTRACTOR to the OWNER before a radiographer will be permitted to perform
production radiography. The certificate record shall include:
i) Background and Experience Record
ii) Training Course Record
iii) Technical Examination Record
iv) Doctor's report on radiographer's Oaecuer 0-1 acquity eye test
v) Date of qualification
10.3 The radiographers shall be required to qualify with each radiographic procedure they use, prior
to performing the work assigned to him in accordance with the specification.
11.0 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any discoloration for at
least three years. All the radiographs shall be presented in suitable folders for preservation
along with necessary documentation.
11.2 All radiographs shall become property of the OWNER.
12.0 EQUIPMENT AND ACCESSORIES
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for providing the
radiographic equipment, radiographic films and all the accessories for carrying out the
radiographic examination for satisfactory and timely completion of the job.
12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be equipped
with suitable mobile/stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and suitably
controlled to allow viewing film densities upto 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of every
man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of Radioactive source of material, CONTRACTOR
shall be solely responsible for complying with all rules and regulations set forth by Atomic
Energy Commission or any other Government agencies of India in this regard and OWNER
shall not be responsible and shall be kept indemnified by the CONTRACTOR for default (s) of
whatever nature by the CONTRACTOR. Safety equipment as considered adequate by the
OWNER for all necessary personnel shall be made available for use and maintained for
immediate and proper use by the CONTRACTOR.
14.0 DISPLAY OF SAFETY INSTRUCTIONS
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Page 27 of 43
14.1 The safety provisions shall be brought to the notice of all concerned by display on a notice
board at prominent place at the work spot. The person responsible for the “Safety” shall be
named by the CONTRACTOR.
15.0 ENFORCEMENT OF SAFETY REGULATIONS
15.1 To ensure effective enforcement of the rules and regulations relating to safety precautions, the
arrangement made by the CONTRACTOR shall be open to inspection by OWNER or its
representatives.
16.0 FIRST AID AND INDUSTRIAL INJURIES
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of sub-
contractors.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for treatment of
industrial injuries. Names of those providing these services shall be furnished to OWNER
prior to start of work and their telephone no. shall be posted prominently in CONTRACTOR'S
field office.
16.3 All critical industrial injuries shall be reported promptly to the OWNER and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of physician
shall be furnished to the OWNER.
17.0 NO EXEMPTION
17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from the
operation of any other act or rules in force.
Page 167 of 1963

Page 28 of 43
EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD

Sheet 1 of 3
A: Tested at (Site name) Date :

Manufacturer’s Name :
Brand Name :
Batch Number & Size tested :
Classification & Code :
Intended for welding in position :
In combination with (if any) :
Code of Reference (used for testing) :
Special Requirements (if any) :
B: All-weld Tensile Test

Base Material used :
Pre-heat temperature :
Post weld heat treatment details :
Visual examination :
Radiographic examination results :
Tensile test results :
Identification No. U.T.S. Yield Point Elongation Remarks
1.
2.
C. Impact Test Results
Test Temperature : Notch in :
Type of Specimens (Charpy) : Size of Specimens :
Specimen No. Impact Value Average

1
2
3
4
5
Page 168 of 1963

Page 29 of 43
EXHIBIT - A
Sheet 2 of 3
D. Chemical Analysis Results
Electrode Size Result :
Batch No. :
%C %S %P % Si % Mn % Cr % Ni % Mo Other
E. Fillet Weld Test Results :
Welding Positions :
Base Materials :
Size of electrode used :
Visual Inspection Results : 1)
2)
3)
Macro Test Results :
Fracture Test Results :
Remarks :
F. Other Test Results :
1. Transverse tensile test :
In combination with :
Base material used :
Position of welding :
Preheat temperature :
Post weld heat treatment :
Radiography :
Identification No. U.T.S. Fracture in Remarks
Page 169 of 1963

Page 30 of 43
EXHIBIT - A
Sheet 3 of 3
2. Guided Bend Test :
Position Identification No. Root, Face or Side Bend Remarks

1
2
3
4
5
Any other tests :
Conclusions :
--------------------- -------------------- -------------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER)
Page 170 of 1963

Page 31 of 43
EXHIBIT-B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
Sheet 1 of 1
Name of the Heat-treater:
Name of the Project : Specification Reference No.
1. General Details : 2. Furnace Details
Name of the : Type of Heating : Gas/Oil/Elec.
Equipment Res./Induction
Name of the : Type of Heating : (Tick mark)
Assembly/Part
Assembly/Part : Capacity (Size) :
Drawing No.
Material : Maximum Temp.( C) :
Method of temp. :
Measurement
Atmosphere Control :
3. Heat Treatment Cycle Details :
Changing Temp. C
Rate of heating, C/Hr
Soaking Temp. C
Soaking Time, hrs.
Rate of Cooling, C/Hr.
Mode of Cooling
4. Other Details, if any :
Notes:
The following documents shall be furnished along with the specifications :
i) Material test certificates
ii) Assembly/Part Drawing.
--------------------- -------------------- -------------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER)
Page 171 of 1963

Page 32 of 43
EXHIBIT – C: RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST

Sheet 1 of 3
Project/Contract Contractor
Pipe and fitting material
Process
Outside
diameter
Pipe
thickness
Joint design (Sketch attached)
Make and type of Diameter Current Voltage
filler metal
Root
Second run
Other runs
Other electrical a.c/d.c Electrode negative/Positive
characteristics
Shielding gas
Type of mixture
Flow
Shielding flux
Position
Direction of welding :
Root : Vertical up*/ Vertical down
Second run : Vertical up*/ Vertical down
Other runs : Vertical up*/ Vertical down
Number of welders :
Root
Second run
Other runs
Page 172 of 1963

Page 33 of 43
EXHIBIT - C
Sheet 2 of 3
Time lapse between commencement of second

run and commencement of other runs
Minimum number of runs before joint allowed
to cool
Maximum time between commencement and
completion of weld
Type of line-up clamp
Removal of clamp after run
Lowering off after run
Cleaning
Preheating
Minimum temperature, ˚C Ambient temperature, ˚C
Type of heater to be used
Interpass temperature
Minimum, ˚C Maximum, ˚C
Post weld heat treatment
Speed of travel
Test Results
State acceptable ‘non-acceptable (with
reasons) or give numerical results
Non-destructive tests
Visual
Radiograph
Page 173 of 1963

Page 34 of 43
EXHIBIT – C
Sheet 3 of 3
Destructive tests 1 2 3 4
Transverse tensile
Tensile strength (with units)
Fracture location
Test temperature
Macro-examination
Fillet weld fracture
Hardness survey :
Type Load Location of hardness measurements (Sketch)
Hardness range :
Parent metal
Heat affected zone
weld
Charpy V-notch impact tests
Specimen location and size
Notch location
Test temperature
Results (with units)
Additional test(s) and results. e.g. chemical analysis, micro-examination, CTOD tests, Bend tests,
Nick Break test.
The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of specification.
Contractor Inspector
Position Witnessed by
Date Date
Page 174 of 1963

Page 35 of 43
EXHIBIT – D: RECORD FORM FOR WELDER QUALIFICATION TEST
Sheet 1 of 1
Welder test certificate Test no.
Project/Contract Date
Contractor Inspector
Welder’s name
Address
Pipe material
Pipe thickness
Pipe outside diameter

Welding process Root Fill and cap
Electrode/wire
Root Current Voltage

Second run Current Voltage
Full and cap Current Voltage

Direction of travel Root : Vertical up*/ Fill and cap :
Vertical down Vertical up*/
Vertical down
Reason for failure
Visual
Non-destructive testing
Butt joint
Fillet weld
Number of attempts
Comments
Accepted date Time Signed by Contractor Signed by Inspector
* Delete as necessary
Page 175 of 1963

Page 36 of 43
EXHIBIT – E: WELDER’S IDENTIFICATION CARD
Name :
Identification : Photograph
Date of Testing :
Valid till :
Approval of Welding :
Welding Position :
Material :
Diameter :
Diameter range approved :
Wall thickness :
Thickness range approved :
Type of welding consumables :
Approved by : Employers’ Signature with seal
Page 176 of 1963

Page 37 of 43
EXHIBIT – F: RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
Sheet 1 of 1
1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia & Thickness
6. Type of weld joint
7. Radiation Source (X-ray, iridium)
8. Type of equipment (External/Internal)
9. Intensifying screens and material
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation source
or specimen.
11. Geometric relationship (Source local spot size, max and min source strength, object to film
distance, radiation angle with respect to weld and film).
12. Limit of film coverage
13. Film type and make
14. Exposure Time
15. Processing (time temperature for development stop bath or rinse, fixation, washing, drying
etc.)
16. Density
17. Sensitivity
18. Type of pentameter
Approval of the OWNER Signature of CONTRACTOR

with seal
Page 177 of 1963

Page 38 of 43
Page 178 of 1963

Page 39 of 43
Page 179 of 1963

Page 40 of 43
Page 180 of 1963

Page 41 of 43
Page 181 of 1963

Page 42 of 43
Page 182 of 1963

Page 43 of 43
Figure 5
Page 183 of 1963

WELDING SPECIFICATION CHARTS A922-020-02-42-WSC-0001
FOR PIPELINE AND HOT TAP Rev. 2
WELDING Page 1 of 10
WELDING SPECIFICATION CHARTS FOR PIPELINE

AND HOT TAP WELDING

JOB NO. : A922

2 23.12.2016 WSC FOR PIPING CLASSES ADDED S K Mishra P Chowdhary A Roy
1 21.11.2016 Revised & ReIssued for Tender S K Mishra P Chowdhary A Roy
0 09.09.2016 Issued for Tender P V Chitti P Chowdhary A Roy

Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL-1641-1924 Rev.1
Page 184 of 1963

WELDING SPECIFICATION A922-020-02-42-WSC-0001
CHARTS FOR PIPELINE AND Rev. 2
HOT TAP WELIDNG Page 2 of 10
CONTENTS
GENERAL NOTES ......................................................................................................................... 3

WSC for 8.625" Line pipe from DT at EOL Jamnagar to RT at SV-1 Sapar ............................... 4
(MANUALWELDING) ..................................................................................................................... 4
WSC for 8.625" Line pipe from DT at EOL Jamnagar to RT at SV-1 Sapar (MANUAL
WELDING) ..................................................................................................................................... 5
WSC for 14" Line pipe between existing SV Station and new SV Station at Sapar (MANUAL WELDING) 6
Welding Specification Chart For Piping Classes: AA9A, BA9A, DA9A, EA9A.......................... 7
Welding Specification Chart For Piping Class: AA3A ................................................................ 8
Welding Specification Chart For Piping Classes: AL9A, BL9A, DL9A, EL9A ........................... 9
Annexure-1: Guideline For Hot Tap Welding Procedure .......................................................... 10
Page 185 of 1963

GENERAL NOTES
1.1 Scope
This document covers the welding specification charts for the line pipes mentioned in the
Pipelines details (Document no. A922-000-83-41-MDX-0010 Rev.0) and PMS (Document
no. A922-000-83-41-SP-0010_2). The WPS and the PQR applicable for field fabrication
shall be made in conformity with this document. No deviation is acceptable.
1.2 Reference Standards
This document shall be read in conjunction with the latest revisions/editions of the following
documents:
a) ASME Boiler and Pressure Vessel Codes
Section II Part C (2015) – Specification for Welding Rods, Electrodes, and Filler Metals
Section V (2015) – Nondestructive Examination,
b) EIL Standard No. 6-44-0016 for Non Destructive Examination Requirements of Piping
c) Job Specification No. A922-020-02-42-WSP-0001, Welding Specification for Pipeline
1.3 Abbreviations:
PMS : Piping Material Specification

PQR : Procedure Qualification Record
SMAW : Shielded Metal Arc Welding
UTS : Ultimate Tensile Strength
WSC : Welding Specification Chart
WPS : Welding Procedure Specification
Page 186 of 1963

WSC for 8.625" Line pipe from DT at EOL Jamnagar to RT at SV-1 Sapar
(MANUALWELDING)
PIPES API 5L Gr. X-65 PSL-2 (WALL THICKNESS: 7.4mm)
FITTINGS ---
MATERIAL
SPECIFICATIONS FLANGES ---
OTHERS ---
BASE METAL `S’ NO 1

GROOVE JOINTS
WELDING PROCESS
BUTT OTHER THAN BUTT
ROOT PASS: SMAW FILLER PASS: SMAW ROOT PASS: --- FILLER PASS: ---
FILLET JOINTS/ SOCKET JOINTS: NOTE-1
GROOVE JOINTS
ROOT PASS: ASME SFA 5.1 FILLER PASS: ASME SFA 5.5 ROOT PASS: ---- FILLER PASS: ---
WELDING MATERIALS
E6010 E8010-P1/E8045-P2 (NOTE-2)
FILLET JOINT/SOCKET JOINTS: NOTE-1

BACKING RING: NA CONSUMABLE INSERT: NA
JOINT PREPARATION ASME B31.4
GASES PURGING: - SHIELDING: ---

GAS COMPOSITION PURGING: - SHIELDING: ---
PREHEATING PREHEAT TEMP: 80 °C MIN. (NOTE-3) POST HEATING: -
INTERPASS TEMPERATURE : 200 °C MAX.
HOLDING TEMP: - HOLDING TIME: -
POST WELD HEAT TREATMENT RATE OF HEATING: - MIN. HOLDING TIME: -
METHOD OF COOLING: - RATE OF COOLING: -
MECHANICAL PROPERTY CHARPY `V’ NOTCH VALUE: (NOTE-4) MIN: 38 J AVERAGE: 45 J

REQUIREMENTS
AT TEMPERATURE: -29 °C
HARDNESS: 250HV10 MAX.
CODE OF FABRICATION ASME B31.4/API 1104 & OISD 214
TECHNICAL NOTES:
1. FILLET JOINTS/SOCKET JOINTS AND TIE-INS SHALL BE MADE BY SMAW PROCESS USING LOW HYDROGEN ELECTRODE ONLY.
2. EACH BATCH OF FILLER MATERIALS SHALL BE QUALIFIED AS PER ASME SECTION II PART C AND SHALL MEET THE MINIMUM
ULTIMATE TENSILE STRENGTH OF THE LINE PIPE (API 5L Gr. X-65 PSL-2). CHARPY IMPACT TESTING SHALL BE CARRIED OUT
AT -29 DEGREE CELSIUS AND ACHIEVE THE IMPACT VALUE SPECIFED IN TECHNICAL NOTE NO. 4. THE DIFFUSIBLE H2
CONCENTRATION SHALL BE LIMITED TO A MAXIMUM OF 8 ml PER 100 gm OF WELD METAL IRRESPECTIVE OF THE TYPE OF
CONSUMABLES.
ONLY LHE SHALL BE USED FOR CROSSING AND TIE-IN JOINTS.
3. THIS IS THE MINIUM PREHEAT TEMPERATURE REQURIED DURING MANUAL WELDING PROCESS.
4. DURING PROCEDURE QUALLIFICATION, STANDARD SIZE CHARPY TEST PIECES SHALL DEMONSTRATE SINGLE MINIMUM
IMPACT VALUE OF 38 J AND AVERAGE IMPACT VALUE OF 45 J. THE TEST TEMPERATURE SHALL BE -29 DEGREE CELSIUS.
5. THIS SPECIFICATION CHART SHALL BE READ ALONG WITH DOCUMENT NO. A922-020-02-42-WSP-0001.
6. FOR WELDING BETWEEN API 5L Gr. X-65 PSL-2 AND API 5L Gr. X-70 PSL-2, WELDING CHART PROVIDED IN PAGE 6 OF 10 OF THIS
DOCUMENT SHALL BE FOLLOWED.
Page 187 of 1963

WSC for 8.625" Line pipe from DT at EOL Jamnagar to RT at SV-1 Sapar (MANUAL WELDING)
PIPES API 5L Gr. X-56 PSL-2 (WALL THICKNESS: 11.1 mm)
FITTINGS ---
MATERIAL
OTHERS ---

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW FILLER PASS: SMAW ROOT PASS: - FILLER PASS: -
GROOVE JOINTS
ROOT PASS: AWS SFA 5.1 FILLER PASS: AWS SFA 5.5 ROOT PASS: - FILLER PASS: -
WELDING MATERIALS
E6010 E7010-P1
FILLET JOINT/SOCKET JOINT: NOTE-1

GASES PURGING: - SHIELDING: -

GAS COMPOSITION PURGING: - SHIELDING: -
PREHEATING PREHEAT TEMP: 80 °C MIN. POST HEATING: -
CONTINUITY OF WELDING AND PREHEAT: 200 °C MAX.

REQUIREMENTS
AT TEMPERATURE: -29 °C
HARDNESS: 250HV10
TECHNICAL NOTES:
1. FILLET JOINTS SHALL BE MADE BY SMAW PROCESS USING LOW HYDROGEN ELECTRODE ONLY. FILLER PASSES FOR TIE-IN
JOINTS SHALL BE MADE BY LOW HYDROGEN ELECTRODE (E7018).
2. DURING PROCEDURE QUALLIFICATION, STANDARD SIZE CHARPY TEST PIECES SHALL DEMONSTRATE SINGLE MINIMUM
IMPACT VALUE OF 33 J AND AVERAGE IMPACT VALUE OF 40 J. THE TEST TEMPERATURE SHALL BE -29 DEGREE CELSIUS.
3. THIS SPECIFICATION CHART SHALL BE READ ALONG WITH DOCUMENT NO. A922-020-02-42-WSP-0001 .
4. WELDING PROCEDURES SPECIFIED FOR API 5L GR.X-65 LINE PIPE (Page 4 of 10) SHALL BE FOLLOWED FOR WELDING BETWEEN
API 5L GR.X-65 & API 5L GR.X-56 MATERIAL.
Page 188 of 1963

WSC for 14" Line pipe between existing SV Station and new SV Station at Sapar (MANUAL WELDING)
PIPES API 5L Gr. X-70 PSL-2 (WALL THICKNESS: 9.5 mm)
FITTINGS ---
MATERIAL
OTHERS ---

GROOVE JOINTS
WELDING PROCESS
ROOT + HOT PASS: FILLER PASS: SMAW ROOT PASS: --- FILLER PASS: ---
SMAW
GROOVE JOINTS
ROOT+ HOT PASS: AWS

SFA 5.1 E6010 + ASME SFA FILLER PASS: AWS SFA 5.5 ROOT PASS: - -- FILLER PASS: - --
WELDING MATERIALS
5.5 E8010-P1 (NOTE:2) E8018-G/E-9045 P2 (NOTE-2)
FILLET JOINT/SOCKET JOINT: NOTE-1

GASES PURGING: - SHIELDING: -

GAS COMPOSITION PURGING: - SHIELDING: -
PREHEATING PREHEAT TEMP: 150 °C MIN. (NOTE-3) POST HEATING: -
INTERPASS TEMPERATURE : 200 °C MAX.
REQUIREMENTS
AT TEMPERATURE: (-) 29°C
HARDNESS: 250HV10 MAX.
TECHNICAL NOTES:
1. FILLET JOINTS/SOCKET JOINTS SHALL BE MADE BY SMAW PROCESS USING LOW HYDROGEN ELECTRODE ONLY. THIS
WELDING CHART IS APPLICABLE FOR CROSSING AND TIE-IN WELD JOINTS.
2. EACH BATCH OF FILLER MATERIALS SHALL BE QUALIFIED AS PER ASME SECTION II PART C AND SHALL MEET THE MINIMUM
ULTIMATE TENSILE STRENGTH OF THE LINE PIPE (API 5L Gr. X-70 PSL-2). CHARPY IMPACT TOUGHNESS TEST TEMPERATURE
SHALL BE DONE AT MINUS (-) 29 °C AND ACHIEVE THE IMPACT VALUE SPECIFIED IN TECHNICAL NOTE NO. 4. THE DIFFUSIBLE
H2 CONCENTRATION SHALL BE LIMITED TO A MAXIMUM OF 8 ml PER 100 gm OF WELD METAL IRRESPECTIVE OF THE TYPE OF
CONSUMABLESS.
E8045-P2 CAN BE USED IN PLACE OF E9045-P2 IF THE CONSUMABLE MANUFACTURERS CAN PROVIDE GUARANTEED MINIMUM
ULTIMATE TENSILE STRENGTH & YIELD STRENGTH VALUE AND THE PROVEN PAST TRACK RECORD FOR E8045-P2. EACH
BATCH OF E8045-P2 SHALL BE TESTED TO VERIFY THE ACTUAL ULTIMATE TENSILE STRENGTH & YIELD STRENGTH BEFORE
USING AT SITE FOR MANUAL WELDING OF API 5L GR.X70 PIPELINE. ONLY LHE SHALL BE USED FOR CROSSING AND TIE-IN
WELD JOINTS.
3. PREHEATING IS REQURIED DURING SMAW PROCESS. THE PREHEATING SHALL BE CARIED OUT BY A SUITABLE INDUCTION
HEATING EQUIPMENT MEANT FOR PIPELINE AND THE TEMPERATURE SHALL BE MEASURED AT A DISTANCE AWAY FROM THE
HEATED BAND AND MONITORED THROUGH OUT THE WELDING OF THE JOINT TILL THE COMPLETION OF THE CAPPING PASS.
NO OXY-FUEL PREHEATING SHALL BE PERMITTED FOR ANY REASON. THE INTERPASS TEMPERATURE SHALL BE LIMITED TO
200°C MAXIMUM.
4. DURING PROCEDURE QUALLIFICATION, STANDARD SIZE CHARPY TEST PIECES SHALL DEMONSTRATE SINGLE MINIMUM IMPACT
VALUE OF 40 J AND AVERAGE IMPACT VALUE OF 50 J. THE TEST TEMPERATURE SHALL BE -29 DEGREE CELSIUS.
6. THIS WELDING CHART SHALL BE USED FOR WELIDNG BETWEEN GR.X-70 TO GR.X-60 MATERIAL.
Page 189 of 1963

Welding Specification Chart For Piping Classes: AA9A, BA9A, DA9A, EA9A
PIPES ASTM A 333 GR.6, API 5L GR.X-42 PSL2, API 5L GR.X-52 PSL2
FITTINGS ASTM A 350 GR.LF2 CL.1, ASTM A 420 GR.WPL6, MSS SP-75
MATERIAL GR.WPHY-42, MSS SP-75 GR.WPHY-52
SPECIFICATIONS ASTM A 350 GR.LF2 CL.1, ASTM A 694 GR.F-42, ASTM A 694 GR.F-52
FLANGES
OTHERS -
BASE METAL `P/S’ NO 1

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW/ FILLERPASS: SMAW/GTAW ROOTPASS: GTAW FILLER PASS: SMAW/
GTAW (NOTE-1) (NOTE-2) /SMAW GTAW
FILLET JOINTS/ SOCKET JOINTS: SMAW
GROOVE JOINTS
ROOT PASS: E6010/ FILLER PASS: E7016/ FILLER PASS: E7016/

ROOT PASS: E6010/
WELDING MATERIALS ER70S-2 (NOTE-2) E7018 / ER70S-2 E7018 / ER70S-2
ER70S-2 (NOTE-2)
(NOTE-2) (NOTE-2)
FILLET JOINT/SOCKET JOINT: E7016/E7018

GASES PURGING: - SHIELDING: ARGON

GAS COMPOSITION PURGING: - SHIELDING: 99.995 %
PREHEAT TEMP: +10°C MIN./ 100°C MIN. FOR
PREHEATING INTERPASS: 315°C MAX.
THK.>25.4 MM (NOTE-3)
POST HEATING: -
MECHANICAL PROPERTY CHARPY `V’ NOTCH VALUE: (NOTE-4) MIN: 27 J AVERAGE: ---
REQUIREMENTS
AT TEMPERATURE: -29C
HARDNESS: 250 HV MAX.
CODE OF FABRICATION ASME B31.4/API 1104/ASME SECTION IX & OISD 214
TECHNICAL NOTES:
1. THE ROOT PASS FOR SINGLE SIDE WELDING SHALL BE DONE BY GTAW PROCESS.
2. FOR PIPING SIZES 2” OD AND BELOW SHALL BE ENTIRELY WELDED BY GTAW PROCESS.
3. PRE-HEAT TEMPERATURE OF ATLEAST 50°C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR THK>=12.5 mm & < 25 mm.
4. DURING PROCEDURE QUALLIFICATION, STANDARD-SIZE CHARPY TEST PIECES SHALL DEMONSTRATE SINGLE MINIMUM
IMPACT VALUE OF 27 J. THE TEST TEMPERATURE SHALL BE MINUS (-) TWENTY NINE DEGREE CELSIUS OR COLDER.
5. THIS WELDING SPECIFICATION CHART SHALL BE READ ALONG WITH DOCUMENT NO. A922-020-02-42-WSP-0001.
6. DURING WELDING OF ANY GRADE OF AA9A/ BA9A/DA9A/EA9A PIPING MATERIAL TO API 5L GR.X65/API 5L GR.X70 PSL 2 MATERIAL,
WELDING CHART APPLICABLE TO API 5L GR.X65/API 5L GR.X70 PSL 2 SHALL BE USED.
Page 190 of 1963

Welding Specification Chart For Piping Class: AA3A

PIPES IS-1239, IS-3589 GR.330
FITTINGS ASTM A 105, SATM A 234 GR.WPB, IS-3589 GR.330

MATERIAL
SPECIFICATIONS ASTM A 105
FLANGES
OTHERS -
BASE METAL `P/S’ NO 1

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW FILLERPASS: SMAW/GTAW ROOTPASS:
FILLER PASS: SMAW
(NOTE-2) SMAW
GROOVE JOINTS
ROOT PASS: E6010 FILLER PASS: E6013/ FILLER PASS: E7016/

WELDING MATERIALS ROOT PASS: E6010
E7016/ E7018 E7018 /E6013
FILLET JOINT/SOCKET JOINT: E7016/E7018

GASES PURGING: - SHIELDING: ---

GAS COMPOSITION PURGING: - SHIELDING: ---
PREHEATING INTERPASS:
POST HEATING: -
MECHANICAL PROPERTY CHARPY `V’ NOTCH VALUE: --- MIN: --- AVERAGE: ---
REQUIREMENTS
AT TEMPERATURE: ---
HARDNESS: ---
TECHNICAL NOTES:
2. THIS WELDING SPECIFICATION CHART SHALL BE READ ALONG WITH DOCUMENT NO. A922-020-02-42-WSP-0001.
Page 191 of 1963

Welding Specification Chart For Piping Classes: AL9A, BL9A, DL9A, EL9A
PIPES ASTM A 333 GR.6, API 5L GR.X-42 PSL2
FITTINGS ASTM A 350 GR.LF2 CL.1, ASTM A 420 GR.WPL6, MSS SP-75
MATERIAL GR.WPHY-42
SPECIFICATIONS ASTM A 350 GR.LF2 CL.1, ASTM A 694 GR.F-42
FLANGES
OTHERS -
BASE METAL `P’ NO 1

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW/ FILLERPASS: SMAW/GTAW FILLER PASS: SMAW/
GTAW (NOTE-1) ROOTPASS: GTAW
(NOTE-2) GTAW
GROOVE JOINTS
ROOT PASS: E6010/ FILLER PASS: E7016-1/ FILLER PASS: E7016-1/

ROOT PASS: ER80S-Ni1
WELDING MATERIALS ER80S-Ni1 (NOTE-2) E7018-1 / ER80S-Ni1 E7018-1 / ER80S-Ni1
(NOTE-2)
(NOTE-2) (NOTE-2)
FILLER JOINT/SOCKET JOINT: E7016-1/E7018-1

GASES PURGING: - SHIELDING: ARGON

GAS COMPOSITION PURGING: - SHIELDING: 99.995 %
PREHEATING INTERPASS: 315°C MAX.
POST HEATING: -

REQUIREMENTS
AT TEMPERATURE: -45C
HARDNESS: 250 HV MAX.
TECHNICAL NOTES:
1. THE ROOT PASS FOR SINGLE SIDE WELDING SHALL BE DONE BY GTAW PROCESS.
2. FOR PIPING SIZES 2” OD AND BELOW SHALL BE ENTIRELY WELDED BY GTAW PROCESS.
4. DURING PROCEDURE QUALLIFICATION, STANDARD-SIZE CHARPY TEST PIECES SHALL DEMONSTRATE SINGLE MINIMUM
IMPACT VALUE OF 27 J. THE TEST TEMPERATURE SHALL BE MINUS (-) FORTY FIVE DEGREE CELSIUS.
6. DURING WELDING OF ANY GRADE OF AA1A/ BA1A/DA1A PIPING MATERIAL TO API 5L GR.X65/API 5L GR.X70 PSL 2 MATERIAL,
WELDING CHART APPLICABLE TO API 5L GR.X65/API 5L GR.X70 PSL 2 SHALL BE USED.
Page 192 of 1963

Annexure-1: Guideline For Hot Tap Welding Procedure

1. The Hot tap welding procedure shall comply with API 2201 and API 1104 Appendix B
standards and any other requirements given in the tender document.
2. Welding Procedure shall be established for every Hot tap welding procedure.
3. The Proposed Welding Procedure Specification (PWPS) shall contain the following details as a
minimum and submit to EIL for review and approval:
 Pipeline/Piping process operating conditions (pressure, temperature, Process fluid, flow

rate (M/S).
 Proposed Pipeline/Piping process operating conditions (pressure, temperature, Process
fluid, flow rate (m/s) during hot tap welding activities.
 The fluid details (fluid type, flow rate etc.) to be used during procedure qualification shall
also be mentioned in the PWPS.
 Welding parameters
 Schematic sketches of all weld joints
4. The qualified welding procedures shall include heat input for each pass, Welding sequence
followed and other details.
5. It is recommended to meet the following requirements during hot tap welding operation:
 Only string technique is allowed
 Weld heat input range: 1.2-1.5KJ/mm. Higher heat input is permitted subject to qualification
of weld procedure.
 Process fluid operating pressure during welding shall be 50% of Maximum Allowed
Operating Pressure.
 Low hydrogen electrodes with dia. 2.4, 3.2 to be used.
 Cross sectional hardness during PQR < 250 BHN.
Page 193 of 1963

ADDENDUM TO DOCUMENT NO.
STANDARD SPECIFCATION NO. A922-020-02-42-PCS-0001
6-79-0020, JAMNAGAR-LONI Rev.0
PIPELINE PROJECT Page 1 of 2
ADDENDUM TO
STANDARD SPECIFICATION TO SURFACE
PREPARATION AND PROTECTIVE COATING
(6-79-0020 Rev.0)

JOB NO. : A922

0 23.12.2016 Issued For Tender S S Pandey P Chowdhary A Roy
Rev. No. Date Purpose Prepared by Reviewed by Approved by
Page 194 of 1963

ADDENDUM TO DOCUMENT NO.
STANDARD SPECIFCATION NO. A922-020-02-42-PCS-0001
6-79-0020, JAMNAGAR-LONI Rev. 0
PIPELINE PROJECT Page 2 of 2
AMMENDMENTS/ADDITIONAL REQUIREMENTS
Specification No. : 6-79-0020 Rev.0
Title : Standard Specification for Surface Preparation and Protective Coating (New
Construction)
Following amendments/additional requirements shall be applicable:
1. Refer clause 2.2.2

Add d. Galvanized steel
2. Refer Table 8.0 Coating System for Gratings, Rollings & Stationary Ladders, Spiral
Stairways and Hand Rails in all location
Table 8.0 stands deleted.
3. Protective coating System specified in Clause 10.2 of Table 10.0 shall be applicable for
external surfaces of un-insulated and above ground CS items covered in Table 10 for
design temperature range of -45 to 65°C.
4. Refer Table 15.0, Coating under insulation (Coastal or inland plants). All unit areas and
off-sites, Sl. No.15.2.2
Sl.No.15.2.2 shall be read as below:
Coating System Total Final

Surface Preparation
Sl. Design DFT
& Pre-erection/Shop (Post-Erection/Field) (Note-1)
No. Temp. in in Microns Remarks
o Primer
C (min.)
Primer/ Finish coat
intermediate
SSPC-SP-10;
1coat of F-9 @ 75µ 135
DFT/coat for up to 3 coats of F-12
15.2.2 121 to 5 4 0 400 oC none @ 20µ DFT/coat -
1 coat of F-12 @20µ 80

DFT/coat for 400-540 oC
Page 195 of 1963

SPECIFICATION NO.
SPECIFICATION FOR MAGNETIC
CLEANING & EGP A922-000-02-42-EGP-0001
Rev. 0
Page 1 of 12
GAIL INDIA LIMITED
SPECIFICATION FOR
MAGNETIC CLEANING &
ELECTRONIC GEOMETRY PIGGING
CLIENT : GAIL INDIA LTD

PROJECT: CAPACITY AUGMENTATION OF JAMNAGAR-LONI
JOB NO. : A922
0 18.11.16 Issued For Tender SSP SKM AR
Rev.No Date Purpose Prepared by Checked by Approved by
Page 196 of 1963

SPECIFICATION NO.
Rev. 0
Page 2 of 12
CONTENTS
1.0 SCOPE OF WORK .......................................................................................................................... 3
1.1 INTRODUCTION .......................................................................................................................... 3
1.2 OBJECTIVE ................................................................................................................................ 3
1.3 INFORMATION TO BE FURNISHED BY BIDDER ............................................................... 3
1.4 SCOPE OF WORK .................................................................................................................... 4
2.0 TECHNICAL SPECIFICATIONS ....................................................................................................... 6
2.1 INTENT ........................................................................................................................................ 6
2.2 PROPELLING MEDIUM ............................................................................................................ 6
2.3 MAGNET CLEANING PIG RUNS............................................................................................ 6
2.4 ELECTRONIC GEOMETRY PIG (EGP) RUNS..................................................................... 7
2.5 DEFECT SIGNIFICANCE ......................................................................................................... 7
2.6 DATA ANALYSIS ....................................................................................................................... 8
2.7 FINAL WORK REPORT ............................................................................................................ 8
2.8 ABNORMAL SITUATIONS: ...................................................................................................... 9
2.9 UNSUCCESSFUL EGP RUN ................................................................................................. 10
3.0 PROFORMA FOR MAGNET CLEANING & EGP............................................................................. 11
FORM A: PROFORMA FOR MAGNET CLEANING PIG DETAILS DIAMETER OF TOOLS ...... 11
FORM B: PROFORMA FOR ELECTRONIC GEOMETRY PIG DETAILS DIAMETER OF EGP .. 12
Page 197 of 1963

SPECIFICATION NO.
Rev. 0
Page 3 of 12
1.0 SCOPE OF WORK
1.1 INTRODUCTION
M/s Gail India ltd.(GAIL) proposes to lay an approximately 17.0 km long 8 inch pipeline
from EOL DT to SV-1 (RIL- Samakhiali Section) for transportation of LPG. It is proposed
to clean the following pipeline of M/s GAIL using magnetic cleaning pigs so as to remove
all the metallic “Constructional debris “ and carry out Electronic Geometry Pigging
(EGP) survey to verify “As laid” status of the pipeline in respect of the
geometry defects, if any. For details, refer pipe schematic (drawing no. A922-000-83-
41-30011).
1.2 OBJECTIVE
The objective of the present survey is to clean “constructional metallic debris” of the
pipeline and obtain the record of internal geometry in "As laid" condition of the pipeline. It
is therefore required to run the magnetic cleaning pig and Electronic Geometry Pig
(EGP) so as to identify, characterize (Sizing and Location), and evaluate any
geometrical injurious defects that might have got introduced during installation.
1.3 INFORMATION TO BE FURNISHED BY BIDDER
The bidders are free to avail back up services from any international pigging company of
repute for specialized services including special pigs, personnel, data analysis etc.
However, the bidder in his bid shall clearly mention the name, address, contact
person, telephone, fax, e-mail etc. of the company whose services are proposed to be
availed by the bidder. Bidder to note that the main bidder shall be responsible for the
entire scope of work in conformity with all provisions of the tender document. Bidder to
submit memorandum of understanding in this regard.
The bidder must specify in his offer the maximum length which can be inspected in
one single continuous run by the tool proposed by him. It is required to complete the
entire run length of each segment of the pipeline in a single run.
Page 198 of 1963

SPECIFICATION NO.
Rev. 0
Page 4 of 12
- Specifications of magnet cleaning pigs and EGP for required pipe sizes.
- Details of EGP in following respect (as per attached Proformas A and B).
Max. % of nominal pipeline ID tool can pass (% of ID)
Minimum deformation level reported (as % of ID)
Accuracy of measurement (% of ID)
Bend radius the tool is able to negotiate
Accuracy of locating indication with respect to axial length (Meters)
- Details of pig tracking equipment and pig tracking procedure.
- Pig stuck contingency plan and method for pig retrieval.
- Proposed methodology for execution of pipeline pigging.
- Schedule of activities etc.
1.4 SCOPE OF WORK
Essentially the Scope of work comprises of running the magnetic cleaning pig and
EGP through each segment of the pipeline provided to the contractor before
commissioning. If permanent launcher and receiver are not ready, contractor has to
do the EGP and magnetic cleaning with temporary launcher and receiver then the
contractor shall arrange the same at no extra cost and time implication to Client.
All facilities /services numerated below (not limited to) which the contractor deems
necessary to fulfill the work shall have to be arranged by him at no extra cost and time to
Client.
1.4.1 DETAILED SCOPE OF WORK
Mobilization of all equipment e.g. magnet cleaning pigs, EGP, air compressors, temporary
launcher and receiver, spares, consumables, communication system, transportation and
personnel in adequate number for completion of entire works within the contract
price without depending turnaround time of bringing the pig received from previous
run from receiver station to launch station. As such no turn around period shall be
allowed. It is expressly understood that this does not limit the scope of work of the
contractor in any way. The quantities to be mobilized for different equipment
(different types of pigs) accessories, spares, and consumables need to be carefully
evaluated by the bidder taking in to the consideration that cleaning and geometry
inspection of each segments should be carried out without any constraint. Contractor
shall submit operation manual/procedure manual and data sheets for pigs before
commencing the job for Client’s approval.
Page 199 of 1963

SPECIFICATION NO.
Rev. 0
Page 5 of 12
Since the job is sandwiched between mechanical completion and commissioning

/preservation of the pipeline, Contractor to deploy adequate manpower and tools,
equipments in sufficient number so that magnetic pigging and EGP works can be
executed simultaneously on different segments. Also, the EGP Contractor to liaison with
pipeline contractor regarding availability of the work front.
Transportation of the tools and personnel at the site from one pigging section to
another as per availability of the work front.
Any arrangement to be done on permanent launching and receiving facilities for

injecting pressurized air if same is not available.
Organize placement of various types of pigs into launcher and retrieval of the pig from the
receiver including launching and receiving operations.
Carrying out cleaning of pipeline, if required to the satisfaction of EGP contractor, in

the event of cleaning and swabbing carried out by pipeline contractor is not
satisfactory to run EGP tool.
Conduct calibration test of the electronic geometry tool at the contractor’s facilities
prior to mobilization of the tool and submission of the calibration report. The consultant
shall review the report of the calibration /pull through test to ascertain the diagnostic
capability.
Preparation and submission of total work procedure and operation manual for various
pigging activities for Client’s approval before start of work.
Carrying out adequate number of magnet cleaning pig runs by running suitable magnet
cleaning pigs in each pipeline segment covered under scope of work as per technical
specification, approved procedure and direction of Engineer- in-charge.
Contractor to carry out EGP runs in each pipeline segment covered under scope of
work for each pipeline segment to generate valid and interpretable geometry data of
the pipeline and analysis of data of the EGP survey to detect the nature, extent and
location of geometry defect as detailed elsewhere in this job specifications.
Preparation and submission of daily site report after completion of each pigging
activity.
Preparation and submission of preliminary report based on the result of the electronic
geometry pigging. This report shall be submitted at site within three days of retrieval of
EGP from receiver.
Page 200 of 1963

SPECIFICATION NO.
Rev. 0
Page 6 of 12
Demobilization of all equipment, tools and personnel on completion of field activities

for all segments.
Final data analysis of the geometry Inspection at the EGP contractor's data analysis
centre.
Preparation and submission of the final report for each segment within one month after
completion of field activities of the particular segment for approval/acceptance by
owner/consultant as per technical specifications.
2.0 TECHNICAL SPECIFICATIONS
2.1 INTENT
The intent of the specification is to set forth the requirements of the Electronic
Geometry Survey of the pipelines to help bidder quote his unit rate price in the
schedule of rates.
This requirement is not intended to be all inclusive and use of guidelines set forth does
not relieve the contractor of his responsibility of successfully carry out all activities and to
obtain reliable and valid data from the EGP tool about condition of the pipeline as
defined under Scope of work.
2.2 PROPELLING MEDIUM
Since pipeline is not commissioned, contractor shall use air as propelling medium for
which single compressor of 900 cfm capacity shall be used. The compressor should
have the capacity to develop pressure upto 10KG/CM2. Contractor shall also keep one
compressor of the same capacity mentioned above as stand by. However, Contractor
should mobilize higher capacity compressors in order to complete the magnetic
cleaning and electronic geometry inspection to meet any contingency like stuck up pig/
early completion of pigging work in view of commissioning schedule of pipeline. The air
should be reasonably dry and free from dust particles. Contractor has to arrange all
the facilities required for pressurizing air into the pipeline and running the pigs at
required speed so that valid and interpretable data by running EGP is generated by
using the above media
2.3 MAGNET CLEANING PIG RUNS
Prior to launching of EGP, contractor shall complete all activities required to establish
adequate cleanliness of pipeline to the satisfaction of the contractor and to verify the
internal geometry of the pipeline with relation to ovality, dent etc. Contractor shall
decide the number of magnet cleaning pig runs and the choice of the magnet cleaning pig
Page 201 of 1963

SPECIFICATION NO.
Rev. 0
Page 7 of 12
for each cleaning run as suitable for the purpose to obtain internal condition adequately
clean so as to obtain valid and interpretable inspection data from the EGP and to
safeguard EGP against damage due to debris in the pipeline.
However, the ferrous debris permitted with magnetic cleaning pig shall not exceed 5
Kg/100KM. In case debris received is more than this amount, the contractor shall be
required to make subsequent run(s) until at least the above limit is achieved.
The cleaning pigs for successive cleaning pig runs shall be selected by the contractor in
such a manner that effective cleaning i.e. 5kg/100km ferrous debris is achieved.
2.4 ELECTRONIC GEOMETRY PIG (EGP) RUNS
The EGP should be capable of recording the entire length of each segment i.e. from
launcher to receiver in one single run and therefore its electronic recorder system
should have requisite data storage capacity. Battery life therefore should be adequate to
commensurate with the run time required to travel the pipe length of each segment and
the drive cups should have requisite resistance to wear and tear to maintain effective
sealing throughout the entire run time.
The measurement shall cover the entire 360o of internal pipe wall circumference using
properly oriented and sufficient no of sensors. The tool shall be capable to identify and
locate the following features as a minimum.
- Individual Girth weld
- Dent, ovality, buckles, wrinkles/ripples or any other out of roundness, change in

pipeline I.D. and difference of thickness.
- Valves or any partially closed valves.
- Tap-off
2.5 DEFECT SIGNIFICANCE
The following information/performance is expected out of the EGP inspection:
2.5.1 Inspection of entire length of each segment to be completed in one single run. The
length of each pigging segment shall be based on the length of hydro testing of the
pipeline and distance between Sectionalizing Valve (SV) or the status of pipeline
length available at the time of mechanical completion. The typical length of the hydro
testing span would be 40 to 75 Km or more as per the status of mechanical completion of
the pipeline.
2.5.2 Accuracy of defects:
The best accuracy offered and guaranteed by the bidder for each category of defect
Page 202 of 1963

SPECIFICATION NO.
Rev. 0
Page 8 of 12
should be clearly spelt out. However, the tool should have minimum capabilities as under.
- Minimum detection level for dent ( at the specified accuracy) : 2% of ID
- Measurement accuracy for dent: -25% of the value in mm measured by the tool
- Minimum detection level for ovality: 5% of ID
- Measurement Accuracy for ovality: +/- 2% of ID
- Location Accuracy Axial: 0.1% from permanent feature, within pipe +/- 20cm
- Circumferential location accuracy: +/- 15 degree
- The tool should be capable of negotiating minimum 3D bend and 15%reduction in pipe
ID.
Any deformation existing on the weld (circumferential or longitudinal) to be reported.
2.6 DATA ANALYSIS
Bidder shall carry out the data analysis for EGP at his data analysis centre. The
analysis shall consist of minimum of following: -
- Defect sizing (Depth & length) for all "significant defects" (Deformation ± 2%
of ID).
- Identification of all pipeline permanent features e.g. valves, tees etc.
- Identification of potentially hazardous defects likely to affect structural integrity of the

pipeline.
- The contractor will transfer all the processed data generated on a CD with user-
friendly operation on a compatible PC.
Providing all the raw and processed data along with the software package for enabling
Client to study the data as required. The software should be user friendly.
2.7 FINAL WORK REPORT
The bidder shall include in his offer the most appropriate reporting procedure
envisaged for the subject pipeline. This will have to be mutually agreed between the
successful bidder and Client.
However, any reporting system shall include but not limited to the following:
- A detailed report in respect of each pipe segment of running each of the pre-
inspection tools such as magnet cleaning pig.
Page 203 of 1963

SPECIFICATION NO.
Rev. 0
Page 9 of 12
- Detailed report about running of the EGP including but not limited to the
operational and functional details.
- Details describing the type, size and location of individual mechanical defects.
The location of each defect should be suitably listed with reference to permanent
pipeline features, circumferential location, girth weld no., relative and absolute
distance.
- A detailed report in respect of each defect for which sizing has to be done
indicating its length, depth and axial as well as circumferential location suitably
referenced.
- Preliminary site report for each pipe segment for each running of magnet
cleaning, and EGP runs stating comments/observations of each run, pig condition,
operating parameters, and total time required.
- Velocity plot of the EGP along the length of the segment.
The format and proforma of the above report shall be mutually agreed upon between
the successful bidder and Client. The above report to be submitted in four copies of bound
volume.
Final processed inspection log shall also be compiled in a CD having user-friendly

operation on a Compatible PC along with the operating software necessary for
review/analysis of data. This is required to facilitate selection of significant defects,
their chainage and sizing. Contractor will furnish this CD and viewer as part of report.
2.8 ABNORMAL SITUATIONS:
The objective of this section is to write down foreseeable abnormal circumstances for
taking appropriate measures, should such a condition arise during implementation of
project.
Client/EIL has foreseen the following abnormal conditions. However, if the bidder
foresees any other abnormal condition, he is free to make a mention of the same in his
technical bid offer.
2.8.1 TOOL FAILURE
Contractor is required to get valid interpretable data for the pipeline. In case
contractor's equipment fails to perform electronic geometry inspection to generate valid
data, contractor will make extra runs to get valid and interpretable data without any
additional cost and time implication to the company.
Page 204 of 1963

SPECIFICATION NO.
Rev. 0
Page 10 of 12
2.8.2 STUCK-UP TOOL
The bidder shall detail out a contingency plan in his bid as proposed by him in case
any of the pigs get stuck up. The plan shall identify procedure for exactly locating the
stuck up pig, detail procedure for retrieval of pig, equipment, including support facilities
required to retrieve the pig.
If pig does not move from stuck up location, by any of suggested measure, then the
pipeline section shall have to be cut for retrieval of pig. Contractor shall carry out
necessary fabrication and modification of pipe with new pipe piece after retrieval of pig
at no cost to the company in the event of pig stuck situation for reason attributable to
contractor. The pipe shall be issued to contractor by company as free issue material.
However, locating the stuck up pig and its retrieval shall always be responsibility of the
contractor. After modification pigging contractor shall run gauge pig to check internal
restriction, if any.
2.9 UNSUCCESSFUL EGP RUN
EGP run shall be considered not successful, if, at the end of the EGP, the contractor is
not able to deliver valid and interpretable data.
Page 205 of 1963

K
3.0 PROFORMA FOR MAGNET CLEANING & EGP
FORM A: PROFORMA FOR MAGNET CLEANING PIG DETAILS DIAMETER OF

TOOLS
Sr. No Description Bidders details
MAGNET CLEANING PIG
1 Minimum % of ID that the MAGNET CLEANING pig pass
without damaging pig and pipe
2 Number of magnets mounted on pig
3 Number of modules and length of tool
4 Weight of pig
5 Bend radius able to negotiate
6 Schematic sketch of magnet pig enclosed indicating
configuration.
Page 206 of 1963

K
FORM B: PROFORMA FOR ELECTRONIC GEOMETRY PIG DETAILS DIAMETER OF

EGP
Sr. No Description Bidders details or Yes/NO
ELECTRONIC GEOMETRY PIG
1.0 Weight of tool

2.0 Number of Modules of tools and length of tool
3.0 Principle of operation
4.0 Capability of inspecting Maximum length in single
run.
5.0 Pressure range
6.0 Temperature range
7.0 Battery life
8.0 Capability of detecting 2% dent YES/NO
9.0 Accuracy for depth sizing for dent
10.0 Speed range for data generation
11.0 Number of sensors
12.0 Frequency or distance of sampling
13.0 Capability to identify following as a minimum
13.1 Individual girth weld YES/NO
13.2 Dent and Ovality YES/NO
13.3 Out of roundness YES/NO
13.4 Valves or any partially closed valve YES/NO
14.0 Minimum % of ID that the EGP pig pass without
damaging pig and pipe
15.0 Axial & Circumferential accuracy of locating defect
from reference marker/pipeline feature
16.0 Accuracy of measurement for depth of ovality
17.0 Bend radius the tool is able to negotiate
18.0 Schematic sketch enclosed indicating configuration
19.0 Any other tool specific information
Page 207 of 1963

ADDENDUM DOCUMENT No.
TO A922-000-83-41-AD-0005
STANDARD SPECIFICATION NO. Rev. 0
6-71-0005 Page 1 of 2
ADDENDUM TO STANDARD SPECIFICATION

FOR
HIGH FREQUENCY WELDED (HFW) LINE PIPE (ONSHORE)
(6-71-0005, Rev 4)

JOB NO. : A922
0 11.08.2016 ISSUED AS ADDENDUM RB AR/ NR MSG

Date Purpose
No by by by
Page 208 of 1963

TO A538-000-83-41-AD-0005
6-71-0005 Page 2 of 2
AMENDMENTS/ADDITIONAL REQUIREMENTS
Specification No. : 6-71-0005, Rev 4
Title : STANDARD SPECIFICATION FOR HIGH

FREQUENCY WELDED (HFW) LINE PIPE
(ONSHORE)
1. Refer Clause 9.8 of the Specification no. 6-71-0005.

CVN impact test temperature indicated as “0°C” in sub-clause nos. 9.8.2.1, 9.8.2.2 &
9.8.3 shall be read as “(-) 29°C”.
Page 209 of 1963

TO A922-000-83-41-AD-0041
6-71-0041 Page 1 of 4
ADDENDUM TO STANDARD SPECIFICATION

FOR
3 LAYER POLYETHYLENE COATING OF LINEPIPES
(6-71-0041, Rev 3)

JOB NO. : A922
0 11.08.2016 ISSUED AS ADDENDUM RB AR/ NR MSG

Date Purpose
No by by by
Page 210 of 1963

TO A922-000-83-41-AD-0041
6-71-0041 Page 2 of 4
AMENDMENTS/ADDITIONAL REQUIREMENTS
Specification No. : 6-71-0041, Rev 3
Title : STANDARD SPECIFICATION FOR 3 LAYER

POLYETHYLENE COATING OF LINEPIPES
1. Refer clause 5.3.2, Properties of Polythene Compound:

i. Refer Sl. Nos. 5.3.2 (f):
The ‘Volume Resistivity’ requirement mentioned in the table shall be “≥1016 Ohm-
cm”, instead of “≥1016 Ohm-cm”.
ii. Refer Sl. Nos. 5.3.2 (i):
The Test Temperature of ‘Elongation at break’ shall be “23°C”, instead of “230 C”.
2. Refer clause 5.3.3, Properties of Applied Coating System:

i. Refer Sl. Nos. 5.3.3 (a):
The test temperatures requirement for ‘Bond strength’ mentioned in the table
shall be “23°C or more”, & “80°C or more”, instead of “23°C”, & “80°C”
respectively.
ii. Refer Sl. Nos. 5.3.3 (f):
The test temperatures requirement for ‘Cathodic Disbondment’ mentioned in the
table shall be “23°C or more”, “65°C or more”, & “80°C or more”, instead of
“23°C”, “65°C”, & “80°C” respectively.
3. Refer clause 7.1. the following sub-clause shall be added:
“g. Details of chemical pre-treatment facilities including process control and

inspection equipment for phosphoric acid wash, de-ionized water wash and
chromate wash.”
4. Clause 7.4.3a shall be added as follows:
“ 7.4.3a Chemical Pre-treatment
7.4.3a.1 Phosphoric Acid Wash followed by De-ionized Water Wash
The procedure to apply the chemical pre-treatment viz. phosphoric acid wash
followed by de-ionized water wash shall be in accordance with the recommendations
of the manufacturer and shall result in intended cleaning requirements of this
specification. Working solution preparation, maintaining concentration, application
procedure including method of spreading, spreading rate, drying times, etc.
depending upon the cleanliness/temperature of the incoming pipe and the line speed
shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line
speed vs. dwell time, rinsing procedure, testing & control, rectificatory measures,
drying procedure etc. shall be clearly established during PQT. Also the quality of the
de-ionized water shall be established during PQT.
Page 211 of 1963

TO A922-000-83-41-AD-0041
6-71-0041 Page 3 of 4
7.4.3a.2 Chromate Treatment
The procedure to apply the chromate treatment shall be in accordance with the
recommendations of the manufacturer. Working solution preparation, maintaining
concentration, application procedure including method of spreading, spreading rate,
drying times, etc. depending upon the temperature of the incoming pipe and the line
speed shall be established. Temperature of the chemical, pipe pre-heat temperature
vs. line speed, pipe heating after chromating and time limit within which the pipe to
be heated, testing & control, rectificatory measures, shall be clearly established
during PQT.”
5. Refer clause 7.5.3, Inspection of all test pipes. The following sub-clause shall be
added:
“c. pH of pipe surface before and after phosphoric acid wash.

d. Visual inspection of chromate coating.”
6. Refer clause 8.6. The clause stands replaced with the following:
“8.6 Chemical Pre-treatment with Phosphoric Acid Solution
8.6.1 All pipes shall be provided chemical pre-treatment with phosphoric acid solution.
10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used to
remove all soluble salts and other soluble contaminants.
The CONTRACTOR shall provide data sheets and supporting documentation for
the phosphoric acid to be used. The documentation shall verify that the phosphoric
acid is suitable for the treatment of line pipe prior to the application of the specific
fusion bonded epoxy powder being applied and the final coating will meet fully the
requirements of this specification.
8.6.2 The pipe temperature immediately prior to the phosphoric acid treatment shall be in
the range of 45°C to 75°C. Phosphoric acid treatment shall be followed immediately
by washing with de-ionized water. De-ionized water used shall conform to the
following requirements:
Sl. No. Properties Unit Requirement
a. Turbidity NTU 1 max.
b. Conductivity mho/cm 5 max.
c. Hardness - Nil
d. Total Alkalinity as CaC03 mg/l 2 to 3
e. Chloride as Cl- mg/l 1 max.
f. Sulphate as SO4= mg/l 1 max.
g. PH - 6.5 to 7.5
Page 212 of 1963

TO A922-000-83-41-AD-0041
6-71-0041 Page 4 of 4
Tests to determine the above properties shall be carried out in accordance with
“Standard Methods for the Examination of Water and Wastewater” published jointly
by American Public Health Association, American Water Works Association and
Water Pollution Control Federation.
Quality of the de-ionized water shall be monitored at the start of each shift and at
every four hours interval. Non-compliance of de-ionized water with respect to the
above requirements shall cause for stoppage of the operations.
8.6.3 The pH of the pipe surface shall be determined both before and after the de-ionized
water rinse initially on each pipe and in case of consistent results, the frequency
may be relaxed to once per hour at the discretion of COMPANY Representative.
The measured pH shall be as follows:
Before de-ionized water wash : 1 to 2

After de-ionized water wash : 6 to 7
8.6.4 After the de-ionized water wash, the pipe shall be dried with dry air and preheated
to a temperature of 65°C to 85°C.
8.6.5 The salt tests shall be carried out after de-ionized water rinse. One test shall be
carried out at one end of each pipe. The acceptance criteria shall be 2g/cm2. An
approved salt meter (SCM 400 or equivalent) shall be used to carry out salt tests
and shall be calibrated in accordance with the equipment manufacturer’s
recommendations.”
7. Refer clause no. 9.2.2, The entire clause (i.e. Table & paragraph(s)) stands
replaced by the following table:
Pipe Size Minimum Coating Thickness
(Specified Outside Diameter) (mm)
Up to 103/4" (273.1 mm) 2.5
From 123/4" ( 323.9mm) to 18" (457mm) 2.5
From20" (508.0mm) to 30" (762) 2.8
32" and above 3.3
Page 213 of 1963

ADDENDUM TO BOLT TENSIONING Document No.
AND A922-000-16-54-DD-0001
BOLT TIGHTENING REQUIREMENTS Rev. No. 0
Page 1 of 5
गेल (इंडिया) लललिटे ि

GAIL (India) LIMITED
CAPACITY AUGMENTATION OF JAMNAGAR-LONI PIPELINE

PROJECT (LPG PIPELINE)
जामनगर-लोनी पाइपलाइन क्षमता विस्तार पररयोजना (एल पी जी पाइपलाइन)
ADDENDUM TO BOLT TENSIONING

AND
BOLT TIGHTENING REQUIREMENTS
0 26-12-16 ISSUED FOR IMPLEMENTATION PVKK PG/SVRS SVRS

Reviewed Approved
Rev. No Date Purpose Prepared by
by by
Template No. 5-0000-0001-T1 Rev. 2 / 28.11.2014 Copyrights EIL – All rights reserved
Page 214 of 1963

Document No.
ADDENDUM TO BOLT TENSIONING A922-000-16-54-DD-0001
AND Rev. No. 0
BOLT TIGHTENING REQUIREMENTS Page 2 of 5
TABLE 1 BOLT TENSION AND TORQUE VALUES
Design Test Material Bolt Bolt

S Piping PIPE SCH/
Rating CA Press. Press. Bolt size No. of bolt tension, torque,
no. Spec SIZE THK Temp. °C Flange Pipe Bolt Gasket
kg/cm2 kg/cm2 kg kg-m
1 AA3A 1/2 150 HVY 1.5 10.55 65 13.188 A105 IS-1239 (BLACK) A193 Gr. B7 BS7531 GR X 1/2 4 684 2.1
2 AA3A 3/4 150 HVY 1.5 10.55 65 13.188 A105 IS-1239 (BLACK) A193 Gr. B7 BS7531 GR X 1/2 4 855 2.6
3 AA3A 1 150 HVY 1.5 10.55 65 13.188 A105 IS-1239 (BLACK) A193 Gr. B7 BS7531 GR X 1/2 4 1027 3.1
4 AA3A 1-1/2 150 HVY 1.5 10.55 65 13.188 A105 IS-1239 (BLACK) A193 Gr. B7 BS7531 GR X 1/2 4 1255 3.8
9 AA3A 8 150 6 1.5 10.55 65 13.188 A105 IS-3589 GR.330 A193 Gr. B7 BS7531 GR X 3/4 8 3014 13.0
12 AA3A 14 150 6 1.5 10.55 65 13.188 A105 IS-3589 GR.330 A193 Gr. B7 BS7531 GR X 1 12 5499 31.0
13 AA3A 16 150 8 1.5 10.55 65 13.188 A105 IS-3589 GR.330 A193 Gr. B7 BS7531 GR X 1 16 5499 31.0
14 AA3A 18 150 8 1.5 10.55 65 13.188 A105 IS-3589 GR.330 A193 Gr. B7 BS7531 GR X 1-1/8 16 7263 45.5
17 AA9A 1/2 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 684 2.1
18 AA9A 3/4 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 855 2.6
19 AA9A 1 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 1027 3.1
20 AA9A 1-1/2 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 1597 4.8
24 AA9A 6 150 12.7 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 8 3972 17.2
25 AA9A 8 150 S80 3 19.11 65 23.89 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 3/4 8 4931 21.3
26 AA9A 10 150 14.3 3 19.11 65 23.89 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 7/8 12 5135 25.5
27 AA9A 12 150 15.9 3 19.11 65 23.89 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 7/8 12 5326 26.5
28 AA9A 14 150 15.9 3 19.11 65 23.89 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 1 12 6249 35.2
29 AA9A 16 150 15.9 3 19.11 65 23.89 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 1 16 5999 33.8
Page 215 of 1963

Document No.
AND Rev. No. 0

S Piping PIPE SCH/
30 AL9A 1/2 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 684 2.1
31 AL9A 3/4 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 855 2.6
32 AL9A 1 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 1027 3.1
33 AL9A 1-1/2 150 S160 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 1597 4.8
37 AL9A 6 150 12.7 3 19.11 65 23.89 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 8 3972 17.2
38 BA9A 1/2 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 741 2.2
39 BA9A 3/4 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 1373 5.0
40 BA9A 1 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 1647 6.0
41 BA9A 1-1/2 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 4 2740 11.8
45 BA9A 6 300 12.7 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 12 5205 22.5
46 BA9A 8 300 S80 3 50 65 62.5 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 7/8 12 7608 37.8
47 BA9A 10 300 14.3 3 50 65 62.5 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 1 16 8748 49.3
48 BA9A 12 300 15.9 3 50 65 62.5 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 1-1/8 16 11554 72.4
51 BL9A 1/2 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 741 2.2
52 BL9A 3/4 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 1373 5.0
53 BL9A 1 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 1647 6.0
54 BL9A 1-1/2 300 S160 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 4 2740 11.8
58 BL9A 6 300 12.7 3 50 65 62.5 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 12 5205 22.5
59 DA9A 1/2 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 970 2.9
60 DA9A 3/4 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 1373 5.0
61 DA9A 1 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 2013 7.4
62 DA9A 1-1/2 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 4 4520 19.5
Page 216 of 1963

Document No.
AND Rev. No. 0

S Piping PIPE SCH/
66 DA9A 6 600 12.7 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1 12 8998 50.7
67 DA9A 8 600 S80 3 100.2 65 125.25 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 1-1/8 12 12875 80.6
68 DA9A 10 600 14.3 3 100.2 65 125.25 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 Spiral wound SS 1-1/4 16 14751 101.5
72 DL9A 1/2 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1/2 4 970 2.9
73 DL9A 3/4 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 1373 5.0
74 DL9A 1 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 5/8 4 2013 7.4
75 DL9A 1-1/2 600 S160 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 3/4 4 4520 19.5
79 DL9A 6 600 12.7 3 100.2 65 125.25 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 Spiral wound SS 1 12 8998 50.7
80 EA9A 1/2 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 3/4 4 2877 11.9
81 EA9A 3/4 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 3/4 4 3698 15.3
82 EA9A 1 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 7/8 4 4565 21.7
83 EA9A 1-1/2 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 1 4 6999 37.7
86 EA9A 4 900 S120 3 150.11 65 187.64 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 RTJ - Soft Iron 1-1/8 8 8583 51.4
90 EA9A 12 900 20.6 3 150.11 65 187.64 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 RTJ - Soft Iron 1-3/8 20 17294 124.1
91 EA9A 14 900 22.2 3 150.11 65 187.64 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 RTJ - Soft Iron 1-1/2 20 21674 168.3
93 EL9A 1/2 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 3/4 4 2877 11.9
94 EL9A 3/4 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 3/4 4 3698 15.3
95 EL9A 1 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 7/8 4 4565 21.7
Page 217 of 1963

Document No.
AND Rev. No. 0

S Piping PIPE SCH/
96 EL9A 1-1/2 900 S160 3 150.11 65 187.64 A 350 GR.LF2 CL.1 A 333 GR.6 A320 GR.L7 RTJ - Soft Iron 1 4 6999 37.7
99 EL9A 4 900 S120 3 150.11 65 187.64 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 RTJ - Soft Iron 1-1/8 8 8583 51.4
100 EL9A 6 900 S120 3 150.11 65 187.64 A 694 GR.F-52 API 5L GR. X52 PSL2 A193 Gr. B7 RTJ - Soft Iron 1-1/8 12 10234 61.3
Note:
1. Refer to "Standard Specification for Application of Torque and Hydraulic Bolt Tension for Flange Joints" doc no 6-76-0002 rev 2 for criteria,
methodology and guidelines for application of the above values.
Page 218 of 1963

SPECIFICATION FOR DOCUMENT No.
GEOTEXTILE BAGS FOR A922-000-83-41-SP-0007
ANTI-BUOYANCY
Page 1 of 5
SPECIFICATION FOR GEOTEXTILE BAGS

FOR
ANTI -BUOYANCY


JOB NO. : A922
0 04.01.17 Issued as Job Specification VS AR NR

Date Purpose
No by by by
Page 219 of 1963

ANTI-BUOYANCY
Page 2 of 5
TABLE OF CONTENTS
1.0 SCOPE
2.0 DESIGN
3.0 MATERIAL
4.0 DELIVERY, STORAGE AND HANDLING
5.0 MARKING
6.0 OTHER TECHNICAL REQUIREMENTS
7.0 INSTALLATION
8.0 DOCUMENTATION
Page 220 of 1963

ANTI-BUOYANCY
Page 3 of 5
1.0 SCOPE
1.1 This specification covers the minimum requirements for design, manufacture and
supply of non-biodegradable geo-textile bags (made from polypropylene fabric)
intended to be used for providing anti-buoyancy measures when filled with
Gravel/stone ballast materials.
2.0 DESIGN
2.1 Geo-textile bags shall be suitable for filling with Gravel/stone ballast materials for
8.625” three layer polyethylenes (3LPE) coated line pipes for anti buoyancy
measures in place of concrete coating.
2.2 Composition and the details of materials shall be as per recommendation of

manufacturer
2.3 The geo-textile bags shall meet the following requirements:
a. Body fabric material must be rated for geo-textile use and as such must be
woven with minimum permeability rating to suit specified Gravel/stone ballast
materials.
b. Geo-textile bags shall be of top loading fabric-type made from woven
polypropylene material.
c. The center to center spacing between a set of geo-textile bags shall be kept
minimum possible but in no case shall it exceed the following:-
Pipe Wall Maximum Geotextile

Pipe O.D.
Thickness Bag Spacing
Inch (mm) mm m ( C/C )

8.625“ (219.1) 7.4 6.0
2.4 Manufacturer shall take prior approval from Owner on details of geo-textile bags and
design calculations.
2.5 The fabric weights to be used in the pipeline should be from a manufacturer with a
minimum of 5 years continuous, successful experience in production and installation
of geo-textile fabric weights for pipeline buoyancy control application. Manufacturing
plants must be an ISO 9002 certified facility to ensure consistency in quality.
2.6 The proposed bags and associated straps etc. shall not be detrimental to the pipeline
coating in any manner.
2.7 Repair of bags, in any manner is not permitted.
3.0 MATERIAL
Page 221 of 1963

ANTI-BUOYANCY
Page 4 of 5
3.1 The body fabric must be treated for UV protection and longevity. The weight of the
body fabric must be a minimum of 400 gms/m2.
3.2 All material used in the fabrication of geo-textile bags such as webbing, lifting loops,
threads etc. shall be polypropylene material.
3.3 All webbing must have a minimum individual tensile rating of at least 2268 kg. With a
combined safety rating of 4 times the capacity.
3.4 Body fabric must have a maximum elongation rating of 15% and be stable within a pH
range between 2 to 12.
3.5 All testing should be as per ASTM or equivalent standards
4.0 DELIVERY, STORAGE AND HANDLING
4.1 Geo-textile bags shall be delivered on pallets with a black protective cover for easy
handling and storage.
4.2 Protective cover to be maintained to ensure the proper protection from oil, dirt and
sunlight.
5.0 MARKING
5.1 On each black protective cover the following shall be marked by suitable means
“Maintain cover or provide separate cover on bags until use. Ensure proper protection
from oil, dirt, sunlight etc.”.
5.2 Each geo-textile bag shall be marked by indelible paint or other suitable methods with
the following minimum information:
a. Product model
b. Name of Manufacturer
c. Dimensions of bag in mm.
d. Weight carrying capacity (Total weight when filled)
e. Year, month of manufacture and product batch number
6.0 OTHER TECHNICAL REQUIREMENTS
6.1 Manufacturer shall provide skilled persons for initial assistance / on the job training
during filling and installation of supplied geo-textile bags till the pipeline installation
contractor will get trained in filling & installation to the satisfaction of Engineer In
charge.
7.0 INSTALLATION
7.1 The geo-textile bags shall be filled by using proper sized filling hoppers with
appropriate stone as recommended by manufacturer.
Page 222 of 1963

ANTI-BUOYANCY
Page 5 of 5
7.2 While picking up fabric weights for transportation, it shall be ensured that all hooks
and clevises are free of large, sharp defects that may damage the lift straps. Only
suitable devices or bag type slings shall be used during lifting.
7.3 Trailers with rails or strapping to secure the load shall be used for transportation to
site. The bags shall not be stacked
7.4 Weights are to be kept in upright and leaning in supported position in ROU for easy
accesses to the lifting loops.
7.5 Extra trench width and depth shall be excavated to accommodate the Geo– textile
bags. Backhoe or side boom shall be used for installation of the same.
8.0 DOCUMENTATION
Following documents shall be submitted for review before installation of geo-textile
bags :-
8.1 All necessary calculations to demonstrate the suitability of proposed geo-textile bags
for pipeline anti-buoyancy measures under the specified design conditions. The
manufacturer shall provide an undertaking that the proposed geo-textile bags are
suitable for 8.625” 3 layer polyethylene (3LPE) coated line pipes. The three layers PE
coating shall be 2.5 mm thick.
8.2 All details of proposed geo-textile bags (such as dimensions, material used etc.) shall
be furnished. Contractor shall highlight any special features if any.
8.3 General arrangement drawings of all items viz. set of geo-textile bags, hopper,
loading arrangement etc.
8.4 Details of all associated equipments (hoppers etc), spares, tools etc required to fill,
transport and install geo-textile bags on the pipeline.
8.5 Complete descriptive technical catalogues describing the materials offered along with
samples of geo-textile bags, its properties, testing results and installation instruction
as applicable specifically to the project, Specific storage and handling instructions.
8.6 Manufacturer shall highlight any precautions / safety measures to be taken.
Page 223 of 1963

DOCUMENT NO.
JOB STANDARD FOR
DIMENSIONS OF STUD A922-000-83-41-SP-0006,
BOLTS Rev 0
Page 1 of 5
JOB STANDARD FOR DIMENSIONS OF STUD-BOLTS

(PIPELINE ENGINEERING DEPARTMENT)

CLIENT PIPELINE SECTION
: 22101501
CODE
JOB NO. : A922
0 22.12.16 Issued for bids VS AR NR

Date Purpose
No by by by
Page 224 of 1963

DOCUMENT NO.
JOB STANDARD FOR
BOLTS Rev 0
Page 2 of 5
PRESSURE RATING: 150#
BOLT LENGTH LISTED BELOW ARE VALID FOR

BOLT A COMPRESSED GASKET THK. OF
NOM PIPE UPTO 3.2 mm
SIZE
INCHES
FLANGE TO FLANGE WITH
DIA NO.
(RF) FIG. 8 FLANGE
1/2 1/2 4 2 1/4 2 1/2
3/4 1/2 4 2 1/2 2 3/4
1 1/2 4 2 1/2 2 3/4
1 1/4 1/2 4 2 3/4 3 1/4
1 1/2 1/2 4 2 3/4 3 1/4
2 5/8 4 3 1/4 3 3/4
2 1/2 5/8 4 3 1/2 4
3 5/8 4 3 3/4 4
3 1/2 5/8 8 3 1/2 4
4 5/8 8 3 3/4 4 1/4
5 3/4 8 3 3/4 4 1/4
6 3/4 8 4 4 3/4
8 3/4 8 4 1/4 5
10 7/8 12 4 3/4 5 1/2
12 7/8 12 4 3/4 5 3/4
14 1 12 6 1/4 7 1/4
16 1 16 7 8 1/4
Page 225 of 1963

DOCUMENT NO.
JOB STANDARD FOR
BOLTS Rev 0
Page 3 of 5
BOLT LENGTH LISTED BELOW ARE

BOLT VALID FOR A COMPRESSED GASKET
NOM PIPE THK.OF UPTO 3.2 mm
SIZE
INCHES
FLANGE TO WITH
DIA NO.
FLANGE (RF) FIG. 8 FLANGE
1/2 1/2 4 2 1/2 3

3/4 5/8 4 3 3 1/2
1 5/8 4 3 3 1/2
1 1/4 5/8 4 3 1/4 3 3/4
1 1/2 3/4 4 3 1/2 4
2 5/8 8 3 1/2 4
2 1/2 3/4 8 4 4 1/2
3 3/4 8 4 1/4 4 3/4
3 1/2 3/4 8 4 1/4 5
4 3/4 8 4 1/2 5 1/ 4
5 3/4 8 4 3/4 5 1/ 2
6 3/4 12 5 5 3/ 4
8 7/8 12 5 1/2 6 1/ 2
10 1 16 7 1/4 8 1/ 2
12 1 1/8 16 8 9 1/ 4
14 1 1/8 20 8 1/4 9 3/ 4
16 1 1/4 20 8 3/4 10 1/ 2
Page 226 of 1963

DOCUMENT NO.
JOB STANDARD FOR
BOLTS Rev 0
Page 4 of 5

NOM PIPE THK.OF UPTO 3.2 mm
SIZE
INCHES
FLANGE TO WITH
DIA NO.
1/2 1/2 4 3 3 1/ 2
3/4 5/8 4 3 1/2 4
1 5/8 4 3 1/2 4
1 1/4 5/8 4 3 3/4 4 1/ 4
1 1/2 3/4 4 4 1/4 4 3/ 4
2 5/8 8 4 1/4 4 3/ 4
2 1/2 3/4 8 4 3/4 5 1/ 2
3 3/4 8 5 5 3/ 4
3 1/2 7/8 8 5 1/2 6 1/ 4
4 7/8 8 5 3/4 6 1/ 2
5 1 8 7 1/2 8 1/ 2
6 1 12 7 3/4 8 3/ 4
8 1 1/8 12 8 3/4 10
10 1 1/4 16 9 3/4 11 1/ 4
12 1 1/4 20 10 11 3/ 4
14 1 3/8 20 10 3/4 12 3/ 4
16 1 1/2 20 11 1/2 13 3/ 4
Page 227 of 1963

DOCUMENT NO.
JOB STANDARD FOR
BOLTS Rev 0
Page 5 of 5

NOM PIPE THK.OF UPTO 5 mm
SIZE
INCHES
FLANGE TO WITH
DIA NO.
1/2 3/4 4 4 1/ 4 4 3/ 4
3/4 3/4 4 4 1/2 5
1 5/8 4 5 5 1/ 2
1 1/2 1 4 6 1/2 7 1/ 4
2 5/8 8 5 3/4 6 1/ 2
3 5/8 8 5 3/ 4 6 1/ 2
4 1 1/ 4 8 8 8 3/ 4
6 1 1/ 4 12 8 3/4 10
8 1 3/ 8 12 10 1/ 4 11 3/ 4
10 1 3/ 8 16 10 3/4 12 1/ 2
12 1 3/ 8 20 11 1/ 2 13 1/ 2
14 1 1/ 2 20 12 1/ 4 14 1/ 2
16 1 5/ 8 20 13 15 1/ 2
Page 228 of 1963

REV. DATE REVISION BY CHECKED APPD. APPD.
0 20/12/16 ISSUED AS JOB STANDRAD GS AR NR
JLPL CAPACITY AUGUMENTATION
PROJECT
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they
will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
RIGHT OF USE (ROU) DURING CONSTRUCTION
RIGHT OF USE (ROU) AFTER COMPLETION OF WORK
LOCATION OF PIPELINE IN ROU

WITH RESPECT TO DIRECTION OF FLOW
NOTES:-
DRAWING NO. REV.

TYPICAL RIGHT OF USE FOR
ENGINEERS INDIA LIMITED A922-000-83-41-ST-0002 0
NEW DELHI PIPELINES
1-1641-0504 REV.0 A4-210x297
Page 229 of 1963

0 08.11.16 ISSUED WITH PMS RB RB MSG
JLPL CAPACITY AUGMENTATION PROJECT
SW FLANGE WN FLANGE
BALL VALVE 300 350

BALL VALVE
WITH PUP PIECE WITH PUP PIECE
3/4" WELDOLET 3/4"
SOCKOLET
2" & ABOVE (150#, 300# & 600#) 2" & ABOVE (900#)
PROCESS VENT ON LINES 2" & ABOVE
2" & ABOVE (150#, 300# & 600#) 2" & ABOVE (900#)
SOCKOLET
WELDOLET
300 BALL VALVE 350

BALL VALVE
3/4" 3/4"
SW FLANGE WN FLANGE
PROCESS DRAIN ON LINES 2" & ABOVE
PROCESS_VENT_&_DRAIN DRAWING NO. REV.

ENGINEERS INDIA LIMITED CONNECTION_DETAILS A922-000-83-41-ST-0011 0
NEW DELHI (AA9A,AL9A,BA9A,BL9A,DA9A,DL9A
EA9A,EL9A) SHEET 1 0F 2
Page 230 of 1963

0 08.11.16 ISSUED WITH PMS RB NR MSG
SW FLANGE WN FLANGE
BALL VALVE 300 BALL VALVE 350

TEE 3/4" TEE 3/4"
3/4" TO 1 1/2" (150#, 300# & 600#) 3/4" TO 1 1/2" (900#)

PROCESS VENT ON LINES 3/4" TO 1 1/2"
3/4" TO 1 1/2" (150#, 300# & 600#) 3/4" TO 1 1/2" (900#)
TEE TEE
BALL VALVE 300 BALL VALVE 350

3/4" 3/4"
SW FLANGE WN FLANGE
PROCESS DRAIN ON LINES 3/4" TO 1 1/2"
OTHER CASES
PROCESS_VENT_&_DRAIN DRAWING NO. REV.

ENGINEERS INDIA LIMITED CONNECTION_DETAILS A922-000-83-41-ST-0011 0
NEW DELHI (AA9A,AL9A,BA9A,BL9A,DA9A,DL9A
Page 231 of 1963

0 08.11.2016 ISSUED WITH PMS RB NR MSG
PIPING INST.
FULL COUPLING (TYP.)

SW 6000# B 16.11
BALL VALVE 300

WITH PUP PIECE
3/4"
SOCKOLET
150#, 300# & 600#
ABOVE GROUND
2" & ABOVE PIPING
S160 PIPE
PIPING INST.
BW END AS PER B16.25
BALL VALVE 350

WITH PUP PIECE
3/4"
BALL VALVE 350

WITH PUP PIECE
WELDOLET 3/4"
900#
ABOVE GROUND
2" & ABOVE PIPING
PG, PI & PT CONNECTON DETAIL

ON ABOVE GROUND 2" & ABOVE PIPING
PRESSURE_GAUGE_INSTRUMENTS DRAWING NO. REV.

ENGINEERS INDIA LIMITED CONNECTION_DETAILS
A922-000-83-41-ST-0012 0
NEW DELHI (AA9A,AL9A,BA9A,BL9A,DA9A,DLA9
Page 232 of 1963
STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
$‘fgar falitu INDIA LIMITED
A ,,, - .csa Under,. ^gt
HIGH FREQUENCY WELDED (HFW)
LINE PIPE (ONSHORE)
6 - 71 - 0005 Rev. 4
Page 1 of 31
'gT4' 5oar s
ZII§141§4 fffg 1117W flf7-47
00q)
STANDARD SPECIFICATION
FOR
LINE PIPE
(ONSHORE)
2
18.03.16
09.01.14
31.07.06
REVISED & REISSUED AS STANDARD
SPECIFICATION
SPECIFICATION
NS
NS
MKM
e
RK
DD
\,em
VM
AS
v.)---/
SC
SC
SPECIFICATION
1 17.10.98 SK SJ VC AS
SPECIFICATION
0 09.06.89 ISSUED AS STANDARD SPECIFICATION MK GD RKD/SA RCPC
Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose Convenor Chairman
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 233 of 1963

ENGINEERS HIGH FREQUENCY WELDED (HFW)
$igar Eifireg INDIA LIMITED LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
Page 2 of 31
Abbreviations:
API American Petroleum Institute

ASTM American Society for Testing and Materials
CE Carbon Equivalent
CVN Charpy V-Notch
FBH Flat Bottomed Holes
HAZ Heat Affected Zone
HFW High Frequency Welded
ID Inside Diameter
KvL Charpy value in pipe longitudinal direction
KvT Charpy value in pipe transversal direction
MPQT Manufacturing Procedure Qualification Tests
MPS Manufacturing Procedure Specification
NDT Non Destructive Testing
OD/ D Outside Diameter, Specified
t Wall Thickness, Specified
UT Ultrasonic testing
Pipeline Engineering Standards Committee
Convenor : Mr. Vinay Mittal
Members : Mr. Brij Raj Meena

Mr. M. S. Gunjiyal
Mr. Gagan Deep Singh
Mr. Raj Kishore
Mr. S. Ghosal (Process-2)
Mr. Rajiv Kumar (PDD)
Mr. R.K. Singh (Inspection)
Mr. K.V.K. Naidu (Projects)
Page 234 of 1963

el ENGINEERS HIGH FREQUENCY WELDED (HFW)
Ogal lajteg INDIA LIMITED 6-71-0005 Rev. 4
t .1nderta, ^g1 LINE PIPE (ONSHORE)
Page 3 of 31
CONTENTS
1 SCOPE 4
3 NORMATIVE REFERENCES 4
6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION 4
8 MANUFACTURING 5
9 ACCEPTANCE CRITERIA 6
10 INSPECTION 12
11 MARKING 17
12 COATINGS AND THREAD PROTECTORS 18

13 RETENTION OF RECORDS 18
14 PRODUCTION REPORT 18
15 INSPECTION OF FIELD TESTS & WARRANTY 18
Annex B 20
Annex C 22
Annex E 23
Annex Q (New) 28
FIGURE: 10.2.4.9.1 29
FIGURE: 10.2.5.3 30
FIGURE: E.1 31
Page 235 of 1963

arcs INDIA LIMITED 6-71-0005 Rev. 4
. t - gn .1nnena.^gt LINE PIPE (ONSHORE)
Page 4 of 31
1 SCOPE
This specification establishes the minimum requirements for the manufacture of high
frequency welded steel line pipe in accordance with the requirements of API (American
Petroleum Institute) Specification 5L, Forty—Fifth Edition, 2012 and makes restrictive
amendments to API Specification 5L. Unless modified and/or deleted by this specification,
the requirements of API Specification 5L shall remain applicable.
The sections, paragraphs and annexes contained herein have the same numbering as that of
API Spec 5L in order to facilitate reference. Additional requirements, which are not specified
in API Spec 5L, have also been numbered and marked as "(New)".
The coverage by this specification is limited to line pipe to be used in onshore pipelines
transporting non—sour hydrocarbons in liquid or gaseous phase. The product specification
level for line pipe to be supplied as per this specification shall be "PSL 2".
The Manufacturer shall have a valid license to use API Monogram in accordance with the
requirements of Specification 5L, Forty—Fifth Edition, 2012 for line pipe as Product
Specification Level PSL 2.
1.1 Pipe Size

(New)
This Specification shall be applied to line pipe of size 4'/2" OD thru 20" OD (both sizes
included).
3 NORMATIVE REFERENCES
The latest edition (edition enforce at the time of issue of enquiry) of following additional
references are included in this specification:
ASTM
ASTM E112-12 : Standard Test Methods for Determining Average Grain size
6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION
6.1 Pipe grade and steel grade
6.1.2 Line pipe supplied to this specification shall conform to Product Specification Level 2 (PSL
2) as given in Table 1 of this specification and consists of an alpha or alphanumeric
designation that identifies the strength level of the pipe. The steel name (designating a steel
grade), linked to the chemical composition of the steel, additionally includes a suffix that
consists of a single letter (M) that identifies the delivery condition as per Table 3 of this
specification.
Table 1 of API Spec 5L stands replaced by Table 1 of this specification.
Table 1— Pipe grades, steel grades and acceptable delivery conditions
PSL Delivery Condition Pipe grade/ steel grade a,b

BM, X42M, X46M, X52M, X56M,
PSL 2 Thermomechanical rolled
X60M, X65M & X7OM
a Deleted
b The suffix (M) for PSL 2 grades belongs to steel grade
Page 236 of 1963

$1g-zir tajleg INDIA LIMITED LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
Page 5 of 31
6.2 Delivery condition
6.2.2 The delivery condition for starting material shall be in accordance with Table 1 of this
specification.
8 MANUFACTURING
8.1 Process of Manufacture
Pipe furnished to this specification shall be manufactured in accordance with the applicable
requirements and limitations given in Table 2 of API Spec 5L and Table 3 of this
specification.
Table 3 — Acceptable manufacturing routes for PSL 2 pipe
Type of Pipe heat Delivery

Starting Material Pipe forming
pipe treatment condition
Thermomechanical-rolled Heat treating a of

HFW Cold forming M
coil weld area only
a See clause 8.8 of this specification for applicable heat treatment
High frequency electric welding shall be performed with a minimum welding current
frequency of 200 kHz. The welding system shall have an integrated control in which
following data as a minimum shall be monitored:
- Welding Temperature
- Welding speed
- Current and Voltage
Abutting edges of the coil shall be milled or machined immediately before welding. The
width of the coil shall be continuously monitored.
8.3 Starting Material
8.3.2 Line pipe furnished to this specification shall be made from steel produced in basic oxygen
or electric arc furnace. Steel shall be made by continuous casting only.
8.3.3 The steel used for manufacture of pipe shall be fully killed and fine grained with ASTM
grain size number 7 or finer as per ASTM E 112.
8.8 Treatment of weld seams in EW and LW pipes
8.8.2 LW pipe and PSL 2 HFW pipe
The weld seam and the entire Heat Affected Zone (HAZ) shall be heat treated so as to
stimulate a normalizing heat treatment in order to control the grain structure so that no
untempered martensite remains in the weld seam and the HAZ, and the mechanical properties
of heat treated zone approximate that of the parent metal.
Heat treatment temperature of the weld seam and the entire HAZ shall be continuously
measured and recorded.
Page 237 of 1963

eief ENGINEERS HIGH FREQUENCY WELDED (HFW)
taiWitg INDIA LIMITED 6-71-0005 Rev. 4
I .1norn. ri LINE PIPE (ONSHORE)
Page 6 of 31
8.9 Cold sizing and cold expansion
8.9.1 Pipes furnished to this specification shall be non-expanded.
8.11 Jointers
8.11.1 Jointers on pipes are not permitted.
9 ACCEPTANCE CRITERIA
9.2 Chemical composition
9.2.2 For pipes supplied as per this specification, the chemical composition of each heat of steel
on product analysis shall be as given in Table 5 of this specification.
Table 5 — Chemical composition for pipe
Element Mass fraction based upon heat and product analyses (%)
Cb 0.16 max. (For Grade B to X56)
0.12 f max. (For Grade X60 to X70)
Si 0.15 m (New) min.
0.45 max.
Mn b 1.20 max. (For Grade B to X46)
1.40 max. (For Grade X52 & X56)
1.60 max. (For Grade X60 & X65)
1.70 max. (For Grade X70)
P 0.020 max.
S 0.015 max.
V 0.05 max. (For Grade B to X56)
0.08 d max. (For Grade X60 to X70)
Nb 0.05 max. (For Grade B to X56)
Ti 0.04 max. (For Grade B to X46)
0.06 d max. (For Grade X65 & X70)
Al n (New) 0.02 o (New) min.
0.07 max.
Cr 0.20 max.
Mo 0.10 max.
Cu 0.35 max.
Ni 0.20 max.
N "(New) 0.012 max.
B 0.0005 max.
Page 238 of 1963

•

ENGINEERS
$ifgal taale'g
- INDIA LIMITED
fla nsert.^g,
LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
Page 7 of 31
Table 5 — Chemical composition for pipe
a Based upon product analysis as per clause 9.2.4 and 9.2.5 of API Spec 5L, the CEpcm limits apply
if C 0.12% and CEllw limits apply if C > 0.12%. For pipes of all grades, sizes and wall
thicknesses, Carbon Equivalent shall comply with the following limits:
CEpcm 0.20 %
CEnw 0.40 %
Boron content shall be considered in CEpcm formula even if it is less than 0.0005%.
b Deleted
c Deleted
d Nb+V+Ti<0.15 %
e Deleted
f Deleted
g Deleted
h Deleted.
i Deleted
j Deleted
k Deleted
1 Deleted
(New) m Minimum for Si is not applicable for Al killed steel.
(New) n Al/N shall be minimum 2 (not applicable to titanium-killed steel or titanium-treated steel).
(New) o Applicable for Al killed steel.
9.2.3 For heat analysis and product analysis, all the elements listed in Table 5 of this specification
shall be analyzed and reported, even if those are not purposely added but are present as
residuals only.
If alloying elements other than those specified in Table 5 of this specification are added to
the steel, the limits of the additional components shall be agreed with the Purchaser.
9.3 Tensile properties
9.3.2 The finished pipe (after all heat treatment & sizing operations) shall conform to the
requirements of Table 7 of API Spec 5L and as modified herein.
The actual yield strength shall be as close as possible to the specified minimum yield strength
(SMYS) but in no case it shall exceed the limits specified here under:
API Spec 5L Grade Permissible in excess of SMYS, MPa (psi)

Upto and including X46 131 (19,000)
X52 to X60 125 (18,000)
X65 to X70 120 (17,400)
The ratio of body yield strength and body tensile strength of each test pipe on which yield
strength and ultimate tensile strength are determined, shall not exceed 0.90.
The tensile strength of the weld (after heat treatment of the weld seam) shall be equal to or
higher than the specified minimum tensile strength of the base metal.
The minimum elongation of base metal shall be determined in accordance with the formula
given in foot note (f) of Table 7 of API Spec 5L, however, minimum elongation in no case
shall be less than 20%.
Page 239 of 1963

51gal taf5ift INDIA LIMITED 6-71-0005 Rev. 4
e lndeetax LINE PIPE (ONSHORE)
Page 8 of 31
9.6 Flattening test
Acceptance criteria for flattening tests shall be as follows:

a) For HFW pipe of grade > X60 and t > 12.7 mm, there shall be no opening of the weld
before the distance between the plates is less than 66% of the original outside
diameter. For all other combinations of pipe grade and specified wall thickness, there
shall be no cracks or breaks in either weld or parent metal before the distance between
the plates is less than 50% of the original outside diameter. Dye penetrant testing
shall be used to positively confirm the presence of crack, break or opening.
b) For HFW pipe with a D I t> 10, there shall be no cracks or breaks other than in the
weld before the distance between the plates is less than 33% of the original outside
diameter.
c) For all pipes, there shall be no evidence of lamination or burnt metal during the entire
test before opposite walls of the pipe meet.
Note: The weld extends to a distance of 13 mm on each side of the weld line. The original outside diameter is
the specified outside diameter.
9.8 CVN impact test for PSL 2 pipe
9.8.1 General
9.8.1.2 From the set of three Charpy V-notch impact test pieces, only one is allowed to be below the
specified average absorbed energy value and shall meet the minimum single absorbed energy
value requirement as specified in Table 8 of this specification.
9.8.2 Pipe body tests

9.8.2.1 The average (set of three test pieces) absorbed energy value (KvT) for each pipe body test
shall be as specified in Table 8 of this specification, based upon full sized test pieces at a test
temperature of 0°C (32°F) or at a lower test temperature as specified in the Purchase Order.
Table 8 — CVN absorbed energy requirements
for pipe body, weld and HAZ of PSL 2 pipe
Full-size CVN absorbed energy (Kyr) a, b [J]
Pipe Grade
Average Minimum
B 40 33
X42 40 33
X46 40 33
X52 40 33
X56 40 33
X60 " 42 35
X65 45 38
X70 50 40
a The required KvL (longitudinal direction test pieces) values shall be 50% higher than the required
KvT values.
b Testing shall be performed at a test temperature of 0°C (32°F) or at a lower temperature as specified
in the Purchase Order.
Page 240 of 1963

eiENGINEERS HIGH FREQUENCY WELDED (HFW)
lfgaf 0151--eg INDIA LIMITED LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
'Oa , lnnen.^:11
Page 9 of 31
9.8.2.2 The minimum average (set of three test pieces) shear fracture area shall be at least 85 % with
one minimum value of 75%, based at a test temperature of 0 °C (32 °F) or at a lower test
temperature as specified in the Purchase Order.
9.8.3 Pipe weld and HAZ tests
The average (set of three test pieces) absorbed energy value (KvT) for each pipe weld and
HAZ test shall be as specified in Table 8 of this specification, based upon full-size test pieces
at a test temperature of 0°C (32°F) or at a lower test temperature as specified in the Purchase
Order.
9.10 Surface conditions, imperfections and defects
9.10.1 General
9.10.1.2 All pipes shall be free from cracks, sweats, leaks and slivers. Pipe containing such defects
shall be treated in accordance with clause C.3 b) or c) of API Spec 5L.
9.10.3 Arc burns
9.10.3.2 Arc burns shall be treated in accordance with clause C.3 b) or c) of API Spec 5L. As a
reference method for confirming the existence of an arc burn, the area shall be buffed with
wire brush or sanding disc and etched with 10% solution of ammonium persulfate or a 5%
solution of nital.
However, arc burns can be considered for acceptance, in case the same is re-crystallized by
seam heat treatment. In such case, the Manufacturer shall demonstrate the re-crystallization
to Purchaser by taking a sample as per clause 10.2.3.8 (New) of this specification.
9.10.4 Laminations
Any lamination or inclusion either extending into the face or bevel of the pipe or present
within 50 mm from pipe ends shall be classified as defect. Pipes that contain such defects
shall be rejected or cut back until no lamination or inclusion is present at the pipe ends and
shall be treated in accordance with clause C.3 b) or c) of API Spec 5L.
9.10.5 Geometric deviations
9.10.5.2 For dents, the length in any direction shall be < 0.5 D and the depth, measured as the gap
between the extreme point of the dent and the prolongation of the normal contour of the pipe,
shall not exceed the following:
a) 3.2 mm for cold-formed dents with sharp-bottom gouges and not encroaching upon the
specified minimum wall thickness.
b) 6.4 mm for other dents.
c) 1 mm at the pipe ends, i.e. within a length of 100 mm at each of the pipe ends.
d) Any dent on weld and heat affected zone (HAZ).
Dents that exceed the above specified limits shall be considered as defect and shall be treated
in accordance with clause C.3 b) or c) of API Spec 5L. Acceptable cold-formed dents with
sharp-bottom gouges shall be treated in accordance with clause C.2 of API Spec 5L & as
modified in this specification.
Page 241 of 1963

HIGH FREQUENCY WELDED (HFW) 6-71-0005 Rev. 4
ligar IRA& ENGINEERS
INDIA LIMITED LINE PIPE (ONSHORE)
.!ndertax^gi
Page 10 of 31
9.10.6 Hard Spots
Any hard spot larger than 50 mm (2.0 in) in any direction and hardness greater than 248HVio
shall be classified as defect and treated in accordance with clause C.3 b) or c) of API Spec
5L.
9.10.7 Other surface imperfection
Other surface imperfections found by visual inspection or non-destructive inspection shall

be investigated, classified and treated as follows:
a) Imperfections that have a depth < 0.05 t and do not encroach on the minimum specified
wall thickness shall be classified as acceptable imperfections and shall be treated in
accordance with Clause C.1 of this specification.
b) Imperfections that have a depth > 0.05 t and do not encroach on the minimum specified
wall thickness shall be classified as defects, and shall be dressed-out by grinding in
accordance with Clause C.2 of API Spec 5L and as modified in this specification or shall
be treated in accordance with clause C.3 b) or c) of API Spec 5L.
c) Imperfections that encroach on the minimum specified wall thickness shall be classified
as defects and treated in accordance with clause C.3 b) or c) of API Spec 5L.
9.11 Dimensions, mass and tolerances
9.11.3 Tolerances for diameter, wall thickness, length and straightness
9.11.3.1 The diameter and out-of-roundness shall be within the tolerances given in Table 10 of this
specification.
Table 10 — Tolerances for diameter and out-of-roundness
Specified outside Out-of-roundness

Diameter tolerances d
diameter tolerance 4')
(D) Pipe except , Pipe except
mm (in) Pipe end a' Pipe end a'c
the end a the end a
— 0.4 mm to 0.015 D upto

D < 168.3 (6%) ± 0.0075 D 0.020 D a maximum
+ 1.6 mm
of 2.0 mm
168.3 (6%) < D
273.1 (10%) ± 0.0075 D ± 0.005 D 0.020 D 2.0 mm
± 0.0075 D upto
D > 273.1 (10%) a maximum of ± 1.6 mm 0.020 D 3.0 mm
± 3.0 mm
a The pipe end includes a length of 100 mm at each of the pipe extremities.
b Deleted
c The diameter tolerance and out-of-roundness tolerance shall apply on inside diameter. The inside
diameter, based on circumferential measurement, shall be calculated as ID = (D — 2t).
d For determining compliance to the diameter tolerances, the pipe diameter is defined as the
circumference of the pipe in any circumferential plane divided by Pi (a).
e Out-of-roundness tolerances apply to maximum and minimum diameters as measured with bar gage,
(New) caliper, or device measuring actual, maximum and minimum diameters.
Page 242 of 1963

k_Stae.iel. ENGIN EERS HIGH FREQUENCY WELDED (HFW)
taareg INDIA LIMITED 6-71-0005 Rev. 4
LINE PIPE (ONSHORE)
,nneriax '91
Page 11 of 31
9.11.3.2 In addition to API requirements, the wall thickness of each pipe shall be checked along the
circumference at both ends and at the mid location of pipe body at 12 0' clock, 3 0' clock, 6
0' clock and 9 0' clock positions. The tolerances for wall thickness shall be as given in Table
11 of this specification.
Table 11 — Tolerances for wall thickness
Wall thickness Tolerances C , d

(mm) (mm)
+ 0.20
t < 15.0 mm t
— 0.0 t
+ 3.0 mm
t> 15.0 mm
— 0.0 mm
a Deleted
b Deleted
c The + ye tolerance for wall thickness does not apply to the weld area.
d See 9.13.2 of API Spec 5L and as modified herein for additional restrictions.
9.11.3.3 All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with length
between 10.0 m and 11.5 m can also be accepted for a maximum of 5% of the ordered
quantity. The minimum average length of the entire ordered quantity in any case shall be
12.0 m. Overall length tolerance shall be (-) Zero and (+) One pipe length to complete the
ordered quantity. Table 12 of API Spec 5L stands deleted.
9.11.3.4 The tolerances for straightness shall be as follows:
a) The total deviation from a straight line over the entire pipe length shall not exceed 12
mm, as shown in Figure 1 of API Spec 5L.
b) The local deviation from straight line in 1.0 m (3.0 11) portion at each pipe end shall be
< 3.0 mm (0.120 in), as shown in Figure 2 of API Spec 5L.
9.12 Finish of pipe ends
9.12.5 Plain ends
9.12.5.6 During removal of inside burrs at the pipe ends, care shall be taken not to remove excess
(New) metal and not to form an inside cavity on bevel. Removal of excess metal beyond the
minimum wall thickness as indicated in clause 9.11.3.2 of this specification shall be a cause
for re-bevelling. In case root face of bevel is less than that specified, the pipe ends shall be
re-bevelled and rectification by filing or grinding shall not be done.
9.12.5.7 Bevel Protectors

(New)
Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel
protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they
can be re-used by coating applicator for providing on externally anti-corrosion coated pipes
subsequent to coating of line pipe.
9.16 Reverse Bend Test

(New)
All pipes shall meet the minimum acceptance criteria for Reverse Bend Test as follows:
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ENGINEERS
I -err 0154-eg INDIA LIMITED
4r
LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
Page 12 of 31
A specimen which fractures completely prior to the engagement of mandrel and specimen as
specified in clause 10.2.4.9 (New) of this specification, or which reveals cracks or ruptures
in the weld or heat affected zone longer than 4 mm shall be rejected. Cracks less than 6 mm
long at the edges of the specimen shall not be cause for rejection. Dye penetrant testing shall
be used to positively confirm cracks or openings.
10 INSPECTION
10.1 Types of inspection and inspection documents
10.1.3 Inspection documents for PSL 2 pipes
10.1.3.1 Inspection certificate 3.2 in accordance with EN 10204 shall be issued for each dispatched
pipe by Purchaser's authorized representative.
10.2 Specific inspection
10.2.1 Inspection frequency
10.2.1.2 For PSL 2 pipe, the inspection frequency shall be as given in Table 18 of this specification.
Table 18 — Inspection frequency of pipe

Sl. no. Type of inspection Frequency of inspection
1. Heat analysis a One analysis per heat of steel
2. Product analysis b Two pipes per lot (maximum 100 pipes) per
heat
3. Tensile testing of the pipe body Two pipes per test unit of not more than
100 pipes per heat
4. Tensile testing of the Two pipes per test unit of not more than
longitudinal weld seam of pipe c 100 pipes per heat
5. CVN impact testing of the pipe Once per test unit of not more than 50 pipes
body
6. CVN impact testing of the weld Once per test unit of not more than 50 pipes
and HAZ of pipe
7. Flattening test of pipe As shown in Figure 6 a) of API Spec 5L
8. Reverse Bend Test (New) Same as Figure 6 a) of API Spec 5L
9. Hardness testing Any hard spot exceeding 50 mm (2.0 in) in
any direction
10. Hydrostatic testing Each pipe
11. Weighing of pipe Each pipe shall be measured and recorded
12. Wall thickness measurement d Each pipe
13. Pipe diameter and out-of- Each pipe
roundness d
14. Length Each length of pipe shall be measured and
recorded
Page 244 of 1963

4afazitil ENGINEERS HIGH FREQUENCY WELDED (HFW)
Mieg INDIA LIMITED 6-71-0005 Rev. 4
A :•.,ta , ■ nnerlak LINE PIPE (ONSHORE)
Page 13 of 31
Table 18 — Inspection frequency of pipe
Si. no. Type of inspection Frequency of inspection

15. Straightness d Each pipe
16. Tolerances for the weld seam d Each pipe
a) Radial offset of coil edges
b) Height of flash and
c) Depth of groove after
trimming of inside flash
17. Visual inspection Each pipe
18. Metallographic testing (including At least one finished pipe from each lot of
Vicker's hardness test) of the 50 pipes per heat or at least once per
longitudinal seam weld of pipe as operating shift (12 hrs max.) whichever is
defined in clause 10.2.5 of this occurring more frequently and whenever
specification changes of grade, diameter or wall thickness
are made and whenever significant
excursions from operating heat treatment
conditions are encountered and at the
beginning of the production of each
combination of specified outside diameter
and specified wall thickness.
19. Other dimensional testing Random testing, with the details left to the
discretion of the manufacturer
20. Non-destructive inspection In accordance with Annex E of API Spec
5L and as modified herein
a Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by the
Manufacturer prior to start of pipe production.
b Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat are
also represented.
c Pipe produced by each welding machine shall be tested at least once per week.
d Measurement shall be recorded at least 3 times per operating shift (12 hrs maximum).
e "Test unit" is as defined in clause 4.62 of API Spec 5L.
10.2.2 Samples and test pieces for product analysis
Samples shall be taken, and test pieces prepared, in accordance with ISO 14284 or ASTM
El 806. Samples used for product analysis shall be taken from finished pipes only.
Samples for product analysis from coil may be used provided the traceability of samples is
guaranteed.
10.2.3 Samples and test pieces for mechanical tests
10.2.3.1 General
In addition to API Spec 5L requirements, samples and test pieces for various types of tests
shall be taken from Figure 5 b) and Figure 6 a) of API Spec 5L and Figure 10.2.4.9.1 &
10.2.5.3.2 of this specification, whichever is applicable, and as given in Table 20 of this
specification.
Page 245 of 1963

(3tif ENGINE ERS HIGH FREQUENCY WELDED (HFW)
$V-zn• tajteg INDIMITED
A LI 6-71-0005 Rev. 4
LINE PIPE (ONSHORE) Page 14 of 31
Table 20 — Number, orientation and location of test pieces

per sample for mechanical tests
Number, Orientation and location

of test pieces per sample a
Sample
Type of test Specified outside diameter, D
Location
mm ( n)
< 219.1 mm (8.625 in) ? 219.1 mm (8.625 in)
Tensile 1L90 1T180
Pipe body
CVN 3T90 3T90
Tensile -- 1W b
CVN 3W and 3HAZ 3W and 3HAZ
• Seam Weld
1W
Hardness
(As shown in figure 10.2.5.3 of this specification)
Pipe body and Flattening As shown in figure 6 a) of API Spec 5L

weld Reverse Bend As shown in figure 10.2.4.9.1 of this specification
a See figure 5 (b) of API Spec 5L for an explanation of the symbols used to designate orientation and
location.
b Test specimen shall be tested for ultimate tensile strength only.
10.2.3.2 Test pieces for the tensile test
Rectangular test pieces, representing the full wall thickness of the pipe, shall be taken in
accordance with ASTM A370 and as shown in Figure 5 b) of API Spec 5L.
Longitudinal tensile tests for pipe body with specified outside diameter, D < 219.1 mm
(8.625 inch) shall be carried out on a strip specimen representing full wall thickness of the
pipe prepared according to ASTM A370.
Transverse tensile test for pipe body with specified outside diameter, D> 219.1 mm (8.625
inch) shall be carried out on flattened rectangular test pieces.
For tensile test piece, both inside and outside flash of weld in excess of pipe wall thickness
shall be removed from the test piece either by grinding or machining.
10.2.3.3 Test pieces for the CVN impact test
In addition to the API Spec 5L requirements, following shall also be applicable:
The test pieces shall be prepared in accordance with ASTM A370. Non-flattened test pieces
shall be used. The axis of the notch shall be perpendicular to the pipe surface.
Charpy V-notch impact testing shall be performed on full—sized test pieces. However, if
preparation of full size test piece is not possible, then standard sub-sized test pieces shall be
prepared as per ASTM A370.
Lower pipe sizes wherein preparation of transverse sub-sized specimen is not possible, CVN
impact testing shall be carried out on longitudinal test specimen [see Note 'a' of Table 8 of
this specification].
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Page 15 of 31
10.2.3.7 Test pieces for flattening test
The test pieces shall be prepared in accordance with ISO 8492. The length of each test piece
shall be > 60 mm.
Minor surface imperfections may be removed by grinding.
10.2.3.8 Test pieces for Macrographic and metallographic tests

(New)
Test piece for metallographic testing shall be taken transverse to the longitudinal weld seam
as indicated in Figure 10.2.5.3 of this specification. The test piece shall be suitably ground,
polished and etched to reveal the macro-structure.
10.2.3.9 Test pieces for Reverse bend test

(New)
Ring specimen of width between 100 mm to 115 mm shall be taken from the pipe. Reverse
bend test shall be carried out as per clause 10.2.4.9 (New) of this specification.
10.2.4 Test methods
10.2.4.3 CVN impact test
The Charpy test shall be carried out in accordance with ASTM A370.
10.2.4.7 Flattening test
In addition to the API Spec 5L requirements, following shall also be applicable:
The flattening test shall be carried out in accordance with ISO 8492.
10.2.4.9 Reverse bend test

(New)
The mandrel shall be plunged into the test piece prepared in accordance with clause 10.2.3.9
(New) of this specification, with the weld in contact with the mandrel, to such a depth that
the angle of engagement between mandrel and specimen reaches 60° as shown in figure
10.2.4.9.1 of this specification. If the combination of diameter & wall thickness of pipe and
radius of mandrel is such that the angle of engagement cannot reach 60°, then the mandrel
shall be plunged into the specimen until opposite walls of the specimen meet.
Selection of Mandrel
The reverse bend test shall be carried out with a mandrel, whose radius (R), or width (A)
shall be calculated for any combination of diameter, wall thickness and grade with the
following formula:
1.4 (D - t) t
A = 2R -
e (D - 2t) - 1.4 t
Where,
D - Specified outside diameter of pipe, mm
t - Specified wall thickness of pipe, mm
1.4 - Peaking factor
e - Strain
Minimum value of 'e' shall be as per Table 23 of API Spec 5L reproduced as below:
Page 247 of 1963

Ogeff fai5Ereg INDIA LIMITED 6-71-0005 Rev. 4
LINE PIPE (ONSHORE)
Page 16 of 31
Table 23 — Strain values for guided-bend test
Pipe grade Strain value

è'
Gr. B 0.1375
X42 0.1375
X46 0.1325
X52 0.1250
X56 0.1175
X60 0.1125
X65 0.1100
X70 0.1025
10.2.5 Macrographic and metallographic tests
10.2.5.3 The test piece shall be visually examined using a minimum 40X magnification to provide
evidence that heat treatment of weld zone is adequate and there is no untempered martensite
or detrimental oxides from the welding process present along the weld seam. The
metallographic examination shall be documented on micrographs (at 10X to 20X
magnification). In case imperfections or defects are observed, it will become a cause for re-
evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's
Representative.
Vickers hardness tests shall be carried out on each test piece taken for metallographic
examination in accordance with ISO 6507-1, at locations indicated in Fig. 10.2.5.3 of this
specification. Indentation in the HAZ shall start as close to the fusion line as possible. The
resulting Vickers hardness value at any point shall not exceed 248HVio. The maximum
difference in hardness between the base metal and any reading taken on the weld or heat
affected zone shall be less than 80HVio. Modalities of retest shall be in accordance with
clause 10.2.12.7 of API Spec 5L.
10.2.6 Hydrostatic test
10.2.6.1 Test pressure shall be held for a minimum period of 15 seconds for all sizes and grades of
pipes.
10.2.6.2 In addition to the requirements of API Spec 5L, following shall also be applicable:
The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and
maximum range of 4 times the test pressure. The test-pressure measuring device shall be
calibrated by means of a dead-weight tester only. The test configuration shall permit bleeding
of trapped air prior to pressurization of the pipe.
10.2.6.5 The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress)
generated is at least 95% of SMYS, computed based on the Equation (6) indicated in clause
10.2.6.5 of API Spec 5L. Table 26 of API Spec 5L stands deleted.
10.2.7 Visual inspection
10.2.7.1 Each pipe shall be visually examined for entire external surface and internal surface to the
extent feasible and shall be free of defects in finished condition. Visual examination shall be
carried out in a sufficiently illuminated area; minimum 1000 lx. If required additional lights
shall be used to obtain good contrast and relief effect between imperfections and
backgrounds.
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$4fgeg fatareg INDIA LIMITED 6-71-0005 Rev. 4
!ndeda. LINE PIPE (ONSHORE) Page 17 of 31
10.2.8 Dimensional testing
10.2.8.1 Diameter measurements shall be made with a circumferential tape only.
10.2.8.7 The measuring equipment requiring calibration or verification under the provisions of API
Spec 5L shall be calibrated with manual instruments at least once per operating shift (12
hours maximum). Such calibration records shall be furnished to Purchaser's Representative
on request.
10.2.10 Non-destructive inspection
Non-destructive inspection shall be performed in accordance with Annex E of API Spec 5L

and as modified herein.
10.2.11 Reprocessing
This clause of API Spec 5L stands cancelled.
10.2.12 Retesting
10.2.12.1 Recheck analyses
Modalities of recheck analysis shall be as per API Spec 5L as applicable to the lot being
tested (see Table 18 of this specification). However, during individual testing, each pipe shall
be fully analyzed to meet the requirements of Table 5 of this specification.
10.2.12.9 Reverse bend retests

(New)
Reverse bend retest provisions shall be same as specified for flattening retests in clause
10.2.12.3 of API Spec 5L.
11 MARKING
11.1 General
11.1.1 Pipe manufactured in accordance with this specification shall be marked by the manufacturer
as per the requirements of API Spec 5L and as modified herein. Marking shall be in English
language and International System (SI) of Units.
11.1.5 Marking shall also include Purchase Order number, item number, pipe number and heat
(New) number.
11.2 Pipe markings
11.2.1 k) Actual length in metres and actual pipe weight in kg shall be marked.
(New)
11.2.2 c) Paint used for stencil marking shall withstand a temperature up to 250°C expected to
(New) be experienced during further external anti-corrosion coating operations of line pipe
by coating applicator.
11.2.3 The pipe number shall be placed by cold rolling or low stress dot marking or vibro-etching
on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In
case of non-availability of either cold rolling or low stress dot marking facility in pipe mill,
an alternative marking scheme of a permanent nature may be proposed by the Manufacturer.
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INDIA LIMITED 6-71-0005 Rev. 4
LINE PIPE (ONSHORE)
.1 t Inrle110
Page 18 of 31
11.2.7 A colour code band shall be marked on inside surface of finished pipe for identification of
pipes of same diameter but different wall thickness, as indicated in the Purchase Order.
The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm
from the pipe ends.
12 COATINGS AND THREAD PROTECTORS
12.1.1 Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of
any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area.
Bevels shall be free of any coating.
13 RETENTION OF RECORDS
In addition to the records indicated in API Spec 5L, the Manufacturer shall retain the records
of all additional tests and calibration records mentioned in this specification including the
hard copy records of ultrasonic testing carried out on pipe/coil as well as pipe ends.
14 PRODUCTION REPORT
(New)
The Manufacturer shall provide one electronic copy and six hard copies of production report
in English language indicating at least the following for each pipe. International system of
units (SI) shall be adopted.
- Pipe number
- Heat number from which pipe is produced
- Pipe length and weight
- Pipe grade
The Manufacturer shall provide one electronic copy and six hard copies of acceptance
certificates which shall include the results of all tests required as per this specification and
performed on delivered material giving details of, but not limited to, the following:
- All test certificates as per clause 10.1.3 of API Spec 5L and as modified herein.
- Records of qualification of welders and procedures for repair welding.
- Certified reports of dimensional inspection, surface imperfections & defects.
- Data on test failures, rejected heats/lots, etc.
- All other reports and results required as per this specification.
The certificates shall be valid only when signed by the Purchaser's Representative. Only
those pipes, which have been certified by the Purchaser's Representative, shall be dispatched
from the pipe mill.
In the event of small quantities of pipes supplied against this specification, the production
report may consist of only test certificates required as per clause 10.1.3 of API Spec 5L and
as modified herein and other test reports/results required as per this specification.
15 INSPECTION OF FIELD TESTS & WARRANTY

(New)
Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails
under field hydrostatic test if such failure is caused by a material/ manufacturing defect in
the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding,
excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test
pressure will not exceed that value which will cause a calculated hoop stress equivalent to
95 percent of specified minimum yield strength.
Page 250 of 1963

_It11
- ENGINEERS HIGH FREQUENCY WELDED (HFW)
5.fgar tapteg INDIA LIMITED LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
is • I
Page 19 of 31
In case Manufacturer so desires, he will be advised at least two weeks in advance so that his
Representative may witness the hydrostatic test in field, however, the testing and leak (if
any) finding and repair operation shall not be postponed because of absence of the
Manufacturer's Representative.
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ei ENGINEERS HIGH FREQUENCY WELDED (HFW)
0141--eg INDIA LIMITED 6-71-0005 Rev. 4
LINE PIPE (ONSHORE)
t "91
Page 20 of 31
Annex B
Manufacturing Procedure Qualification for PSL 2 Pipe
B.1 INTRODUCTION
B.1.1 This annex specifies additional provisions that apply for the PSL 2 pipes ordered as per this
specification.
B.1.2 Two lengths each of completely finished pipes from two different heats (i.e. a total of four
pipe lengths) shall be selected at random for testing as per clause B.5.1 of this specification
to verify that the manufacturing procedure results in the quality of pipes which are in
complete compliance with this specification. The pipes thus tested shall be considered to be
the test pipes required per heat or per lot as per relevant clauses of this specification.
These manufacturing procedure qualification tests (MPQT) shall be repeated upon any
change in the manufacturing procedure as deemed necessary by Purchaser's Representative.
The manufacturing procedure qualification tests shall be carried out on pipes for each wall
thickness, each diameter and each grade of steel.
B.1.3 Verification of the manufacturing procedure shall be by qualification in accordance with

clause B.3, B.4 and B.5 of API Spec 5L and as modified herein.
Note: In the event of small quantities of pipes ordered against this specification, like those for bends and
other similar applications, as specifically called out in the Purchase Order, the manufacturing
procedure qualification test as per clause B.5.1 of this specification shall not be carried out. Pipes in
such case shall be accepted based on regular production tests.
B.3 CHARACTERISTICS OF THE MANUFACTURING PROCEDURE

SPECIFICATION
Before pipe production commences, Manufacturing Procedure Specification (MPS) for

manufacturing of pipes and Statistical process control charts shall be prepared by pipe
manufacturer (including all information as per clause B.3 a), b) and e) of API Spec 5L) and
submitted for approval of the Purchaser.
B.5 MANUFACTURING PROCEDURE QUALIFICATION TESTS (MPQT)
B.5.1 For the qualification of the manufacturing procedure, all tests & inspections specified in
Table 18 and clause B.5.2 of this specification shall be conducted on all the pipes selected
for testing as per clause B.1.2 of this specification.
B.5.2 The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned
below. The report shall be agreed and signed by Purchaser's Representative, prior to start of
regular production.
The various tests to be conducted on each pipe shall be as follows. The test method and
acceptance values shall be as per this specification unless specified differently in this Annex.
a. Visual Examination
All pipes shall be examined visually for dimensional tolerances and apparent surface
defects.
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1. :1 • aa lnnena. LINE PIPE (ONSHORE)
Page 21 of 31
b. Ultrasonic Examination
The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic
equipment.
c. Mechanical Properties
The mechanical properties of all pipes shall be tested and shall meet the requirements
of this specification. Purchaser's Representative will select the places in pipe from
where the test pieces shall be extracted.
The following tests shall be conducted:
i. Flattening test
Two (2) flattening test pieces shall be extracted; one test piece shall be tested with
weld at 0° and other at 90°.
ii. Tensile test

Tensile tests shall be conducted on:
For pipe with specified outside diameter, D < 219.1 mm (8.625 inch):
— Two (2) longitudinal test pieces from base metal
For pipe with specified outside diameter, D> 219.1 mm (8.625 inch):
— Two (2) transverse test pieces from base metal
— Two (2) transverse test pieces from the longitudinal weld seam
iii. Metallographic tests

Six (6) weld cross—section test pieces, three (3) from each end of pipe weld seam
shall be taken for metallographic examination. Two of these shall be tested for
hardness at room temperature after etching.
iv. CVN impact testing

CVN impact test shall be performed on test pieces extracted as follows:
— Four sets of three (3) transverse test pieces each from base metal
— One set of three (3) transverse test pieces with weld in middle
— One set of three (3) transverse test pieces with HAZ in middle
The minimum average (set of three test pieces) absorbed energy value (KvT) at the
test temperature specified in clause 9.8 and Table 8 of this specification shall be
complied with for test pieces extracted from base metal, weld and HAZ.
v. Fracture toughness testing

Four (4) sets of CVN base metal test pieces shall be tested at — 40°C, — 10°C, 0°C
and + 20° C for shear area and absorbed energy to produce full transition curve.
The minimum average (set of three test pieces) shear fracture area at the test
temperature specified in clause 9.8 of this specification shall be complied with. For
other temperatures, the value shall be for information only.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
Page 253 of 1963

laraelei ENGINEERS HIGH FREQUENCY WELDED (HFW) 6-71-0005 Rev. 4
Itgar feligteg INDIA LIMITED LINE PIPE (ONSHORE)
.nn.
Page 22 of 31
Annex C
Treatment of surface imperfections and defects
C.1 TREATMENT OF SURFACE IMPERFECTIONS
Surface imperfection not classified as defect as per this specification shall be cosmetically
dressed—out by grinding.
C.2 TREATMENT OF DRESSABLE SURFACE DEFECTS
C.2.3 Complete removal of defects shall be verified by local visual inspection and by suitable non-
destructive inspection. To be acceptable, the wall thickness in the ground area shall be in
accordance with clause 9.11.3.2 of this specification.
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.4 -AI, UnrIerta.."11
LINE PIPE (ONSHORE) Page 23 of 31
Annex E
Non-destructive inspection for other than sour service or offshore service
The Purchaser reserves the right to depute its Representative(s) to perform inspection and
witness tests in all phases of manufacturing and testing starting from steelmaking to finished
line pipe ready for shipment. Manufacturer shall comply with the provisions regarding
inspection notice, plant access, compliance and rejection mentioned in the Annex Q (New)
of this specification. The Manufacturer shall give the Purchaser reasonable notice of the
starting date of normal production and the work schedule. Any action or omission on part of
Purchaser's Representative shall not relieve the Manufacturer of his responsibility and
obligation to supply material in strict accordance with this specification.
E.1 QUALIFICATION OF PERSONNEL
E.1.1 All personnel performing NDT activities shall be qualified in the technique applied, in
accordance with latest edition of ISO 9712, ISO 11484 or ASNT No. ASNT-TC-1A or
equivalent.
All NDT shall be performed in accordance with written procedures. These procedures shall
have prior approval of the Purchaser.
Inspector Qualification
Acceptable qualification for NDT inspectors shall be as specified below:
For UT
For UT, at least one Level III qualified inspector shall be available to the mill for overall
supervision. Level III inspectors shall be ASNT Level III or ACCP Professional Level
III and certified in applicable method.
A level II inspector is required for shift supervision, manual weld inspection and
calibration of all systems (both manual and automated).
(ii) For all other NDT methods

Evaluation of indications : Level II & Level III inspector
E.3 METHODS OF INSPECTION
E.3.1 General
E.3.1.1 The electric weld of the pipe shall be inspected by ultrasonic methods (Refer Table E.1 of
API Spec 5L) for full length (100%) for the entire thickness, using automatic ultrasonic
equipment in accordance with clause E.5 of API Spec 5L and as modified in this
specification.
E.3.1.3 Location of NDT equipment in the manufacturer's facility shall be such that final inspection
of weld seam of pipe shall be performed after hydrostatic testing.
E.3.2 Pipe End Inspection — Welded Pipe
E.3.2.1 Pipe ends including weld at the pipe ends not covered by automatic ultrasonic equipment
shall be inspected by manual ultrasonic equipment with same sensitivity and capability as
automatic equipment, or, such non—inspected pipe end shall be cut—off. Records in
accordance with E.5.4 of API Spec 5L shall be maintained.
Page 255 of 1963

af-ae, ENGINEERS HIGH FREQUENCY WELDED (HFW)
lizgur fagreg INDIA LIMITED
,t , lndert. ^gi LINE PIPE (ONSHORE)
6-71-0005 Rev. 4
Page 24 of 31
E.3.2.3 Ultrasonic inspection in accordance with the method described in ISO 10893-8 shall be used
to verify that the 50 mm (2.0 in) wide zone at each pipe end is free of any laminar
imperfections in the circumferential direction.
E.3.2.4 Bevel face of each pipe end shall be magnetic particle inspected for the detection of laminar
(New) imperfections in accordance with ISO 10893-5.
E.5 ULTRASONIC AND ELECTROMAGNETIC INSPECTION
E.5.1 Equipment
E.5.1.1 In addition to the API Spec 5L requirements, all automatic ultrasonic equipment shall have
an alarm device, which continuously monitors the effectiveness of the coupling. The
equipment for the automatic inspection shall allow the localization of both longitudinal and
transverse defects corresponding to the signals exceeding the acceptance limits of the
reference standard. The equipment shall be fitted with a paint spray or automatic marking
device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic
testing equipment shall be provided with recording device. In addition, an automatic weld
tracking system shall be provided for correct positioning of the probes with respect to weld
centre.
E.5.2 Ultrasonic and electromagnetic inspection reference standards
E.5.2.1 The reference standard (calibration pipe) shall have the same specified diameter and wall
thickness as specified for the production pipe being inspected.
E.5.2.2 Reference standards shall be of sufficient length to permit calibration of ultrasonic inspection
equipment at the speed to be used in normal production.
The reference standard (calibration pipe) shall also be of the same material, type and have
the same surface finish and heat treatment as the pipe being inspected.
E.5.2.3 Reference standards
E.5.2.3.1 Reference standards for pipe weld UT:

(New)
Reference standard shall contain as reference indicators i.e. machined notches as given in
Table E.7 of this specification.
Table E.7 of API Spec 5L stands replaced by Table E.7 of this specification.
Table E.7 — Reference indicators
Reference indicators
Item Number of notches and orientation a

Notch Type b
OD ID
Weld Seam 1L 1L N10
a The symbol indicates the orientation of the notch i.e. L = Longitudinal. Reference indicators shall
be located as per Figure E.1 of this specification.
b Dimensions of Notch type N 10 shall be 0.1 t x 50 mm x 1 mm (Depth x maximum Length x
maximum width), where, 'V is the specified wall thickness. The depth tolerance is ± 15% of the
specified notch depth or ± 0.05 mm, whichever is greater.
Page 256 of 1963

,5--itraele? ENGINEERS HIGH FREQUENCY WELDED (HFW)
'ig-ar Rift INDIA LIMITED 6 71 0005 Rev. 4
- -
' fla LINE PIPE (ONSHORE) Page 25 of 31
E.5.2.3.2 Reference standards for coil/ pipe body UT:

(New)
Reference standard for the ultrasonic inspection of coil or pipe body (except the coil
edges/pipe ends) shall contain continuous machined notch of following dimension:
a) width, w : 8 mm, with a tolerance +0.8/ — 0.0 mm
b) depth, d : 0.25 t < d < 0.5 t, where 't' is the specified wall thickness
Reference standard for the ultrasonic inspection of coil edges (area adjoining weld seam)/
pipe ends shall have 6.4 mm (IA inch) diameter FBH of a depth 0.5 t, where 't' is the specified
wall thickness.
E.5.3 Instrument standardization
E.5.3.2 The instrument shall be calibrated with appropriate reference standard (refer E.5.2 of API
Spec 5L and as modified herein) at following intervals:
- Once at the beginning of each operating shift (12 hours maximum).

- Once in between of each operating shift i.e. 3 hrs to 4 hrs after the first
- Every time there is change in probes or working condition of the UT machine.
- Every time the running of the system gives rise to doubts on its efficiency.
If during the above calibration verification, it is found that the equipment has not functioned
satisfactorily in the opinion of the Purchaser's Representative, all the pipes or coils already
inspected after the previous verification shall be inspected again at Manufacturer's cost.
E.5.5 Acceptance limits
E.5.5.2 For ultrasonic inspection of pipe/coil, any imperfection that produces an imperfection greater
than the acceptable limits shall be treated as following:
a) Locations showing indications above the acceptance limits during automatic ultrasonic
inspection may be re-examined by manual ultrasonic method. If no defects are located
during re-examination, the original findings may be ignored. Additional scanning may
be requested by Purchaser's Representative to check questionable areas.
E.5.6 Disposition of defects found by ultrasonic and electromagnetic inspection
Disposition of any imperfection in pipe/coil that produces an indication greater than the
acceptable limits as specified in Table E.9 (New) of this specification shall be classified as
defect and shall be given disposition as specified in (e) or (f) of E.10 of API Spec 5L.
E.7 RESIDUAL MAGNETISM
E.7.2 The longitudinal magnetic field shall be measured on all sizes of pipes. Measurement on pipe
in stack shall not be considered valid. Such measurements shall be taken on the root face or
square cut face of finished plain-end pipes.
E.7.3 Measurements shall be made using Hall — effect gaussmeter only.
E.7.4 Measurements shall be made on each end of a pipe for 5% of the pipes produced but at least
once per 4 hr per operating shift (12 hrs maximum).
E.7.6 Four readings shall be taken approximately 90° apart around the circumference of each end
of the pipe. The average of the four readings shall not exceed 2.0 mT (20 gauss) and no single
Page 257 of 1963

0 el ENGINEERS HIGH FREQUENCY WELDED (HFW)
A . nerta, ^g1 LINE PIPE (ONSHORE) Page 26 of 31
reading shall exceed 2.5 mT (25 gauss). All residual magnetism measurements shall be
recorded.
E.8 LAMINAR IMPERFECTIONS IN THE PIPE BODY OF EW, SAW AND COW
PIPES
E.8.1 The coil, except the longitudinal coil edges (area adjoining weld seam), shall be
ultrasonically tested for laminations using an oscillating or straight running pattern of probes
in accordance with ISO 10893-9 amended as follows:
- The distance between adjacent scanning tracks shall be sufficiently small to ensure
detection of minimum allowed imperfection size. The minimum coverage during
automatic ultrasonic inspection shall be > 20 % of the coil surface uniformly spread
over the area.
- Acceptance limit for laminar imperfection in the coil, except the longitudinal edges,
shall be as per Table E.9 (New) of this specification. Disposition of defects shall be as
per clause E.5.6 of this specification.
Table 3 of ISO 10893-9 stands replaced by Table E.9 (New) of this specification.
E.9 LAMIMAR IMPERFECTIONS ALONG THE STRIP/ PLATE EDGES OR PIPE

WELD SEAM OF EW, SAW AND COW PIPES
The longitudinal edges of the coil (area adjoining weld seam) shall be 100% ultrasonically
inspected in accordance with ISO 10893-9 amended as follows:
- UT shall be performed over 25 mm wide zone along each side of the trimmed
longitudinal edges of the coil.
- Acceptance limit for laminar imperfection in the longitudinal edges of the coil shall be
as per Table E.9 (New) of this specification. Disposition of defects shall be as per clause
E.5.6 of this specification.
Table 2 of ISO 10893-9 stands replaced by Table E.9 (New) of this specification.
Table E.9 – Acceptance criteria for laminar imperfection in coil/ pipe body (New)
Maximum individual Minimum imperfection
imperfection size considered Maximum
Location
Area Lengthb Area Lengthb Width' density a
mm2 Min mm2 Min mm
Coil, except the 10

1000 100 d 300 35 8
longitudinal edges [per 1.0 m x 1.0 m]
Longitudinal edges 4
500 40 — 20 —
of the coil [per 1.0 m length]
a Number of imperfections of size smaller than the maximum imperfection size and greater than the
minimum imperfection size.
b Length is the dimension at right angles to the scan track.
c Width is the dimension parallel to the scan track.
d Any planar imperfection which is not parallel to the coil surface is not acceptable.
e For an imperfection to be larger than the minimum imperfection size, the minimum area, minimum
length and minimum width given for the coil/ pipe body, all have to be exceeded.
Page 258 of 1963

faeiel ENGINEERS HIGH FREQUENCY WELDED (HFW)
Igar tatiteg INDIA LIMITED 6-71-0005 Rev. 4
• .1.. ,1,11 , 9) LINE PIPE (ONSHORE) Page 27 of 31
E.10 DISPOSITION OF PIPES CONTAINING DEFECTS
c) The repaired area shall be 100% rechecked by magnetic particle or ultrasonic

inspection to ensure complete removal of defects. However for repair of cosmetic type
of defects, MPI may not be conducted if so directed by Purchaser's Representative on
case to case basis. The pipes having a thickness less than the minimum allowed in
accordance with this specification, after repair by grinding shall be treated for
disposition in accordance with (e) or (f) of clause E.10 of API Spec 5L.
E.11 ROTARY ULTRASONIC INSPECTION OF PIPE (ALTERNATIVE METHOD)

(New)
As an alternative, full pipe may be ultrasonically inspected after welding of longitudinal
seam by rotary ultrasonic testing method (pipe in rotating condition) in accordance with ISO
10893-8 amended as follows:
- The coverage area during ultrasonic inspection shall be 100 % of the pipe body
including weld seam, sides of the weld seam and pipe ends.
- The reference standard for the weld seam as per clause E.5.2.3.1 and Table E.7 of this
specification shall be used for the rotary ultrasonic testing.
If the manufacturer opts for rotary ultrasonic testing of full pipe in accordance with this
clause, then, the requirement for ultrasonic inspection as per clause E.3.1.1, E.3.2.3, E.8 and
E.9 of API Spec 5L and as modified herein shall not be applicable.
Page 259 of 1963

4G92eie-7 ENGINEERS HIGH FREQUENCY WELDED (HFW)
Itgar EiOleg INDIA LIMITED 6-71-0005 Rev. 4
^11 LINE PIPE (ONSHORE) Page 28 of 31
Annex Q (New)
Purchaser Inspection
Q.1 INSPECTION NOTICE
Advance notice shall be given by the manufacturer prior to the start of production to the
purchaser to inspect/ witness the manufacturing activities including tests.
Q.2 PLANT ACCESS
The inspector representing the purchaser shall have unrestricted access, at all times while
work of the contract of the purchaser is being performed, to all parts of the manufacturer's
works that will concern the manufacture of the pipe ordered. The manufacturer shall afford
the inspector all reasonable facilities to satisfy the inspector that the pipe is being
manufactured in accordance with this specification. All inspections should be made at the
place of manufacture prior to shipment, unless otherwise specified on the purchase order,
and shall be so conducted as not to interfere unnecessarily with the operation of the works.
Q.3 COMPLIANCE
The manufacturer is responsible for complying with all of the provisions of this
specification. The purchaser may make any investigation necessary to be satisfied of
compliance by the manufacturer and any reject any material that does not comply with this
specification.
Q.4 REJECTION
If the Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall
be adequate reason to refuse final inspection of subsequent pipes until the cause has been
investigated and corrective action taken by the Manufacturer.
Page 260 of 1963

5=4-ar Meg INDIA LIMITED 6-71-0005 Rev. 4
-, ± • •
0, t7 , LINE PIPE (ONSHORE) Page 29 of 31
FIGURE: 10.2.4.9.1
REVERSE BEND TEST
Page 261 of 1963

,z..1 ENGINEERS HIGH FREQUENCY WELDED (HFW)
Igar Meg INDIA LIMITED LINE PIPE (ONSHORE)
6 - 71 - 0006 Rev. 4
A .'fla r!nderla ■ ^91
Page 30 of 31
BASE METAL HEAT TREATED ZONE BASE METAL
FUSION LINE
E
E
H. A. Z.
LOCATIONS WHERE HARDNESS MEASUREMENT

TO BE CARRIED OUT.
H.A.Z. HEAT AFFECTED ZONE
FIGURE: 10.2.5.3
METALLOGRAPHIC SPECIMEN AND

LOCATIONS FOR HARDNESS MEASUREMENT
Page 262 of 1963

4Gdf&r& ENGINEERS HIGH FREQUENCY WELDED (HFW)
Ogar INDIA LIMITED 6 - 71 - 0005 Rev. 4
,.., : Au. ,inert. LINE PIPE (ONSHORE) Page 31 of 31
L1 L2
WELD SEAM/FUSION LINE
L1 Longitudinal inside notch (N10) at weld line

L2 Longitudinal outside notch (N10) at weld line
FIGURE: E.1
REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM
Page 263 of 1963

5i1MTIeT ENGINEERS PIPELINE BALL VALVES 6-71-0014 Rev. 4
$1gLII
7 itti INDIA LIMITED
.
A G„. ol India U ae„ri ng (ONSHORE) Page 1 of 15
LII * IMWI c GrICI clIcroal

RI 11114) fai4R-r
FOR
PIPELINE BALL VALVES
(ONSHORE)
4 01.03.12 REVISED & REISSUED AS STANDARD

SPECIFICATION SKJ VM DM
3 22.11.06 REVISED & REISSUED AS STANDARD MKM

SPECIFICATION VM AS VC
2 19-10-01 REVISED & REISSUED AS STANDARD MKM

SPECIFICATION KKS SJ GRR
1 16-12-98 REVISED & REISSUED AS STANDARD ASr
SPECIFICATION LD VC AS
0 09-06-89 ISSUED AS STANDARD SPECIFICATION MK GD RKD/SA
Standards Standards
No Date Purpose Convenor Chairman
by by
Approved by
Format No. 8-00-0001-61 Rev. 0 Copyright EIL - All rights reserved
Page 264 of 1963

IstfradokENGNEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
PIPELINE BALL VALVES 6-71-0014 Rev. 4
Ogelf lati INDIAinrnaUMITED (ONSHORE)
ARANA,013ADASO IA GAN AI unaenaking ■
Page 2 of 15
Abbreviations:
ASME American Society of Mechanical Engineers

BHN Brinell hardness number
DN Nominal Size
LC Lock Close (valve locked in full close position)
LO Lock Open (valve locked in full open position)
MSS-SP Manufacturers Standardization Society — Standard Practice
NPS Nominal Pipe Size
RTJ Ring Type Joint
SSPC Steel Structures Painting Council
Members: Mr. S K Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Dr. R. S. Bhatia (Piping)
Mr. R. Chaudhury (SMMS)
Mr. A. K. Chaudhary (PDD)
Mr. S. S. Lotay (Inspection)
Mr. G. K. Iyer (HO Construction)
Mr. M. P. Jain (Projects)
Page 265 of 1963

lafte? a ENGINEERS PIPELINE BALL VALVES
Llfc WV INDIA LIMITED 6-71-0014 Rev. 4
IA Gov? of India undenaking) (ONSHORE) Page 3 of 15
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE DOCUMENTS 4
3.0 MATERIALS 5
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS 6
5.0 INSPECTION AND TESTS 10
6.0 TEST CERTIFICATES 12
7.0 PAINTING, MARKING AND SHIPMENT 13
8.0 SPARES AND ACCESSORIES 13
9.0 DOCUMENTATION 13
FIG.4.9 VENT, DRAIN AND SEALANT DETAILS 15
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 266 of 1963

‘ialeift
-ra -- ENGINEERS PIPELINE BALL VALVES 6-71-0014 Rev. 4
Ig",al &Reg NS INDIA LIMITED (ONSHORE) Page 4 of 15
1.0 SCOPE
This specification covers the minimum requirements for design, manufacture, testing and
supply of carbon steel ball valves of size DN 50 mm (2") and above and ANSI pressure rating
Class 150# thru 900# for use in onshore pipeline systems handling non-sour hydrocarbons in
liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
2.0 REFERENCE DOCUMENTS
2.1 All valves shall be manufactured and supplied in accordance with the American Petroleum
Institute (API) Specification 6D, Twenty Third edition, April 2008 / ISO 14313:2007,
Petroleum and Natural Gas Industries — Pipeline Transportation Systems — Pipeline valves,
with additions and modifications as indicated in the following sections of this specification.
2.2 Reference has also been made in this specification to the latest edition (edition enforce at the
time of issue of enquiry) of the following Codes, Standards and Specifications.
ASME B31.3 Process Piping.
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids.
ASME B31.8 Gas Transmission and Distribution Piping Systems.
ASME B16.5 Steel Pipe Flanges and Flanged Fittings.
ASME B 16.10 Face-To-Face and End-To-End Dimensions of Valves.
ASME B 16.25 Butt-welding Ends.
ASME B16.34 Valves - Flanged, Threaded and Welding Ends.
ASME BI 6.47 Large Diameter Steel Flanges.
API 1104 Welding Pipelines and Related Facilities.
ASME Sec VIII Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Sec IX Boiler and Pressure Vessel Code - Welding and Brazing
Qualifications
ASTM A-370 Standard Test Methods and Definitions for Mechanical

Testing of Steel Products.
ASTM B 733 Auto catalytic Nickel Phosphorous Coating on Metals.
MSS-SP-6 Standard Finishes for Contact Faces of Pipe Flanges and

Connecting-end Flanges of Valves and Fittings.
MSS-SP-44 Steel Pipeline Flanges.
SSPC-VIS-1 Steel Structures Painting Council Visual Standard.
Page 267 of 1963

ft
ISIdatie? ENGINEERS
bibta EtileGW7 INDIA LIMITED
STANDARD SPECIFICATION FOR
PIPELINE BALL VALVES
STANDARD SPECIFICATION No.
6-71-0014 Rev. 4
(ONSHORE)
IA Goo of India Undedaking) Page 5 of 15
2.3 In case of conflict between the requirements of this specification, API 6D and the Codes,
Standards and Specifications referred in clause 2.2 above, the requirements of this
specification shall govern.
3.0 MATERIALS
3.1 Material for major components of the valves shall be as indicated in Valve Data Sheet. Other
components shall be as per Manufacturer's standard (suitable for the service conditions
indicated in Data Sheet) and shall be subject to approval by Company. In addition, the
material shall also meet the requirements specified hereinafter.
All process-wetted parts, metallic and non-metallic, and lubricants shall be suitable for the
service specified by the Company. Manufacturer shall confirm that all wetted parts are
suitable for treated water/seawater environment, which may be used during field testing.
Non-metallic parts of the valves (including 0-rings, soft seals etc.) intended for hydrocarbon
gas service shall be resistant to explosive decompression.
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 to further field
welding by Company shall not exceed 0.43 on check analysis for each heat of steel used, as
calculated by the following formula:
Mn Cr+Mo+V Ni+Cu
CE- C+ +
6 5 15
3.4 For Valves specified to be used for Gas service or LPG service, Charpy V-notch test, on each
heat of base material shall be conducted as per API 6D-Clause 7.5, for all pressure containing
parts such as body, end flanges and welding ends as well as bolting material for pressure
containing parts. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0
°C. Test procedure shall conform to ASTM A 370. The average absorbed energy value of
three full sized specimens shall be 27 J. The minimum impact energy value of any one
specimen of the three specimens analysed as above, shall not be less than 22 J.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material
standard shall be complied with.
3.5 For Valves specified to be used for Gas service or LPG service, Hardness test shall be carried
out as per ASTM A370 for each method of manufacture and each heat of steel used in the
manufacture of valves. A full thickness cross section shall be taken for this purpose and the
maximum hardness of the materials of valve components shall not exceed 248 HVIo.
3.6 For all such valves where Carbon Steel is used as ball material, the ball shall have 75
micrometers (.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B 733 with
following classification:
SC2, Type II, Class 2.
The hardness of plating shall be minimum 50 RC.
Page 268 of 1963

Safrada ENGINEERS PIPELINE BALL VALVES
stran Flfirag'W INDIA LIMITED 6-71-0014 Rev. 4
2724WMOCCI.1) uneertomg )
,.Go„ of India (ONSHORE) Page 6 of 15
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS
4.1 Valve design shall meet the requirements of API Specification 6D and shall be suitable for the
service conditions indicated in the Valve Data Sheet. The ASME Boiler & Pressure Vessel
Code, Section VIII, Division I shall be used to design the valve body. Allowable stress
requirements shall comply the provisions of above code. In addition, corrosion allowance
indicated in Valve Data Sheet shall be considered in valve design. The manufacturer shall
have valid license to use API monogram on valves manufactured as per API 6D.
4.2 For above ground valves, body design shall be either fully welded or bolted type. For buried
valves, valve body design shall be fully welded type only. Valve body joints with threads are
not permitted.
4.3 Ball shall be of single piece, solid type construction
4.4 Valves shall be Full bore (FB) or Reduced bore (RB) as indicated in the Valve Data Sheet.
Full bore valves shall be suitable for the passage of all types of pipeline pigs including
instrumented intelligent pigs and regular cleaning, batching and scraper pigs on regular basis
without causing damage to either the valve component or the pig. The full bore valve shall
provide an unobstructed profile for pigging operations in either direction. Full bore valves
shall be designed to minimize accumulation of debris in the seat ring region to ensure that
valve movement is not impeded.
The bore size of reduced bore valves shall be corresponding to that of a full bore valve of
smaller nominal diameter as indicated in Table 4.4 of this specification. For sizes of a
particular rating not covered in API 6D, the bore size of the reduced bore valve shall be as per
Manufacturer's standard.
TABLE - 4.4
Nominal Valve size Nominal Valve size
Nominal Valve Siize Nominal Valve Size
for Reduced Bore for Reduced Bore
DN ,,,,,, (NPS inches) DN n,„, (NPS inches) DN ,„„, (NPS inches) DN „,„, (NPS inches)
50 40 (1.5) 600 (24) 500 (20)
80 50 650 (26) 550 (22)
100 (4) 80 700 (28) 600 (24)
150 (6) 100 (4) 750 (30) 600 (24)
200 (8) 150 (6) 800 (32) 650 (26)
250 (10) 200 (8) 850 (34) 700 (28)
300 (12) 250 (10) 900 (36) 750 (30)
350 (14) 250 (10) 950 (38) 800 (32)
400 (16) 300 (12) 1000 (40) 850 (34)
450 (18) 350 (14) 1050 (42) 900 (36)
500 (20) 400 (16) 1200 (48) 1050 (42)
550 (22) 450 (18)
4.5 Ball mounting shall be trunnion or pivot type only. Valve design shall minimize the possibility
of debris ingress into the trunnion as far as practicable.
Page 269 of 1963

0Ra-deENGINEERS PIPELINE BALL VALVES
5' @zit lEtwegw INDIA LIMITED 6-71-0014 Rev. 4
ere4W.3,7,11 (A Gov( of India Undertakung( (ONSHORE) Page 7 of 15
4.6 For valves with primary metal to metal contact and secondary soft seats, 0-rings or other seals
if used for drip tight sealing shall be encased in a suitable groove in such a manner that it can
not be removed from seat ring and there is no extrusion during opening or closing operation of
valve at maximum differential pressure corresponding to valve class rating. The seat rings
shall be so designed as to ensure sealing at low as well as high differential pressures.
For soft seated valves seat rings may be provided with soft insert. The same shall be positively
locked in position. All such ball valves shall comply fire safe design and qualified by fire
testing as per API 6FA specification for Fire Test for Valves.
4.7 Valves shall be designed to withstand a sustained internal vacuum of at least I (one) milli-bar
in both open and closed positions.
4.8 Valves shall have double block and bleed feature to facilitate complete flush, drain and
venting of the valve body cavity.
4.9 Full Bore valves of nominal valve size DN 200 mm (8") & above and Reduced Bore valves of
nominal valve size DN 250 mm (10") & above, shall have provision for secondary sealant
injection under full line pressure for seat and stem seals. All sealant injection connections
shall be provided with a block valve and internal non-return valve. Valve design shall have a
provision to replace the sealant injection fitting under full line pressure. Location and
arrangement of sealant point shall be as per Fig. 4.9.
4.10 Valves shall be provided with vent and drain connections. Location and arrangement of vents
and drains shall be as per Fig. 4.9. Body vent and drain shall be provided with valves (Ball or
Plug type). Number and size shall be as per Fig. 4.9.
4.11 Valve design shall ensure repair of stem seals/packing under full line pressure.
4.12 Full Bore valves of nominal valve size DN 200 mm (8") & above and Reduced Bore valves of
nominal valve size DN 250 mm (10") & above, shall be equipped with support foot and lifting
lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot shall
be kept minimum. The location and size of support foot/lifting lugs shall ensure unrestrictive
operation of vent/drain valves.
4.13 Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high
alloy steel components. Suitable insulation shall be provided as required.
4.14 For valves to be used in liquid service, the body cavity over-pressure shall be prevented by
self-relieving seat rings/assemblies. Self-relieving seat rings shall relieve at a body cavity
differential pressure not exceeding 50% of the valve class rating pressure.
4.15 a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt
welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged
body valves shall be integrally cast/forged with the body of the valve. Face to face/end
to end dimensions shall conform to API 6D. Face-to-face and end-to-end dimensions
for valve sizes not specified in API 6D shall be in accordance with ASME B 16.10.
Face-to-face and end-to-end dimensions not shown in API 6D or in ASME B 16.10
shall be as per Manufacturer Standard and shall be subject to approval by Company.
b) Flanged ends, if specified, shall have flanges as per ASME B16.5 for valve sizes upto
DN 600 mm (24") excluding DN 550 mm (22") and as per MSS-SP-44/ASME B
16.47 Series A for valve sizes DN 550 mm (22") and for DN 650 mm (26 inches) and
above. Flange face shall be either raised face or ring joint type (RTJ) as indicated in
Page 270 of 1963

ENGINEERS PIPELINE BALL VALVES 6-71-0014 Rev. 4
,
Og7leg, INDIA LIMITED (ONSHORE)
IA Govt CO India Undertaking)
Page 8 of 15
Valve Data Sheet. Flange face finish shall be serrated or smooth as indicated in Valve
Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.
Butt weld end preparation shall be as per ASME B 16.25. The thickness of the pipe to
which the valve has to be welded shall be as indicated in the Valve Data Sheet. In case
difference exists between thickness of welding ends of valve and connecting pipe, the
welding ends of valve shall have bevel preparation as per ASME B31.4 or ASME
B31.8 as applicable.
In case of all Butt welded end valves (including soft seated valves or valves with
primary metal to metal and secondary soft seats), actual yield strength of valve body
shall not be less than 2/3 rd of the specified minimum yield strength (SMYS) of the
connecting line pipe material.
e) For soft seated valves with Butt welded end, valves shall be provided with pup pieces
on either side of length 200 mm each for size up-to 8" & 250 mm for size 10" and
above, with material same as or higher to valve body material. Length of pup piece
shall be confirmed by manufacturer so as to avoid damage to seats during field
welding or post weld heat treatment. Pup piece thickness shall be calculated for the
class rating. Vendor shall provide for each type (considering size, grade and thickness
of the pup pieces used for all offered valves) of pup piece, test rings (500 mm long)
from pup piece material for field weld procedure qualification. Valves shall be tested
along-with pup piece.
4.16 Design of weld end valves shall be such that during field welding operations, the soft seals or
plastic components of the valve (where ever used) are not liable to be damaged. The
manufacturer shall furnish necessary field welding instructions and post-weld test procedure
to demonstrate integrity and leak-tightness of valves after field welding operations.
4.17 Valve shall be provided with ball position indicator and stops of rugged construction at the
fully open and fully closed positions.
4.18 Valves shall be suitable for either buried or above ground installation as indicated in Valve
Data Sheet.
4.19 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions.
In case of below ground LTCS valves, Stem extension material shall be equivalent to
Stem Material.
Valves provided with stem extension shall have water proof outer casing. Length of
stem extension shall be as indicated in Valve Data Sheet. The length indicated
corresponds to the distance between centerline of the valve opening and the top of
mounting flange for valve operating device (gear operator/power actuator as
applicable).
c) Vent and drain connections and sealant injection lines shall be terminated adjacent to
the valve operator by means of suitable piping anchored to the valve body. The pipe
used shall be API 5L Gr. B / ASTM A 106 Gr. B, with Sch. 160 for sizes 0.5 to 0.75
inch and Sch. 80 for sizes 1.0 to 1.5 inch. Fittings shall be ASTM A105/ASTM A234
Gr. WPB, Socket welded ANSI class 6000.
Page 271 of 1963

BALL VALVES
Wes 6-71-0014 Rev. 4
ale? ENGINEERS
sig- W INDIA LIMITED
(ONSHORE)
IA Go,n v■oa Undenaangl Page 9 of 15
Stem extension and stem housing design shall be such that the complete assembly will
form a rigid unit giving positive drive under all conditions with no possibility of free
movement between valve body, stem extension or its operator.
Outer casing of stem extension shall have %"" or 1/2" NPT plugs at the top and bottom,
for draining and filling with oil to prevent internal corrosion.
4.20 Operating Devices
Valves shall have a power actuator or manual operator as indicated in the Valve Data
Sheet. In case of manual operator, valve sizes, DN 100 mm (4") shall be wrench
operated and valve sizes, DN 150 mm (6") shall be gear operated. Each wrench-
operated valve shall be supplied with wrench. Valve design shall be such that damage
due to malfunctioning of the operator or its controls will only occur in the operator
gear train or power cylinder and that damaged parts can be replaced without the valve
cover being removed.
The power actuator shall be in accordance with the Company Specification issued for
the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time
shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to
full close to full open /full open to full close under maximum differential pressure
corresponding to the valve rating. For actuated valves, the actuator's rated torque
output shall be 1.25 times the break torque required to operate the ball valve under the
maximum differential pressure corresponding to the Valve Class Rating.
For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, the total
force required to operate the valve does not exceed 350N. However. failing to meet
above requirement , vendor shall offer Gear operated valves. Manufacturer shall also
indicate the number of turns of hand wheel in case of gear operators (along with their
offer) required for operating the valve from full open to full close position. The
number of turns shall not exceed 250 for valve sizes up-to 24" and 450 for valve sizes
above 24".
Direction of operation of hand wheel or wrench shall be in clock-wise direction while

closing the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully
encased in water proof/splash proof enclosure and shall be filled with suitable grease.
4.21 The tolerance on internal diameter and out of roundness at the ends for welded ends valves
shall be as per connected pipe specification as indicated in the Valve Data Sheet.
4.22 When indicated in Material Requisition, valves shall have locking devices to lock the valve
either in full open (LO) or full close (LC) positions. Locking devices shall be permanently
attached to the valve operator and shall not interfere with operation of the valve.
4.23 All welds shall be made by welders and welding procedures qualified in accordance with the
provisions of ASME Section IX. The procedure qualification shall also include impact test and
hardness test when required as per Clause 3.4 and 3.5 of this specification and shall meet the
requirements as specified therein.
4.24 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 body valves. Such repairs shall be carried
out at casting supplier's care only. Repair shall be carried out before any heat treatment of
Page 272 of 1963

SW"ENGINEERS PIPELINE BALL VALVES 6-71-0014 Rev. 4
LJI 015.1pg, INDIA LIMITED (ONSHORE)
india Undertakung)
IA Gov% AI Page 10 of 15
casting is done. Repair welding procedure qualification shall also include impact test and
hardness test when required as per Clause 3.4 and 3.5 of this specification and shall meet the
requirements as specified therein. Heat treatment and radiography shall be repeated after the
weld repair.
4.25 No casting is permitted for stem and stem extension material of all valves. Valve stem shall be
capable of withstanding the maximum operating torque required to operate the valve against
the maximum differential pressure corresponding to applicable class rating. The combined
stress shall not exceed the maximum allowable stresses specified in ASME section VIII,
Division 1. For power actuated valves, the valve stem shall be designed for maximum output
torque of the selected power actuator (including gear box, if any) at valve stem.
4.26 Wherever specified for the parts of valve in valve datasheets, minimum thickness of stelliting
shall be 1.6 mm.
5.0 INSPECTION AND TESTS
5.1 The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests
shall be, but not limited to, the following:
5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves shall be
free from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly
cleaned and free from dirt, rust and scales.
5.1.2 Dimensional check on all valves shall be carried out as per the Company approved drawings.
5.1.3 Chemical composition and mechanical properties shall be checked as per this specification
and relevant material standards, for each heat of steel used.
5.1.4 Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer.
Body castings of all valves shall be radiographically examined as per ASME B 16.34.
Procedure and acceptance criteria shall be as per ASME BI6.34. The extent of the
radiography shall be as under:
Pressure Class Rating Valve Size Extent of Radiography

ANSI 150 # Class < DN 600 mm (24") Nil
> DN 650 mm (26") 100%
ANSI 300 # Class < DN 400 mm (16") Nil
> DN 450 mm (18") 100%
ANSI 600 # Class and above All sizes 100%
Radiography shall be performed after the final heat treatment also.
All castings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B16.34.
All valves, with body fabricated from plates or made by forgings, shall be
ultrasonically examined in accordance with the procedure and acceptance standard of
Annexure E of ASME B 16.34.
Page 273 of 1963

are? ',it ENGINEERS PIPELINE BALL VALVES 6-71-0014 Rev. 4
A'Rarla5regliwy
INDIA LIMITED
(ONSHORE)
Goa of India Undedaking) Page 11 of 15
All forgings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B16.34.
c) Bodies and bonnets made by welded assembly of segments of castings, forgings,

plates or combinations thereof shall be examined, as applicable, by methods of 5.1.4
(a) for cast components or 5.1.4 (b) for forged components and plates.
5.1.5 Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.4 or ASME B31.8 as applicable and API 1104.
5.1.6 Welds, which in Company's opinion cannot be inspected by radiographic methods, shall be
checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per
ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively.
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 50 mm from the end.
Laminations shall not be acceptable.
Weld ends of all cast valves subject to welding in field shall be 100% radiographically
examined and acceptance criteria shall be as per ASME B16.34.
After final machining, all bevel surfaces shall be inspected by dye penetrant or wet
magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the
defects between 6.35 mm and 1.59 mm that are separated by a distance less 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 cavities filled with sealant, grease or other
foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic
shell test or tested independently. Test pressure shall be held for at least 30 minutes for both
Shell & Seat test. No leakage is permissible during hydrostatic testing. The body cavity self-
relieving feature meeting the requirements of clause 4.14 of this specification shall also be
checked.
5.1.9 A supplementary air seat test as per API 6D (Appendix C, Para C.3.3 Type II) shall be carried
out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is
allowed. Test pressure shall be held for at least 15 minutes.
5.1.10 Valves shall be subjected to Operational Torque Test as per API 6D (Appendix C, Para C.6)
under hydraulic pressure equal to maximum differential pressure corresponding to the
applicable ANSI class rating of valve. It shall be established that the force required to operate
the valve does not exceed the requirements stated in section 4.20 (c) of this specification.
5.1.11 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve
Manufacturer's works. At least five Open-Close-Open cycles without internal pressure and
five Open-Close-Open cycles with maximum differential pressure corresponding to the valve
rating shall be performed on the valve actuator assembly. The time for Full Open to Full Close
shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the
opening and closing time is with in the limits stated in Valve Data Sheet.
Hand operator provided on the actuator shall also be checked after above testing, for
satisfactory manual over-ride performance.
Page 274 of 1963

el fit ENGINEERS PIPELINE BALL VALVES
$11g-arelategWINDIA LIMITED 6-71-0014 Rev. 4
min avow A Govt of Ind* Undertakmg) (ONSHORE) Page 12 of 15
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 do not meet the requirements,
retesting/rejection of the lot shall be decided by the Company's Inspector.
5.1.12 Subsequent to successful testing as specified in clause 5.1.10 and 5.1.11 above, one (I) valve
out of the total ordered quantity shall be randomly selected by the Company Representative
for cyclic testing as mentioned below:
The valve shall be subjected to at least 100 Open-Close-Open cycles with maximum
differential pressure corresponding to the valve rating.
Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.
In case this valve fails to pass these tests, the valve shall be rejected and two more valves shall
be selected randomly and subjected to testing as indicated above. If both valves pass these
tests, all valves manufactured for the order (except the valve that failed) shall be deemed
acceptable. If either of the two valves fails to pass these tests, all valves shall be rejected or
each valve shall be tested at the option of manufacturer.
Previously carried out test of similar nature shall be considered acceptable if the same has
been carried out by Manufacturer in last two years. Valves of two sizes below and two sizes
above the size of valve previously tested, and rating similar or one rating lower of valve tested
previously, shall be qualified.
5.1.13 Checks shall be carried out to demonstrate that the dissimilar metals used in the valves are
successfully insulated as per the requirement of clause 4.13 of this specification.
5.2 Company reserves the right to perform stage wise inspection and witness tests as indicated in
clause 5.1 above at Manufacturer's works prior to shipment. Manufacturer shall give
reasonable access and facilities required for inspection to the Company's Inspector. Company
reserves the right to require additional testing at any time to confirm or further investigate a
suspected fault. The cost incurred shall be to Manufacturer's account.
In no case shall any action of Company or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves.
Inspection and tests performed/witnessed by the Company's Inspector shall in no way relieve
the Manufacturer's obligation to perform the required inspection and tests.
6.0 TEST CERTIFICATES
Manufacturer shall submit the following certificates:

Mill test certificates relevant to the chemical analysis and mechanical properties of the
materials used for the valve construction as per the relevant standards.
Test certificates of hydrostatic and pneumatic tests complete with records of timing
and pressure of each test.
Test reports of radiograph and ultrasonic inspection.
Test report on operation of valves conforming to clause 5.1.10, 5.1.11 and 5.1.12
of this specification.
e) All other test reports and certificates as required by API 6D and this specification.
Page 275 of 1963

Siirtade, ENGINEERS PIPELINE BALL VALVES
aeaen natesW INDIA LIMITED 6-71-0014 Rev. 4
IA Goof of India Undedakingl (ONSHORE) Page 13 of 15
The certificates shall be considered valid only when signed by Company's Inspector. Only
those valves which have been certified by Company's Inspector shall be dispatched from
Manufacturer's works.
7.0 PAINTING, MARKING AND SHIPMENT
7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot
blasting to SP-6 in accordance with "Steel Structures Painting Council - Visual Standard
SSPC-VIS-1". For the valves to be installed underground, when indicated in Valve Data
Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of
suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. For coastal
area, painting shall be suitable for highly corrosive environment.
7.2 All valves shall be marked as per API 6D. The units of marking shall be metric except
nominal diameter, which shall be in inches.
7.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces,
securely attached to the valves. Bevel ends shall be protected with metallic or high impact
plastic bevel protectors.
7.4 All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
7.5 Packaging and shipping instructions shall be as per API 6D.
7.6 On packages, following shall be marked legibly with suitable marking ink:
Order Number
Manufacturer's Name
Valve size and rating
Tag Number
e) Serial Number
8.0 SPARES AND ACCESSORIES
8.1 Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning and supply of such spares shall be included in the price
quoted by Manufacturer.
8.2 Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves and price for such spares shall be quoted
separately.
9.0 DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized below. Number
of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.
9.1 At the time of bidding, Manufacturer shall submit the following documents:
a) General arrangement/ Sectional drawing & blow-up drawing of seat assembly shall be
submitted. Number of turns for Gear Operated valves shall be indicated in the GA or
shall be furnished separately.
Page 276 of 1963

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No
OlfaaeLft ENGINEERSPIPELINE BALL VALVES 6-71-0014 Rev. 4
sigzu lalgleg.W
INDIA LIMITED (ONSHORE) Page 14 of 15
Reference list of similar ball valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating,
service etc.
Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque.
e) Copy of valid API 6D Certificate.
0 In case of soft seated valves, copy of Fire Safe test certificate of qualifying valve as
per API 6FA carried out in last 10 years shall be furnished.
Details of support foot including dimensions and distance from valve centreline to
bottom of support foot.
List of recommended spares required during start-up and commissioning & 2 years of
normal operation and maintenance.
9.2 After placement of order, the Manufacturer shall submit the following drawings, documents
and specifications for Company's approval:
Detailed sectional drawings showing all parts with reference numbers and material
specifications.
Assembly drawings with overall dimensions and features. Drawing shall also indicate
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 the painting scheme. Complete
dimensional details of support foot (where applicable) shall be indicated in these
drawings.
Manufacture of valves shall commence only after approval of the above documents. Once the
approval has been given by Company, any changes in design, material and method of
manufacture shall be notified to Company whose approval in writing of all changes shall be
obtained before the valve is manufactured.
9.3 Within 30 days from the approval date, Manufacturer shall submit to Company the approved
drawings, documents and specifications as listed in clause 9.2 above.
9.4 Prior to shipment, Manufacturer shall submit to Company following:
Test certificates as per clause 6.0 of this specification.
Manual for installation, erection, maintenance and operation instructions including a

list of recommended spares for the valves.
9.5 All documents shall be in English language only.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
Page 277 of 1963

lalanda ENGINEERS PIPELINE BALL VALVES
AlRar eialegW INDIA LIMITED 6-71-0014 Rev. 4
(ONSHORE)
IA GovI of India underlaleng) Page 15 of 15
ABOVE GROUND INSTALLATION

SEALANT
INJECTION (NOTE-2)
VFNT VALVE
WITH PLUG
SEALANT SEALANT
INJECTION INJECTION (NOTE-2)
(NOTE-2)
DRAIN VALVE
,...„_/WITH PLUG
FULL BORE VALVES NOTES:-

VALVE SIZE, DN(mm A, DN(mm) B, DN(mm) 1 ALL VALVES (BALL OR PLUG) AND PLUGS FOR A AND
50 AND 150 - 15 B SHALL BE APPROVED BY THE PURCHASER.
25 2 SEALANT POINTS SHALL BE PROVIDED FOR FULL
200 TO 600 15
BORE VALVES OF NOMINAL VALVE SIZE 200 mm (8")
650 & ABOVE 15 40
& ABOVE AND REDUCED BORE VALVES OF NOMINAL
REDUCED BORE VALVES VALVE SIZE, DN 250 mm (ID") AND ABOVE ONLY.
SEALANT LINES SHALL HAVE PROVISION TO REPLACE THE
VALVE SIZE, DN(mm)IA, DN(mm) B, DN(mm' SEALANT INJECTION FITTING UNDER FULL LINE PRESSURE.
50 AND 200 15 SEALANT LINES SHALL HAVE BLOCK VALVE & INTERNAL
250 TO 750 15 25 NON RETURN VALVE.
ABOVE 750 15 40 3 ALL VENT/DRAIN CONNECTION SHALL BE WELDED WITH
THE BODY.
UNDERGROUND INSTALLATION
300 EALANT 350 300

(NOTE
GROUND BLEED ' —VENT VALVES
—151Tra
LEVEL — DRAIN VALVES
SEALANT LINE
DRAIN LINE
11111 i
//.):k\
DRAIN LINE (B)
VENT LINE (A)
(C)
;II
—VENT VALVE
Wr, DRAIN VALVE
FB VALVES DN 50 mm(2") TO DN 150 mm(6") FB VALVES ). DN 200 mm(8")

RB VALVES DN 50 mm(2") TO DN 200 mm(6") RB VALVES ). DN 250 mm(10")
FULL BORE (FB VALVES NOTES:—

VALVE SIZE, DN(mm) A, DN(mm) B, DN(mm) C, DN(mm) 1 ALL VALVES (BALL OR PLUG) AND PLUGS FOR A AND
50 AND 150 15 B SHALL BE APPROVED BY THE PURCHASER.
200 TO 300 25 25 - 2 SEALANT POINTS SHALL BE PROVIDED FOR FULL
350 TO 600 25 25 - BORE VALVES OF NOMINAL VALVE SIZE 200 mm (8")
40 & ABOVE AND REDUCED BORE VALVES OF NOMINAL
650 & ABOVE 40 -
VALVE SIZE, DN 250 mm (ID") AND ABOVE ONLY.
SEALANT LINES SHALL HAVE PROVISION TO REPLACE THE
REDUCED BORE (RB) VALVES SEALANT INJECTION FITTING UNDER FULL LINE PRESSURE.
VALVE SIZE, DN(mm) A, DN(mm) B, DN(mm) C, DN(mm) SEALANT LINES SHALL HAVE BLOCK VALVE & INTERNAL
50 AND 200 - - 15 NON RETURN VALVE.
25 25 - 3 ALL VENT/DRAIN CONNECTION IN BURIED SECTION

250 TO 400
SHALL BE OF WELDED CONSTRUCTION.
450 TO 750 25 25 -
BOO & ABOVE 40 40
FIGURE-4.9
Page 278 of 1963

STANDARD SPECIFICATION STANDARD SPECIFICATION No.
q.1 ENGINEERS FOR LONG RADIUS BENDS FOR
• laifZtt ,Techr2m1 IA Govt of Ind. Undertaking} ONSHORE PIPELINES Page 1 of 11
Claq 4 W4(411*11 AITZM e15 *1
111141 1-4F-9ti
FOR
LONG RADIUS BENDS FOR
ONSHORE PIPELINES
REVISED AND REISSUED AS STANDARD A pN

5 27.05.13 SKJ VM DM
SPECIFICATION
4 27.03.09 NKS RK VM ND
SPECIFICATION
3 21.11.06 MKM VM AS VC
SPECIFICATION
2 22.10.01 MKM KKS SJ GRR
SPECIFICATION
1 12.11.98 SK SJ VC AS
SPECIFICATION
0 09.06.89 ISSUED AS STANDARD SPECIFICATION MK GD RKD/ SA
Standards Standards
Rev. Committee Bureau
Prepared Checked
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright El L All rights reserved
Page 279 of 1963

ENGINEERS
f=g-arRA& INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
(A Govt of India Undertaking)
ONSHORE PIPELINES Page 2 of 11
Abbreviations:

EW Electric Welded
MSS-SP : Manufacturers Standardization Society — Standard Practice
OD Outside Diameter
OLAC Oxygenated Low Alloy Carbon
SAW Submerged Arc Welded
TMCP Thermo Mechanical Control Process
SMYS Specified Minimum Yield Strength
NB Nominal Bore
Members : Mr. S K Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Mr. Rajeev Kumar (PDD)
Mr. R K Singh (Inspection)
Mr. G. K. Iyer (Construction)
Mr. KVK Naidu (Projects)
Page 280 of 1963

ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ei
Ogar i"Wrdg
cIT,W
INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
„MOAN ) (A Gov! of India Undettakmg)
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE DOCUMENTS ...4
3.0 MATERIAL .4
4.0 MANUFACTURE .5
5.0 INSPECTION AND TESTS .7
7.0 MARKING, PACKING AND SHIPMENT 8
8.0 DOCUMENTATION 9
9.0 BEND MANUFACTURING PROCEDURE QUALIFICATION 10
Page 281 of 1963

ogM INDIA LIMITED
IA Govt of India Undertaking)
ONSHORE PIPELINES
6-71-0021 Rev. 5
Page 4 of 11
1.0 SCOPE
This specification covers the minimum requirements for manufacture and supply of long
radius bends made from carbon steel line pipes for use in onshore pipeline systems handling
hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
Reference has been made in this specification to the latest edition (edition enforce at the time
of issue of enquiry) of the following codes, standards and specifications:
a) ASME B 31.4 Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids.
b) ASME B 31.8 Gas Transmission and Distribution Piping Systems
c) ASME B 16.9 Factory-Made Wrought Steel Buttwelding Fittings
d) ASME B 16.25 Buttwelding Ends
e) API 5L Specification for Line Pipe
f) ASTM A 370 Standard Test Methods and Definitions for

MechanicalTesting Steel Products
g) MSS-SP-75 Specification for High Test Wrought Welding Fittings
h) Company Specifications for Line Pipe
6-71-0001 Standard Specification for Longitudinal Seam

Submerged Arc Welded Line Pipe (Onshore)
6-71-0005 Standard Specification for Electric Welded Line Pipe

(Onshore)
6-71-0006 Standard Specification for Seamless Line Pipe
Note: In case any Particular Job Specification for Line Pipe is included in the
Project Tender Document, the same shall be applicable in place of Line
pipe specifications mentioned above.
In case of conflict between the requirements of above reference documents and this
specification, the requirements of this specification shall govern.
3.0 MATERIAL
3.1 Bends shall be fabricated from steel line pipe manufactured in accordance with the latest
revision of the Company's Specifications referred in Section 2.0 (d) above. The type of pipe
to be used for fabrication of bends shall be as indicated in the Purchase Order. Pipes with
positive wall thickness tolerances shall be used for fabrication of bends.
3.2 Unless specified otherwise in the Purchase Order, the line pipes for fabrication of bends shall
be procured by the Manufacturer.
3.3 The finished product shall be evaluated for mechanical properties and micro structural
stability.
Page 282 of 1963

ENGINEERS
Ogaf fao6
,a1Tdn evrage ds.nraqq,
INDIA LIMITED
In GOO °" ^°. Undeddk.9)
ONSHORE PIPELINES
6-71-0021 Rev. 5
Page 5 of 11
3.4 Mechanical testing of test bends performed during the bend manufacturing procedure
qualification as per Section 9.0 of this specification, shall ensure that all bends made
according to the Company approved bend manufacturing procedure have the required
mechanical properties and destructive testing of production bend is not required. However,
Company reserves the right to require destructive testing whenever production bending
parameters or heat treatment parameters deviate from those established in the Company
approved bend manufacturing procedure.
4.0 MANUFACTURE
4.1 Material grade, bend size, bend radius and bend angle shall be as indicated in the Purchase
Order. Unless specified otherwise, the bending radius for bends shall be minimum six times
the specified outside diameter.
4.2 Bends shall be manufactured by high frequency induction heating and forming method. Once
the bending operation has commenced no stoppage shall be permitted until the entire bend
has been completed. If bending temperature, bending rate, cooling medium volume or heat
treatment temperature depart from the Company approved bend manufacturing procedure,
then the pipe shall be discarded and another bend shall be made in its place.
4.3 Heat treatment shall be carried out for all finished bends. Post hot bending heat treatment
shall be carried out to the same cycle that the original material received for its production in
order to bring the metallurgical condition back to its original state and heat treatment
procedure shall be such that the mechanical properties and steel microstructure of the
finished bends comply with the minimum requirements specified in the applicable line pipe
specification referred under clause 2.0. Heat treatment procedure shall be submitted and prior
approval of company shall be obtained on heat treatment procedure.
When TMCP and OLAC steels are used, specific approval of the proposed heat treatment
shall be obtained before bending process is employed. Heat treatment shall be carried out for
all finished bends in case it is established during bending procedure qualification that heat
treatment is required to meet the specification requirements.
4.4 When bending SAW or Electric Welded Pipes, the longitudinal seam shall be located in the
plane of minimum deformation or neutral axis. Acceptable tolerance on location of the
longitudinal weld seam shall be ± 5°.
4.5 All bends shall be provided with a tangent length at both ends. Tangent length shall be 500
mm or pipe outside diameter whichever is more.
4.6 Unless otherwise specified differently in the Purchase Order, the bevels at the ends shall be
as per the relevant pipe specification.
4.7 Bends shall not have any circumferential joint.
4.8 No repair by welding is allowed on any part of the bends.
4.9 Bulges, dents and flat areas shall not appear within 100 mm front end of the bend. For the
remaining part of the bend these deviations from the original contour of the pipe are
permitted provided these deviations do not exceed 6.0 mm. The same shall not extend (in
any direction) over a distance of more than 25% of nominal diameter of the bend.
4.10 The excess weld material at the inside of the bend in case of bends made from SAW pipes,
shall be removed over a distance of 100 mm at both ends.
Page 283 of 1963

`t1
I el ENGINEERS
INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
rafeR ereOeterrel..erattrir IA Govt of India Undertaking)
4.11 Tolerances
The dimensions of bends shall be controlled to make sure that they are manufactured
according to the tolerances indicated below, in addition to the requirements of MSS-SP-75.
However, the ends of finished pipe bend shall meet the dimensional tolerances of the relevant
pipe specification referred in Clause 2.0.
4.11.1 Following tolerances shall be applicable for Bend Angle and Bend Radius:
Bend Angle : f 0.5 degree from the specified angle

Bend Radius : ± 1% of bending nominal radius (radius as indicated in Clause 4.1 above).
4.11.2 The Manufacturer shall measure the wall thickness of the pipe before bending along both the
inside and outside radii of the bend between and including the start and stop points of the
bend arc angle, at intervals approximately equal to pipe diameter or 300 mm whichever is
less. The wall thickness shall be measured ultrasonically after bending at the same locations
as measured before bending. In addition, the wall thickness of the tangents shall also be
measured. These measurements shall be taken at four equally spaced locations around the
pipe circumference. The measured wall thickness shall be atleast equal to:
tmin 0.95(tactuarAt)
where:
tactual Actual wall thickness of pipe used for bending
At 0.35 mm for a wall thickness < 10 mm
0.5 mm for a wall thickness > 10 mm
4.11.3 When the pipes are free issue (or thickness of the pipes is specified in MR) the thickness of
finished bend shall comply with the requirement of 4.11.2. When pipes for manufacturing LR
bends are to be procured by manufacturer and thickness of finished LR bends is specified in
the MR, thickness specified of the bends shall be the minimum thickness achieved after
bending with tolerance as -0.0. Manufacturer shall procure pipes to achieve tm,„ of LR bends
as described in 4.11.2 above.
4.11.4 Out of roundness tolerance on the body and ends of the bend shall be as follows:
Body
Measurements of the outside diameter shall be taken in the plane of the bend at locations
where wrinkles are present (0Dmax •) and at locations where wrinkles are not present (0D„,,n ).
Out of roundness shall be considered acceptable, if the value of ((0D.-0Dmin )/OD. ) does
not exceed 2.0%.
The measurements shall be made over the circumference of the bend either at distances
approximately equal to pipe diameter or 300 mm whichever is less. Minimum three
measurements shall be taken for each bend.
Ends
Out-of-roundness over a length of 100 mm from the end shall comply with the requirements
of relevant company specification referred in Clause 2.0.
Page 284 of 1963

ENGINEERS
Wag Miareg INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
tan, eremt,trt.fframt 10 Govt of Indta Undeffakmg)
4.11.5 Off-Plane
Off-Plane of bends shall not exceed (0/90) x 10 mm, where 8 is the bend angle in degree or
the tolerance limit specified in MSS-SP-75, whichever is less. The measurement shall be in
accordance with MSS-SP-75.
4.11.6 Squareness
Bevel and squareness of bend ends shall comply with the requirements of relevant company
specification referred in Clause 2.0.
5.0 INSPECTION & TESTS
5.1 The manufacturer shall perform all inspection and tests as per the requirements of this
specification and MSS-SP-75 prior to shipment, at his Works. Such inspection and tests shall
be as a minimum, but not limited to, the following:
Verify that the unfinished product arriving at Manufacturer's shop is in full

compliance with the pipe specification as referred in Clause 2.0 of this specification.
b) Visual inspection.
c) Dimensional and tolerances check as per MSS-SP-75 and requirements of Section

4.0 of this specification.
d) Check heat treatment, if carried out, as required and maintain its records.
e) Temperature against time recorder charts for each induction heating.
f) The non-destructive inspection on the finished bend shall be carried out as given
below:
All seam welds of bends manufactured from SAW pipes shall be 100%
radiographed and seam welds of bends manufactured from EW pipe shall
be 100% ultrasonically tested. The acceptance criteria shall be same as
given in applicable pipe specification referred under clause 2.0 of this
specification.
The full circumference of both ends of each bend after bevelling shall be
ultrasonically tested for laminations over a length of 25 mm and
acceptance limits shall be as per pipe specification as referred in Clause 2.0
of this specification.
The finished bends shall be magnetic particle inspected on the outside and
inside radii to include the area encompassed 30 degrees either side of the
line passing through the plane of the bend. Acceptance criteria shall be as
per ASME Sec. VIII Appendix 6.
g) A check shall be performed on each bend by passing a gauging pig consisting of

two discs having a diameter equal to 95% of the inside diameter of the pipe,
connected rigidly together at a distance equal to 500 mm. Details of the gauging pig,
including its dimensions shall be approved by Company.
5.2 Company's Inspector reserves the right to perform stage wise inspection and witness tests on
all bends as indicated in Clause 5.1 at Manufacturer's works, prior to shipment.
Page 285 of 1963

ENGINEERS
taweg
fg-a>117,
f eiek1W .3,40571) INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
Govt of Indla Undertakow
Manufacturer shall give reasonable notice of time and shall provide without charge
reasonable access and facilities required for inspection, to the Company's Inspector.
Inspection and tests performed or witnessed by Company's Inspector shall in no way relieve
the Manufacturer's obligation to perform the required inspection and tests. Under no
circumstances any action of the Company's Inspector shall relieve the Manufacturer of his
responsibility for the material and quality of the bends.
The Manufacturer shall submit the following Certificates:
a) Test certificates of chemical analysis, mechanical tests, heat treatment, NDT,

dimensional inspection and hydrotest carried out on pipe used for fabrication of
bend.
These test certificates are not required when pipe is supplied as free issue by the
Company.
b) Certificates of non-destructive test/examination carried out on bends.
c) Records of heat treatment, if carried out for bends.
d) Certified reports of dimensional tolerance of bends.
e) Certificates of all other tests as required in this specification.
The Certificates shall be valid only when signed by Company's Inspector. Only those bends
which have been certified by Company's Inspector shall be dispatched from Manufacturer's
works.
7.0 MARKING, PACKING AND SHIPMENT
7.1 All bends shall be marked as per MSS-SP-75.
7.2 All loose and foreign material i.e. rust, grease, etc. shall be removed from inside and outside
of the bends.
7.3 A coat of antirust paint shall be applied on the bends for protection during transit and storage.
Type of paint shall be as agreed upon with the Company.
7.4 Both ends of all bends shall be suitably protected to avoid any damage during transit by
means of metallic or high impact plastic bevel protectors.
7.5 Package shall be marked legibly with suitable marking ink to indicate the following:
a) Order Number
b) Package Number
c) Manufacturer's Name
d) Size (Inches) and wall thickness (mm)
e) Radius of bend (mm).
Page 286 of 1963

ENGINEERS
eg
Iii fa0- INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
IA Govt at Ind Undertakmg)
8.0 DOCUMENTATION

of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.
8.1 All documents shall be in English language.
8.2 At the time of bidding, bidder shall submit the following documents:
a) Reference list of previous supplies of bends of similar specifications.
b) Brief description of manufacturing including heat treatment and quality control

facilities of the Manufacturer's Works.
c) Brief description of manufacturing and quality control facilities of the

Manufacturer's works.
8.3 Within two weeks of placement of order, the Manufacturer shall submit bend manufacturing
procedure including manufacturing, inspection, testing procedures, quality control manual
and quality plans.
The Bend Manufacturing Procedure shall detail the following, as a minimum:
a) Sequence of operation
b) Induction forming process including bending temperature, temperature control,

bending rate, cooling rate and cooling procedure;
c) Temperature measurement and calibration
d) Post bend heat treatment procedure including temperature and time.
e) Dimensional control procedure
f) Pipe material used for bend manufacture
g) NDT procedures
h) Quality Control and Quality Plans
Upon successful completion of the bend manufacturing procedure qualification as per

Section 9.0 of this specification, Manufacturer shall submit the qualified procedure to
Company for approval. Regular production of bends shall commence only after the bend
manufacturing procedure has been qualified and approved by Company.
Once the approval has been given by Company any change in material and method of
manufacture and quality control shall be notified to Company whose approval in writing of
all such changes shall be obtained before the bends are manufactured.
8.4 Within two weeks from the approval date, Manufacturer shall submit to Company the
approved drawings, documents and specifications as listed in clause 8.3 above.
8.5 Prior to shipment, the Manufacturer shall submit test certificates as listed in Section 6.0 of
this specification.
Page 287 of 1963

ENGINEERS
z INDIA LIMITED LONG RADIUS BENDS FOR
O ea,r (A Govt of India Undertaking)
ONSHORE PIPELINES
6-71-0021 Rev. 5
Page 10 of 11
9.0 BEND MANUFACTURING PROCEDURE QUALIFICATION
9.1 Prior to start of production bending, Manufacturer shall demonstrate the suitability of the
proposed manufacturing procedures for producing pipe bends including the post-bending
heat cycle, that meet the requirements of this specification, by mechanically testing
additional bend(s) (test bends). The bending procedure shall be qualified in the presence of
Company Representative.
9.2 Test bends shall be made by using the pipe specified in Clause 2.0 of this specification. One
test bend is required per 'heat lot' where a heat lot is deemed to include all bends of the same
diameter, wall thickness, mill heat number and bend forming parameters such as, bending
temperature, bending rate, cooling medium volume & heat treatment temperature (excluding
bend angle). The test bend shall be bent to an angle of 90°.
9.3 Inspection and Testing of Bends
9.3.1 All finished test bends shall meet the requirement of dimensional tolerances, inspection and
non-destructive testing requirements specified in Section 4.0 and 5.0 of this specification.
9.3.2 In addition, all finished test bends shall be subjected to following mechanical testing to
confirm that the bends manufactured meet all mechanical property requirements of linepipe
specifications referred in Clause 2.0 of this specification. Test procedure and acceptance
criteria shall be in accordance with the linepipe specification referred in Clause 2.0 of this
specification. The test specimen shall be taken from the bent portion of the bend only.
a) Tensile Test
One tensile test shall be conducted on the base material of finished test bend, to
establish yield strength, ultimate tensile strength and elongation. The specimen shall
be taken longitudinal or transverse to the axis as specified in the relevant pipe
specification. In case of bends of 450 mm (18") NB and larger, the specimen shall
be taken at inside radius and one at outside radius of the bend.
b) All Weld Tensile Test
In case of bends fabricated from SAW pipes, an all weld tensile test shall be
conducted to establish yield strength, ultimate tensile strength and elongation of
weld material on bend.
c) Guided Bend Test/Reverse Bend Test
For bends manufactured from SAW pipes one face and one root guided bend test
shall be performed. For bends manufactured from EW pipes, reverse bend test shall
be carried out. Test method and acceptance criteria shall be same as given in
applicable pipe specification referred under clause 2.0 of this specification.
d) Hardness Test
Hardness testing shall be performed "thru thickness" on a test ring removed from
the middle of the bend. Four specimens shall be prepared one from each quadrant.
In case of bends fabricated from SAW/EW pipes, one specimen shall the have
longitudinal weld seam in the middle. Hardness shall be checked for base metal,
weld metal and HAZ. In addition, hardness test shall be performed at spots where
dents, bulges or wrinkles have been formed on the bends.
Page 288 of 1963

ENGINEERS
$1gar faf54-"eg INDIA LIMITED LONG RADIUS BENDS FOR 6-71-0021 Rev. 5
1.77ff eilM IA Goof of ■
nclia Undertakmg)
e) Fracture Toughness Test
Charpy-V-notch test temperature shall be the same as specified in the relevant pipe
specifications referred in Clause 2.0. Three base material specimens shall be taken
longitudinal or transverse to the axis as specified in the relevant pipe specification.
In case of bends fabricated from SAW and EW pipes, three transverse weld material
specimens shall be taken with weld in the middle. In case of bends of 450 mm (18")
NB and larger, the base material specimens shall be taken at the outside radius of
the bend.
f) Hydrostatic test
Bends shall be hydrostatically tested to test pressure that shall result in hoop stress
corresponding to 90% of SMYS of pipe material. Test pressure shall be held for a
minimum period of fifteen (15) seconds.
Should test bends fail to comply with the above requirements, the bend manufacturing
procedure shall be disqualified. The Manufacturer shall revise the manufacturing procedure
and re-qualify the same at his own cost and time.
Upon completion of the successful procedure qualification, manufacturer shall provide a

written bending procedure for each test bend. The submitted procedure shall indicate in
addition to the details as per Clause 8.3, tolerances on various controlling parameters.
Page 289 of 1963

r ENGINEERS
Ofazieleh SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
tageg W INDIA L IMITED
Go„ a ma unam*.q■ (SIZE UPTO DN 400 mm (16")) Page 1 of 7
Maim Ri4 1 * fffg L
faMgr
(trwi alto 400 'PTA (16")'ff-W)
FOR
SEAMLESS FITTINGS & FLANGES
(SIZE UP TO DN 400 mm (16"))
V.` QI ;-
:i.j? (A44&/t
4 16-02-12 REVISED 8 REISSUED AS STANDARD Wer S KJ VM DM
SPECIFICATION
3 21-11-06 REVISED & REISSUED AS STANDARD MKM SK AS V C.
SPECIFICATION
2 25-10-01 REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
SPECIFICATION
1 21-09-98 REVISED & REISSUED AS STANDARD ALP ASo VC AS
SPECIFICATION
Standards Standards
Prepared Checked Committee Bureau
Rev. Date Purpose Convenor Chairman
No by by
Approved by
Page 290 of 1963

,FMEumom
ERS STANDARD SPECIFICATION FOR
SEAMLESS FITTING & FLANGES
(SIZE UPTO DN 400 mm (16"))
6-71-0024 Rev. 4
Page 2 of 7
Abbreviations:

ASTM American Society of Testing of Materials
BHN Brinell Hardness Number
CE Carbon Equivalent
DN Nominal Diameter
LPG Liquified Petroleum Gas
LTCS Low Temperature Carbon Steel
MSS-SP Manufacturers Standardization Society — Standard Practice
RTJ Ring Type Joint
Members : Mr. S.K. Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Format No. 8-00.0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 291 of 1963

ENGINEERS SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
Itgar Ell5legieir
INDIA LIMITED
Gn Undeltalng) (SIZE UPTO DN 400 mm (16")) Page 3 of 7
CONTENTS
1.0 SCOPE 4
3.0 MANUFACTURER'S QUALIFICATION 4
4.0 MATERIALS 5
5.0 DESIGN AND MANUFACTURE 5
8.0 PAINTING, MARKING AND SHIPMENT 7
9.0 DOCUMENTATION 7
Page 292 of 1963

55ftre ENGINEERS SEAMLESS FITTING & FLANGES
SEAMLESS Rev. 4
ligzirleS INDIA LIMITED (SIZE UPTO DN 400 mm (16"))
JAG., wmund..,,,, Page 4 of 7
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture and supply of
following carbon steel flanges and fittings of size upto DN 400 mm (16") to be installed in
onshore pipeline systems handling non-sour hydrocarbons in liquid or gaseous phase including
Liquefied Petroleum Gas (LPG):
Flanges such as welding neck flanges, blind flanges, spectacle blinds, spacers and
blinds etc.
Seamless fittings such as tees, elbows, reducers, caps, outlets etc.
of issue of enquiry) of the following Codes, Standards and Specifications:
ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids
ASME B31.8 - Gas Transmission and Distribution Piping Systems
ASME B16.5 - Pipe Flanges and Flanged Fittings
ASME B16.9 - Factory Made Wrought Steel Butt Welding Fittings
ASME B 16.11 - Forged Steel Fittings, Socket Welding and Threaded
ASME B 16.48 - Steel Line Blanks
API 1104 Specification for Welding Pipeline and Related Facilities
ASME Sec VIII - Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Sec IX - Qualification Standard for Welding and Brazing Procedures,

Welders, Brazers and Welding and Brazing Operators
ASTM A 370 - Standard Test Methods and Definitions for Mechanical

Testing of Steel Products
k. MSS-SP-25 Standard Marking System for Valves, Fittings, Flanges and

Unions
1. MSS-SP-97 Forged Carbon Steel Branch Outlet Fittings — Socket

Welding, Threaded and Butt welding Ends
In case of conflict between the requirements of this specification and the Codes, Standards and
Specifications referred above, the requirements of this specification shall govern.
3.0 MANUFACTURER'S QUALIFICATION
Manufacturer who intends bidding for fittings must possess the records of a successful proof
test, in accordance with the provisions of ASME B 16.9. These records shall be submitted at
the time of bidding qualifying the entire range of fittings offered.
Page 293 of 1963

- ENGINEERS
aairelak SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
Igzir talateg VW WA LIMITED
...g, (SIZE UPTO DN 400 mm (16")) Page 5 of 7
4.0 MATERIAL
4.1 The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed Material
for flanges and fittings shall comply with the material standard indicated in the Material/
Purchase Requisition. In addition, the material shall also meet the requirements specified
hereinafter.
4.2 Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the
following formula:
Mn Cr+Mo+V Ni+Cu
CE=C+ +
6 5 15
4.3 For flanges and fittings specified to be used for Gas service or LPG service, Charpy V-notch
test shall be conducted on each heat of steel used. Unless specified otherwise, the Charpy V-
notch test shall be conducted at 0° C in accordance with the impact test provisions of ASTM A
370 for flanges and fittings. Results of charpy test shall be recorded
The average absorbed impact energy values of three full-sized specimens shall be 27 joules.
The minimum impact energy value of any one specimen of the three specimens analysed as
above, shall not be less than 22 Joules.
When Low Temperature Carbon Steel (LTCS) materials are specified for flanges and fittings
in Purchase Requisition, the Charpy V-notch test requirements of applicable material standard
shall be complied with.
4.4 For flanges and fittings specified to be used for Gas service or LPG service, Hardness test
shall be carried out in accordance with ASTM A 370 for each heat of steel used. Hardness
testing shall cover at least 10% per item, per size, per heat, per manufacturing method. A full
thickness cross section shall be taken for this purpose and the maximum hardness shall not
exceed 248 HV I o. Hardness shall be recorded.
4.5 In case of RTJ (Ring Type Joint) flanges, the groove hardness shall be minimum 140 BHN.
Ring Joint flanges shall have octagonal section of Ring Joint.
5.0 DESIGN AND MANUFACTURE
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the requirements of
ASME B16.5.
5.2 Spectacle blind and spacer & blind shall conform to the requirements of ASME B 16.48. For
sizes upto DN 400 mm (16") handle projection dimensions of spacers & blinds shall be as per
EIL Std. 7-44-0166.
5.3 Butt welded end fittings such as tees, elbows, reducers, etc. shall be seamless type and shall
conform to ASME B16.9. Socket weld and screwed end fittings shall conform to ASME B
16.11 . Ring joint Fig.8 flanges, spacers & blinds shall be female type only.
5.4 Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in accordance with
MSS-SP-97.
5.5 Type, face and face finish of flanges shall be as specified in Material/ Purchase Requisition.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL-All rights reserved
Page 294 of 1963

zllc'
• ENGINEERS
IntlaUndadimg)
SEAMLESS FITTING & FLANGES
SEAMLESS
(SIZE UPTO DN 400 mm (16"))
6-71-0024 Rev. 4
Page 6 of 7
5.6 Flanges and fittings manufactured from bar stock are not acceptable.
5.7 All butt weld ends shall be bevelled as per ASME B 16.5/ASME B 16.9/MSS-SP-97 as
applicable.
5.8 Repair by welding on flanges and fittings are not permitted.
6.1 The Manufacturer shall perform all inspections and tests as per the requirement of this
specification and the relevant codes, prior to shipment at his works. Such inspections and tests
shall be, but not limited to the following:
6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the
flanges and fittings shall be free from any strikes, gauges and other detrimental defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 for flanges,
ASME B 16.48 for spacers and blinds and ASME B16.9/MSS -SP-97 as applicable for fittings
and as per this specification.
6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.
6.1.4 All finished wrought weld ends shall be 100% tested for lamination type defects by ultrasonic
test. Any lamination larger then 6.35 mm shall not be acceptable.
6.1.5 Magnetic particle or liquid penetrant examination shall be performed on cold formed butt
welding tees with extruded outlets as per applicable material standard.
6.2 Purchaser's Inspector reserves the right to perform stage wise inspection and witness tests, as
indicated in clause 6.1 of this specification at Manufacturer's Works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide, without charge,
reasonable access and facilities required for inspection, to the Purchaser's Inspector.
Inspection and tests performed/witnessed by Purchaser's Inspector shall in no way relieve the
Manufacturer's obligation to perform the required inspection and tests.
Manufacturer shall furnish the following certificates:
Test certificates relevant to the chemical analysis and mechanical properties of the
materials used for manufacture of flanges and fittings as per relevant standards and
this specification.
Test Reports on non destructive testing.
c) The certificates for each fitting stating that it is capable of withstanding without
leakage a test pressure, which results in a hoop stress equivalent to 100 % of the
specified minimum yield strength for the pipe with which the fitting is to be attached
without impairment of serviceability.
Page 295 of 1963

larazreidah ENGINEERS SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
ant 0151e1gWir WA LIMITED (SIZE UPTO DN 400 mm (16"))
UndeftaXnal
441P7TelAWCOISFOral lA Sp. pp,,. Page 7 of 7
8.0 PAINTING, MARKING AND SHIPMENT
8.1 After all inspection and tests required have been carried out; all external surfaces shall be
thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill
coating for protection against corrosion during transit and storage. The coating shall be easily
removable in the field.
8.2 Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage
during transit. Metallic or high impact plastic bevel protectors shall be provided for fittings
and flanges. Flange face shall be suitably protected to avoid any damage during transit.
8.3 All flanges and fittings shall be marked as per applicable dimension/manufacturing standard.
9.0 DOCUMENTATION

of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT
document/Material Requisition.
9.1 Prior to shipment, the Manufacturer shall submit test certificates as listed in clause 7.0 of this
specification.
9.2 All documents shall be in English Language only.
Page 296 of 1963

OOZE? ENGINEERS FOR CASING INSULATORS AND 6-71-0035 Rev. 4
Ekleg
5111/ INDIA LIMITED
END SEALS Page 1 of 10
au-gtuftzr 194-al At ated7 Thle

Crl
rff‘
- 4-111 ch indribT
FOR
CASING INSULATORS AND END SEALS

SPECIFICATION
REVISED & REISSUED AS STANDARD VC
3 22.11.06 SPECIFICATION MKM VM AS
2 24.10.01 REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
SPECIFICATION
1 REVISED & REISSUED AS STANDARD PKM ASr VC AS
12.10.98 SPECIFICATION
0 08.01.90 ISSUED AS STANDARD SPECIFICATION SK RKD SA
Standards Standards
Date Purpose by by Convenor Chairman
No
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright DL — All rights reserved
Page 297 of 1963

4.Rangas ENGINEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
g -lagethw INDIA wimp
5 7 CASING INSULATORS AND END 6-71-0035 Rev. 4
(A Gait al India unaciak .91 SEALS Page 2 of 10
Abbreviations:

DN Diameter Nominal

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Page 298 of 1963

alzitq a ENGINEERS
CASING INSULATORS AND END 6-71-0035 Rev. 4
$.1g:a tataierwir INDIA
IA Govt
LIMITED
SEALS
of India Undenapng)
Page 3 of 10
CONTENTS
PART-A CASING INSULATORS
1.0 SCOPE 4
2.0 FUNCTION 4
3.0 DESIGN 4
4.0 MATERIAL 5
PART-B CASING END SEALS
1.0 SCOPE 6
2.0 FUNCTION 6
3.0 DESIGN 6
4.0 MATERIAL 6
PART-C SUPPLEMENTARY REQUIREMENTS
Page 299 of 1963

ISilf=eadft ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
da-nr EifYlegWINDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4

coal at India undedaking) SEALS Page 4 of 10
PART - A CASING INSULATORS
1.0 SCOPE
This specification covers the minimum requirements of design, material, manufacture and
supply of casing insulators intended to be used for cased pipeline crossings.
2.0 FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing pipe and
electrically isolate the carrier pipe from the casing pipe at the cased crossings.
The casing insulators shall have the following properties:
Resist cold flow and will not soften at design temperature
Resist corrosion.
Have low friction, to offer less resistance to carrier pipe movement.
Resist mechanical damage while being pulled into the casing.
Have high electrical insulating value and low water absorption, thus preventing
leakage and maintain electrical isolation between carrier and casing pipes.
Have high compressive and impact strength in order to ensure a permanent support to
the carrier pipe.
3.0 DESIGN
The arrangement of insulator shall be generally in accordance with Fig. 3.0. It shall be made
in segments duly held together with cadmium/XYLAN plated bolts and nuts, to be supplied
with casing insulators. The number of segments shall be two for pipe diameters upto DN 300
mm (12"). For larger diameter, the number of segments may be more than two, but their
number shall be kept minimum.
As an alternate design in accordance with fig. 3.1 the casing insulator element shall be a
flexible section containing a toothed male butt strap at one end and an appropriately toothed
female slot on the other end. The same shall be wrapped over the outer surface of the carrier
pipe and locked positively. The insulator rings should be fastened onto the carrier pipe with
the appropriate tool to be provided by the casing insulator manufacturer. No metallic parts or
attachments should be considered in the casing insulator element assembly. The design of
casing insulator should allow for onsite adjustments for any variances within the allowable
O.D. range of pipeline and should grip the pipe firmly without any chances of horizontal
movement or breakage of the insulator rings during installation.
The skid height shall be such that it is slightly less than the value obtained by following
formula:
Casing Internal Dia — Carrier Outer Dia

2
Manufacturer shall obtain prior approval from OWNER on casing insulators drawings/design.
Page 300 of 1963

ds, ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
stair fameg FINDIA LIMITED
q- CASING INSULATORS AND END 6-71-0035 Rev. 4
iNPn ewe/Re cr, Ov05/1/ IA Goy/ o/ ioo unoenakingi SEALS Page 5 of 10
4.0 MATERIAL
Casing insulators shall be made of injection moulded high density polyethylene or other
material, equivalent or superior, as approved by OWNER.
The material shall meet the following specifications:
Property Value ASTM Test Method

Dielectric strength 450-500 Volts/Mil D-149
Compressive strength 3200 psi D-695
Tensile strength 3100-5000 psi D-638, D-651
Impact strength 4.0 ft.lb./inch of notch D-256
Water Absorption 0.01% D-570
Manufacturer shall furnish material test certificates of the components used in the assembly of
casing insulators as per the requirements of clause 4.0 of this specification.
Page 301 of 1963

aglilei ENGINEERS CASING INSULATORS AND END
sibtar EllMeg, INDIA LIMITED
IA Cori of India underlaiong) SEALS
6-71-0035 Rev. 4
Page 6 of 10
PART - B CASING END SEALS
1.0 SCOPE
This specification covers the minimum requirements of design, material, fabrication and
supply of casing end seals intended to be used for pipeline cased crossings.
2.0 FUNCTION
Casing end seals are intended to be used for sealing the annular space between casing pipe and
carrier pipe at casing ends so as to prevent ingress of moisture and water.
3.0 DESIGN
The seals shall be suitable for the casing and carrier pipe diameters as applicable for each case.
The casing end seal shall be flexible to cater for the expansion and contraction of carrier and
casing pipes and shall be able to tolerate both angular and concentric misalignment of casing
pipe without loss of sealing efficiency.
The design of the casing end seals shall permit easy installation of the seal to the cased
pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated life of the buried
pipeline.
Manufacturer shall obtain prior approval from OWNER on casing end seals design/drawings.
4.0 MATERIAL
The casing end-seals shall be made of heat shrink high density radiation cross linked
polyethylene with an adhesive having a melt point suitable for the pipeline service
temperature and ambient temperatures foreseen during construction. End seals material shall
be resistant to heat, cold, vibration, impact, abrasion, corrosive fluids, disbonding, organic and
bio-deterioration. Manufacturer shall confirm compatibility of end seals with carrier pipe
coating.
Casing end seals shall meet following minimum property requirements:
a) Backing (Sleeve and closure patch)
Property Minimum Value Test Method
Tensile strength 2200 psi ASTM D 638
Ultimate Elongation 400 % ASTM D 638
Heat Shock No Visual Cracks, ASTM D 2671

Flow or Drips at 250°C, 4 hours
Page 302 of 1963

ENGINEERS
enINDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4
/gM an MAW AA SAWA) IA WA 01 intha Underlakm9I SEALS Page 7 of 10
Adhesive
Ring and Ball 90°C ASTM E 28

Softening Point
Lap Shear 60°C - 25 psi ASTM D 1002

23°C - 250 psi
(2 inch/min.)
System (As Applied)
Peel strength 5 pli ASTM D 1000

(To casing and carrier (10 inch/min.)
pipe and closure patch)
Manufacturer shall furnish material test certificates of the components used in the assembly of
casing end seals as per the requirements of this specification.
Page 303 of 1963

Ord-Cele ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
$1g7 &gift'," INDIA LIMITED
Goofof India Un4en".9)
CASING INSULATORS AND END
SEALS
6-71-0035 Rev. 4
Page 8 of 10
PART - C SUPPLEMENTARY REQUIREMENTS
1.0 The manufacturer shall replace, at no extra cost, any material not conforming to the material
and performance requirements of this specification.
2.0 Manufacturer shall submit detailed specification of the materials used in the assemblies, along
with instructions for handling, use and installation of the material for OWNER approval prior
to procurement.
3.0 Manufacturer shall submit all the documents, test reports, records and other information to
OWNER for record after approval as per clause 2.0 above. Number of Copies (Hard copies /
soft copies etc.) shall be as indicated in CONTRACT document.
Page 304 of 1963

ard#SENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
Ogar Etraegw INDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4
n)
anznewnwmag WG0,AmmuundertakM SEALS Page 9 of 10
FIG.3.0
Page 305 of 1963

afaeief
am(c ENGINEERS
$11g-eir INDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4

IA Gnu of India Undertaking) SEALS Page 10 of 10
BOTT011 YO
FIG 3.1
Page 306 of 1963

ISifte? ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
$e-1T falar
eg
, INDIA LIMITED 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
IA Go,n of Isla Uraerlaking)
OF LINEPIPES Page 1 of 29
(114.141V1 i fg V51
iftreffirotff 4q9.
foR 1-4-4vr
FOR
3 LAYER POLYETHYLENE COATING
OF LINEPIPES

3 26.11.12
SPECIFICATION sj \w-VM DM
2 REVISED & REISSUED AS STANDARD

31.08.06 MKM VM AS VJN
SPECIFICATION
1 REVISED AND REISSUED AS STANDARD
11.12.98 KKS RK VC AS
SPECIFICATION
0 01.08.89 ISSUED AS STANDARD SPECIFICATION GD RKD SA
Standards Standards
No by by
Approved by
Page 307 of 1963

ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev.3
01 Go./ of India urrierlakingli OF LINEPIPES Page 2 of 29
Abbreviations:

CD Cathodic Disbondment
DIN Deutsches Institut Fur Normung
DSC Differential Scanning Calorimetry
ESCR Environmental Stress Crack Resistance
FBE Fusion Bonded Epoxy
ISO International Organization for Standardization
PE Polyethylene
PQT Procedure Qualification Tests

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Mr. Rajeev Kumar (PDD)
Mr. R.K.Singh (Inspection)
Page 308 of 1963

18110-42re?a?: ENGINEERS 3 LAYER POLYETHYLENE COATING
sitcal Etkleg WS INDIA LIMITED
IA Govt al India unaepulanco OF LINEPIPES
6-71-0041 Rev. 3
Page 3 of 29
CONTENTS
1.0 SCOPE 4
3.0 PLANT SCALE AND INSTALLATION 5
4.0 MATERIALS 6
5.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING 7
6.0 MEASUREMENT AND LOGGING 10
7.0 COATING PROCEDURE AND QUALIFICATION 10
8.0 PIPE SURFACE PREPARATION 16
9.0 COATING APPLICATION 18
11.0 HANDLING, TRANSPORTATION AND STORAGE 25
12.0 REPAIR OF COATING 26
13.0 MARKING 28
14.0 QUALITY ASSURANCE 28
ANNEXURE - I
LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS 29
Page 309 of 1963

PII=End ENGINEERS 3 LAYER POLYETHYLENE COATING
sga IdPieg O INDIA LIMITED 6-71-0041 Rev. 3
IA G. 0 India Underlakinw OF LINEPIPES Page 4 of 29
1.0 SCOPE
This specification covers the minimum requirements for supply/arrangement of all materials,
plant, equipment, plant sites, consumables, utilities and application including all labour,
supervision, inspection and tests etc. for application of external anti-corrosion coating of pipes by
using 3 Layer Side Extruded Polyethylene coating conforming to ISO 21809 — 1: 2011 'Petroleum
and Natural Gas Industries — External Coatings for buried and submerged pipeline transportation
systems — Part 1: Polyolefin Coatings', and the requirements of this specification.
Reference has also been made to the latest edition (edition enforce at the time of issue of enquiry)
of the following standards, codes and specifications. The edition enforce at the time of floating the
enquiry shall be termed as latest edition.
a) ISO 21809-1 :2011 : Petroleum and Natural Gas Industries — External Coatings for
Buried and Submerged Pipeline Transportation Systems — Part 1:
Polyolefin Coatings
b) ISO 21809-2 :2007 : Petroleum and Natural Gas Industries — External Coatings for
Buried and Submerged Pipeline Transportation Systems — Part 2:
Fusion — Bonded Epoxy Coatings
c) ASTM D-149 Standard Test Methods of Dielectric Breakdown Voltage and

Dielectric Strength of Solid Electrical Insulating Materials at
Commercial Frequencies.
d) ASTM D-257 : Standard Test Methods for D — C Resistance or Conductance of

Insulating Materials
e) ASTM D-792 : Standard Test Method for density and specific gravity (relative
density) of Plastics by displacement.
0 ASTM D-1238 : Test Method for Flow Rates of Thermoplastics by Extrusion
g) ASTM D-1603 : Test Method for Carbon Black in Olefin Plastics
h) ASTM D-1693 : Test Method for Environmental Stress Cracking of Ethylene

Plastics
i) API RP 5L1 : Recommended Practice for Railroad Transportation of Line pipe
j) API RP 5LW : Transportation of Line Pipe on Barges and Marine Vessels
k) DIN EN 10204 : Metallic Products — Types of Inspection Documents
I) DIN 53735 : Testing of Plastics: Determination of Melt Index of

Thermoplastics.
m) ISO 8501-1 Preparation of Steel Substrates before Application of Paints and

Related Products — Visual Assessment of Surface Cleanliness:
Part 1 — Representative Photographs of the Change of
Appearance imparted to Steel when Blast Cleaned with different
Abrasives
Page 310 of 1963


larma-ei ENGINEERS 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
51g-a fdffteg W
INDIA LIMITED
IP Gan of !Ma underlaking) OF LINEPIPES Page 5 of 29

n) ISO 8502 — 3 : Preparation of Steel Substrates before Application of Paints and
Related Products — Part 3 — Assessment of Dust on Steel Surfaces
Prepared for Painting (Pressure Sensitive Tape Method)
o) ISO 9002 : Quality Systems: Model for Quality Assurance in Production,

Installation and Servicing
p) ISO 306 : Plastics — Thermoplastic materials — Determination of Vicat

softening temperature
q) ISO 15512 : Plastics — Determination of water content
r) ISO 527-2 Determination of tensile properties — Part 2: Test conditions for

moulding and extrusion plastics
s) ISO 527-3 : 3 Plastics — Determination of tensile properties — Part 3: Test

conditions for films and sheets
t) ISO 868 : Plastics and ebonite — Determination of indentation hardness by

means of a durometer (Shore hardness)
u) ISO 11357 Plastics — Differential Scanning Calorimetry (DSC) — Part 7:

Determination of crystallization kinetics
v) ISO 11124 Preparation of Steel Substrates Before Application of Paints and

Related Products
w) API 5L Specification for Line Pipe
x) ASME B31.8 Gas Transmission and Distribution Piping Systems.
y) ASME B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid

Petroleum Gas, Anhydrous Ammonia, and Alcohols
The Contractor shall be familiar with the requirements of these documents and shall make them
readily available at the coating plant to all persons concerned with carrying out the works specified
in this specification.
3.0 PLANT SCALE AND INSTALLATION
3.1 Contractor shall size coating plant(s) after evaluating the scale of work and the time schedule
required for the works. Coating plant(s), both new and existing, shall be installed into a yard
whose geometry and dimensions are such as to allow the execution of a continuous work schedule.
For this purpose the Contractor shall ensure non-stop work execution owing to prohibitive adverse
weather conditions and install requisite equipment and plant in roofed and adequately weather-
protected areas.
3.2 Plant equipment, machinery and other facilities shall be in first class operating condition to at least
meet the job requirements of quality and production. Worn out and improvised plants are not
acceptable.
3.3 The Contractor shall, at his own responsibility and cost, provide and prepare all necessary area for
the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other
temporary installation. For each area, Contractor shall provide necessary agreements as required
Page 311 of 1963


15101-rieT a ENGINEERS 3 LAYER POLYETHYLENE COATING
solg7 Wage INDIA LIMITED 6-71-0041 Rev. 3
Gorl d intha Undenalorg) OF LINEPIPES Page 6 of 29
with the land owner(s)/relevant Authorities, and, on work completion, to clean and pay settlement
and claims for damages, as applicable.
3.4 The Contractor shall at its own responsibility and cost, provide for water and power supply and
other utilities and consumables and obtain authorization regarding access roads and other permits
required for the execution of works conforming to all the requirements of the governing
Authorities.
3.5 The Contractor shall at its own expense provide a fully equipped laboratory and test facilities with
adequate inventory to carry out tests required for the procedure qualification and regular
production. Outside testing for qualification and regular production is not acceptable to Company.
3.6 The Contractor shall be fully responsible for adherence to all statutory regulations applicable for
handling and disposal of the hazardous chemicals during the coating works.
3.7 The Contractor shall be responsible for obtaining all statutory approvals/clearances from relevant
Authorities including Pollution Control Board, as applicable for the coating plant(s).
4.0 MATERIALS
4.1 The three layer coating system shall comprise of a powder epoxy primer, polymeric adhesive and a
medium density polyethylene topcoat. Coating materials shall be suitable for the service
conditions and the pipe sizes involved. The coating materials i.e. epoxy powder; adhesive and
polyethylene compound shall have proven compatibility. The coating system and materials shall
be pre-qualified and approved by Company in accordance with provisions of Annexure I of this
specification. Contractor shall obtain prior approval from Company for the coating system and
coating materials.
4.2 The coating materials Manufacturer shall carry out tests for all properties specified in Para 5.3.1
and 5.3.2 for each batch of epoxy, adhesive and polyethylene compound. In addition, the
Manufacturer shall also furnish Infra-red Scan for each batch of epoxy powder. The coating
materials Manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for each batch of
materials supplied to Contractor and the same shall be submitted to Company for approval prior to
their use.
4.3 In addition to Manufacturer's certificate, the Contractor shall draw samples from each batch of
epoxy, adhesive and polyethylene in the presence of Company Representative and test for the
following properties at the coating yard at least one week prior to its use, to establish compliance
with the Manufacturer's test certificates.
a. Epoxy Powder:
i. Gel Time
ii. Cure time
iii. Moisture content
iv. Thermal Characteristics (Tgl, Tg2, AEI)
b. Adhesive:
i. Specific Gravity
ii. Melt Flow Rate
iii. Vicat Softening Point
iv. Moisture content
c. Polyethylene:
i. Melt Flow Rate
ii. Specific Gravity
iii. Vicat Softening Point
Page 312 of 1963


lainta ENGINEERS 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
nreg„ INDIA UMITED
IA OnN s Enda underskon) OF LINEPIPES Page 7 of 29
iv. Moisture Content

v. Oxidative Induction Time
In case of failure of any of the above tests in a batch, that batch of material shall be tested for all
other tests required as per Para 5.3.1 and 5.3.2 including the tests which failed. If all tests pass, the
batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected
and shall not be used for the coating.
4.4 All materials to be used shall be supplied in sealed, damage free containers and shall be suitably
marked with the following minimum information:
a. Name of the Manufacturer

b. Type of Material
c. Batch Number
d. Place and Date of Manufacture
e. Shelf Life/ Expiry Date (if applicable)
f. Quantity
All materials noted to be without above identification shall be deemed suspect and shall be
rejected by Company. Such materials shall not be used for coating and shall be removed from site
and replaced by Contractor at his expense.
4.5 Contractor shall ensure that all coating materials are properly stored in accordance with the
Manufacturer's recommendation at all times, to prevent damage and deterioration in quality prior
to use.
4.6 Contractor shall be required to use all materials on a date received rotation basis, i.e. first in - first
used basis.
5.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING
5.1 The coating shall be able to withstand a maximum in service operating temperature of 80°C and
shall conform to 'Class B' as per ISO 21809-1:2011.
5.2 The topcoat polyethylene used shall be a black readymade compound, fully stabilized against
influence of ultraviolet radiation (i.e. sunlight), oxygen in air and heat (due to environmental
temperature as specified above). No appreciable changes shall occur during exposure to such
environments up to at least a period of 6000 hours. The Contractor shall submit certificate from
Manufacturer in this regard.
5.3 Properties
Properties of coating system and coating material shall comply the requirements indicated in
subsequent paragraphs. In case the coating / material properties are tested as per test
methods/standards other than specified herein below, the same may be accepted provided the test
procedures and test conditions are same or more stringent than the specified.
5.3.1 Properties of Epoxy Powder and Adhesive
Contractor shall choose brand of epoxy powder and adhesive as per Annexure-I that will achieve
the functional requirements and properties of coating system as specified in Para 5.1 and 5.3.3 of
this specification respectively.
5.3.1.1 Epoxy powder properties shall meet the properties listed below
Page 313 of 1963

ENGINEERS
(rE) INDIA LIMITED 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
IA Govi d/ India Undenakm) OF LINEPIPES Page 8 of 29
SI. No. Properties Unit Requirement Test Method
ISO 21809-1
a. Moisture Content % mass < 0.5
Annexure K
? 95 and within
Minimum glass transition ISO 21809-1
b. oC manufacturer's
temperature (Tg2 ) Annexure D
specification
Within 20% of the

nominal value ISO 21809-1
c. Gel time at 205° C ± 3° C s
specified by the Annexure J
manufacturer
Within ± 0.05 of the

manufacturer's ISO 21809-1
d. Density WI Annexure N
specified nominal
value
The colour of epoxy powder shall be either green or dark red or any other colour approved by
Company except grey colour.
5.3.1.2 Copolymer grafted adhesive shall have the following properties:
a. Melt Flow Rate g/10

> 1.0 ASTM D 1238
(190°C / 2.16 kg) minutes
b. Vicat Softening Point °C > 100 ISO 306
c. Specific Gravity - > 0.930 ASTM D 792
d. Elongation at break at 23°C % > 600 ISO 527-2
e. Tensile yield strength at 23°C MPa >8 ISO 527-2
f. Water Content % < 0.1 ISO 15512
5.3.2 Properties of Polyethylene Compound
a. Tensile Strength @ + 23 °C N/mm2 ISO 527-2 or

> 17
ISO 527-3
b. Melt Flow Rate g/10

> 0.25 ASTM D 1238
(190°C / 2.16 kg) minutes
c. Specific Gravity @ + 23 °C g/cm3 >: 0.930 (MDPE)

ASTM D 792
> 0.941 (HDPE)

Page 314 of 1963

ce ENGINEERS 3 LAYER POLYETHYLENE COATING
faileue, INDIA LIMITED 6-71-0041 Rev. 3
eida5realanni) A Gnat at India Undettakinal OF LINEPIPES Page 9 of 29
d. Hardness @ + 23 °C Shore D ? 55 (MDPE)

ISO 868
? 60 (HDPE)
e. Water Absorption, 24 hours, % ASTM D 570

< 0.05
@ + 23 °C ISO 15512
f. Volume Resistivity @ + 23°C Ohm-cm > 1016 ASTM D 257
g. Dielectric withstand, 1000 Volts/mm > 30,000 ASTM D 149

Volt/sec rise @ + 23 °C
h. Vicat Softening Point °C > 110 ISO 306
i. Elongation at break at 230 C % ASTM D 638

> 600 ISO 527-2
or ISO 527-3
j. Oxidative Induction Time in Minutes

Oxygen at 220°C, Aluminium 10
pan, no screen ISO 11357
k. Environmental Stress Crack Hours

Resistance (ESCR) (for F50)
• Medium Density
300 ASTM D1693
[Condition "C]
300
• High Density
[Condition "B"]
1. Carbon Black Content % >2 ASTM D 1603
n UV resistance and thermal % ISO 21809-1

AMER < 35
ageing Annexure G
5.3.3 Properties of Applied Coating System
a. Bond Strength (Peel Strength) ISO 21809-1

• @23°C N/ mm > 15 Annexure C C.5
• @80 °C >3 hanging mass
b. Impact Strength
Joules per
(Min. of 30 impacts on body mm of ISO 21809-1
along the length. No >7
coating Annexure E
breakdown allowed when thickness
tested at 25 KV)
c. Indentation Hardness
ISO 21809-1
• @ 23 +/- 2°C mm < 0.2 Annexure F
• @ 80 +/- 2°C <
_ 0.3

Page 315 of 1963


1:5111Raq ENGINEERS
os-f irevregW INDIA LIMITED
b. Go.4 S unaets*Prgl
OF LINEPIPES
6-71-0041 Rev. 3
Page 10 of 29
d. Elongation at Failure % > 400 ISO 527-3
•
8
e. Coating Resistivity (*) Ohm — m2 10 mm. DIN 30670
f. Cathodic Disbondment mm
Average <7
• 23 °C/28d;-1.5V ISO 21809-1
radius of <7
• 65 °C/24h;-3 .5V Annexure H
Cathodic
• 80 °C/28d;-1.5V < 15
disbondment
g. Degree of Cure of Epoxy

ISO 21809-1
• Percentage Cure, A H % 95 Annexure D
• A Tg °C <
_5
h. Hot Water Immersion test mm Average < 2, and ISO 21809-1

Maximum < 3 Annexure M
i. Flexibility No cracking at an angle

ISO 21809-1
of 2.0 ° per pipe
Annexure I
diameter length
5.4 The acceptable combinations of coating material shall be as per Annexure-I.
6.0 MEASUREMENT AND LOGGING
Contractor shall maintain records in computer using MS ACCESS database Software containing
all the relevant data of individual pipe and pipe coating including pipe number, heat number,
diameter, length, wall thickness, defects, coating number, batches of materials, sampling, testing,
damages, repairs, rejects and any other information that Company considers to be relevant and
required for all incoming bare pipes and Company approved outgoing coated pipes as applicable.
Contractor's documentation shall be designed to ensure full traceability of pipe and coating
materials through all stages of coating and testing. Contractor shall submit this information in the
form of a report at the agreed intervals. The above data shall also be provided in MS ACCESS
format in Compact Disc (CD). Contractor shall provide one Computer Terminal to Company
Representative for monitoring/tracking of the above. The Contractor shall also submit the material
balance details to Company for information at the end of each shift.
7.0 COATING PROCEDURE AND QUALIFICATION
7.1 Upon award of the CONTRACT, the Contractor shall submit within two (2) weeks, for Company
approval, a detailed report in the form of bound manual outlining, but not limited to, the following:
a. Details of plant(s), location(s), layout, capacity and production rate(s).
b. Details of the equipment available to carry out the coating works including surface
preparation, epoxy powder application and its recycling system, adhesive & polyethylene
extrusion, moisture control facilities available for coating materials.
c. Details of process control and inspection equipment required for the coating process such
as temperature control, thickness control, holiday testers, etc.
Page 316 of 1963

sad ENGINEERS 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
51gzr taI5leg W INDIA
A Go. of
LIMITED
intha undertaking) OF LINEPIPES Page 11 of 29
Facilities in the yard for unloading, handling, transport, production, storage, stockpiling,
loading of bare and coated pipes and warehouses for storage of other coating materials.
e. Plant Organization Chart and availability of manpower including coating specialist
f. Details of utilities/facilities such as water, power, fuel, access roads and communication
etc.
After Company has given approval; no change in plant set-up shall be made. However,
unavoidable changes shall be executed only after obtaining written approval from Company.
7.2 At least four (4) weeks prior to the commencement of production coating, a detailed procedure of
the Contractor's methods, material proposed, etc., shall be formulated by the Contractor and
submitted for Company approval in the form of a bound manual. The procedure shall include, but
not limited to, the following information and proposals:
a. Pipe inspection at the time of bare pipe receipt.
b. Steel surface preparation, including preheating, removal of steel defects, method of pipe
cleaning, dust removal, abrasive blast cleaning and surface profile; methods of
measurements and consumables.
c. Pipe heating, temperatures and control prior to epoxy application.
d. Complete details of raw materials including current data sheets showing values for all the
properties specified together with quality control and application procedure
recommendations from manufacturer(s).
e. Application of FBE powder, adhesive and polyethylene, including characteristics,

temperature, line speed, application window, curing time, etc.
f. Quenching and cooling, including time and temperature.
g. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting formats,
including instrument and equipment types, makes and uses, etc
h. Detailed method of repair of coating defects duly classified depending upon nature and
magnitude of defects and repair thereof including coating stripping technique
i. Details of instrument and equipment calibration methods including relevant standards and
examples of calibration certificates.
j. Complete details and inventory of laboratory and equipment for procedure qualification and
regular production
k. Pipe handling and stock piling procedures
1. Sample of recording and reporting formats, including laboratory reports, certificates and
requirement as per clause 6.0 of this specification.
m. Complete details of test certificates for raw materials including test methods and standards
used.
n. Test certificates from PE compound manufacturer for tests for thermal aging, coating
resistivity and aging under exposure to light. These test certificates shall not be older than
three years.
Page 317 of 1963


ENGINEERS 3 LAYER POLYETHYLENE COATING
IA Govt at Ind.Undertaking) OF LINEPIPES Page 12 of 29
o. Health, Safety and Environment Plans.

Storage details of coating materials and chemicals.
P.
q. Continuous temperature monitoring at various stages of coating
Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of
the above procedure from Company. No change in the procedure shall be made after the Company
has given approval. However, unavoidable changes shall be executed only after obtaining written
approval from Company.
7.3 Prior to start of production, the Contractor shall, at his expense, carry out a coating PQT for each
pipe diameter on max. wall thickness, for each type of pipe, for each coating material combination,
and for each plant, to prove that his plant, materials, and coating procedures result in a quality of
end product conforming to the properties stated in clause 5.3, relevant standards, specifications
and material manufacturer's recommendations. Contractor shall give seven (7) working days notice
to witness all procedures and tests.
A batch representing a normal production run, typically 15 pipes, shall be coated in accordance
with the approved coating procedure and the coating operations witnessed by Company
Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and partly
with both epoxy and adhesive layers.
At least 5 (five) test pipes shall be selected by Company Representative for coating procedure
approval tests and shall be subjected to procedure qualification testing as described hereinafter.
Company Representative shall witness all tests. Out of 5 (five) test pipes, 1 (one) pipe partly
coated with epoxy and partly coated with both epoxy and adhesive layers shall be included.
Remaining 4 (four) test pipes shall have all three layers.
During PQT, the Contractor shall qualify various procedures forming a part of coating operations
as detailed subsequently.
7.4 Qualification of Procedures
7.4.1 Epoxy Powder Application & Recycling
During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of
monitoring system, line speed v/s coating thickness, etc. shall be established. Dew point of air
used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be recorded
during the PQT.
Also, the Contractor shall remove samples of reclaimed powder from the reclamation system.
These samples of reclaimed powder shall be subject to a detailed visual examination, thermal
analysis and moisture content tests. The properties of the reclaimed powder shall be within the
range specified by the Manufacturer of epoxy powder. In case the properties of the reclaimed
powder are out of the range specified by the Manufacturer, Contractor shall not the use the
reclaimed powder during the regular production.
7.4.2 Pipe Pre-heating
The Contractor shall establish the temperature variation due to in-coming pipe temperature, line
speed variation, wall thickness variation, emissivity, interruptions, etc and document the same
during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and
recording system including alarm/hooter shall be demonstrated to the Company Representative.
Page 318 of 1963

151101-zre? ENGINEERS 3 LAYER POLYETHYLENE COATING
0144fregi IA GM el India tlnderWang) OF LINEPIPES Page 13 of 29
7.4.3 Surface Preparation
The procedure to clean and prepare the pipe surface shall be in accordance with the requirements
of this specification. The ratio of shot to grit shall be established during procedure qualification
testing, such that the resultant surface profile is not dished and rounded. The qualification shall be
performed through a visual inspection, measurement of roughness and check of the presence of
dust on the abrasive blast cleaned pipe surface.
7.4.4 Coating Application
The Company Representative will check the correctness of each coating application operation,
values of the main parameters of each operation, pre-heating pipe surface temperature prior to
epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature
and flow rate of co-polymer adhesive and polyethylene, etc. and the same shall be recorded. These
values shall be complied with during regular production.
7.5 Qualification of Applied Coating
7.5.1 Tests on pipe coated partly with epoxy and partly with epoxy & adhesive layers
a. Degree of Cure
Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and the samples
shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure
mentioned in clause A8 of ISO 21809-2 Fusion bonded epoxy coating. Care shall be taken to
remove the samples of MI film thickness avoiding inclusion of steel debris. Glass transition
temperature differential (ATg) and % cure (All) shall comply with the specified requirements.
b. Epoxy Layer Thickness
Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12 o'clock
positions. The thickness shall comply with the specified thickness requirements.
c. Adhesive layer Thickness
Adhesive layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12'o
clock positions. The thickness shall comply with the specified thickness requirements.
d. Holiday Inspection
Entire pipe shall be subject to holiday inspection and the test voltage shall be set to exceed 5
v/micron of epoxy thickness specified for the portion coated only with epoxy layer.
e. Dry Adhesion
Dry adhesion test shall be carried out as per clause A.4 of ISO 21809-2 Fusion bonded epoxy
coating. The rating obtain shall be either 1 or 2.
f. 24 h Adhesion Test
Adhesion Test (24 hrs) shall be carried out on the epoxy coated pipe as per clause A.15 of
ISO 21809-2 Fusion bonded epoxy coating. The rating obtain shall be either 1 to 3.
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15iNzieT„
ft ENGINEERS 3 LAYER POLYETHYLENE COATING
stig-ptlaglegW , INDIA LIMITED 6-71-0041 Rev. 3
A Go. a Ma undertaking) OF LINEPIPES Page 14 of 29
g. Flexibility test
2° flexibility test shall be carried out as per clause A.12 of ISO 21809-2 Fusion bonded epoxy
coating. No cracking should be observed.
h. Porosity Test
Cross section porosity and interface porosity tests shall be carried out on the epoxy coated
pipe. Test method and acceptance criteria shall comply as per clause A.11 of ISO 21809-2
Fusion bonded epoxy coating.
7.5.2 Tests on pipes coated with all three layers
a. Bond Strength (Peel Test)
Five test pipes shall be selected for bond strength tests. On each of the selected pipes, three
peel tests shall be performed for each specified temperature i e one at each end and one in the
middle of the pipe and specified requirements shall be complied with, i.e. bond strength as
well as mode of separation. Length of peel shall be minimum 65 mm. None of these samples
shall fail.
b. Impact Strength
Three test pipes shall be selected for impact strength test and the test shall meet the specified
requirements.
c. Indentation Hardness
Two samples for both temperatures from all pipes shall be taken. If any one of these samples
fails to satisfy the specified requirements, then the test shall be repeated on four more
samples. In this case, none of the samples shall fail.
d. Elongation at failure
Six samples each from three coated pipes i.e. 18 samples in all shall be tested and the test
shall comply the specified requirement. Only one sample per pipe may fail.
e. Cathodic Disbondment Test
Three CD tests shall be carried out for the total lot of test pipes having all three layers. One
test shall be carried out for 28 days, 23 °C, second test for 24 hours duration and third test for
80 °C, 28 days. The tests shall comply the specified requirement. Whenever Procedure
Qualification is necessitated for different pipe size with same coating material combination,
24 hours test only be conducted. 28 days CD test is not mandatory in this case.
f. Holiday Inspection
All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in
Para 10.4. (b).
g. Coating Thickness Measurement
All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be as
per Para 10.3.
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(A GAN of India undetumne) OF LINEPIPES Page 16 of 29
h. Air Entrapment
One sample each from pipe body and on weld (if applicable) shall be taken from all four
coated pipes and the specified requirements shall be complied with.
i. Degree of Cure
Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe
and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC)
procedure. Silicon coated sulphite paper shall be placed between the epoxy layer and
adhesive layer immediately after epoxy application, to ensure physical separation of epoxy &
adhesive as well as to prevent contamination of epoxy with adhesive layer, at a location from
where the epoxy samples are to be removed for the test. Care shall be taken to remove the
samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature
differential (ATg) and % cure (AH) shall comply with the specified requirements.
Hot Water Immersion
One test pipe shall be selected for hot water immersion test. The test method and acceptance
criteria shall be as per annexure M of ISO 21809 Part 1- Polyolefin Coatings.
k. Flexibility
One test pipe shall be selected for Flexibility test. The test method and acceptance criteria
shall be as per annexure I of ISO 21809 Part 1- Polyolefin Coatings.
7.5.3 Inspection of all test pipes
All pipes shall be subject to the following inspections:
a. Surface cleanliness, surface roughness measurements and dust control immediately after
second abrasive blast cleaning and salt test.
b. Visual inspection of finished coating, cut back dimension, internal/external cleanliness, end
sealing and bevel inspection.
Acceptance criteria for all inspection and testing shall be as specified in this specification.
7.6 After completion of the qualification tests and inspection as per para 7.4 and 7.5 above, the
Contractor shall prepare and issue to Company for approval a detailed report of the above tests and
inspection including test reports/certificates of all materials and coatings tested. Only upon written
approval from Company, Contractor shall commence production coating.
7.7 On successful completion of PQT, coating of all five (5) test pipes shall be removed and
completely recycled as per the approved coating procedure specification, at Contractor's expense.
Remaining pipes will be accepted by Company provided they meet the requirements of this
specification and need not be stripped and re-cycled.
7.8 The Contractor shall re-establish the requirements of qualification and in a manner as stated before
or to the extent considered necessary by Company, in the event of, but not limited to, the
following:
Every time there is a change in the previously qualified procedure.
Every time there is a change in the manufacturer and change in formulation of any of the raw
materials and change in location of raw material manufacture.
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151frad ENGNEE RS 3 LAYER POLYETHYLENE COATING
*1 -0 INDIA LIMITED 6-71-0041 Rev. 3
Sta °Meg) (A Geri of
India Undetaking) OF LINEPIPES Page 16 of 29
Every time the coating yard is shifted from one location to the other or every time the critical
coating equipments (induction heater, epoxy spray system, extruder, etc) are shifted.
Any change in line speed during coating application.
Any time when in Company's opinion the properties are deemed to be suspect during regular
production tests.
7.9 Company reserves the right to conduct any or all the test required for qualification through an
independent laboratory or agency at the cost of Contractor when in Company's opinion, the results
are deemed suspect. Company's decision shall be final.
8.0 PIPE SURFACE PREPARATION
8.1 Unless specified otherwise, the pipes shall be supplied free from mill applied oils but may be
subject to contamination occurring during transit.
8.2 Prior to cleaning operation, Contractor shall visually examine the pipes and shall ensure that all
defects, flats and other damages have been repaired or removed. The Contractor shall also remove
marking stickers, if any, present within the pipe. Record shall be kept of such marking on the
stickers to ensure traceability of pipe after coating.
8.3 Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond or
coating quality shall be removed prior to coating application. Contaminants may be removed by
the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil
and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in accordance with
SSPC-SPI. Steel surface shall be allowed to dry before abrasive cleaning.
8.4 All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasive blast cleaning. The
external surface of the pipe shall be cleaned using 2 no. dry abrasive blast cleaning units to achieve
the specified surface cleanliness and profile.
The abrasive blast cleaning units shall have an effective dust collection system to ensure total
removal of dust generated during blast cleaning from the pipe surface. During abrasive blast
cleaning, the metallic abrasive shall be continuously sieved to remove "fines" and "contaminants"
and the quality checked at every four hours. Abrasives used for blast cleaning shall comply ISO-
11124.
8.5 Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into the pipe
during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively
the Contractor may link the pipes suitably together to prevent the entry of any short/grit into the
pipe.
8.6 All pipes shall be tested for salt contamination after blast cleaning unit. One test shall be carried
out on each pipe. The acceptance criteria shall be 2ug/cm2. An approved salt meter (SCM 400 or
equivalent) shall be used to carry out salt tests and shall be calibrated in accordance with the
equipment manufacturer's recommendations. Any pipe having salt contamination exceeding
2p.g/cm2 shall be either reblasted or deionised water washed and then rechecked for salt
contamination. In case salt level less than 2 .tg/cm2 is consistently achieved, the frequency of salt
contamination testing may be relaxed to at least one pipe per hour at the sole discretion of the
8.7 Abrasive cleaning carried out shall be such that the resultant surface profile is not dished and
rounded when viewed with 30X magnification. The standard of finish for cleaned pipe shall
conform to near white metal finish to Sa 2 1/2 of ISO 8501-1. Surface of pipe after abrasive blast
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a 1/1GoN Mk& Undenalungi OF LINEPIPES Page 17 of 29
cleaning shall have an anchor pattern of 50 to 100 microns (Rz). This shall be measured for each
pipe by a suitable instrument such as surface profile depth gauge. In addition the pipe surface after
blast cleaning shall be checked for the degree of cleanliness (Sa 2%), degree of dust and shape of
profile. Degree of dust shall comply the requirements of ISO 8502 — 3. Acceptance limit shall be
either quality rating 2 or Class 2. Tape used for assessment of degree of dust shall comply IEC
454-2. Pressure shall be exerted on the applied tape using a 4 kg roller, prior to peeling-off to
assess the degree of dust.
8.8 All pipes shall be visually examined for presence of any shot/grit/loose material left inside the pipe
during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to remove the
same before the pipes are processed further. In addition, inside surface of the pipe shall also be
visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking
to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused
at the middle of the pipe at one end while inspection is carried out visually from other end. Any
foreign material or shots/grit present in the pipe shall be completely removed by mechanical brush,
high pressure air jets, by tilting of pipe, etc.
8.9 At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The
Contractor shall measure the ambient conditions at regular intervals during blast cleaning and
coating operations and keep records of prevailing temperature, humidity and dew point.
8.10 The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or
any other foreign material, nor shall the surface or its anchor pattern be scarred or burnished. All
blast cleaned pipe surface shall be kept in dust free enclosure prior to coating. After blast cleaning,
all surfaces shall be thoroughly inspected under adequate lighting to determine anchor pattern,
quality of blasting and identify any surface defects prior to coating application. All surface defects
such as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations, slugs or any
other defects considered injurious to the coating integrity made visible during blast cleaning shall
be reported to the Company Representative and on permission from Company Representative,
such defects shall be removed by filing or grinding. After any grinding or mechanical repairs, the
remaining wall thickness shall be checked and compared with specified thickness. Any pipes
having thickness less than 95% of specified thickness shall be kept aside and disposed off as per
the instructions of Company Representative. The method employed to remove surface defects
shall not burnish or destroy the anchor pattern or contaminate the surface. Pneumatic tools shall
not be used unless they are fitted with effective air/oil and water traps. Wherever burnishing
results in destruction of anchor pattern, the anchor pattern shall be restored by suitable means.
Pipes having damages repaired by grinding and ground areas more than 50mm in diameter shall be
re-blasted.
Any dust or loose residues that have been accumulated during blasting and/or during
filing/grinding operations shall be removed by vacuum cleaning.
If contamination of surface occurs, the quality of blast cleaning method and process shall be
examined. If the surface roughness is outside the specified limit, the blast cleaning material shall
be checked and replaced.
8.11 Upon Completion of the blasting operations, the quality control supervisor shall accept the pipe for
further processing or return for re-blasting after removal of defects/imperfections. In case
imperfections are considered detrimental to the coating quality, the same shall be reported to
Company's Representative for final decision on rejection or re-blasting/removal of defects. Re-
blasting/removal of defects or returning pipe to the yard shall be at the Contractor's cost.
Company's Representative, in additions, reserves the right to initiate any of the above actions
during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal
finish, etc.
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151Prire? ENGINEERS 3 LAYER POLYETHYLENE COATING
fetialeg) (A Gov't d India undensong) OF LINEPIPES Page 18 of 29
8.12 In order to ensure that pipe with defects are not processed further, provisions shall be available to
lift the pipes from inspection stand.
8.13 The total allowable elapsed time between completion of the blasting operations and
commencement of the pre-coating and heating operations shall be such that no detectable
oxidation of the surface occurs. Relative humidity readings shall be recorded every half an hour
during the blasting operations in the immediate vicinity of the operations. The maximum elapsed
time shall not exceed the duration given below:
Relative Humidity % Maximum elapsed time
> 80 2 hours
70 to 80 3 hours
< 70 4 hours
Any pipe not processed within the above time-humidity requirement shall be completely re-
blasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions have not
been exceeded.
8.14 Pipe handling between abrasive blasting and pipe coating shall not damage the surface profile
achieved during blasting. Any pipe affected by the damage to the surface exceeding 200mm2 in
area and/or having contamination of steel surface shall be rejected and sent for re-blasting.
9.0 COATING APPLICATION
The external surface of the cleaned pipe conforming to clause 8.0 of this specification shall be
immediately coated with 3-layer extruded polyethylene coating in accordance with the procedures
approved by Company, relevant standards and this specification. In general the procedure shall be
as follows:
9.1 Pipe Heating
9.1.1 Immediately prior to heating of pipe, all dust and grit shall be removed from inside of the pipe by a
combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be made to
protect the bevel ends from getting damaged during the coating operation.
9.1.2 Induction heater or gas fired heating shall be used for heating the pipe. The method shall be
capable of maintaining uniform temperature along the total length of the pipe, and shall be such
that it shall not contaminate the surface to be coated. In case of induction heating, appropriate
frequency shall be used to ensure 'deep heating' and intense skin heating is avoided. Gas fired
heating system shall be well adjusted so that no combustion products are deposited on the steel
surface. This shall be demonstrated on bare pipes prior to start of PQT. Oxidation of the cleaned
pipe surfaces prior to coating (in the form of blueing or other apparent oxide formation) is not
acceptable.
9.1.3 External surface of the pipe shall be heated to about 190 °C or within a temperature range (min. to
max.) as recommended by the powder manufacturer. Required pipe temperature shall be
maintained as it enters the coating chamber.
9.1.4 Temperature of the pipe surface shall be continuously monitored & recorded by using suitable
instruments such as infrared sensors, contact thermometers, thermocouples etc. The recording
method shall allow to correlate each linepipe. The monitoring instrument shall be able to raise an
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Sge fe5reg} INDIA LIMITED
GoN of India Undenafringi OF LINEPIPES Page 19 of 29
alarm/activate audio system (hooter) in the event of tripping of induction heater/gas fired heater or
in the event of pipe temperature being outside the range recommended by the manufacturer. Any
deviation from the application temperature range recommended by manufacturer shall be rectified.
If immediate rectification is not feasible, the production shall be stopped until cause of deviation
has been removed. Any pipe coated during the duration of temperature deviation shall be identified
by marking and rejected. Such rejected pipes shall be stripped, re-cleaned and recoated.
9.1.5 Temperature measuring & monitoring equipment shall be calibrated twice every shift and/or as per
Company Representative's instruction.
9.1.6 Contractor shall ensure that pipe surface emissivity variations are minimised during pipe heating.
To avoid significant variance, more than once blasted joints should be coated at the same time and
not mixed with joints blasted only once.
9.2 Pipe Coating
9.2.1 Subsequent to pipe heating, coating consisting of following layers shall be applied onto the pipe.
i. Electrostatic application of epoxy powder of minimum dry film thickness 0.200 mm, unless
otherwise specified. The maximum thickness shall not exceed the epoxy thickness specified
by epoxy powder manufacturer.
ii. Grafted co-polymer adhesive application by extrusion, minimum thickness 0.200 mm.
iii. Polyethylene application by extrusion.
The coated pipe shall be subsequently quenched and cooled in water for a period that shall
sufficiently lower the temperature of pipe coating to permit handling and inspection.
9.2.2 Minimum total thickness of finished coating shall be as under:
Pipe Size Minimum Coating Thickness

(Specified Outside Diameter) (mm)
Up to 10%" (273.1 mm) 2.1
From 12%" ( 323.9mm) to 18" (457mm) 2.5
From20" (508.0mm) to 30" (762) 2.8
32" and above 3.3
In case HDPE material is used as top coat, 10% reduction in minimum coating thickness is
permissible.
9.2.3 Coating materials shall be inspected in accordance with the manufacturer's recommendation prior
to coating application and it shall be ensured that the materials are moisture free. In case the
relative humidity exceeds 80%, the adhesive and polyethylene material shall be dried using hot dry
air as per the directions of Company Representative.
9.2.4 Prior to starting the application of fusion bonded epoxy powder, the recovery system shall be
thoroughly cleaned to remove any unused powder remaining from a previous line pipe coating
application. The use of recycled powder shall be permitted subject to:
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; 1WegW: INDIA LIMITED 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
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a) Satisfactory qualification of the reclaimed system during PQT stage.
b) The proportion of the reclaimed powder in the working mix does not exceed 20% at any
one time.
c) The quality of the recycled powder being routinely checked during production, at a
minimum frequency of once per shift and consistently meets the requirements stated at para
5.3.1.
9.2.5 Dry air, free of oil and moisture shall be used in the coating chamber and spraying system and
filters, dehumidifier/dryer as required along with control & monitoring system shall be provided
for this purpose. Dew point of air used to supply the fluidised bed, epoxy spray system and epoxy
recycling system shall be at least (—) 40°C and this shall be shall be monitored during the regular
production.
9.2.6 Air pressure in the epoxy spray guns shall be controlled, continuously monitored and recorded by
using suitable instruments. The air pressure shall be controlled within the limits established during
coating procedure qualification. The monitoring system shall be able capable of raising an alarm /
activate audio system (hooter) in the event of change in air pressure beyond the set limits. Any
deviation from the pre-set limits shall be rectified. If immediate rectification is not feasible, the
production shall be stopped until cause of deviation has been removed. Any pipe coated during the
duration of air pressure deviation shall be identified by suitable marking and rejected. Such
rejected pipes shall be stripped and recoated.
9.2.7 Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed and
within the window recommended by the manufacturer. The Contractor shall establish, to the
satisfaction of the Company Representative, that the adhesive is applied within the gel time
window of epoxy and at the temperature recommended by the adhesive manufacturer. The
Contractor shall state the minimum and maximum time interval between epoxy and adhesive
application at the proposed pre-heat temperature and line speed.
9.2.8 Extruded polyethylene layer shall be applied over the adhesive layer within the time limit
established during PQT stage and within the time/temperature range recommended by the
manufacturer. The extrusion temperatures of the adhesive and polyethylene shall be continuously
recorded. The monitoring instruments shall be independent of the temperature control equipment.
The instruments shall be calibrated prior to start of each shift.
9.2.9 Contractor shall ensure that there is no entrapment of air or void formation along the seam weld
(where applicable) during application of coating. Air entrapment below the coating and also along
the coating overlap shall be prevented by forcing the coating on to the pipe using high pressure
roller of suitable design during coating application. In case it is not adequately achieved,
Contractor shall supplement by other methods to avoid air entrapment. The methods used shall be
witnessed and approved by Company.
9.2.10 Resultant coating shall have a uniform gloss and appearance and shall be free from air bubbles,
wrinkles, holidays, irregularities, discontinuities, separation between layers of polyethylene &
adhesive, etc.
9.2.11 Coating and/or adhesive shall terminate 120mm (+) 20 / (-) 0 mm from pipe ends. The adhesive
shall seal the end of applied coating. Contractor shall adopt mechanical brushing for termination of
the coating at pipe ends. Edge of the coating shall be shaped to form a bevel angle of 30° to 45°.
Wherever specified the cut back shall be 150mm (+) 20 / (-) 0 to facilitate automatic welding.
9.2.12 Failure to comply with any of the above applicable requirement and of the approved procedure
shall be cause for the rejection of the coating and such coating shall be removed in a manner
approved by Company at Contractor's expense.
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/01 el ENGINEERS LAYER POLYETHYLENE COATING
INDIA LIMITED 3 6-71-0041 Rev. 3
51&17 OF LINEPIPES Page 21 of 29
10.1 General
The Contractor shall establish and maintain such quality assurance system as are necessary to
ensure that goods or services supplied comply in all respects with the requirements of this
specification. The minimum inspection and testing to be performed shall be as indicated
subsequently herein.
Immediately following the coating, each coated pipe shall be visually checked for imperfections
and irregularities of the coating. The coating shall be of natural colour and gloss, smooth and
uniform and shall be blemish free with no dust or other particulate inclusions. The coating shall
not show any defects such as blisters, pinholes, scratches, wrinkles, engravings, cuts, swellings,
disbonded zones, air inclusions, tears, voids or any other irregularities. Special attention shall be
paid to the areas adjacent to the longitudinal weld (if applicable), adjacent to the cut-back at each
end of pipe and within the body of the pipe.
In addition inside surface of the pipe shall also be visually inspected for presence of any foreign
material or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside
surface shall be examined using sharp floodlight focussed at the middle of the pipe at one end
while inspection is carried out visually from other end.
10.3 Coating Thickness
a. The coating thickness shall be determined by taking at least 10 measurements at locations

uniformly distributed over the length and periphery of each pipe. In case of welded pipes,
five of the above readings shall be made at the apex of the weld seam, uniformly distributed
over the length of the coated pipe. All readings must meet the minimum requirements.
However, localized coating thickness of less than the permissible minimum thickness can be
tolerated on the condition that it does not attain a total extent of more than 5 cm2 per meter
length of coated pipe, and the actual coating thickness does not drop more than 10% below
the permissible minimum coating thickness at these locations. The frequency of thickness
measurement as stated above shall be initially on every pipe, but may be reduced depending
upon consistency of results, at the sole discretion of Company Representative. Results of all
measurements shall be recorded.
b. Thickness of epoxy and adhesive shall be measured at the beginning of each shift and
whenever the plant re-starts after any stoppage for compliance. Coating of epoxy and
adhesive on portion of pipe required for this purpose, stripping and recoating of such partly
coated pipes shall be at Contractor's expense.
c. Coated pipes not meeting the above requirements shall be rejected. Rejected coated pipes
shall be stripped and re-coated in accordance with approved procedure, at Contractor's
expense.
10.4 Holiday Detection
a. Each coated pipe length shall be checked over 100% of coated surface by means of a
"holiday detector" of a type approved by Company for detecting holidays in the finished
coating.
b. The holiday detector shall be a low pulse D.C. full circle electronic detector with audible
alarm and precise voltage control complying with DIN VDE 0433 Part 2. The set voltage for
inspection shall be minimum 25 kV. Travel speed shall not exceed 300 mm/s.
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ENGINEERS 3 LAYER POLYETHYLENE COATING
Seig7185r
eg, IA Geri d India UM4vns.°) OF LINEPIPES Page 22 of 29
c. Contractor shall calibrate the holiday detector at least once every 4 hours of production.
Contractor shall have necessary instruments or devices for calibrating the holiday detector.
d. Any pipe coating shall be rejected if more than 1(one) holiday & area more than 100 cm 2 in
size are detected in its length attributable to coating process.
e. Holidays, which are lesser in size than those mentioned in (d) above, shall be repaired in
accordance with a approved procedure and shall be at Contractor's expense.
10.5 Bond Strength (Peel Test)
a. Contractor shall conduct bond strength test for composite coating as per Clause 5.3.3(a) of
this specification. A minimum of 65 mm length shall be peeled. First 20 mm and last 20 mm
shall not be counted for assessment of bond strength.
b. The frequency of test for cut back portions shall be every 2 hrs and for middle of pipe shall
be 4hrs. On each selected pipe, bond strength shall be performed for each specified
temperature. Test shall be performed at each cut back portion and one in the middle of pipe.
The system shall disbond/separate cohesively either in adhesive layer or in polyethylene
layer. Majority of the peeled off area on the pipe shall show presence of adhesive.
Disbondment/separation at epoxy to steel interface or epoxy / adhesive interface or adhesive
/ polyethylene interface shall not be permitted. The failure mode shall be recorded for each
test.
c. In case the test fails to comply the specified requirement, the Contractor shall test the
preceding and succeeding coated pipe. If both pipes pass the test, then the remainder of the
pipe joints in that shift shall be deemed satisfactory. If either pipe fails to meet the specified
requirements, all pipes coated during that shift shall be tested until the coating is proved
acceptable. Rejected coated pipes shall be stripped and re-coated in accordance with
approved procedure, at Contractor's expense.
10.6 Impact Strength
a. Impact strength test shall be conducted as per clause 5.3.3(6) of this specification. Initially
the frequency of test shall be two (2) coated pipes per shift that may be further reduced to
one coated pipe per 2 weeks depending upon consistently acceptable results at the sole
discretion of Company's Representative.
b. Minimum thirty (30) impacts located equidistant along the length of coated pipe shall be
performed.
c. Immediately after testing, the test area shall be subjected to holiday detection at the same
voltage as used prior to impact strength test. The pipe shall be rejected if any holiday is
noted in the test area.
d. Impact Strength Test shall be carried out at every change in batch of PE.
e. In case of test failure, retesting and disposal of coated pipe shall be as per Para 10.5 (c)
above.
10.7 Indentation Hardness
a. Indentation hardness test shall be as per clause 5.3.3(c) of this specification. The frequency
of test shall be initially 2 (two) coated pipes per shift, which shall be further reduced to one
test each on 2 coated pipes per week at random after 1 week of consistently acceptable
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ENGERS
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our g,INDIA LIMITED
3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
Gil M India um...mg) OF LINEPIPES Page 23 of 29
results. Two samples for each temperature shall be taken from the cut back portion of coated
pipe and one in the middle of the pipe for this test..
b. Indentation Hardness Test shall be carried out at every change in batch of PE.
c. In case of test failure, retesting and disposal of coated pipe shall be as per Para 10.5(c)
above.
10.8 Air Entrapment Test
a. Strips from bond strength tests (peel test) or coated pipe may be used to help determine the
porosity of the finished coating. Strip shall be also cut from longitudinal weld (if applicable)
at cut back portion and examined for the presence of voids.
b. Bond strength strip shall be viewed from the side and at the failure interface. At the pipe
bond strength test location, utility knife shall be used to cut the edge of the coating to a 45°
angle and view with a microscope. Similar examination shall be done in the coating cut back
area.
c. One sample each either on the bond strength strip or coated pipe and strip cut from the
longitudinal weld (if applicable) shall be examined for air entrapment per shift. Strips shall
be viewed from the side.
d. All examination shall done using a 30X magnification hand-held microscope. The
polyethylene and adhesive layers shall have no more than 10% of the observed area taken up
with air entrapment (porosity or bubbles). Air entrapment shall not occupy more than 10%
of the thickness in each case. Bubbles shall not link together to provide a moisture path to
the epoxy layer.
e. In case of test failure, retesting and disposal of coated pipe shall be as per Para 10.5 (c)
above.
10.9 Degree of Cure
a. Epoxy film samples shall be removed from cut back portion of the coated pipe using
hammer and cold chisel and the samples shall be taken for cure test using DSC procedure.
Silicon coated sulphite paper shall be placed between the epoxy layer and adhesive layer
immediately after epoxy application, to ensure physical separation of epoxy & adhesive as
well as to prevent contamination of epoxy with adhesive layer, at a location from where the
epoxy samples are to be removed for the test. Care shall be taken to remove the samples of
full film thickness avoiding inclusion of steel debris. Glass transition temperature
differential (ATg) and % cure (AH) shall comply the specified requirements.
b. 151 pipe shall be subjected to this test and thereafter frequency shall be once per shift. Pipe
shall be selected randomly by Company Representative during the middle of a shift. Suitable
provisions/arrangements as per the instructions of Company Representative shall be made
by the Contractor for this purpose
c. In case of test failure, production carried out during the entire shift shall be rejected, unless
the Contractor proposes a method to establish the compliance with the degree of cure
requirements of all pipes coated during that shift.
10.10 Epoxy Layer Adhesion Test
a. Adhesion of epoxy layer shall be determined at ambient temperature using method specified
in clause 7.5.1 (e)
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b. Frequency of this test shall be once per shift. The test shall be carried out at the cut back
portion on the pipe from which the Degree of Cure test has been carried out as per Para 10.9
above
c. In case of test failure, retesting and disposal of coated pipe shall be as per Para 10.9(c)
above.
10.11 Cathodic Disbondment Test
a. 24 hours CD test shall be conducted as per clause 5.3.3 (f) of this specification.
b. The frequency of this test shall be Onces per day.
c. In case the test fails to conform to the specified requirement, at the option of the Contractor,
all pipes coated after the previous acceptable test and prior to next acceptable test shall be
rejected or the test shall be repeated using two additional samples taken from the same end
of the affected pipe.
d. When both retests conform to the specified requirement, the lot of pipes shall be accepted.
When one or both the retests fail to conform to the specified requirement, all coated pipes
after previous acceptable test and prior to next acceptable shall be rejected. All rejected
pipes shall be stripped, re-cleaned and re-coated. Company may consider a further retest
program to determine whether any of the affected pipe meet the criteria for acceptance upon
written request by the Contractor.
10.12 Elongation at break
a. Elongation at break shall be carried out as per requirement of clause 5.3.3 (d)
b. The test frequency shall be once for each batch of PE.
c. In case the test fails to comply the specified requirement, the Contractor shall test the two
preceding and two succeeding coated pipe. If both pipes pass the test, then the remainder of
the pipe joints in that batch shall be deemed satisfactory. If either pipe fails to meet the
specified requirements, all pipes coated with that batch of PE shall be tested until the coating
is proved acceptable. Rejected coated pipes shall be stripped and re-coated in accordance
with approved procedure, at Contractor's expense.
10.13 Hot water immersion
a. Hot water immersion shall be carried out as per requirement of clause 5.3.3 (h)
b. The test frequency shall be once per day.
c. In case the test fails to comply the specified requirement, the Contractor shall test the two
preceding and two succeeding coated pipe. If both pipes pass the test, then the remainder of
the pipe joints in that day shall be deemed satisfactory. If either pipe fails to meet the
specified requirements, all pipes coated in that day shall be tested until the coating is proved
acceptable. Rejected coated pipes shall be stripped and re-coated in accordance with
approved procedure, at Contractor's expense.
10.14. Damages occurring to pipe coating during above tests shall be repaired in accordance with
approved coating repair procedure.
10.15 Repairs occurring on account of the production tests are however excluded from above mentioned
limitations at Para 10.4(d) above.
Page 330 of 1963

STANDARD SPECIFICATION No
OWE& *7a) ENGINEERS
lig-cattt5,1ft) INDIA LIMITED
IA Sort Incka Undertalorgl OF LINEPIPES
6-71-0041 Rev. 3
Page 25 of 29
10.16 Company reserves the right to perform inspection and witness tests on all activities concerning the
pipe coating operations starting from bare pipe to finished coated pipe ready for despatch and also
testing of raw materials. Contractor shall give reasonable notice of time and shall provide without
charge reasonable access and facilities required for inspection to the Company's representative.
Inspection and tests performed or witnessed by Company's representative shall in no way relieve
the contractor's obligation to perform the required inspection and tests.
10.17 In case rate of defective or rejected pipes and/or samples tests are 10% or more for a single shift
(typically 8 hours), Contractor shall be required to stop production and carry out a full and detailed
investigation and shall submit findings to Company for approval. Contractor shall recommence the
production only after getting the written permission from Company.
Under no circumstances any action or omission of the Company's Representative shall relieve the
Contractor of his responsibility for material and quality of coating produced. No pipes shall be
transported from the coating plant unless authorised by Company in writing.
11.0 HANDLING, TRANSPORTATION AND STORAGE
11.1 The Contractor shall be fully responsible for the pipe and for the pipe identification marking from
the time of "taking over" of bare pipe from Company until such time that the coated line pipes are
'handed over' and/or installed in the permanent installation as the case may be according to the
provisions of the CONTRACT.
At the time of "taking over" of bare pipes Contractor shall inspect and record all the relevant
details referred above including pipe defects in the presence of Company. All pipes shall be
checked for bevel damages, weld seam height, dents, gouges, corrosion and other damages.
Company Representative shall decide whether pipe defects / damages are suitable for repair.
Damage to the pipes that occur after the Contractor has taken delivery such as dents, flats, or
damage to the weld ends shall be cut off or removed and pipes rebevelled and repaired again as
necessary. The cost of this work, as well as that of the pipe lost in cutting and repair shall be to the
Contractor's account. All such works shall be carried out after written approval of the Company.
Any reduction in length shall be indicated in the Contractor's pipe tracking system.
11.2 The Contractor shall unload, load, stockpile and transport the bare pipes within the coating plant(s)
using suitable means and in a manner to avoid damage to pipes.
The Contractor shall stockpile the bare pipes at the storage area of the coating plant. The
Contractor shall prepare and furnish to Company a procedure/calculation generally in compliance
with API RP-5L1 for stacking of pipes of individual sizes, which shall be approved by Company
prior to commencement.
11.3 The Contractor shall load, unload, transport and stockpile the coated pipes within the coating plant
using approved suitable means and in a manner to avoid damage to the pipe and coating. The
Company shall approve such procedure prior to commencement of work.
11.4 Coated pipes may be handled by means of slings and belts of proper width (minimum 60 mm)
made of non- abrasive/non-metallic materials. In this case, pipes to be stacked shall be separated
row by row to avoid damages by rubbing the coated surface in the process of taking off the slings.
Use of round sectional slings is prohibited. Fork lifts may be used provided that the arms of the
forklift are covered with suitable pads, preferably rubber.
113 Bare/coated pipes at all times shall be stacked completely clear from the ground, at least 300 mm,
so that the bottom row of pipes remains free from any surface water. The pipes shall be stacked at
a slope so that driving rain does not collect inside the pipe. Bare/coated pipes may be stacked by
placing them on ridges of sand free from stones and covered with a plastic film or on wooden
Page 331 of 1963

STANDARD SPECIFICATION No
at z e ENGINEERS
INDIAinn.LIMITED
3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
If 16 1 , M Govt unaenam OF LINEPIPES Page 26 of 29
supports provided with suitable cover. This cover can be of dry, germ free straw covered with
plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as
to avoid permanent bending of the pipes.
Stacks shall consist of limited number of layers such that the pressure exercised by the pipes own
weight does not cause damages to the coating. Contractor shall submit calculations for Company
approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced
for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe
sections having the same diameter and wall thickness. The weld seam of pipes shall be positioned
always in a manner so as not to touch the adjacent pipes.
The ends of the pipes during handling and stacking shall always be protected with bevel
protectors.
11.6 The lorries used for transportation shall be equipped with adequate pipe supports having as many
round hollow beds as there are pipes to be placed on the bottom of the lorry bed. Total width of the
supports shall be at least 5% of the pipe length and min. 2 no. support shall be provided. These
supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal
load from the pipes. The rubber protection must be free from all nails and staples where pipes are
in contact. The second layer and all following layers shall be separated from the other with
adequate number of separating layers of protective material such as straw in plastic covers or
mineral wool strips or equivalent, to avoid direct touch between the coated pipes.
All stanchions of Lorries used for transportation shall be covered by non-abrasive material like
rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and
other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated
surface. Slings or non-metallic straps shall be used for securing loads during transportation. They
shall be suitably padded at the contact points with the pipe
11.7 Materials other than pipes and which are susceptible of deteriorating or suffering from damages
especially due to humidity, exposure to high thermal excursions or other adverse weather
conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and
shall be replaced at Contractor's expenses. These materials shall always be handled during loading,
unloading and storage in a manner so as to prevent any damage, alteration and dispersion. When
supplied in containers and envelopes, they shall not be dropped or thrown, or removed by means
of hooks, both during the handling operations till their complete use. During unloading, transport
and utilization, any contact with water, earth, crushed stone and any other foreign material shall be
carefully avoided.
Contractor shall strictly follow Manufacturer's instructions regarding storage temperature and
methods for volatile materials that are susceptible to change in properties and characteristics due to
unsuitable storage. If necessary the Contractor shall provide for a proper conditioning.
11.8 In case of any marine transportation of bare/coated line pipes involved, the same shall be carried
out in compliance with API RP 5LW. Contractor shall furnish all details pertaining to marine
transportation including drawings of cargo barges, storing/stacking, sea fastening of pipes on the
barges/marine vessels to the company for approval prior to undertaking such transportation works.
In addition contractor shall also carry out requisite analyses considering the proposed
transportation scheme and establish the same is safe and stable. On-deck overseas shipment shall
not be allowed.
12.0 REPAIR OF COATING
Contractor shall submit to Company, its methods and materials proposed to be used for executing
a coating repair and shall receive approval from Company prior to use. In open storage the repair
coating materials must be able to withstand a temperature of at least (+) 80°C without impairing its
Page 332 of 1963

larEa4.1-) ENONEERS
sigar fafAeg LIMITED
Gart of incla undertaltingi
OF LINEPIPES
6-71-0041 Rev. 3
Page 27 of 29
serviceability and properties. Contractor shall furnish manufacturer's test certificates for the repair
materials clearly establishing the compliance of the repair materials with the applicable coating
requirements indicated in this specification.
All pipes leaving coating plant shall have sound external coating with no holiday or porosity on
100% of the surface.
Defects, repairs and acceptability criteria shall be as follows:
Pipes showing porosities or very small damage not picked up during holiday test and having
a surface less than 0.5 cm2 or linear damage (cut) of less than 3 cm shall be repaired by stick
using material of same quality.
Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up
during holiday test, having a total reduced thickness on damaged portion not less than 2 mm
and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without
exposing to bare metal.
Defects of size exceeding above mentioned area or holidays of width less than 300 mm shall
be repaired with heat shrink repair patch by exposing the bare metal surface.
Defects exceeding the above and in number not exceeding 2 per pipe and linear length not
exceeding 500 mm shall be repaired using heat shrinkable sleeves of HTLP 80 or equivalent.
Pipes with bigger damage shall be stripped and recoated.
In case of coating defect close to coating cut back, Contractor shall remove the coating
throughout the entire circumference of the pipe down to the steel surface and increase the
coating cut back length. Now if the coating cut back exceeds 140 mm of linear length of
pipe then the coating shall be repaired by the use of heat shrink sleeves thereby making up
the coating cut back length of 120 mm.
Notwithstanding the above, if any defect exceeds 70 mm from the original coating cut back length,
the entire coating shall be removed and the pipe shall be recycled through the entire coating
procedure.
Irrespective of type of repair, the maximum numbers of repair of coating shall be as follows:
Holiday repair of size < 100 cm2 attributable to process of coating application shall be
maximum one number per pipe.
In addition to the above, defects to be repaired by heat shrink patch/sleeve shall be

maximum 2 (two) per pipe.
Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The
above is exclusive of the repairs warranted due to testing as per this specification.
All repairs carried out to coating for whatever reason shall be to the account of Contractor.
Cosmetic damages occurring in the polyethylene layer only need not be repaired by exposing up to
steel surface, as deemed fit by the Company Representative. In any case the Contractor shall
establish his material, methods and procedure of repair that result in an acceptable quality of
product by testing and shall receive approval from Company prior to use.
Page 333 of 1963


law ENGINEERS 3 LAYER POLYETHYLENE COATING 6-71-0041 Rev. 3
afaWreg, WA LIMITED
India uneerts.g1
(A GoN of OF LINEPIPES Page 28 of 29
Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coating
thickness no less than the parent coating thickness. Contractor shall test repairs to coating as and
when required by Company.
13.0 MARKING
Contractor shall place marking on the outside surface of the coating at one end of the coated pipe,
and marking shall indicate, but not limited to the following information:
a. Pipe number, Heat number

b. Diameter & Wall thickness
c. Coated pipe number
d. Colour band
e. Any other information considered relevant by Company.
f. Pipe Manufacturer Name
g. inspection Mark/Punch
Contractor shall obtain prior approval on marking procedure to be adopted from the Company.
14.0 QUALITY ASSURANCE
14.1 The Contractor shall have established within his organisation and, shall operate for the contract, a
documented Quality System that ensures that the requirements of this specification are met in all
aspects. The Quality System shall be based upon ISO 9001/2 or equivalent.
14.2 The Contractor shall have established a Quality Assurance Group within its organisation that shall
be responsible for reviewing the Quality System and ensuring that it is implemented.
14.3 The Contractor shall submit the procedures that comprise the Quality System to the Company for
agreement.
14.4 The Contractor's Quality System shall pay particular attention to the control of Suppliers and Sub-
contractors and shall ensure that the requirements of this specification are satisfied by the
Suppliers and Sub-contractors operating Quality system in their organisation.
14.5 The Contractor shall, prior to the commencement of work, prepare and issue a Quality Plan for all
of the activities required satisfying the requirements of this specification. The plan shall include
any sub-contracted work, for which the sub-contractors Quality Plans shall be submitted. The plan
shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality
control, inspection, testing and certification activities with reference to the relevant procedures and
the acceptance standards.
14.6 The Contractor's Quality system and associated procedures may, with due notice, be subject to
formal audits. The application of quality control by the Contractor will be monitored by the
Company Representatives who will witness and accept the inspection, testing and associated work
required by this specification.
Page 334 of 1963

1580laeiENGINEERS 3 LAYER POLYETHYLENE COATING
felRr
a g i INDIA LIMITED 6-71-0041 Rev. 3
(A GoN n11MU Undenakingi OF LINEPIPES Page 29 of 29
ANNEXURE-I
LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS
The following combinations of coating materials are considered acceptable. In case any of the
combinations listed below are offered, details regarding properties of the offered materials need
not be furnished with bid. However, In the event of award of contract, Contractor shall furnish the
combination(s) proposed and re-confirmation of compatibility of the proposed combination (s)
from the raw materials Manufacturers.
Epoxy Powder Adhesive PE Compound

(Manufacturer) (Manufacturer) (Manufacturer)
CORRO-COAT EP-F 2001 FUSABOND 158D SCLAIR 35 BP HDPE

(JOTUN) (DUPONT) (NOVACOR)
CORRO-COAT EP-F
2002HW
LUPOLEN 4552 D SW
(JOTUN) LUCALEN G3710E
00413
(LYONDELLBASELL)
or (LYONDELLBASELL)
SCOTCHKOTE 226N
(3M)
PE 50-6109
(BASF)
or
CORRO-COAT EP-F 2001/ ME 0420 HE 3450
2002HW/1003HW (BOREALIS) (BOREALIS / BOROUGE)
(JOTUN)
or
SCOTCHKOTE 226N
(3M)
CORRO-COAT EP-F 2001 LE - 149 V ET 509 B

(JOTUN) (HYUNDAI ENGINEERING (HYUNDAI
PLASTICS) ENGINEERING
PLASTICS)
Although the above combinations would be acceptable to Company, the responsibility of

suitability for application, performance and compliance to the coating system requirements shall
unconditionally lie with the Contractor.

Page 335 of 1963

Vi12-ada ENGINEERS FOR FIELD JOINT COATING
5g-ar 0151eg's INDIA LIMITED 6-71-0044 Rev. 3
(A Geri nos undenakmg) (ONSHORE PIPELINE) Page 1 of 12
Ow Alg. Atrff
*- fug -m-4-w 1-4-4RT
miimoivo
FOR
FIELD JOINT COATING
(ONSHORE PIPELINES)
govv,-"4
3 18.05.12 REVISED & REISSUED AS STANDARD RK SKJ VM DM
SPECIFICATION
2 06.11.06 REVISED & REISSUED AS STANDARD MKM VM AS VC
SPECIFICATION
1 12.10.98 REVISED & REISSUED AS STANDARD SM TBG VC AS
SPECIFICATION
0 01.08.89 ISSUED AS STANDARD SPECIFICATION MK GD RKD SA
Standards Standards
No Date Purpose by by Convenor Chairman
Approved by
Page 336 of 1963

FOR FIELD JOINT COATING 6-71-0044 Rev. 3
(ONSHORE PIPELINE) Page 2 of 12
Abbreviations:

DIN Deutsches Institut ftir Normung
Members : Mr. S. K. Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Mr. A.K. Chaudhary (PDD)
Mr. G.K. Iyer (HO Construction)
Mr. M.P. Jain (Projects)
Page 337 of 1963

Oliatieta ENGINEERS
Stg-ar Eti teg w
NDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
,A Gov' of Ma UntleflaMing) (ONSHORE PIPELINE) Page 3 of 12
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS AND EQUIPMENT 5
4.0 APPLICATION PROCEDURE 7
6.0 REPAIRS 11
Page 338 of 1963

Atoovo tolalvA) IA Gat of GU undettatoo9) (ONSHORE PIPELINE) Page 4 of 12
1.0 SCOPE
1.1 This specification establishes the minimum requirements of materials, equipment and
installation of field joint anti-corrosion coating of buried onshore pipelines (for design
temperature upto 65°C) factory coated with either three layer polyethylene or fusion bonded
epoxy coating, by heat shrink wraparound sleeves or by cold applied tapes conforming to DIN
EN 12068 — "Cathodic Protection — External Organic Coatings for the Corrosion Protection of
Buried or Immersed Steel Pipelines used in Conjunction with Cathodic Protection — Tapes and
Shrinkable Materials" and the requirements of this specification. Unless modified/replaced by
this specification, all requirements of DIN EN 12068 shall remain fully applicable and
complied with.
This specification shall be read in conjunction with the conditions of all specifications and
documents included in the Contract between Company and Contractor. Unless specified
otherwise, all sections of this specification shall apply to all specifications referred in this
specification.
Reference has also been made to the latest edition (edition enforce at the time of issue of
enquiry) of the following standards, codes and specifications:
ASTM D-149 : Standard Test Methods of Dielectric Breakdown voltage and

Dielectric strength of solid electrical insulating materials at
commercial frequencies.
ASTM D-257 : Standard Test Methods for D-C Resistance or conductance of

insulating materials
ASTM D-570 : Standard Method of Test for Water Absorption of Plastics.
ISO 8502 — 3 Preparation of Steel Substrates before Application of Paints and

Related Products —Part 3 - Assessment of Dust on Steel
Surfaces Prepared for Painting (Pressure Sensitive Tape
Method).
e) ISO 8503 — 1 Part 1: Specification and definitions for ISO surface profile
comparator for the assessment of abrasive blast cleaned
surfaces.
0 ISO 8503 — 4 Part 4: Methods for calibration of ISO surface profile

comparator and for the determination of surface profile — Stylus
instrument procedure.
SIS-055900 Pictorial Surface Preparation Standard for Painting Steel

Surfaces.
SSPC-SP I Steel Structure Painting Council.
i) DIN EN 12068 : Cathodic Protection — External Organic Coatings for the

Corrosion Protection of Buried or Immersed Steel Pipelines
used in Conjunction with Cathodic Protection — Tapes and
Shrinkable Materials.
In case of conflict between the requirements of this specification and that of above referred
documents, the requirements of this specification shall govern.
Page 339 of 1963

The CONTRACTOR shall be familiar with the requirements of these documents and shall
make them readily available at the site to all personnel concerned with carrying out the works
specified in this specification.
3.0 MATERIALS AND EQUIPMENT
3.1 Field joint anti-corrosion coating material shall be either heat shrinkable wraparound sleeve or
cold applied tape suitable for a maximum operating temperature of (+) 60°C (T ma,c) and shall
conform to designation EN 12068 - C HT 60 UV. In addition, the field joint anti-corrosion
coating shall comply the requirements specified in para 3.2 of this specification.
3.1.1 Heat shrinkable wraparound sleeves:
Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized,
ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear
strength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of
a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing
shall be provided with suitable means (thereto-chrome paint, dimple, or other means) to
indicate the desired heat during shrinking in field is attained. The sleeve shall be supplied in
pre-cut sizes to suit the pipe diameter and the requirements of overlap.
The total thickness of heat shrinkable wraparound sleeve in the as applied condition shall be as
follows:
Thickness (mm)
Pipe Size On Pipe body On Weld Bead
(Specified Outside Diameter) (Min.) (Min.)
Up to 18" (457 mm) 2.2 1.8
20"( 508 mm) to 30" (762 mm) 2.5 2.0
32"(813 mm) & above 3.0 2.5
The heat shrink wraparound sleeve shall have the required adhesive properties when applied on
various commercial pipe-coating materials. The pre-heat and application temperatures required
for the application of the shrink sleeve shall not cause loss of functional properties of the pipe
coating.
The Contractor shall propose the manufacturer's details, heat shrinkable sleeve details/
properties and the specific grade of field joint coating system meeting the requirements of this
specification. Contractor shall propose only those coating systems that have been previously
used for pipelines of same or higher size than the size indicated in tender, for a length of 50 km
and above in a single project for similar operating conditions.
3.1.2 Cold Applied Tapes:
Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap. The inner
and outer wraps shall be asymmetric 3-ply tape with co-extruded polyethylene carrier film and
butyl rubber adhesive layers on both sides. The inner layer of butyl rubber adhesive of inner
wrap shall have a thickness of min. 1.0 mm. The inner and outer wraps are to be spirally
wrapped with 55% overlap, equivalent to two layers each providing a total minimum thickness
of 3.0 mm on the pipe body and 2.5 mm on the weld.
Page 340 of 1963

satirada ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
gga emeg Imy INDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
(-I AMR anam, (A GM al India Linden:Sinai (ONSHORE PIPELINE) Page 6 of 12
The Contractor shall propose only those cold applied tape coating systems that have been
previously used in pipelines of size 16" and above and a length of 50 km and above in a single
project for similar operating conditions.
3.2 Functionl Requirements of Field Joint Coating
3.2.1 Properties of the PE backing shall be as follows:

Tensile Strength
N/mm2 ^ 12 DIN EN 12068
@ + 25°C
Ultimate Elongation @ +25°C. % ^ 250 DIN EN 12068
Dielectric withstand with 1000 KV ^ 30 ASTM D 149
Volts/sec
Water absorption, ASTM D 570
% ^. 0.05
@ + 25°C for 24 hours
Volume Resistivity
e. Ohm-cm .^, 10 15 ASTM D 257
@ + 25°C
3.2.2 Functional Properties of Joint Coating System (As applied)
As applied field joint coating system shall comply the requirements of DIN EN 12068, Table 1
and 2 corresponding to designation DIN EN 12068 - C HT 60 UV, except as modified below:
Cathodic Disbondment Resistance at T. i.e 60°C shall be 20 mm when tested as per

Annexure K of DIN EN 12068. Test shall be carried out at (+) 60°C.
Peel Strength shall be as follows:
Requirement for Test Method

Peel Strength Unit Mech. Resistance as per
Class C (minimum) DIN EN 12068
Inner to Inner (+) @ 23°C N/mm 1.5

Outer to Inner @T„,„,,, N/mm 0.3
Annexure B
@ 23°C N/mm 1.5
Outer to Outer
@T.„ N/mm 0.3
@ 23°C N/mm 3.5
To Pipe Surface
@Tmax N/mm 1.0
Annexure C
@ 23°C N/mm 3.5
To Factory Coating
@Tn,„„ N/mm 1.0
Notes
T max shall be (+) 60 °C.
Contractor shall obtain prior approval from Company regarding the Manufacturer of the joint
coating material and the specific grade of the joint coating system. Complete technical details
along with test certificates complying with the requirements of clause 3.2.1 and 3 2 2 shall be
submitted to Company for this purpose. The Contractor shall furnish test certificates from an
Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0
Page 341 of 1963

ajtattflai ENGINEERS
/gar tagtewer WA LIMITED (A Sort al India unciettiong)
FOR FIELD JOINT COATING
(ONSHORE PIPELINE)
6-71-0044 Rev. 3
imit71eleaw7 minim)
Page 7 of 12
independent DIN recognized/approved laboratory for all the properties required for the
specified EN designation of field joint coating and the requirements of this specification.
3.3 The materials shall not be older than their period of validity at the time of application by
Contractor. Deteriorated/decomposed material shall be disposed off and replaced by Contractor
at his own expense.
Contractor shall ensure that the coating materials supplied by him are properly packed and
clearly marked with the following:
Manufacturer's name
Material qualification
Batch number
Date of manufacturing and date of expiry
3.4 Contractor shall ensure that the Manufacturer has carried out all quality control tests on each
batch and manufacturer shall provide test certificates to certify that the supplied materials meet
the manufacturer's specifications as indicated in the purchase order and as approved by
COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall
be submitted by Contractor to Company prior to application. Company reserves the right to
have the materials tested by an independent laboratory.
3.5 Materials shall be stored in sheltered storage in the manufacturer's original packing and away
from direct sunlight and in accordance with manufacturer's instructions.
3.6 Contractor shall provide and maintain mobile facilities which contain all necessary equipment
and its spares for cleaning, coating, repairs, inspection and tests.
3.7 Contractor shall furnish sufficient number of the following equipment and the required spares
as a minimum for inspection and test purposes for each crew:
Fully automatic full circle adjustable holiday detector with a visible and audible signal
system for inspection of coatings.
Thickness gauge for measuring thickness.
Contact type temperature recording thermometer (Digital Pyrometer with flat probe
type contact).
Roughness profile measuring (Stylus) instrument
4.0 APPLICATION PROCEDURE
4.1 General
4.1.1 The application procedure shall be in accordance with manufacturer's instructions and the
minimum requirements specified below whichever are the most stringent and shall be
demonstrated to and approved by the Company. Manufacturer's expert shall supervise the
application and shall be available at site upon request during qualification of application
procedure and during construction at Contractor's cost.
4.1.2 Operators for coating application shall be given necessary instructions and training before start
of work, by the Contractor. To verify and qualify the application procedures, all coating applied
during the qualification test, shall be removed for destructive testing as detailed subsequently in
this specification. Contractor shall only utilize those operators who have been approved/pre-
qualified by the field joint coating manufacturer.
Page 342 of 1963

Itiakteela ENGINEERS
IlgtEllWrg,
a W- ' INDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
IA Gout of India Undertaking) (ONSHORE PIPELINE) Page 8 of 12
4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with
suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose.
Solvent cleaning procedure according to SSPC-SP1 shall be followed.
4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandable
blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be
used and Garnet material with the second one (in case the authority having jurisdiction have no
objection, the contractor may adopt sand blasting instead of garnet material). During blast
cleaning the pipe surface temperature shall be simultaneously more than 5 °C and more than
3°C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than
85 %. Prior to surface cleaning the surfaces shall be completely dry. The surface shall be
cleaned to a grade Sa 21/2 in accordance with Swedish Standard SIS-055900 with a roughness
profile of 50 — 70 microns. Surface roughness profile shall be measured using an approved
profile comparator in accordance with ISO 8503-1 and shall be calibrated prior to the start of
the work in accordance with ISO 8503-3 or ISO 8503-4. The blast cleanliness shall be checked
on every joint and the roughness profile shall be checked 1 every 10 joints.
Dust, girt or foreign matter shall be removed from the cleaned surface by an industrial vacuum
cleaner. The dust contamination allowed shall be of a rating max 2 as per ISO 8502 -3. The
frequency of checking for dust contamination shall be 1 every 10 joints.
Blast cleaned field joint shall be coated within 2 — 4 hours according to the conditions below:
• Relative Humidity (RH) > 80 % 2 hours

• Relative Humidity (RH) 70 - 80 % 3 hours
• Relative Humidity (RH) < 70 % 4 hours
Pipes delayed beyond this point or pipes showing any visible rust stain, shall be blast cleaned
again.
4.1.5 The field joint surface shall be inspected immediately after blast cleaning and any feature of the
steel surface such as weld spatter, scabs, laminations or other imperfections considered
injurious to the coating integrity, made visible during blast cleaning, shall be reported to the
Company Representative and on permission from Company Representative, such defects shall
be removed by filing or grinding. Pipes affected in this manner shall be then re-blasted cleaned
if the defective area is larger than 50 mm in diameter.
4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded
portions of the coating shall be removed and then suitably trimmed. Portions where parent
coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of
the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface of
uncontaminated factory applied coating.
4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the coating in
order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter.
All these substances shall be removed before coating, to the procedures herein described.
4.1.8 Protection coating shall be applied on the joints immediately after the completion of cleaning
operation.
4.2 Application Procedure for Heat Shrink Wraparound/Sleeves
In addition to the requirements stated above, following shall be complied with:
4.2.1 The wrap around sleeve shall be of a size such that a minimum overlap of 50 mm is ensured
(after shrinking) on both sides of the yard applied corrosion coating of pipes.
Page 343 of 1963

IsarazietftENGINEERs FOR FIELD JOINT COATING
sg-ar opiegve INDIAUMITIED 6-71-0044 Rev. 3
imien eremeanaaa.o IA pan of India Undeltakingl (ONSHORE PIPELINE) Page 9 of 12
In the cases where carrier pipe is installed by direct boring/jacking, the overlap on the mill
coating for the leading edges of the joints shall be minimum 200 mm. When this extra overlap
is achieved by providing an additional patch of heat shrink tape/wraparound, it shall be applied
in such a manner that the square edge of the patch on the joint coating is in the direction
opposite to the direction of boring / jacking.
4 2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated either with a
torch moved back and forth over the surface or by induction heating. The minimum pre-heat
temperature shall be as recommended by manufacturer and shall be checked by means of
contact type temperature-recording thermometer (Digital Pyrometer with flat probe type
contact). Temperature indicating crayons shall not be used. Pre-heat temperature shall be
checked on every joint. Care shall be taken to ensure that the entire circumference of the pipe is
heated evenly. Temperature measuring instruments shall be calibrated immediately before the
start of the works and thereafter at intervals recommended by the manufacturer of the
instrument.
4.2.3 Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet film
thickness 200 microns or as per manufacturer's recommendation whichever is higher, to cover
the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating
if recommended by the manufacturer. The wet film thickness of the primer shall be checked on
every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall
be calibrated once per shift.
4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be entirely wrapped
around the pipe within the stipulated time recommended by the manufacturer. Sleeve shall be
positioned such that the closure patch is located to one side of the pipe in 10 or 2 O'clock
position, with the edge of the undergoing layer facing upward and an overlap of min. 50 mm.
Gently heat by appropriate torch the backing and the adhesive of the closure and press it firmly
into place.
4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start
shrinkage of the sleeve beginning from the center of the sleeve and heat circumferentially
around the pipe. Continue heating from the center towards one end of the sleeve until recovery
is completed. In a similar manner, heat and shrink the remaining side. Shrinking has been
completed when the adhesive begins to ooze at the sleeve edges all around the circumference.
The complete shrinking of the entire sleeves shall be obtained without undue heating of
existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The
installed sleeve shall not be disturbed until the adhesive has solidified.
4.3 Application Procedure for Cold Applied Tapes
4.3.1 Cold applied joint protection tape shall be of the type, which can be applied by spiral wrapping
on the pipe.
4.3.2 Immediately after the completion of surface preparation, the approved primer of wet film
thickness 150 microns or as per manufacturer's recommendation whichever is higher, to cover
the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating
if recommended by the manufacturer. Any dirt on the primed surface shall be removed. If the
primer is damaged, the damaged area shall be cleaned and re-primed.
4.3.3 Approximately 100 mm of inner wrap interleaving paper shall be peeled back and inner wrap
shall be applied with the thicker adhesive side to the pipe. Whilst continuously removing the
interleaving paper, the tape shall be spirally applied through a machine to provide a minimum
of 55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air
pockets and also continuously smooth out as the wrapping proceeds. The wrapping shall start
Page 344 of 1963

0511fazre7ah ENONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA LIMITED
Igar fafieg115 FOR FIELD JOINT COATING 6-71-0044 Rev. 3
'"""
IA God of WM Unciertanng) (ONSHORE PIPELINE) Page 10 of 12
and finish to give a minimum 50 mm overlap on to the adjoining yard applied coating. Outer
wrap shall also be applied in similar method.
4.4 Pre-Qualification of Field Joint Coating System
The field joint coating system materials and the procedures proposed by the Contractor shall be
pre-qualified during the sleeve installation start-up phase. Five joints (5) shall be coated with
the requirements of this specification and then inspected and tested in accordance with the
requirements of this specification with respect to the following:
Surface preparation, cleanliness, roughness profile and dust contamination

Pre-heat temperature (as applicable)
Primer thickness
As applied coating thickness
Holiday detection
Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and at over
laps (as applicable). If required to achieve the temperature of (+) 60°C, suitable thermal
blanket may be used.
(vii) Visual appearance and void after installation on the body, area adjoining the weld and
area adjoining the factory applied coating. (To establish voids adjoining the weld and
factory coating, a strip of 50 mm wide and 200 mm long shall be stripped and
examined.)
Company Representative shall witness the tests and inspection. Regular application of field
joint coating shall commence only upon successful completion of the pre-qualification testing.
After successful completion of the pre-qualification testing as above, the entire field joint
coating shall be removed, the pipe surface re-blasted and field joint coating re-applied as per
the requirements of this specification.
Visual inspection of the as applied coating shall be carried out on every joint, for the following:
Mastic extrusion on either ends of the sleeve shall be examined

There shall be no sign of punctures or pinholes or bend failure. The external
appearance of the sleeve shall be smooth, free of dimples, air entrapment or void
formation. All sleeves shall be tested for the presence of voids by knocking on the
sleeves. A hollow sound compared to the remainder of the sleeve may indicate the
presence of voids under the sleeve. Such sleeve shall be tested for adhesion at the
discretion of the Company Representative.
Weld bead profile shall be visible through the sleeve
Visual indicator provided on the backing and the closure patch showing desired heat is
achieved.
5.2 Holiday Inspection
The entire surface of each joint shall be inspected by means of a full circle holiday detector
approved by Company, set to a DC voltage applicable as per the requirements of factory
applied mainline coating specification of Company. Inspection of the sleeves shall be
conducted only after the joint has cooled below 50°C. The holiday detector used shall be
checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in
direct contact with the surface of coating to be inspected.
Page 345 of 1963

ENGINEER.S
lag elaruief UMITED

Govl of India underlaying)
FOR FIELD JOINT COATING
(ONSHORE PIPELINE)
6-71-0044 Rev. 3
Page 11 of 12
No field joint shall be covered or lowered in the trench until it has been approved by the
Company.
5.3 As-applied Coating Thickness
Coating thickness shall be checked by non-destructive methods for each field joint. Average
thickness of the as-applied coating on pipe body shall be established based on measurements at
min. eight locations i.e four measurements on either side of the girth weld at 3, 6, 9 & 12
O'clock positions. To establish the minimum thickness on the girth weld, four measurements
shall be taken on apex on the weld at 3, 6, 9 & 12 O'clock positions. All such measurements
shall be recorded. Company Representative reserves the right to ask for additional
measurements at any location on the field joint coating, whenever doubt arises.
5.4 Peel Strength Testing
5.4.1 One out of every 50 joint coatings or one joint coating out of every day's production, whichever
is stringent, shall be tested to establish the peel strength on steel and factory applied coating.
Contractor shall carry out such testing in the presence of Company Representative.
5.4.2 From each test sleeve selected as above, one or more strips of size 25mm x 200 mm shall be cut
perpendicular to the pipe axis and slowly peeled off.
The required peel strength shall meet the requirements of this specification as applicable for (+)
23 °C or (+) 60 °C whichever is feasible. This test shall be conducted between wrapping &
metal and mill coating & between layers at overlap with joint coating (wherever applicable).
After removal of strip, the bulk of adhesive shall remain adhered to the pipe showing no bare
metal, otherwise, test shall be considered failed. The adhesive layer that remains on the pipe
surface shall generally be free of voids resulting from air or gas inclusion. In case the peel
strength test at a different temperature than that specified is warranted due to the ambient site
conditions, then the peel strength shall comply the recommendation of the manufacturer.
Manufacturer shall be asked to furnish peel strength values corresponding to various expected
temperatures, prior to start of the works.
5.4.3 If the sleeve does not meet the requirements of clause 5.4.2, the adjacent two sleeves shall also
be tested. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve
every twenty five until Company's Representative is satisfied. The test rate can then be reduced
as per clause 5.4.1 at discretion of Company's Representative. If either or both of the adjacent
two sleeves do not meet the requirements of clause 5.4.2, the field coating shall be stopped.
5.4.4 Company Representative reserve the right of 100% removal of sleeves if he is not convinced
that the requirements of clause 5.4.2 are achieved.
6.0 REPAIRS
6.1 If a field joint is detected to be unacceptable after testing as per section 5.0 of this specification
the Contractor shall, at his own cost:
Determine the cause of the faulty results of the field coating.

Mobilise the expert of manufacturer, if required.
Test to the complete satisfaction of Company, already completed field coatings.
(iv) Stop the field coating works until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the Company.
6.2 Contractor shall replace all joint coating found or expected to be unacceptable as per section
Page 346 of 1963

lalfte?fila ENGINEERS
Ita 1d15Ieg WIle INDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
6.3 Contractor shall, at his own cost repair all areas where the coating has been removed for testing
by the Company.
6.4 After the coating work on welded joints and repairs to the coating have been completed the
coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline.
6.5 Company shall be entitled to check the coating on buried pipelines or parts of pipelines with
equipment such as the "Pearson Meter" and the resistance meter. If coating defects are
established, the Contractor shall be responsible for excavation at such points, repairing the
coating, spark testing and backfilling the excavations without extra charge.
7.0 DOCUMENTATION
7.1 Prior to procurement of coating materials, Contractor shall furnish the following information
for qualification of the Manufacturer and material:
Complete information as per clause 3.2 and DIN EN 12068 alongwith descriptive
technical catalogues.
Test certificates and results of previously conducted tests, for all properties listed in
clause 3.2 of this specification.
c. Reference list of previous supplies, in last 5 years, of the similar material indicating the
project details such as diameter, quantity, operating temperature, year of supply,
project name, contact person and feed back on performance.
Once the Company's approval has been given, any change in material or Manufacturer shall be
notified to Company, whose approval in writing of all changes shall be obtained before the
materials are manufactured.
7.2 Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish the
following documents:
Test certificates/results as per Manufacturer's Quality Control Procedure for each batch
of materials.
Specific application instructions with pictorial illustrations.
c. Specific storage and handling instructions.
7.3 All documents shall be in English language only.
Page 347 of 1963

an t
pkgs,,, s ENGINEER s STANDARD SPECIFICATION FOR
iNDIA umfrED CONCRETE WEIGHT COATING OF
eIMPWFOM) .Go, ot India Undeaalungl ONSHORE PIPELINES
6-71-0046 Rev. 4
Page 1 of 12
as. • n
Clal ch5hle Aliff
# Trriw feer
FOR
CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
4 23-04-12 REVISED & REISSUED AS STANDARD

SPECIFICATION NR SKJ VM DM
SPECIFICATION MKM VM AS VC
SPECIFICATION MKM KKS SJ GRR
SPECIFICATION PKG TBG VC AS
0 09-06-89 ISSUED AS STANDARD SPECIFICATION MK GD/RKD SA RCPC
Standards Standard
Rev. Prepared Checked Committee s Bureau
No by by
Approved by
Page 348 of 1963

amadak ENGINEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
51g-ar INDIA UMITED CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
6-71-0046 Rev. 4
IA GoN at Vida Undenakong)
Page 2 of 12
Abbreviations:

IS Indian Standard
Members : Mr. S. K. Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Mr. R. Chaudhary (SMMS)
Page 349 of 1963

laid ENGINEERS CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
IgLIT ,
09eg INDIA LIMITED
IA Gon ONSHORE PIPELINES
ot india underusim Page 3 of 12
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS 5
4.0 COATING REQUIREMENTS 6
5.0 APPLICATION METHOD 6
6.0 EQUIPMENT 6
7.0 MEASUREMENTS AND LOGGING 7
8.0 PROCEDURE QUALIFICATION 7
9.0 APPLICATION OF REINFORCEMENT AND CONCRETE COATING 8
10.0 TOLERANCES 10
11.0 WEIGHING 10
13.0 REPAIRS 11
14.0 MARKING 11
15.0 HANDLING, UNLOADING, STORING AND TRANSPORTATION 12
Page 350 of 1963

afazre? ENGINEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
a-ell iaglegW INDIA LIMITED ONSHORE PIPELINES
IA Got/ of Mao Undertaking) Page 4 of 12
1.0 SCOPE
1.1 This specification covers the minimum requirements for the materials, application, inspection,
handling and other activities for external concrete weight coating of pipelines.
1.2 This specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between Company and Contractor.
1.3 Contractor shall, with care and diligency, execute the work in compliance with all laws, by-
laws, ordinances, regulation, etc. and provide all services and labour, inclusive of supervision
thereof, all materials, excluding the materials indicated as Company supplied materials in the
CONTRACT, equipment, appliances or other things of whatsoever nature required in or about
the execution of the work, whether of temporary or permanent nature.
1.4 Unless otherwise specified, all sections of this specification shall apply to all the specification
referred in this specification.

2.1 Reference has been made in this specification to the latest edition (edition enforce at the time
of issue of enquiry) of the following codes and specifications:
ASTM A-82 Specification for Steel Wire, Plain, for concrete

Reinforcement.
ASTM A-185 Specification for Steel Welded Wire Fabric, Plain, for
Concrete Reinforcement
ASTM A-641 Specification for Zinc Coated (Galvanized) Carbon Steel
Wire.
ASTM C-39 Test Method for Compressive strength of cylindrical
concrete specimens.
ASTM C-138 Test Method for Unit weight, Yield and Air Content of
Concrete.
ASTM C-309 Specification for Liquid Membrane Forming Compounds
for Curing Concrete.
ASTM C-642 Test Method for Specific Gravity, Absorption and Voids
in Hardened Concrete.
IS-383 Indian Standard Specification for Coarse and Fine
Aggregates from Natural Sources for Concrete.
IS-516 Method of Test for Strength of concrete.
IS-1199 Method of Sampling and Analysis of Concrete.
k) IS-8041 Indian Standard Specification for Rapid Hardening
Ordinary Portland Cement.
I) IS-8112 Indian Standard Specification for 43 Grade Ordinary
Portland Cement.
IS-2386 (Parts-I : Indian Standard Methods of Test for Aggregates for
thru' VIII) Concrete.
IS-12269 Indian Standard Specification for 53 Grade Ordinary
Portland Cement.
Page 351 of 1963

SafaeleTe ENGINEERS CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
Sig-a laiReg INDIA LIMITED ONSHORE PIPELINES
imenew.w=ano ,,Geri of Meta linden...91 Page 5 of 12
In case of conflict between the requirements of this specification and that of the above referred
codes and standards, the requirements of this specification shall govern. The Contractor shall
be familiar with the requirements of these documents and shall make them readily available at
the coating plant.
2.2 For the purpose of this specification, the following definition shall hold:
the words 'Shall' and Must' are mandatory;

the words 'Should', 'May' and 'Will' are non-mandatory, advisory or recommended.
3.0 MATERIALS
3.1 The Contractor shall supply all the materials necessary for the performance of the work.
Materials for concrete weight coating shall comply with the following requirements. All the
materials supplied by the Contractor, which in the opinion of Company's
Representative/Inspector, do not comply with the appropriate specifications, shall be rejected
and removed from the site.
3.2 Cement
Ordinary Portland Cement (conforming to IS-8112/ IS-12269) shall be used. Cement which
has hardened or partially set or which has become lumpy shall not be used. Test certificates
from the cement Manufacturer shall be supplied to the Company for all cement delivered to
site.
In case concrete weight coating is to be provided at locations affected by sea water tidal flats
etc., Portland cement in accordance with ASTM C-150 Type III or IS-8041 shall be used.
3.2 Aggregates
3.2.1 Aggregates shall comply with the requirements of IS:383 and shall be tested in accordance
with IS:2386.
3.2.2 Fine Aggregates
`Fine Aggregates' shall mean any of the following, as defined in IS:383:
Natural sand;
Crushed stone sand;
iii) Crushed gravel sand.
Sand shall be well graded from fine to coarse in accordance with Table 4 of IS:383.
3.2.3 Coarse Aggregates
Use of coarse aggregates shall be subject to Company approval.
3.2.4 Aggregates (fine and coarse) shall be clean and free from clay and injurious amounts of salt,
alkali, deleterious substances or organic impurities.
3.3 Water
The water shall be fresh and clean and shall be free from injurious amounts of oils, acids,
alkalis, salts, sugar organic materials or other substances that may be deleterious to concrete
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL — All rights reserved
Page 352 of 1963

O ENGINEERS CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
Rateg INDIA LIMITED ONSHORE PIPELINES Page 6 of 12
or steel. It shall not contain chlorides, sulphates, and magnesium salts. Water from each source
shall be tested prior to its use and shall be approved by Company. Seawater or contaminated
water shall not be used. Water from doubtful sources shall be tested by the Contractor at his
expense and approved by Company before use.
3.4. Reinforcement
Concrete coating shall be reinforced by a layer or layers of steel reinforcement according to

the provisions hereinafter described.
3.4.1 Reinforcement shall consist of welded steel wire fabric manufactured in flat sheets or in rolls
(ribbon mesh) and shall conform ASTM A-185. Wires shall conform to ASTM A-82.
3.4.2 Steel wire shall be galvanised at finished size as per ASTM A-641. The diameter of the wire
and spacing of wires (mesh dimensions) shall be selected according to the following criteria.
3.4.2.1 Wire fabric manufactured in flat sheets shall be 2 x 4 inches max. Steel wire mesh, 13 gauge
U.S. Steel wire (2.4 mm) min. each way.
3.4.2 2 Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. Steel
wires (2mm wire). The above dimensions will be applied unless otherwise specified by
designs. As a rule wire fabric (sheets) shall be used when concrete coating is applied by
casting method, while ribbon mesh (rolls) shall be used when concrete coating is applied by
impingement method.
4.0 COATING REQUIREMENTS
Pipes shall be concrete coated to a thickness and density as specified in the drawings and
CONTRACT documents. The concrete unit weight shall be minimum 2245 kg/m (140
pounds per cubic foot) and the compressive strength shall not be less than 250 kg/cm 2 in 28
days and 165 kg/cm2 in 7 days. Concrete coating shape shall be circular and concentric to pipe
outside diameter. Other concrete coating shapes are not acceptable.
5.0 APPLICATION METHOD
Concrete coating shall be applied either using casting or impingement method. Any alteration
or modifications to the methods described in this specification shall be submitted to the
Company for approval. The application method shall however ensure the basic characteristics
of concrete coating in compliance with the minimum requirements of this specification.
Contractor shall submit to the Company, prior to commencement of work, the

procedure/method of application for approval.
Wherever practical, the total thickness of coating shall be applied in a single pass.
6.0 EQUIPMENT
The equipment used for performing the concrete coating shall be capable of doing so with a
required degree of uniformity with respect to thickness, density and strength. The
proportioning equipment and procedure shall be of the type to assure consistently
proportioned material by weight. Concrete shall be mixed in a mechanical mixer, which shall
ensure thorough mixing of all materials. Any equipment that tends to separate the ingredients
shall not be used. Ready mixed concrete supplied by ready-mixed concrete plant shall be
preferred.
Page 353 of 1963

45ifaeietlah ENGNEERS
4gesernireWeeilif
t
INDIA LIMITED CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
6-71-0046 Rev. 4
niavimo IA Govt of India Underlakingl Page 7 of 12
7.0 MEASUREMENTS AND LOGGING
7.1 All measurements as mentioned below shall be taken during the work stages and clearly
logged in a logbook. A special logbook shall be used for recording tests and trial results. A
logbook shall refer to pipe lengths having the same nominal diameter, and steel wall thickness.
7.2 The following shall be subject to measurement and logging for each pipe length.
a) Line Pipe
1) Field identification number (F)

2) Mill serial number (M)
3) Length (L)
4) Weight (BW)
5) Outside diameter, mm & Wall Thk, mm (OD) / (WT)
b) Corrosion coating
Type of coating (C)

Thickness of corrosion coating, mm (CT)
Weight of coated pipe, kg (CW)
Presence of anode (Yes or No) (A)
Date of Corrosion Coating Application (DCC)
c) Concrete Coating
Batch identification number (B)

Date of placing the concrete coating (T)
Average concrete coating thickness, mm (CCT)
"Dry Weight" of concrete coated pipe (DW)
(Weight and date of weighing or
Related Weight 28 days after placing
of concrete and so identifiable)
"Unit dry weight" of concrete coated pipe (UDW)
"Negative Buoyancy" (unit) of concrete (NB)
Coated pipe
Data can be obtained from Pipe Mill tally Sheets.

Data can be obtained from Coating Plant Tally Sheets.
7.3 No concrete placing shall be allowed before items 1 through 10 listed at clause 7.2, have been
logged.
8.0 PROCEDURE QUALIFICATION
Before commencement of the work, Contractor shall perform all tests, either in laboratory or
in field and trials necessary to properly select type of mix, which meets the requirements of
this specification.
8.1 The type of mix, i.e. the correct combination of the cement, aggregates and water which
results in the desired properties of concrete shall be at first determined for each mix and
following shall be accurately checked and recorded:
proportion and weights of the respective materials used;

the water/cement ratio;
the grading of the aggregates.
Page 354 of 1963

STANDARD
453faelel ENGINEERS WEIGHT COATING OF 6-71-0046 Rev. 4
$11ga MiegNiV INDIA LIMITED ONSHORE PIPELINES
21735,7 .W.p.") (A Gm/ o/ India Undedaking) Pa e 8 of 12
8.2 Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry
specific gravity of the concrete. In parallel, test according to ASTM C-138 shall be performed
so as to determine the expected correlation between concrete weight after placing and dry
specific gravity (28 days after placing). Test for concrete specific gravity at Intermediate time
(7 days after coating) shall be performed.
8.3 When the results of the above tests do not meet the requirements, the mix shall be modified
and concrete samples tested until a proper mix has been determined.
8.4 The mix so determined, shall then be used for sampling of concrete to be submitted to
compressive strength tests as per ASTM C39 or IS-516.
8.5 Frequency of sampling for tests for density and compressive strength of concrete shall be as
follows:
3
"Quantity" of Concrete in the Work (m ) Number of samples
Upto 25 3
26 to 50 4
51 and above 4 plus one additional
sample for each
additional 50 m3 or
part thereof
`Quantity' means the volume of concrete to be used for each qualified mix.
9.0 APPLICATION OF REINFORCEMENT AND CONCRETE COATING
9.1 Two test cubes each per day shall be obtained from batches and tested at the end of 7 days
after coating, for compressive strength and specific gravity.
9.2 The moisture content of the aggregates used shall be such as to maintain a satisfactory control
on the water/cement ratio of the concrete mix.
To maintain the water/cement ratio constant at its correct value, determination of moisture
contents in both fine and coarse (if used) aggregates shall be made as frequently as possible,
the frequency for a given job being determined by the Engineer-in-Charge according to
weather conditions.
9.3 Pipe Length Preparation
Prior to placing of reinforcement, the anti-corrosion coating of each pipe length shall be
carefully inspected visually and by holiday detectors and, if damages are found, they shall be
repaired in accordance with the relevant specification, before start of the work. Foreign
matters, if any, shall be removed from the surface of the anti-corrosion coating.
9.4 Reinforcement Application
9.4.1 Reinforcement shall be placed around the pipe in such a way as to cover the whole pipe length
or sections to be concrete coated. The reinforcement shall not protrude beyond the concrete
coating ends.
9.4.2 Reinforcement shall rest on synthetic resin spacers forming a "Crown" whose number shall be
such as to avoid any contact with the pipe's protective coating. Spacing between the two
consecutive "crown" centres shall be 500 to 1000 mm.
Page 355 of 1963

lsimile?at ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
$1g-elaiRn
l 01 54aU WI INDIA
ereanzenjapr)
LIMITED
(A Goy/ of 1riaa Undenalon91 ONSHORE PIPELINES Page 9 of 12
9.4.3 Splices and attachments shall be done by binding with steel wire having 1.5 mm diameter.
Circular and longitudinal joints of wire fabric in sheets shall be lapped at least for one mesh.
When wire fabric in rolls (ribbon mesh) is used, the spiral lap shall be one mesh while spliced
lap shall be three meshes.
9.4.4 One layer of reinforcement steel shall be provided for concrete thickness less than 50 mm. The
reinforcing steel shall be embedded approximately midway in the concrete coating thickness.
For concrete thickness 50 mm and above two layers of reinforcing steel shall be provided. If
application method requires more than one pass concrete, one reinforcement layer for each
pass is to be applied independently from concrete coating thickness.
In case of one layer of reinforcement, it shall be located approximately in the middle of the
concrete thickness. In case of two layers of reinforcement, layers shall be located at 1/3 rd and
2/3“1 of the concrete thickness. In case of three layers of reinforcement, layer shall be located
at I/4th, 1/2 and 314th of concrete thickness. Contractor shall demonstrate that the procedure
used ensures no physical contract between steel reinforcement and the pipe and the
reinforcement is placed in position as mentioned above.
9.5 Concrete Placing
9.5.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (i.e. after
adding water to mix) and shall be handled in such a way so as to prevent aggregate
segregation and excessive moisture loss. Concrete containers shall continuously be kept clean
and free from hardened or partially hardened concrete.
9.5.2 If casting method is used, once reinforcement and mould have been applied around the pipe,
concrete mixture shall be poured through an opening on the upper section of the same mould.
Concrete shall not be poured from a height greater than 1 metre. During pouring of concrete,
vibrator sets applied inside of pipe or outside the mould shall vibrate the mix so as to obtain
the best possible compactness.
9.5.3 If impingement method is used, placement of concrete shall be upto the specified thickness in
one continuous course, allowance being made for splices of reinforcement and providing
reinforcement in the right location. Concrete shall be projected at high velocity against the
external surface of pipe, to produce a hard, tight-adhering coating of the specified thickness.
9.5.4 No casting shall be interrupted or passes shall be stopped for more than 30 minutes. Before
placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and
wetted to obtain a good bond between the fresh material and the previously placed material.
9.5.5 Suitable means shall be provided to ensure that the temperature of the concrete, when placed,
does not exceed 32°C.
9.5.6 All pipes shall be kept clean and free from cement concrete and grout either inside or outside
of the uncoated sections.
9.5.7 Bevel protectors shall be kept in place throughout the coating application and after.
9.5.8 The coating at each end of the pipe shall be bevelled to a slope of approximately two-to-one
(2:1). It shall terminate about 50 mm short of the end of the corrosion coating applied on the
pipe surface.
9.6 Curing
9.6.1 Immediately after concreting, the exposed surfaces of the concrete shall be protected during
hardening from the effects of sunshine, drying winds, rain, etc. and then after the initial set has
Page 356 of 1963

sitmzE?Atith ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
RaleettrINDIA LIMITED ONSHORE PIPELINES
Gmi of Innedaking) Page 10 of 12
taken place, the concrete coating shall be properly cured. The coated pipe sections shall be
handled gently by suitable means to prevent undue distortion.
9.6.2 Curing shall be performed by application of an approved curing membrane using sealing
compounds and shall meet the requirements of ASTM C-309. The material shall be stored,
prepared and applied in strict conformity with the instructions of the Manufacturer. The
ingredients of any such compound shall be non-toxic and non-inflammable and shall not react
with any ingredient of the concrete, the reinforcement, protective coating or pipe. The
application of the curing compound shall take place immediately after the coating is
completed and preferably before the pipe is removed from the concrete coating apparatus. The
surface of the concrete shall be lightly sprayed with water before applying the curing
compound. The membrane curing period shall not be less than 4 days, during which period the
freshly coated pipes shall not be disturbed. The pipe surface shall be kept wet during daylight
hours for seven days after application of the concrete coating. The concrete coating shall not
be allowed to dehydrate.
Curing of concrete coating may also be done by using jute bags, provided continuous wetting
is ensured by the Contractor.
9.6.3 Before handling and hauling the concrete coated pipes, a check shall be made to make sure
that the concrete coating is properly cured. Stacking and shipment of the coated pipe shall be
initiated only after seven days provided that the concrete coating suffers no damage.
10.0 TOLERANCES
10.1 Contractor shall maintain a surface tolerance of 8 mm (5/16") maximum for the radial distance
between high and low areas of the surfaces. The diameter of each coated pipe shall be
obtained at three (3) or more points, spaced at equal intervals between the end points.
10.2 The acceptable weight tolerance for any single pipe shall be limited to plus five (5) or minus
two (2) percent of the calculated theoretical weight. The theoretical weight shall be calculated
using total weight of the pipe with concrete and corrosion coating.
10.3 The acceptable weight tolerance of any single pipe shall be limited to +5% or -2% of the
calculated weight of concrete. Calculated weight shall consider only the weight of concrete
coating based on approved concrete density and thickness.
11.0 WEIGHING
11.1 The test specimen shall be selected at equal intervals during the course of production.
11.2 Contractor shall weigh each pipe when dry prior to shipment and 28 days after placing of
concrete and mark the weight with paint on the inside of the pipe. The weight mark shall be
followed with letters "DW" meaning Dry Weight.
11.3 In case Contractor opts not to weigh the pipes, the Contractor shall provide 20% extra
concrete coating thickness over the specified concrete thickness at no extra cost and time to
Company.
12.1 After curing, every length of concrete coated pipe shall be non-destructively tested by means
such as "ringing" to determine if any suspected defects are present. In case this indicates
faulty coating, cores shall be removed from coating and inspected. When defective coating
appears from cores, the concrete coating shall be removed from the pipe lengths.
Page 357 of 1963

lorTh
5,g46-il eieVEND NGIIANEE LJASTED CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
wen owenwmarran AGo„ of Vida Undelta10.91 ONSHORE PIPELINES Page 11 of 12
12.2 Every length of concrete coated pipe shall be checked to verify insulation between steel
reinforcement and pipe by means of a megger or equivalent device. To this purpose provisions
should be made during placing of concrete such as to leave at least a point of exposed steel
reinforcement whenever the latter shall terminate inside of concrete coating.
12.3 During the tests as per clause 12.2 above, and before transporting of concrete coated pipes,
every pipe length shall be visually inspected to detect whether any damages and/or defects are
present. Possible damages and/or defects with their allowable limits are described at following
clause 13.0. Repairable concrete coatings shall be clearly marked while the non-repairable
once shall be removed from the pipe lengths.
13.0 REPAIRS
The following repairs are permitted to coating due to unavoidable damage in handling and in
storage (This applies only to concrete that has hardened).
13.1 Spalling due to compression or shearing caused by impact against other objects. Spalling is
defined as damage, which causes a loss in concrete of more than 25 % of the total thickness of
the coating at the point of damage.
13.2 Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the remaining
concrete is sound and reinforcement steel is not exposed, will be accepted without repairs.
Total damage area in one pipe joint shall not exceed 0.1 m2.
13.3 Damage due to spalling of an area of less than 0.1 m2 with reinforcement exposed; and area
more than 0.1 m2 and less than 0.3 m2 shall have the concrete remaining in place over that area
removed as necessary to expose the reinforcing steel throughout the damaged area. Edges of
the spalled area shall be under-cut so as to provide a key lock for the repair material. A stiff
mixture of cement, water and aggregate shall be trowelled into and through the reinforcement
and built up until the surface is level with the coating around the repair. The pipe shall then be
carefully laid with the repaired area at the top and shall be moist cured for a minimum of thirty
six (36) hours before further handling.
13.4 Should the damaged area be more than 0.3 m 2, coating shall be removed around the entire
damaged area. A repair shall be made by satisfactorily restoring the reinforcement, forming
the area with a metal form and pouring a complete replacement of materials similar to that
from which the coating was made. The mixture shall be one (1) part of cement to three (3)
parts of aggregate and the necessary water to produce a slump not to exceed 100 mm (four
inches). The resulting coating shall be equal in weight, density, uniformity, thickness, strength
and characteristics to the originally applied coating. The pipe shall then be carefully laid in a
position where it shall be allowed to remain for a minimum of 36 hours before further
handling.
14.0 MARKING
14.1 Every concrete coated pipe length shall be clearly marked by a suitable type of paint (i.e. red
and/or white lead paint). Markings of concrete coating shall be made inside of pipe close to
bevel end, in such a way that the area involved by welding operations is not affected by paint.
14.2 For each concrete coated pipe length, at one of the two ends, the field identification number
and the date of concrete placing shall be marked, while the dry as well as the wet weight along
with number of days after coating shall be marked at the other end. In addition, Contractor
shall develop a colour coding (band) system to be marked on the outside surface for easy
identification of the coated pipe for each concrete coating thickness, concrete density, pipe
diameter, pipe thickness and pipe material variation.
Page 358 of 1963

4elENNGIDIANEELIMRSTED
FIRM Jv0.0 GOvl Of
I
India undePlaking)
CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
6-71-0046 Rev. 4
Page 12 of 12
15.0 HANDLING, UNLOADING, STORING AND TRANSPORTATION
15.1 Once the pipe sections have been taken on charge, the Contractor, complying with provisions
of the CONTRACT, shall execute their transport together with other material, either supplied
by him or by the Company, from the site of receipt to the coating yard and after concrete
coating completion and acceptance, to delivery point at laying field or storage areas as
previously established providing each time the necessary storages.
15.2 Materials other than pipes and which are susceptible of deteriorating or suffering from
damages especially due to humidity or other adverse weather conditions, shall be suitably
stored and protected.
15.3 During loading, transport, unloading and hauling of inert aggregates, any contact and mixing
with mud, earth, grease and any other foreign material shall be carefully avoided. Precautions
shall be taken to prevent contamination, to maintain the cleanliness and against effects of hot
or cold weather or other adverse climatological condition.
15.4 During the operations of loading, unloading and stock-piling, the pipe sections shall be
handled in such a way so as to avoid dents, cuts, cracks and other damages especially at
bevelled ends or damages to protective and/or concrete coating.
15.5 Stacks shall consist of a limited number of layers such that the pressure exercised by the pipes
own weight does not cause damage to coating. Stacking with more number of layers shall be
agreed upon with the Company provided that each pipe section is separated by means of
spacers suitably spaced so as to avoid stresses and compressed points of contact on the coated
surfaces.
Page 359 of 1963

laifiladdilft ENGINEERS FOR REPAIR OF
ligTjr EIMegilet INDIA UMITED 6-71-0048 Rev. 1
aorop 1,,erwe =praying) IA Gout of Ma tfildettaling) POLYETHYLENE COATING Page 1 of 6
iftWermtff A-crff -gRnTff

1-4-4RT
FOR REPAIR OF
POLYETHYLENE COATING
■‘\ •
•
1 16.05.12 REVISED AND REISSUED AS STANDARD - VM DM
SPECIFICATION SKJ
0 29.10.07 ISSUED AS STANDARD SPECIFICATION MKM VM AS VC

Standards Standards
No by by
Approved by
Page 360 of 1963

lea ENGINEERS FOR REPAIR OF 6-71-0048 Rev. 1
51g7ElfWleGrIBF INDIA LIMITED POLYETHYLENE COATING
allen 2120W all 370+.1) IA Govt a S Undenakingi Page 2 of 6
Abbreviations:
DC Direct Current
EN European Standard
KV Kilo Volt

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Page 361 of 1963

FOR REPAIR OF 6-71-0048 Rev. 1
POLYETHYLENE COATING Page 3 of 6
CONTENTS
1.0 SCOPE 4
2.0 MATERIAL AND EQUIPMENT 4
3.0 APPLICATION PROCEDURE 4
4.0 INSPECTION AND TEST 5
5.0 DOCUMENTATION 6
Page 362 of 1963

01Wide) ENGINEERS FOR REPAIR OF
LII EIVieg e INDIA LIMITED
6-71-0048 Rev. 1
IA Gov, af India Lindedsingj POLYETHYLENE COATING Page 4 of 6
1.0 SCOPE
This specification covers the minimum requirements for materials and equipment, application
procedure and inspection of repair of damaged Polyethylene coatings on steel pipes. This
specification is applicable for repairing damages less than 100mm x 100 mm for pipe sizes
less than 10", 150mm x 150mm for pipe sizes between 12" to 28" and 300mm x 300mm for
pipe sizes more than 28".
If damaged area of coating of the pipeline is larger than above, heat shrinkable sleeve is
recommended.
The repair shall be carried out using repair patch made of radiation cross-linked polyolefin
backing, coated on the inside with semi-crystalline thermoplastic adhesive and filler mastic.
The repair patch shall have thermal indicators to ensure correct heat is being applied during
application.
2.0 MATERIAL AND EQUIPMENT
2.1 The repair material shall be as under:
Repair Patch: radiation cross-linked HDPE (Unexpanded High density polyethylene)

with semi-crystalline thermoplastic adhesive (PERP80 of make Covalence Raychem
or equivalent).
Filler Mastic: PERPFILLER of make Covalence Raychem or equivalent.
PERP melt stick of make Covalence Raychem or equivalent
Liquid Epoxy Primer (two pack)
2.2 The repair material shall be certified by DIN to meet the requirements of ENI2068 Stress
Class CHT 80
2.3 The material shall not be older than their period of validity at the time of application by the
Contractor. Deteriorated/decomposed materials shall not be used.
2.4 Materials shall be stored in sheltered storages in the manufacturer's original packing away
from direct sunlight and in accordance with manufacturer's instructions.
2.5 Contractor shall supply all equipment and manpower required for a skillful application in the
field in accordance with the specification.
3.0 APPLICATION PROCEDURE
3.1 The application procedure to be followed for holiday type of damage shall be in accordance
with manufacturer's instruction and minimum requirement specified below whichever are the
more stringent.
3.1.1 Preparation
Remove coating from damaged area with knife, scraper or power brush. Scrap of the
damaged area and adjacent coating to remove oil, grease, rust, dirt and moisture. Pipe surface
shall be prepared to SA 21/2.
Page 363 of 1963

ISillikEqeENONEERS
51fgar Etwee INDIA LJMITED
FOR REPAIR OF
POLYETHYLENE COATING
6-71-0048 Rev. 1
IA GOA 01 MO. Undertaktigl
Page 5 of 6
3.1.2 Preheating
Preheat the exposed bare metal surface to approx. 80° C and adjacent pipe coating to approx.
60° C with a torch moved back and forth over the surface. Upon preheating, the pipe surface
shall be applied with the two pack epoxy primer to ensure a minimum wet film thickness of
not less than 200 microns to cover the exposed base metal.
3.1.3 Application of the Filler
Plastic filler shall be cut to size and applied to all exposed metal surface. The mastic shall be
heated and smoothed down with a paint scraper to cover all bare metal in a manner such that
all entrapped air is removed and mill applied coating thickness of the pipe is restored.
3.1.4 Application of repair tape
A patch shall be cut from the tape in a manner such that it extends 50 mm (2 inch) beyond the
damaged area on all sides. The patch shall be positioned over the damaged area and heated
until the temperature sensitive paint on the outside of the patch changes colour or dimples on
the backing vanish. It shall be smoothed down to confirm with the contour of lap, and shall be
freed of any air bubbles or wrinkles.
3.2 For cosmetic type of defects such as minor gouging, tearing, and/or scratches, which do not
indicate holiday during holiday inspection, following procedure shall be adopted.
3.2.1 The defective area shall be roughened to remove loose polyethylene coating, oil, grease, dirt,
etc.
3.2.2 This shall be followed by application of patch as detailed in clause 3.1.4.
4.0 INSPECTION AND TEST
4.1 A visual inspection shall be carried out for the following:
Mastic extrusion on ends of the patch shall be examined.
There shall be no sign of punctures or pinholes or bend failure. The external

appearance of the patch shall be smooth, free from dimples, air entrapment or void
formation.
The entire closure patch shall have changed colour uniformly.
4.2 Holiday Inspection
The holiday detector used shall be checked and calibrated daily with an accurate D.C.
Voltmeter. The detector electrode shall be in direct contact with the surface of coating to be
inspected.
The entire surface of the repaired section shall be inspected by means of a full circle holiday
detector approved by Owner set to a D.C. Voltage of at least 25 KV. Inspection of repaired
patch shall be conducted only after it has cooled below 50° C.
4.3 Procedure qualification shall be carried out for repair patch. The value for peel strength to pipe
surface and to factory coating carried out as per EN 12068 shall be 0.5 N/mm minimum at
60°C.
4.4 All repaired joint shall be approved by the Owner.
Page 364 of 1963

FOR REPAIR OF 6-71-0048 Rev. 1
POLYETHYLENE COATING Page 6 of 6
5.0 DOCUMENTATION
5.1 Prior to procurement of coating repair materials, Contractor shall furnish four copies of, but
not limited to, the following for qualification of the Manufacturer and material:
Complete descriptive technical catalogs describing the materials offered along with
samples of repair coating materials, its properties and installation instruction as
applicable specifically to the project.
Test certificate and results of previously conducted tests from independent inspection
agency, for properties listed in Para 4.3 of this specification.
iii) Reference list of previous supplies of the similar material indicating the project details
such as diameter, quantity, service conditions, year of supply, project name, contact
person and feed back on performance.
Once the Company's approval has been given, any change in material or Manufacturer shall be
notified to Company, whose approval in writing of all changes shall be obtained before the
materials are manufactured.
5.2 Prior to shipment of materials from the Manufacturer's works, Contractor shall furnish six
hard copies and an electronic copy of the following:
Test certificates for each batch of materials.
Specific installation instruction with pictorial illustrations.
iii) Specific storage and handling instructions.
5.3 All documents shall be in English Language only.
Page 365 of 1963

0 el ENGINEERS
Oge.1( INDIA LIMITED FOR PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
INIPPI ARM,' MI,RIMA (A Govf of India. UrtOodalongf
(ONSHORE) Page 1 of 38
41§1-1(11i1 PII-Iful (clato * IF7

fafTku
FOR
PIPELINE CONSTRUCTION
(ONSHORE)
p
1^1 CI
4 22.06.15 NS VM SC
SPECIFICATION
3 27.03.09 NKS RK VM ND
SPECIFICATION
2 09.09.05 MKM SK AS VJN
SPECIFICATION
1 15.09.98 KKS RK VC AS
SPECIFICATION
0 09.06.89 ISSUED AS STANDARD SPECIFICATION GD RKD SA RCPC
Standards Standards
Committee Bureau
No by by
Approved by
Page 366 of 1963

ENGINEERS
ogar INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
A lertalk
Abbreviations:
AFC Approved for Construction

ASTM American Society for Testing & Materials
DPT Dye Penetration Test
FOS Factor of Safety
GPRS Ground Penetrating Radar System
HDD Horizontal Directional Drilling
HSE Health, Safety and Environment
MPT Magnetic Particle Testing
NB Nominal Bore
OD Outside Diameter
OFC Optical Fiber Cable
OISD Oil Industry Safety Directorate
RoU Right of Use
RoW Right of Way
U/G Under Ground
US DOT United States Department of Transportation
Members : Mr. Brij Raj Meena

Mr. M. S. Gunjiyal
Mr. Gagan Deep Singh
Mr. Raj Kishore
Mr. S. Ghosal (SMMS)
Mr. Rajiv Kumar (PDD)
Mr. R.K. Singh (Inspection)
Page 367 of 1963

••• ENGINEERS
Og-ar tdf5-4eg ,ter2 INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
co., I Pi lerIA
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS 5
3.0 REQUIREMENT OF RIGHT OF USE AND ACCESS THERETO 6
4.0 RIGHT-OF-USE 8
5.0 HANDLING, HAULING, STRINGING AND STORING OF MATERIALS 11
6.0 TRENCHING 16
7.0 BENDING 21
8.0 LINING UP & WELDING 23
9.0 LAYING 24
10.0 BACK-FILLING 27
11.0 TIEING-IN 29
12.0 SPECIAL INSTALLATIONS ON THE PIPELINE 30
13.0 WORKING SPREAD LIMITATIONS 34
14.0 CLEAN-UP AND RESTORATION OF RIGHT OF USE 34
15.0 MAINTENANCE DURING DEFECTS LIABILITY PERIOD 37
Page 368 of 1963

•

ENGINEERS
fa5l'er, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
1.0 SCOPE
1.1 This specification covers the minimum requirements for the various activities to be carried
out by Contractor for or about the construction of cross-country onshore pipelines.
1.2 The various activities covered in this specification include the following works of pipeline
construction:
- Clearing, grubbing and grading of Right-of-Use;

Construction of all temporary facilities required in connection with the WORKS;
Staking of the pipeline route;
Handling, hauling, stringing and storing of all materials;
Trenching;
Field bending of line pipe;
- Lining-up and Welding;
Pipeline laying;
Backfilling;
Tieing-in;
Installation of auxiliary facilities and appurtenances forming a part of pipeline
construction;
- Clean-up and restoration of Right-of-Use;
- Maintenance during defects liability period.
1.3 This specification shall be read in conjunction with Scope of Work and requirements
indicated in specifications and documents included in the CONTRACT between Company
and Contractor.
1.4 Contractor shall, with due care and diligence, execute the WORK in compliance with all
laws, by laws, ordinances, regulations etc. of the land and provide all services and labour,
inclusive of supervision thereof, all materials, excluding the materials indicated as
"Company Supplied Materials" in the CONTRACT, equipment, appliances or other things of
whatsoever nature required for the execution of the WORK, whether of a temporary or
permanent nature.
1.5 Contractor shall take full responsibility for the stability, suitability and safety of all
operations and methods involved in the WORK. Contractor shall deploy a qualified HSE
Inspector at site before the start of field activities. The deployed HSE Inspector shall prepare
the safety manual/ procedure to be followed during the execution of WORK. The safety
manual/ procedure shall be submitted for approval to the Company's Representative. HSE
Inspector shall ensure approved safety manual/ procedure are administered and enforced
during the execution of WORK. He shall also ensure that field operations personnel are
aware of and practice the policies & procedures set out in the safety manual.
1.6 Contractor shall be deemed to have inspected, examined and independently obtained all
necessary information of WORK area(s) and its surroundings and shall have satisfied
himself as practicable to the form and nature thereof, including sub-surface conditions,
hydrological and climatic conditions, the extent and nature of the WORK and materials
necessary for the completion of the WORK, and the means of access to the WORK area(s).
Page 369 of 1963

fg-ar INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
1.7 Contractor shall be deemed to have obtained and understood all necessary information with
respect to risks, contingencies and all other circumstances, which may influence the WORK.
Any neglect/omission/failure on the part of Contractor in obtaining necessary and reliable
information for performance of WORK shall not relieve him from any liabilities or
responsibilities for completion of WORK.
1.8 Contractor shall, in connection with the WORK, provide and maintain at his own costs, all
lights, guards, fencing, watching etc., when and where necessary or required by Company or
by any duly constituted authority and/or by the authorities having jurisdiction thereof for the
protection of the WORK and properties or for the safety and the convenience of public
and/or others.
1.9 Unless otherwise specified, all sections of this specification shall apply to all the
specifications referred in this specification.
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS
2.1 Reference has been made in this specification to the latest edition of the following codes,
standards and specifications:
a. API Standard 1104 : Welding of Pipelines and Related facilities
b. API 1105 : Bulletin on Construction Practices for Oil and Products

Pipelines
c. ASME B 31.4 : Pipeline Transportation Systems for Liquids and Slurries
d. ASME B 31.8 : Gas Transmission and Distribution Piping Systems
e. BS OHSAS 18001 : Occupational health and safety management systems —

Requirements
f. BS OHSAS 18002 : Occupational health and safety management systems —

Guidelines for the implementation of OHSAS 18001
g. OISD STD 141 : Design, construction and inspection requirements for

cross -country liquid hydrocarbon pipelines
h. OISD STD 214 : Cross-country LPG Pipelines
OISD STD 226 : Natural Gas Transmission Pipelines and City Gas
Distribution Networks
j. Part 192, Title 49 : Transportation of Natural and other Gases by Pipe Line
(US DOT — Pipe Line Safety Standards)
k. Part 195 : Transportation of liquids by Pipe Line (US DOT - Pipe

Line Safety Standards)
1. PNGRB (T4S) : PNGRB Regulations GSR 808(E) Nov'2009
m. Petroleum Rules 2002 : Petroleum and Explosive Safety Organisation
In case of conflict between the requirements of above mentioned codes, standards and
practices, the most stringent requirement shall govern. In case of conflict between the
requirements of this specification and that of the above referred codes, standards and
practices, the requirements of this specification shall govern.
Page 370 of 1963

fixoR: ENGINEERS
Ogzir INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
2.2 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 or recommended.
3.0 REQUIREMENT OF RIGHT OF USE AND ACCESS THERETO
Contractor shall, before starting and clearing operations, familiarize himself with all the
requirements of the Authorities having jurisdiction over the Right of Use (RoU) for WORK
along the pipeline route or in connection with the use of other lands or roads for construction
purposes.
Contractor shall notify Company well in advance during WORK progress, the method of
construction for crossing road, railway, pipeline, cable, canal, river and other existing
obstacles.
Contractor shall not commence WORK on such crossings before having obtained approval
from the Authorities and landowners concerned to the satisfaction of Company. The
crossings shall be installed to meet at all times, the requirements and conditions of the
permit(s) issued by the Authorities concerned. In the absence of any specific requirements by
Authorities, Contractor shall comply with Company's instructions.
The right of ingress and egress to the RoU shall be limited to points where such RoU
intersects ROW of public roads/ railways etc. Arrangements for other access required by the
Contractor shall be made by him (at his own cost and responsibility) and for such accesses
the requirements of this specification shall also apply.
Where the RoU comes within 30 meters of an existing line or facility, Contractor shall
propose and provide methods to safeguard the existing line or facility (e.g. a demarcation
fence). No work is allowed in such areas without Company's prior approval.
Where the RoU comes within the area of influence of high voltage electrical installations, the
following instructions shall be followed:
3.1 Instructions concerning high voltage influencing Safety measures during construction
of pipelines inside the area influenced by high voltage lines.
3.1.1 General
Pipelines, which are constructed inside the area of high voltage lines, may be electrically
influenced by these high voltage lines. The voltage caused by the influence may at times be
so high as to pose a danger to personnel working on the pipeline. It is imperative therefore,
that the instructions given below shall be accurately followed:
3.1.1.1 Personnel doing WORK inside the area influenced by the high voltage system must wear
electrically insulating foot-wear (e.g. rubber knee boots) and wear insulating rubber or
plastic gloves.
3.1.1.2 It is a prerequisite that all personnel involved in construction of the pipeline, which is being
constructed in the area influenced by the high voltage system, must be given clear
instructions on safety measures to be taken while execution of WORK.
3.1.1.3 Vehicles and equipment must be earth-connected. This may be effected by attaching an
uninsulated cable or chain (which touches the ground) of adequate length to the underside of
the vehicle.
Page 371 of 1963

Ifgar iaiWieg INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4

3.1.1.4 If it is not impossible for plant and/or materials to come to within 50m of the centre of the
high voltage system, special measures must be taken to prevent any approach beyond that
distance, unless Clause 3.1.2 is complied with.
3.1.1.5 DURING THUNDERSTORMS OR WHEN DISCHARGES ARE OBSERVED ON

INSULATORS ALL PERSONNEL MUST LEAVE THE AREA OF THE HIGH
VOLTAGE LINE AND PIPELINE.
3.1.1.6 To prevent electrical voltages in a non-buried section of the pipeline from rising to
dangerous values, the length of the pipeline section which has been welded together before
burial must not exceed the length at which the maximum admissible voltage may be induced.
This length shall be calculated using an approved calculation method.
3.1.1.7 Before a pipeline section is lowered into the trench the structure's earth electrodes indicated
in the drawings or determined with calculation method must have been installed and
connected both to the pipeline section already buried and to the section, which is about to be
buried. The electrical connections, which serve the purpose of preventing dangerous
voltages, must have a min. area of 35mm2.
Said connections must not be interrupted until after the permanent safety earth connections
have been installed and connected to the entire uninterrupted pipeline.
3.1.1.8 The welded connection between the pipeline section and the section already buried must be
installed at a distance of at least 50m from the nearest point of a pylon base.
3.1.2 Additional measures for WORK to be done at a distance less than 50m from the centre
of the high voltage system.
If WORK is to be done at a distance less than 50m from the centre of the high voltage
system, the measures indicated below must be complied with, in addition to the instructions
specified in clause 3.1.1.
3.1.2.1 The WORK must not be started until agreement has been reached with the Authorities,
which control the high voltage system, about the implementation of the safety measures
specified in this section.
3.1.2.2 Measures must be taken to prevent excavating and hoisting equipment from approaching
high voltage lines to within any of the following distances.
This distance depends on the voltage carried. For individual connections the distance must
be:
0 - 50 KV 3m
50 - 200KV 5m
200 - 380KV 8m
The measures taken may be as follows:
1. Special selection of equipment, or limiting or blocking certain directions of movement,

or limiting the operational area, thereby making it definitely impossible for any WORK
to be done at a distance from the high voltage line of less than the accepted minimum.
2. In case the measures recommended in 1. above are not feasible, installation of clearly
visible markers of sufficient height or laying out a 'no passage beyond this point' line of
Page 372 of 1963

k71 ENGINEERS
Igzir idfWt&-, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
drums painted bright red and white must prevent any WORK being done inside the
danger area. Furthermore, an inspector must be present all the time.
3.1.2.3 In the event that a vehicle, crane etc. should accidentally come into contact with a live cable
of a high voltage system or flash-over of electrical charge occurs, the driver must not leave
his vehicle because this will pose a serious threat to his life.
The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE.
The driver must not leave his vehicle until he has managed to leave the dangerous area, or
alternatively, when the Electricity Authorities have given notice that the cable(s) have been
put out of circuit. In case a serious fire starts in the vehicle, he is permitted to jump from the
vehicle, clearing it as far as possible, while the jump should possibly be to a dry spot.
Drivers of vehicle or crane working inside the area influenced by high voltage lines shall be
aware regarding the emergency action plan.
4.0 RIGHT-OF-USE
The Contractor is required to perform his construction activities within the width of
Right-of-Use (RoU) set aside for construction of pipeline, unless he has made other
arrangements with the land owner and/or tenant for using extra land. Variation in this width
caused by local conditions or installation of associated pipeline facilities or existing pipelines
will be identified in the field or instructed to the Contractor by Company.
The Right-of-Use boundary lines shall be accurately staked by the Contractor, so as to

prepare the strip for laying the pipeline.
4.1 Stakings
Prior to clearing operations Contractor shall:
1. Install Bench Marks, Intersection Points and other required survey monuments.
2. Stake markers in the centerline of the pipeline at distances of maximum 100 metres for
straight line sections and maximum 10 metres of horizontal bends. Wherever RoU
centerline has been staked on ground, Contractor shall exercise care in accurately
staking the pipeline centerline, in consultation with Company.
3. Stake two RoU markers at least at every 100 metres.
4. Set out a reference line with respect to pipeline centerline at a convenient location.
Markers on reference line shall be at a distance of maximum 100 metres for straight line
sections and maximum 10 metres for horizontal bends.
5. Install distinct markers location and indicating special points, such as but not limited to:
Contract limits, obstacle crossings, change of wall thickness, including corresponding
chainage, etc.
6. Chainage markers shall be installed at every 250 meter.
RoU Markers shall be staked out at the boundary limits of Right-of-Use wherever possible.
RoU Markers shall be painted red with numbers painted in white. Number shall be identical
to centerline marker number with letters A (left side) and B(right side) added, (looking to
flow direction). Reference markers shall also caiTy the same information as its corresponding
centerline markers.
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Markers shall be of suitable material so as to serve their purpose and shall be coloured
distinctly for easy identification. Contractor shall be responsible for the maintenance and
replacement of the reference line markers until the permanent pipeline markers are placed
and the as-built drawings are submitted and approved.
Any deviation from the approved alignment shall be executed by Contractor after seeking
Company approval in writing prior to clearing operations.
4.2 Monuments
All shrines, monuments, border stones, stone walls and the like shall be protected and when
required, removed for safe keeping and replaced in original condition after construction as
directed by Company.
4.3 Fencing
Prior to clearing and grading of the Right-of-Use or stringing of pipe, Contractor shall open
fences on or crossing the construction Right-of-Use and install temporary gates of sound
construction made of similar materials and suitable quality to serve purpose of original
fence. Adjacent posts shall be adequately braced to prevent slackening of the remainder of
the fence. Before such fences are cut and opened, Contractor shall notify the land owner or
tenant, and where practicable, the opening of the fences shall be in accordance with the
wishes of said owner and tenant. In all cases where Contractor removes fences to obtain
WORK room, Contractor shall provide and install temporary fencing, and on completion of
construction shall restore such fencing to its original condition.
Contractor shall install temporary fencing on either side of RoU where in Company's
opinion, it is considered essential to ensure safety and non-interference, especially in areas
like grazing lands, villages etc.
Fencing shall be removable type wherever necessary, to permit crossing of traffic. The type
of fencing must be suitable for the situation in accordance with user. The pole distance shall
not be greater than 6m. The minimum height of the fencing shall be 1.2 m above grade.
Fencing can consist of one or more rows of smooth wire and/or of barbed wire.
Fencing shall be continuously maintained and the thorough-ways inspected to be shut during
the execution of the WORK.
4.4 RoU Clearing and Grading
Any obstacle, which may hinder the construction and laying of the pipeline all along the
pipeline route and for a strip of land of the size provided, shall be removed.
4.4.1 All stumps shall be grubbed on a continuous strip, with a width equal to trench top width
plus two meters on either side centered on the pipeline centerline. Further, all stumps will be
grubbed from areas of the construction Right-of-Use, where Right-of-Use grading will be
required. Outside of these areas to be graded and the mentioned trench strip, and at the
option of Contractor, the stumps may either be grubbed or cut off to ground level. Any
stump cut off must be left in a condition suitable for rubber-tyred pipeline equipment traffic.
4.4.2 All grubbed stumps, timber, bush, undergrowth and roots cut or removed from the Right-of-
Use shall be disposed off in a manner and method satisfactory to Company, land-owner
and/or tenant, and Government Authorities having jurisdiction and as soon as practical after
the initial removal. In no case shall it be left to interfere with the grading and laying
operations. Whenever stumps are grubbed and a hole is left in the ground, Contractor shall
back-fill the hole and compact it to prevent water from gathering in it and making a big hole.
Fornnat No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
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k5--taa_it.-7 ENGINEERS
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4.4.3 Contractor shall grade the pipeline Right-of-Use as required for proper installation of the
pipeline, for providing access to the pipeline during construction, and for ensuring that the
pipeline is constructed in accordance with the most up-to-date engineering and construction
practices.
4.4.4 Contractor shall grade sharp points or low points, without prejudice to section 6.0 (trenching)
of this specification, to allow the pipe to be bent and laid within the limits set forth in these
specifications and drawings as regards the minimum elastic curvature permitted, and shall
drill, blast or excavate any rock or other material which cannot be graded off with ordinary
grading equipment in order to make an adequate working space along the pipeline.
4.4.5 No temporary or permanent deposit of any kind of material resulting from clearing and
grading shall be permitted in the approach to roads, railways, streams, ditches, drainage
ditches and any other position which may hinder the passage and/or the natural water
drainage.
4.4.6 The Right-of-Use clearing and grading operations shall in no case involve embankment
structures of any type and class without prior approval of the authorities having jurisdiction
over the same.
4.4.7 In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other fill
materials, these shall be removed till stable natural ground level is reached so as to ensure
the construction of the pipeline ditch in stable ground.
4.4.8 In the case of Right-of-Use clearing and grading on the hillside or in steep slope areas,
proper barriers or other arrangement/structures shall be provided to prevent the removed
materials from rolling downhill. The Right-of-Use cross fall shall not exceed 10%. Slope of
side hill faces shall be stabilised to prevent landslides.
4.4.9 Wherever the pipeline Right-of-Use runs across, through or alongside farmyards, built-up
areas, groups of trees, forests, groves, horticultural spreads, gardens, grass-fields, ditches,
dikes, roads, paths, railways or any other area with restrictions of some kind, Contractor
shall grade only the width of the Right-of-Use necessary for digging the pipeline trench and
constructing the pipeline. In the said places Contractor shall carry out the works in such a
way that damage resulting from the pipeline construction is kept to a minimum.
4.5 Provision of Detours
Contractor shall do all necessary grading and bridging at road, water and other crossings and
at other locations where needed, to permit the passage of its men and equipment. It is
understood that the Contractor has recognised such restrictive features of the Right-of-Use
and shall provide the necessary detours and execute the works without any extra cost to
Company. Public travel shall not be inconvenienced nor shall it be wholly obstructed at any
point.
Contractor at his own cost shall furnish and maintain watchman detours, lanterns, traffic
lights, barricades, signs, wherever necessary to fully protect the public.
Contractor shall be responsible for moving its equipment and men across or around
watercourses. This may require the construction of temporary bridges or culverts.
Temporary bridging required for Right-of-Use crossing water courses shall be constructed in
consultation with concerned Authorities. Contractor shall ensure that such temporaty works
shall not interfere with normal water flow, avoid overflows, keep the existing morphology
unchanged and shall not unduly damage the banks of water courses. No public ditches or
drains shall be filled or bridged for passage of equipment until Contractor has secured
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written approval of the Authorities having jurisdiction over the same. Contractor shall
furnish Company a copy of such approval.
4.6 Steep and Rocky Terrain
Grading operations could normally be carried out along the Right-of-Use with mechanical
excavators or manually. In certain areas, grading may have to be resorted to exclusively by
blasting.
In rough or steep terrain, Contractor may have to grade access roads and temporary bypass
roads for its own use. Where such access roads do not fall on the Right-of-Use, Contractor
shall obtain necessary written permission from land owners and tenants and be responsible
for all damages caused by the construction and use of such roads, and at no extra cost to
Company.
Wherever rocky terrain is encountered, grading shall be carried out in all types of solid rocks
which cannot be removed until loosened by blasting, drilling, wedging or by other
recognized methods of querrying solid rocks.
Where use of explosives is required in connection with Right-of-Use grading and trenching,
Contractor shall comply fully with requirements of the use of explosives as provided under
clause 6.3 of this Specification and as provided under "Rules for Blasting", Specification
No. 6-71-0061 issued for this purpose.
4.7 High water table location
In the location parallel or perpendicular to river, canals or marshy areas or any other such
areas, Contractor shall ensure the stability of the trench by step cutting or by increasing the
angle of inclination of the trench. Pumps shall be deployed to dewater the trench before
lowering of the pipeline, to maintain the trench in dry condition. In case, water cannot be
removed from the bottom of the trench, then concrete coated pipes shall be used to avoid
floatation of the pipe string in the trench.
4.8 Off Right-of-Use Damages
Contractor shall confine all its operations within limits of the Right-of-Use. Any damage to
property outside RoU shall be restored or settled to the Contractor's account.
Contractor shall promptly settle all off Right-of-Use damage claims. Should Contractor fail
to do so, Company shall give written notice to Contractor that if Contractor does not settle
such claims within seven days after such notice, Company shall have the authority to settle
claims from the account of Contractor.
5.0 HANDLING, HAULING, STRINGING AND STORING OF MATERIALS
5.1 General
The Contractor shall exercise utmost care in handling line pipe and other materials.
Contractor shall be fully responsible for all materials and their identification until such time
that the pipes and other materials are installed in permanent installation. Contractor shall be
fully responsible for arranging and paying for temporary storage areas for the pipeline
materials, however, method of storage shall be approved by Company. Contractor shall
submit a procedure to be followed at site for storage of pipes and other materials including
their identification for Company's approval.
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Contractor shall reimburse the Company for the cost of replacement of all Company
supplied materials damaged during the period in which such materials are in the custody of
the Contractor. It shall be Contractor's responsibility to unpack any packings for the
materials supplied by Company.
Pipe bevel protectors shall always be kept in position during all handling, transportation and
stringing operations and shall be removed only prior to fit-up for welding. After fabrication
and welding, the Contractor shall arrange to return all such bevel protectors at Company's
designated storage yard and as instructed by Company.
5.2 "Taking over" of Line Pipe

-
The following stipulations shall apply in case CONTRACT provides for supply of line pipe,
bare and/or corrosion coated, by Company.
Contractor shall receive and 'take over' against requisition, line pipe from the Company's
designated place(s) of delivery as defined in the CONTRACT. Contractor shall perform
visual inspection of the bare pipes and coating of the corrosion coated pipes, as the case may
be, in the presence of Company and all damages shall be recorded. In the case of corrosion
coated pipes, Contractor at his option may carry out holiday detection at a prescribed set
voltage and record such holidays, in the presence of Company, at the time of 'taking over'.
However, if Contractor proposes to perform only visual inspection of coating at the time of
'taking over', then repair of all holidays found at the time of laying the pipeline shall be
carried out by the Contractor at no extra cost to Company.
The Contractor shall be entitled to extra compensation for repair and rectification of defects
recorded at the time of 'taking over' as per the rate set forth in the "CONTRACT". Repair of
all damages occurring after taking over the delivery of the materials shall be to the
Contractor's cost. In case of delays in handing over of Company supplied materials,
Contractor shall be fully responsible for stopping and rearranging means of transportation at
no extra cost to Company.
5.3 Handling and Hauling of Line Pipe
5.3.1 Bare pipes
Contractor shall unload, load, stockpile and transport the bare pipes using suitable means
and in a manner to avoid denting, flattening, or other damages to pipes. Pipe shall not be
allowed to drop or strike objects, which will damage the pipe but shall be lifted or lowered
from one level to another by suitable equipment. Lifting hooks when used, shall be equipped
with a plate curved to fit the curvature of the pipe. In loading pipe on trucks each length
shall be lowered to position without dropping and each succeeding length shall rest on
special supports on the truck and shall be separated from the adjacent pipes. After loading,
suitable chains and padding shall be used to tie the load securely to each bolster. Pipe, when
stock piled, shall be placed on suitable skid to keep it clear of the ground and flood water.
Care shall be exercised in handling or stock-piling pipes in order to avoid distortion,
flattening, denting or other damages. The Contractor shall provide all necessary timber or
other materials required for the stock-piling. While stacking, the number of allowable layers
of bare pipes shall be calculated as per API RP 5L1 and shall be agreed with Company. The
stacks must be properly secured against sliding and shall consist of pipes of the same
diameter and wall thickness. Adjacent stacks of pipes having different dimensional
characteristics shall be clearly separated.
Pipes which are damaged at the time of delivery or 'taking-over' (when line pipe is supplied
by Company), particularly those which are dented, buckled, or otherwise permanently
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deformed, must be stacked separately and may be transported to the sites only when these
defects have been repaired or eliminated.
5.3.2 Corrosion coated pipes
The Contractor shall load, unload, transport and stockpile the coated pipes using approved
suitable means and in a manner to avoid damage to the pipe and coating. Contractor shall
submit to Company a complete procedure indicating the manner and arrangement used for
handling and stacking of coated pipes for Company approval prior to commencement of
handling operations.
Use of vacuum lifting equipments is preferred. Hooks may also be used for handling the
pipes provided they have sufficient width and depth to fit the inside of the pipe and covered
with soft material like rubber, Teflon or equivalent, so as not to cause damages to bevel or
pipe ends. During hoisting cables/wire ropes shall have sufficient inclination compared to
pipe axis so that they do not come into contact with external coating.
Coated pipes may be handled by means of slings and belts of proper width (minimum 60
mm) made of non-metallic/non-abrasive materials. In this case, pipes to be stacked shall be
separated row by row to avoid damages by rubbing the coated surface in the process of
taking off the slings. Use of round sectional slings is prohibited.
During handling, suitable handling equipments with proper length of booms shall be used.
Forklifts may be used provided that the arms of the forklifts are covered by suitable pads
preferably rubber. Before lifting operations, it is essential to ensure that the pipe surface is
free from foreign materials with sharp edges. Belts/slings when used shall be cleaned to
remove hard materials such as stone, gravel etc. Coated pipes shall not be bumped against
any other pipe or any other objects. Rolling, skidding or dragging shall be strictly forbidden.
Coated pipes at all times shall be stacked completely clear from the ground so that the
bottom row of pipes remains free from any surface water. The pipes shall be stacked at a
slope so that driving rain does not collect inside the pipe.
The coated pipes may be stacked by placing them on ridges of sand free from stones and
covered with a plastic film or on wooden supports provided with suitable cover. This cover
can, for example, consist of dry, germ free straw with a plastic film, otherwise foam rubber
may be used. The supports shall be spaced in such a manner as to avoid permanent bending
of the pipes, particularly in case of small diameter pipes with low wall thickness. The pipes
shall be stacked so that the uncoated bevelled ends are in line at one end, thus making
differences in lengths clearly noticeable.
Stacks shall consist of limited number of layers so that the pressure exercised by the pipes
own weight does not cause damages to the coating. Each pipe section shall be separated by
means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against
falling down and shall consist of pipe sections having the same diameter and wall thickness.
The weld bead of pipes shall be positioned in such a manner so as not to touch the adjacent
pipes.
The ends of the pipes during handling and stacking shall always be protected with bevel
protectors.
The trailers/rail wagons shall be equipped with adequate pipe supports having as many
round hollow beds as the number of pipes to be placed on the bottom of the trailer bed.
Supports shall be provided for at least 10% of the pipe length. These supports shall be lined
with a rubber protection and shall be spaced in a manner as to support equal load from the
pipes. The rubber protection shall be free from all nails and staples where pipes are in
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contact. The second layer and all subsequent layers shall be separated from each other with
adequate number of separating layers of protective material such as straw in plastic covers or
mineral wool strips or equivalent, to avoid direct touch between the coated pipes.
All stanchions of trailers/rail wagons used for transportation shall be covered by non-
abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover
the top of the stanchions and convex portions such as reinforcement of the truck/rail wagon
body, rivets etc. to prevent damage to the coated surface.
5.4 Stringing of Pipe
Pipes shall be unloaded from the stringing trucks and lowered to the ground by means of
Side boom/Hydra crane tractor or swinging crane or other suitable equipment using lifting
devices as mentioned earlier. Dragging or sliding of pipe shall not be permitted. Special
precaution shall be taken during stringing of corrosion coated pipes as per the special
requirements of previous Para. Stringing of pipe shall only be carried out in daylight and
after clearing and grading operations have been completed. Pipe shall not be strung on the
Right-of-Use in rocky areas where blasting may be required, until all blasting is complete
and the area cleared of all debris.
The stringing of the pipe on the Right-of-Use shall be done in such a manner as to cause the
least interference with the normal use of the land crossed and to avoid damage to or
interference with the pipes. The sequence of pipes must be interrupted at suitable intervals,
spaced to coincide with passages, roads, railways and water-courses crossings as well as at
other places if requested by land Owner or tenants to permit use of the land. Also care shall
be taken to provide safe working space between trench edge and the pipe. Pipe shall be
strung on approved soft earth / sand filled bags and wedge. Bottom of pipe shall in no way
touch the ground. There shall be sufficient clearance from bottom of pipe & the ground
level. The pipe shall be supported at minimum two locations.
In case line pipe supply is by different Manufacturers, Contractor shall string all line pipe of
one Manufacturer before commencing the stringing of the line pipe of another Manufacturer.
When parallel pipelines are being constructed, bumping against and contact with the strung
sections of pipe shall be avoided, whether the stringing of the pipes for the individual lines is
carried out separately or simultaneously. When parallel pipes of different sizes are to be laid,
the pipe stringing shall suit the respective location of pipes in the trench.
The pipe lengths must be properly spaced in order to make easier the handling during the
welding phase.
It shall be the responsibility of the Contractor to see that pipe is strung in accordance with
the approved drawings for the proper placement of pipe by size, thickness, grade and other
specifications. Any additional handling of pipes resulting from failure to, comply with these
requirements shall be at the Contractor's expense.
5.5 Repair of Damaged Pipes
After the pipe has been strung on the Right-of-Use, it shall be inspected by the Contractor
and the Company and all defective pipe ends repaired. Defective pipes shall be repaired or
rejected as the Company may direct as per the requirements of clause 5.2 of this
Specification.
5.6 Materials other than line pipe
Contractor shall receive and take over against requisition all Company supplied materials
from Company's designated place(s) of delivery as defined in the CONTRACT. Contractor
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ENGINEERS
5'gar INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
shall perform visual inspection and defects, if any noted, shall be recorded separately. The
Contractor shall be entitled to extra compensation for repair and rectification of such defects
at the rates set forth in the "CONTRACT".
The Contractor shall perform the necessary loading, unloading, hauling from points
designated by the Company and storing, if necessary, of all materials. The Contractor shall
exercise care in handling, hauling, storing and distribution of materials in order to avoid
damage and deterioration of these materials and prevent their theft or loss.
Materials excluding line pipe shall be stored in sheltered storage. Such materials shall not be
strung on the Right-of-Use but shall be transported in covered conveyances for use only at
the time of installation.
Contractor shall ensure that all valves and other materials, wherever applicable, are fitted
with suitable end covers of the type approved by Company. Materials with worked surfaces
such as flanges, pipe fittings, etc. must be stacked and handled so as to avoid contact with
the ground or with substances that could damage them.
The Manufacturer's instructions regarding temperature and procedure for storing materials,
which are subject to alteration of the original properties and characteristics due to unsuitable
storage, must be strictly complied with and, if required, an adequate heat conditioning shall
be provided for these materials.
When material is supplied in containers and packages, it must not be thrown or dropped or
handled using hooks which could damage the container or the materials, either during
loading/unloading or during successive handling, until their final use.
Coating materials, which are susceptible of deteriorating or suffering from damages

especially due to humidity, exposure to high thermal excursions or other adverse weather
conditions, shall be suitably stored and protected. These materials shall be kept permanently
in store, supported above the ground in a dry place protected against the weather and
transported for use only at the time and in the quantities necessary for immediate
application. Deteriorated materials shall not be used and replaced with no extra cost to
Company.
5.7 Identification
Contractor shall provide all pipes, bends etc. greater than 50mm NB with serial numbers as
soon as possible upon the receipt of such materials at site and measure their length and state
it on the pipes, etc. Pipes to be bent shall be measured prior to bending. Identification (i.e.
letter, number and length) shall be indelible.
All serial numbers shall be recorded in a list, which shall also state appurtenant pipe
numbers.
Besides recording the stamped pipe numbers, length of pipe and painted-on serial numbers,
the stamped-in numbers of T-pieces, bends, valves, etc. and the batch numbers of bends, T-
pieces, valves, etc and the make of valves, shall also be recorded in said list.
Before a pipe length, pipe end, etc is cut, the painted serial number and stamped-in pipe
number shall be transferred by Contractor in the presence of Company to either side of the
joint, which is to be made by cutting, and the changes shall be recorded in the above
mentioned list stating the (new) length. The result shall be such that all pipes, pups, etc. of
diameter greater than 50mm NB bear clear marks painted on.
Contractor shall explicitly instruct his staff that parts which cannot be identified must not be
removed, except after permission by Company.
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ENGINEERS
Ogat &gift INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4 •
As a general rule parts shall be marked as described above before being moved. In no
conditions may unmarked parts be incorporated into the WORK.
6.0 TRENCHING
6.1 Location
Contractor shall excavate and maintain the pipeline trench on the staked centerline of the
pipeline taking into account the curves of the pipeline.
In case of common RoU, the centerline of the trench shall be established from the location
of existing pipeline. In case of independent RoU, the centerline of the trench shall be
established from the edge of RoU.
6.2 Excavation
6.2.1 Contractor shall, by the method approved by Company, dig the pipeline trench on the
cleared and graded Right-of-Use. In cultivable land and other areas specifically designated
by the Company, top 300mm of the arable soil on the pipeline trench top width shall be
excavated and stored separately, to be replaced in original position, after backfilling and
compacting rest of the trench.
Suitable crossings shall be provided and maintained over the open RoU, where necessary, to
permit general public, property owners or his tenants to cross or move stock or equipment
from one side of the trench to the other.
Care shall be exercised to see that fresh soil recovered from trenching operation, intended to
be used for backfilling over the laid pipe in the trench, is not mixed with loose debris or
foreign material. The excavated material shall never be deposited over or against the strung
pipe.
6.2.2 In steep slope areas or on the hillside, before commencing the works, proper barriers or
other protection shall be provided to prevent the removed materials from rolling downhill.
Equipments shall also be tied-up suitably to prevent rolling/ toppling of man and material
during trenching activity in steep slopes.
6.2.3 On slopes wherever there is danger of landslide, the pipeline trench shall be maintained open
only for the time strictly necessary. Moreover, the Company may require manual excavation
of trench, local route detouring and limiting the period of execution of the works. The
Contractor shall make adequate arrangements for safe working of the personnel involved in
manual excavation of trench. Wherever trench depth exceeds 2m, Contractor shall take
preventive measures such as shoring & strutting by wooden planks to ensure safety to the
personnel.
6.2.4 In certain sloppy sections, before the trench cuts through the water table, proper drainage
shall be ensured both near the ditch and the Right-of-Use in order to guarantee soil stability.
6.2.5 All sewers drain, ditches and other natural waterways involved in the execution of the works
shall be maintained open and functional. The same applies to canals, irrigation canals, and
pipelines and buried facilities crossed by the ditch for which temporary installations such as
Hume pipes shall be provided as required for passage of water.
6.2.6 Trench in populated areas shall be provided with all protection measures/ barricading with
proper sign boards to avoid possibility of human/ livestock falling in the trench accidently.
6.2.7 Wherever, OFC is to be laid along the pipeline in a common trench, as per Contract, trench
width shall be sufficient to accommodate optical fiber cable (OFC).
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fae, ENGINEERS
lager, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
6.3 Blasting
Blasting for trenching and the related removal of scattered rock and debris caused by the
blasting from the Right-of-Use and/or adjacent property, shall be performed by Contractor
as part of his WORK.
Every possible precaution shall be taken to prevent injuries and damages to persons and
properties during blasting operations, which shall be performed in accordance with Rules for
Blasting, Specification no. 6- 71-0061 issued for the purpose.
6.3.1 All necessary precautions shall be taken to prevent stones from falling outside the Right-of-
Use and in cultivated areas and to avoid any damage to the installations and properties
existing nearby.
6.3.2 Blasting and removal of debris shall be carried out prior to stringing of the pipes.
6.3.3 Company reserves the right to refuse blasting where possible danger exists to property,
existing utilities or other structures. In such locations other methods of excavating rock shall
be proposed by Contractor and shall be approved by Company.
6.4 Normal Cover and Trench Dimensions
The trench shall be excavated to a minimum width so as to provide, on both sides of the
installed pipeline, a clearance as indicated in the job standards/drawings and to a depth
sufficient to provide the minimum cover as indicated below. The dimensions in the table
below shall govern except as noted herein or as shown on the job standards or detailed
construction documents/drawings or as required by authorities having jurisdiction,
whichever is greatest. Minimum depth of cover shall be measured from the top of pipe
corrosion/concrete weight coating (as applicable) to the top of undisturbed surface of the soil
or top of graded working strip or top of road or top of rail whichever is lower. Fill material
in working strip shall not be considered to add to the depth of cover. However, surface of fill
material placed to fill hollows may be used to determine the depth of cover subject to prior
approval by Company.
Location Minimum Cover in meters

a) Industrial, Commercial & Residential Area 1.0/ 1.2 (Note-1)
b) Rocky Terrain 1.0
c) Minor water crossing/canals/drain/nala/stream 1.5
d) River crossings for which scour depth is defined 1.5
(below scour)
e) River crossings (Bank width < 50m) 1.5
(below lowest bed level)
f) Other River crossings (Bank width > 50m) 2.5 (for normal soil)
(below lowest bed level) 1.5 (for rocky strata)
g) Water crossing by HDD 2.5
(below scour level)
h) Uncased/Cased Road Crossings/Station approach 1.2
i) Railways crossing 1.7
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k.Àfa_lt4 ENGINEERS
OgaiiKarde; INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
, .11.14 oq,
Location Minimum Cover in meters

j) Drainage, ditches at roads/railway crossings 1.0/ 1.2 (Note-1)
k) Marshy land and creek area 1.5
Notes:
1. Cover is 1.0 meter for pipelines designed as per ASME B31.8 and 1.2 meters for pipelines as per ASME
B31.4.
2. In case pipeline is located within 15 m from any dwelling unit, the cover shall be increased by 300 mm
over and above that specified.
6.5 Cutting and Removal of Paving
Whenever it is permitted by Authorities and/or Company to open cut a paved road crossing,
or where the line is routed within the road pavement, Contractor shall remove the paving in
accordance with the restrictions and requirements of the Authorities having jurisdiction
thereof or as directed by Company. The open cut for the road crossing shall be carried out
only when the section of pipeline to be laid is complete. After laying the pipeline,
backfilling shall be immediately performed and all the area connected with the works shall
be temporarily restored.
Throughout the period of execution of such works, Contractor shall provide and use warning
signs, traffic lights or lanterns, barricades, fencing, watchman, etc. as required by the local
authorities having jurisdiction and/or Company.
For all roads, paths, walkways etc., which are open-cut, Contractor shall provide temporary
diversions properly constructed to allow the passage of normal traffic with the minimum of
inconvenience and interruptions.
The paving shall be restored to its original condition after the pipeline is installed.
6.6 Extra Depth and Clearance
At points where the contour of the earth may require extra depth to fit the minimum radius
of the bend as specified or to eliminate unnecessary bending of the pipe according to
customary good pipeline practice, or where a deep trench is required at the approaches to
crossings of roadways, railroads, rivers, streams, drainage ditches, and the like, Contractor
shall excavate such additional depth as may be necessary at no extra cost to the Company.
Contractor shall excavate to additional depth where the pipeline approaches and crosses
other pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground
structures, so that the pipeline may be laid with at least 50 centimeters free clearance from
the obstacle or as specified in the drawings, or such greater minimum distances as may be
required by authorities having jurisdiction.
Where the pipeline crosses areas, whose easements specifically require greater than normal
depths of cover, the trench shall be excavated to extra depth in accordance with the Right-of-
Use Agreements or as required.
Contractor shall excavate all such additional depths as may be necessary at no extra cost to
the Company.
6.7 Grades, Bends and Finish of Trench
The trench is to be cut to a grade that will provide a firm, uniform and continuous support
for the pipe. Bends shall be made in the pipe at significant changes in grade of the trench.
Page 383 of 1963

OgZIE Wer', INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4

Company reserves the right to set the grade of the trench and locate the bends if so desired,
in which case Contractor shall excavate, at no extra cost, the trench and bend the pipe to
such a grade. Company desires reduce to a minimum the required number of cold field
bends to lay the pipe to conform to the general contour of the ground and maintain a normal
cover. This can be accomplished by cutting the trench slightly deeper at the crest of ridges
and by gradually deepening the trench in approaches to crossings. Such trenching WORK
shall be done by Contractor at no extra cost to the Company.
Company intends that there will be a minimum of hand grading of the trench bottom.
However, to achieve this, Contractor will have to dig as square a bottom of the trench as
possible with the equipment. This in part can be obtained by adjusting and adopting the
crumbing shoe and digging teeth of the trenching machines and by use of a drag behind the
trenching machines or manually dressing-up the same. Contractor shall do such hand
WORK in the trench as is necessary to free the bottom of the trench from loose rock and
hard clay and to trim protruding roots from the bottom and side walls of the trench.
6.8 Padding
In all cases where rock or gravel or murum/hard soil is encountered in the bottom of the
trench, Company will decide the exact extent of trench padding that may be required. The
thickness of the compacted padding shall not be less than 150mm. In those areas that are to
be padded, the trench shall be at least 150mm deeper than otherwise required, and evenly
and sufficiently padded to keep the pipe, when in place, at least 150mm above bottom of
excavated trench.
Acceptable padding shall be placed under the pipeline before its installation, and around
after installation to establish at both sides and on top of the pipe a permanent layer of
padding. The thickness of compacted padding on top of pipe corrosion coating shall be at
least 150mm. Padding materials that are approved by Company shall be graded soil/sand
and/or other materials containing no gravel, rock, or lumps of hard soil. Suitable sand
approved by Engineer-in-Charge shall be used for padding.
When specified in the CONTRACT, rock shield may be used in place of or in addition to
sand padding as indicated above. Such rock shield shall be in accordance with the
specification issued for the purpose and shall be subject to Company approval.
6.9 Protection of Trench
Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be
made to the Company by reason of its caving either before or after pipe is laid.
All lumber, sheet-piling jacks or other materials that may be necessary to shore the trench, in
order to prevent caving are to be furnished and removed by Contractor.
Contractor shall dewater if necessary, using well point system/concrete grouting for
stabilization of trench wall or other suitable systems, shore or do what else might be required
to excavate the trench, install the pipe in it and backfill the trench in accordance with the
specifications at no extra cost to Company.
6.10 Protection of Underground Utilities and Special Methods
Available details of underground utilities, as far as acquired by Company, shall be indicated

in the Drawings. However, Contractor shall obtain plans and full details of all existing and
planned underground services from the relevant Local Authorities and shall follow these
plans closely at all times during the performance of WORK. Contractor shall be responsible
for location and protection of all underground lines and structures. In special locations the
Page 384 of 1963

ei ENGINEERS
$1fga *kr) INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
use of trenching machine/backhoe may result in damage to property and subsurface

structures likely to be encountered during excavation. At such places, Contractor shall
excavate the trench manually to same specification at no extra cost.
Where the pipeline crosses other underground utilities/structures, the Contractor shall first
manually excavate to a depth and in such a manner that the utilities/structures are located.
Temporary under pinning or any other type of supports and other protective devices
necessary to keep the interfering structure intact shall be provided by the Contractor at his
own cost and shall be of such design as to ensure stability & safety against their possible
failure.
All underground facilities, pipelines, cables shall be located by pipeline locator/ GPRS prior
to excavation.
Despite all precautions, should any damage to any structure/utility etc., occur, the
Owner/Authority concerned shall be contacted by the Contractor and repair shall forthwith
be carried out by the Contractor at his expense under the direction and to the satisfaction of
Company and the concerned Owner/Authority. If Contractor fails to repair in reasonable
time, Company reserves the right to have the repair executed at the cost of the Contractor.
6.11 Encroachments and Working near other Utilities
In locations, where pipeline has to be laid in the body of a road, canal, dyke or other
locations under jurisdiction of Government/Public Bodies, the Contractor shall perform such
WORK without extra compensation, according to the requirement of concerned Authorities.
When it becomes necessary that Contractor has to resort to hand digging, well point,
erection of sheet piling or any other special construction method in these areas, no extra
compensation shall be paid. Contractor shall contact the Authorities concerned in order to
become familiar with their requirements. The facilities damaged during construction shall be
restored to their original condition to the satisfaction of Company/Authority.
In locations, where the pipeline has to be laid more or less parallel to an existing pipeline,
cable and/or other utilities in the Right-of-Use, Contractor shall perform the WORK to the
satisfaction of the Owner/Authority of the existing pipeline/cable/utility. In such locations
Contractor shall perform WORK in such a way that even under the worst weather and
flooding conditions, the existing pipeline/utilities remain stable and shall neither become
undermined nor have the tendency to slide towards the trench.
Contractor shall be liable for any damage occurring to, or resulting from damage to other
pipelines, underground structures/utilities, as laid down in clause 6.10 of this specification.
6.12 Provisions for Anti Buoyancy to the Pipe
Contractor shall check if up-floating danger is present in open trench and then shall take
appropriate measures to prevent up-floating such as applying soil dams and dewatering of
trench or temporary filling of water into the line (in exceptional cases).
In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall be
drained to the extent and for the time required to make a visual inspection of the ditch
bottom. After this inspection, the presence of water will be allowed provided its level does
not cause sliding of the ditch sides and pipe floating before backfilling when no concrete
weighing is provided.
The water pumped out of the ditch shall be discharged into a natural water course.
Page 385 of 1963

ENGINEERS
ligar fatWie7.'r.. , Mir INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
Whenever up-floating of the pipeline after backfilling is to be reckoned with, anti-buoyancy

measures shall be provided by Contractor for such areas of construction, using one or a
combination of the following methods:
weighing by applying a continuous concrete coating around the pipe;
weighing by installing gravel filled Geotextile bags/Saddle weight;
- installing metal anchors screwed into the subsoil in pairs;
- deeper burial of pipeline;
provision of select backfill material.
The above provisions shall be in accordance with the relevant specifications and/or job
standards/drawings.
Contractor shall indicate the option(s) selected to Company for review and approval along
with calculations, wherever applicable.
7.0 BENDING
Contractor shall preferably provide for changes of vertical and horizontal alignment in
pipeline by making elastic bends. Contractor may provide cold field bends, at its option for
change of direction and change of slope. Company at its option, may authorise fabricated
bends for installation at points where in Company's judgment the use of such bends is
unavoidable.
Overbends shall be made in such a manner that the centre of the bend clears the high points
of the trench bottom. Sag bends shall fit the bottom of the trench and side bends shall
conform and leave specified clearance to the outside wall of the trench.
7.1 Elastic Bends
The minimum allowable radius for elastic bends in the buried pipeline including that for
continuous concrete weight coated pipe shall be in accordance with relevant job standards.
The elastic bend shall be continuously supported over its full length. A radius smaller than
permitted in elastic bending shall require a cold bend.
7.2 Cold Field Bends
7.2.1 The radius of cold field bends shall not be less than 40 times the pipe specified outside
diameter for pipe diameters 18 inch and above and shall not be less than 30 times the pipe
specified diameter for pipe diameter less than 18 inch.
7.2.2 Contractor shall use a pipe bending machine of adequate capacity and employ recognized
and accepted methods of bending of coated pipe in accordance with good pipeline
construction practice. However, bending machines shall be capable of making bends without
wrinkles, buckles, stretching and with minimum damage to the coating.
7.2.3 Contractor shall, before the start of the WORK, submit and demonstrate to Company a
bending procedure, which shall conform to the recommendations of the manufacturer of the
bending machine. The procedure shall include amongst other steps- lengths, maximum
degree per pull and method and accuracy of measurement during pulling of the bend. The
bending procedure and the equipment used shall be subject to Company's approval.
Format No. 8 00 0001 F1 Rev. 0

- - -
Page 386 of 1963

,5-ilw_Jt4 oro,i) ENGINEERS
f=g-Z11teif54-67, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
7.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane
passing through the neutral axis of the bend, which shall be installed positioning the
longitudinal weld in the upper quadrants. If horizontal deviations are to be achieved by
joining more adjacent bends, the bending of the pipe lengths shall be made by positioning
the longitudinal welds alternatively 70mm above and below the plane passing through the
neutral axis in such a way that the bends are welded with the longitudinal welds displaced by
about 150mm and situated in the upper quadrants. In case of vertical bends formed from a
number of pipe lengths, the longitudinal welds shall be positioned on the plane passing
through the neutral axis of the bend to the right and left alternatively.
For pipes with helical weld the above requirements are not applicable.
7.2.5 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to avoid
damage to the pipe coating. Where applicable, fully retaining bending shoes shall be used.
Roller type bending machines are preferred.
7.2.6 The ends of each bent length shall be straight and not involved anyway in the bending. The
length of the straight section shall permit easy joining. In no case shall the end of the bend
be closer than 1.5m from the end of a pipe or within one meter of a girth weld.
7.2.7 The ovalization caused on each pipe by bending shall be less than 2.5% of the specified
diameter at any point. Ovalization is defined as the reduction or increase in the internal
diameter of the pipe compared with the nominal internal diameter. A check shall be
performed on all bends in the presence of Company Representative by passing a gauge
consisting of two metallic discs with a diameter equal to 95% of the nominal internal
diameter of the pipe connected rigidly together at a distance equal to 300mm.
7.2.8 The wall thickness of finished bends, taking into account wall thinning at the outer radius,
should not be less than the specified thickness. An indication of wall thinning as a
percentage is given by the following empirical formula:
50
Wall Thinning = n +1
Where 'n' is the inner bend radius divided by pipe diameter. Pipes with measured wall
thickness greater than the nominal wall thickness (i.e. with +ve tolerance) shall normally be
used for making cold field bends.
7.2.9 Cold bend pipes on site shall have the corrosion coating carefully checked with the aid of a
holiday detector for cracks in the coating down to the pipe wall. It must also be checked
whether the coating has disbonded from the pipe wall during bending by beating with a
wooden mallet along the outer radius. Any defects or disbonding of the coating caused
during bending (also forced ridges in the coating) shall be repaired at the Contractor's
expense in accordance with Company approved procedures.
7.2.10 When pipelines are laid in parallel, the horizontal bends shall be concentric.
7.3 Miter and Unsatisfactory Bends
All bends showing buckling, wrinkles, cracks or other visible defects or which are in any
way in disagreement, in whole or in part, with this specification shall be rejected.
No miter bends shall be permitted in the construction of the pipe line. Contractor shall cut
out and remove any bend or bends, which do not meet the specifications and shall replace
the same with bends complying with specification at no additional cost to the Company. In
the event the CONTRACT provides for supply of line pipe by Company, the pipes required
Page 387 of 1963

of-a_iti ENGINEERS
$fgar tVreg INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
for replacement will be furnished by Company, but the cost of replacement of such pipes
shall be borne by Contractor.
Cutting of factory made bends and cold field bends for any purpose are not permitted.
8.0 LINING UP & WELDING
Each length of pipe shall be thoroughly examined internally and externally to make sure that
it is free from visual defects, damage, sever corrosion (sea water pitting), dirt, animals or
any other foreign objects. Each length of the pipe shall be adequately swabbed, either by use
of canvas belt disc of proper diameter, or compressed air blowing or by other methods
approved by the Company. Damaged/corroded pipes shall be kept separate. Each length of
pipe shall be pulled through just before being welded.
All rust and foreign matters shall be removed from the beveled ends by power operated
brush. This shall be affected inside & out side and for a minimum distance of 25 mm from
edge of bevel. The bevel shall be thoroughly inspected at this stage. Should laminations,
split ends or manufacturing defects in the pipe observed, the length of the pipe containing
such defects shall be removed from the line in accordance with relevant specification.
Contractor shall align and weld together the Joints of pipe so as to construct a continuous
pipeline. All welds in the pipeline made by Contractor shall be of strength equal to that of
pipe. All welding shall conform to Company's welding specifications enclosed with the
Contract.
8.1 Pipe Defects and Repairs
It is Contractor's responsibility to rectify all internal and/or external defects.
8.1.1 Acceptability of defects in the pipe detected during inspection at the WORK site shall be
determined in accordance with latest edition of Company's own material specification or
code ASME B31.8/B 31.4 whichever is more stringent.
8.1.2 The maxithum permissible depth of dents in pipes shall be as per applicable linepipe
specification issued by Company.
8.1.3 Dents, which contain a stress concentrator such as scratch, gauge, arc burn or groove, and
dents located at the longitudinal, spiral or circumferential weld shall be removed by cutting
out the damaged portion of pipe as a cylinder.
8.1.4 Repair on line pipe shall be executed as specified in Company's material specification or
Code ASME B 31.8/B 31.4, whichever is more stringent. A record of all repairs shall be
maintained by Contractor. This record, provided with the pipe identification number shall be
submitted to the Company.
8.1.5 If due to cutting or repairs, the pipe identification number is removed, it shall be reprinted
immediately by Contractor in the presence of Company. In the event, the CONTRACT
provides for supply of line pipe by Company, Contractor shall be charged for any pipe
length due to loss of identification number. No pipe without identification number shall be
transported and/or welded into the pipeline.
8.1.6 Repair of damaged pipe ends by hammering and/or heating is not allowed. If the dented area
is minor and at least 200mm away from the pipe end, and the steel is not stretched, severed,
or split in the Company's opinion, the pipe may be straightened with a proper jack.
Page 388 of 1963

0-1Iaeit4 (ow* ENGINEERS
ittte7, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
8.2 Pipe Handling and Skid Spacing
8.2.1 When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings
approved by Company shall be used. Contractor shall submit his method of skidding and
skid spacing for Company's approval. A strip of soft material shall be placed in between skid
and pipe to protect the external coating of the pipe. The material shall be approved by the
Company.
8.2.2 The maximum skid spacing is not allowed before the stringer bead and the top and bottom
reinforcements are completed, provided that the distance between the incomplete weld and
the skid shall not exceed 9 (nine) percent of the skid spacing.
8.2.3 Skids shall be at least 1.20 meter long. For pipe with an 0.D. of 324 mm and larger the skids
in contact with the pipe shall have a width of at least 200mm. For pipe with an 0.D. of less
than 324 mm the skids in contact with the pipe shall have a width of at least 150mm. Pipe
supports shall be stable, so that pipe movement will not cause the supports to move. Skids
shall not be removed under a string before lowering in. The welded pipe shall be maintained
on skids at the minimum distance of 500mm above ground. Crotches shall be installed at
frequent intervals (at least every 10th support) with a greater number required at bends and
undulating grounds.
8.3 Night Caps
At the end of each day's WORK or every time when joining and welding operations are
interrupted, the open ends on the welded strings of pipes shall be capped with a securely
closed metal cap or plug as approved by Company so as to prevent the entry of dirt, water,
or any foreign matter into the pipeline. These covers shall not be removed until the WORK
is to be resumed. The caps/plugs used shall be mechanical type and attached to pipe by tack
welding.
8.4 Temporary Caps
Whenever the welded strings of pipes are left open at intervals to be tied in later after an
appreciable time lag, under roads, railroads, rivers, marshy crossings, etc., temporary caps
approved by Company shall be welded to the ends of the pipe.
9.0 LAYING
9.1 Lowering in Trench
9.1.1 Lowering can start after removal from ditch bottom of all off cuts, pipe supports, stones,
roots, debris, stakes, rock projections upto 150 mm below underside of pipe and any other
rigid materials which could lead to perforation or tearing of the coating. Sand padding,
graded soil and/or other materials containing no gravel, rock shall be provided as required in
accordance with clause 6.8 of this specification in such a way to get an even surface for pipe
laying.
9.1.2 Lowering shall follow as soon as possible, after the completion of the joint coating of the
welded pipe string In the case of parallel pipelines, laying shall be carried out by means of
successive operations, if possible without interruption.
Lowering shall be carried-out during daylight only. Lowering is not permitted during night.
In exceptional cases wherein lowering is carried out in night time, sufficient lighting
arrangements shall be made by Contractor. Sufficiency of lighting shall be to the satisfaction
of Engineer-in-Charge.
Page 389 of 1963

elei ENGINEERS
ogar temeg INDIA LIMITED
011FIT PlikS an,IV11.11 IA C..0,1 01 Ind. Urtdertak.g1
(ONSHORE)
6-71-0051 Rev. 4
Page 25 of 38
9.1.3 Before lowering in, a complete check by a full circle holiday detector for pipe coating and
for field joint coating shall be carried out and all damages repaired at Contractor's cost. All
points on the pipeline where the coating has been in contact with either the skids or with the
lifting equipment during laying, shall be carefully inspected for damages, denting or other
defects and shall be completely repaired. If, after checking, it becomes necessary to place
the pipeline again on supports at the bottom of the trench, these must be padded in such a
way as to prevent damage to the coating, thus avoiding necessity for further repairs when the
pipe is finally raised and laid. Before the last operation, a check must be made of the coating
at points of contact with the supports.
9.1.4 Before lowering in, short completed sections of the pipeline shall be cleaned with
compressed air driven cup Pig or Foam pig in order to remove all dirt, etc. from the inside of
pipe sections. In case such cleaning is proposed by Contractor after lowering, the Contractor
shall obtain approval from the Company.
9.1.5 The pipeline shall be lifted and laid using, for all movements necessary, suitable equipment
of non-abrasive material having adequate width for the fragility of the coating. Care shall be
exercised while removing the slings from around the coated pipe after it has been lowered
into the trench. Any damage caused to the coating shall be promptly repaired. Lowering-in
utilizing standard pipe cradles shall be permitted if Contractor demonstrates that pipe
coating is not damaged. No sling shall be put around field joint coating.
9.1.6 Wherever the pipeline is laid under tension, as a result of an assembly error (for example,
incorrect positioning of bends, either horizontal or vertical), the trench shall be rectified or in
exceptional cases a new assembly shall be carried out, to be approved by Company, so that it
fits the excavation and the laying bed.
9.1.7 Laying shall be carried out under safe conditions so as to avoid stresses and temporary
deformations of the equipments, which may cause damage to the pipeline itself and to the
coating. In case of localised points where the right-of-use is restricted to the minimum
necessary for the transit of mechanical equipment, the laying shall be carried out using other
suitable means. The pipe shall be placed on the floor of the excavation, without jerking,
falling, impact or other similar stresses. In particular, care must be taken that the
deformation caused during the raising of the pipe from the supports, does not exceed the
values for the minimum allowable radius of elastic curvature, so as to keep the stresses on
the steel and on the coating within safe limits. The portion of the pipeline between trench
and banlc shall be supported by as many side-booms as required and approved by Company
for holding the line in gentle S-curve maintaining minimum elastic bend radius as specified
in job standard. Lowering in and back-filling shall preferably be carried out at the highest
ambient temperature.
9.1.8 The pipeline must be laid without interruption for the whole or the length of section
available. Where water is present, no laying shall be permitted until the ditch has been
drained to the extent and for the time necessary to make visual inspection possible of the bed
on which the pipe is to be laid. Following such inspections, the presence of water will be
permitted, provided that it is not so high as to cause cave-in of the walls of the trench or
floating of the pipeline before backfilling, when weighing is not provided for the pipe.
9.1.9 Contractor shall take precautions immediately after lowering in to prevent the movement of
the pipe in trench.
9.1.10 Contractor shall close the two ends of the lowered section with night caps against ingress of
water/mud or any foreign material in the section.
9.1.11 In laying parallel pipelines in the same trench, the minimum distances between the pipelines
indicated in the approved drawings shall be observed. Once the first pipeline has been
positioned, it shall in no way be disturbed by laying of the subsequent pipelines.
Page 390 of 1963

Nr3
Weg muir INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
At every seven meters along the trench sand/earth filled bags shall be placed between the
parallel pipelines so as to ensure maintenance of the minimum stipulated distance between
the parallel lines.
9.2 Overhead Sections and Sections in Tunnel
9.2. 1 The following works shall be completed before proceeding with the assembly and laying of
overhead pipelines:
Construction of the pipe support structures.
Paints and/or coating of the pipe WORK, as indicated in the engineering specification.
9.2.2 The erection of the supports shall be carried out taking care that the elevation and alignment
is in accordance with the drawings.
In the case of metal work supports, pre-fabrication and/or assembly shall take into account
the maximum allowed free span and the supports shall not interfere with the pipeline welds.
9.2.3 In case roller supports are used, the rollers shall be lubricated, then checked for smooth
rotation and, in case of seizure, the defect shall be repaired or roller shall be replaced. In the
case of overhead section where the pipeline is slanting, the alignment of the end supports
shall be made after placing the pipeline in position. Before installation of the pipe section,
all the rollers shall be perfectly centered acting on the seat of the supports plates.
The above alignment operations shall be carried out before connecting the overhead section
with the end of the buried section.
9.2.4 Lifting, moving and laying of the pipeline shall be carried out in accordance with the
provisions of clause 9.1.5.
An insulation sheet shall be installed to isolate the pipe from the support or support from the
earth. The sheet shall be hard polyethylene/ neoprene/ Teflon pads at least 5 mm thick. It
shall extend at least to 10 mm outside the saddles or clamps.
9.2.5 Moving supports, if any, shall be centered on their support and allow for a movement of at
least 300mm in both directions.
9.2.6 A comprehensive report/method statement on the laying operation to be used shall be

submitted to the Company well in advance for approval. The report as a minimum shall
include, but not limited to the following:
a. Method of installation by lifting (as a preferred method).
b. Pulling method and related calculations, whenever lifting method cannot be used.
c. Pulling device and its characteristics including available pull force and FOS/margin
available w.r.t. calculated pulling load.
d. Method of anchoring the pulling device
e. Characteristics of the pulling rope
f. Braking device, if any
g. Pipeline assembly system.
Page 391 of 1963

ENGINEERS
Og-ar tti*le-r, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
10.0 BACK-FILLING
10.1 Backfilling shall not be done until the pipe and appurtenances have the proper fit and the
pipe is following the ditch profile at the required depth that will provide the required cover
and has a bed which is free of extraneous material and which allows the pipe to rest
smoothly and evenly.
Before any such WORK is done, it shall be Contractor's responsibility to first secure the
approval of Company. If any backfilling is done without Company's approval, Company
will have the right to require removal of the backfill for examination, and the cost of such
uncovering and refilling shall be borne by Contractor. Backfilling of trench in water courses
shall be carried out as per the relevant specifications issued for the purpose.
10.2 Backfilling shall be carried out immediately after the pipeline has been laid in the trench,
inspected and approved by the Company, so as to provide a natural anchorage for the
pipeline, thus avoiding long exposure of coating to high temperature, damaging actions of
adverse weather conditions, sliding down of trench sides and pipe movement in the trench. If
immediate back filling is not possible, a covering of at least 200mm of earth, free of rock
and hard lumps shall be placed over and around the pipe and coating. On no account the top
soil from the RoU shall be used for this purpose. In general, the trench shall be dry during
backfilling. Deviations thereof must have prior approval of the Company. The backfill
material shall contain no extraneous material and/or hard lumps of soil, which could damage
the pipe and/or coating or leave voids in the backfield trench. After the initial backfill has
been placed into the trench to a level slightly above the surrounding ground, Contractor shall
compact the backfill material. The surplus material shall be neatly crowned directly over the
trench and the adjacent excavated areas on both sides of the trench as per clause 6.2.1, to
such a height, which will, in Company's opinion, provide adequately for future settlement of
the trench backfill during the maintenance period and thereafter. The crown shall be high
enough to prevent the formation of a depression in the soil when backfill has settled into its
permanent position. Should depression occur after backfill, Contractor shall be responsible
for remedial WORK at no extra cost to Company. Surplus material, including rock, left from
this operation shall be disposed of to the satisfaction of land owner or authority having
jurisdiction at no extra cost to the Company.
A warning mat as per Company standard shall be laid 500 mm below the natural ground
level on the pipeline partial backfilling. For Further requirements reference shall be made to
section 14.0 "Clean-up and Restoration of Right-of-Use" of this specification.
10.3 Rock, gravel, lumps of hard soil or like materials shall not be backfield directly onto the pipe
unless padding and/or rock-shield has been provided as per Section 6.8 of this specification.
When "Padding" as described in Section 6.8 of this specification is to be used, the following
shall be applicable.
Where rock, gravel, lumps of hard soil or like materials are encountered at the time of trench
excavation, sufficient earth, sand or select backfill materials shall be placed around and over
the pipe to form a protective cushion extending at least to a compacted height of 150mm
above the top of the pipe. Select backfill materials for padding that are acceptable to
Company shall be soil, sand, clay or other material containing no gravel, rock or lumps of
hard soil. Whether such padding material would be taken from the adjacent spoil bank or
imported from elsewhere shall be directed by Company. All these works shall be carried out
by Contractor at no extra cost to Company. Loose rock may be returned to the trench after
the required selected backfill material has been placed, provided the rock placed in the ditch
will not interfere with the use of the land by landowner, or tenant.
10.4 When the trench has been dug through drive ways or roads, all backfills shall be executed
with sand or a suitable material as approved by Company and shall be thoroughly
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compacted. In certain cases, special compaction methods, such as moistening or ramming of

the backfill in layers may be required by Company. Company and any public or private
authority having jurisdiction over a road, street or drive way may require that the surface of
the backfill be gravelled with crushed rock or some other purchased material and the road
shall be repaved. In such instances, Contractor shall comply with said requirements at no
extra cost to Company.
10.5 Trenches excavated in dikes which are the property of railways or which are parts of main
roads shall be graded and backfield in their original profile and condition. If necessary, new
and/or special backfill materials shall be supplied and worked-up. The materials required
may include gravel, special stabilization materials or stabilized mixtures. Moreover, special
processing and/or compacting methods shall require the approval of Company and/or
competent authorities.
Stone-pitching/cement lining of Dyke walls, if dismantled during excavation shall be

restored to its original condition after backfilling and compaction to the entire satisfaction of
Company and concerned Authorities.
10.6 The trench in irrigated and paddy fields shall be backfield to within 300mm of the top, then
rammed and further backfield until the trench is completely backfield. Surplus material
remaining after the operation shall be spread over the RoU as specified in Section 14.0
"Clean-up and Restoration of Right-of- Use", of this specification.
10.7 At the end of each day's WORK, backfilling shall not be more than 500 meters behind the
head end of lowered-in pipe, which has been padded and approved for backfill. The backfill
shall be maintained by Contractor against washouts and spreading etc., until the completion
and final acceptance of the WORK by Company.
10.8 Contractor shall furnish materials and install slope breakers/ trench plugs in the trench in
steep areas (slope generally 10% and more) including cross drains for the purpose of
preventing erosion of the back fill. The type of breakers installed shall be as per the
approved drawings. Breakers shall be constructed of grout bags filled with a mixture of 10:1
Sand: Portland cement at Company's direction. Contractor may propose other methods such
as foam dams etc. which shall be subject to approval by Company. Such works shall be at no
extra cost to Company. Contractor shall pay attention to the direction of backfilling in such
steep areas.
10.9 When backfilling the trenches in sloping terrains or steep areas, where in the opinion of the
Company the backfill may be washed out of the trench, sheet piling or other effective water
breakers across the trench shall be provided by Contractor. This is to divert the flow of water
away from the trench into normal drainage followed before laying of the line. In no case, the
water is to be drained via the trench or via channels other than those followed before the line
was laid.
10.10 Contractor shall leave the pipe uncovered at certain locations to allow Company to survey
the top of the pipe and the level of the pipeline in the backfield trench. Within 48 hours after
backfilling, Company shall have carried out such survey and informed Contractor of any
realigning, if required. Thereafter Contractor shall compact the backfill.
The maximum allowable deviation from the centerline for land sections as staked out by
Company and as referenced by Contractor after backfilling is limited to following:
Pipeline dia upto and including 600 NB 200mm
Pipeline dia greater than 600 NB 300mm
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10.11 Before backfilling of the trench, Contractor shall comply with the requirements of Clause
10.12 Stabilization of backfill shall be carried out by the Contractor in sandy areas and other such
places, as directed by the Company. Contractor shall carry out the stabilization to have a
consolidated cover over the pipeline at no extra cost to Company.
The backfill shall be stabilized preferably with 150mm layer of marl, mattresses of gatch
other than straw or other stable materials. The width of stablisation shall be at least 3.0
meters on either side of the pipeline, plus one meter for every 10 meters height of dune
(where the line passes through the dune areas).
10.13 Temporary markers shall be installed during backfilling and the survey as per clause 10.10
to locate the pipeline axis. These markers shall then be replaced with permanent pipeline
markers.
10.14 Backfilling shall be preferably carried out at the highest ambient temperature. Backfilling in
station approach area shall be by select soil as per drawings.
10.15 In certain areas like U/G pipeline crossings, overhead power cable crossings etc, special care
to be taken by putting concrete slab/plastic grating before backfilling. Size and thickness of
concrete slab/plastic grating shall comply applicable job standard and approved by
Company.
10.16 For areas prone to seismic activities, special backfill shall be provided as per contract
requirements.
11.0 TIEING-IN
11.1 The unconnected sections of the pipeline at various locations have to be tied in after the
sections are coated, lowered and backfield. The sections to be connected shall have at the
ends, sections of over lapping, uncovered pipe of sufficient length to absorb, without
inducing excessive stresses in the steel, small displacements necessary for perfect alignment
and connection of the ends.
11.2 Tie-in shall preferably be carried out at ambient temperatures corresponding to the average
operating temperature in the case of a pipeline conveying fluids at normal temperatures and
at the maximum ambient temperature in the case where the pipeline is carrying fluids at high
temperature.
11.3 Contractor shall carry out tie-in-welding (including necessary cutting, bevelling, grinding of
pipe weld seams and line-up etc.) cleaning, priming, coating and backfilling for the tie-in
portion as per relevant specifications. Contractor shall also excavate the required bell-holes
for the welding. Bell holes made to facilitate welding shall provide adequate clearance to
enable the welders to exercise normal welding ability and skill. All tie-in welds shall be
radiographically examined. If the depth of bell hole exceeds 2.0 m, then either step cutting
or shoring and strutting shall be carried out to avoid caving/ collapse of soil into the bell
hole.
11.4 The tie-in should be done in such a way as to leave a minimum of strain in the pipe. If
necessary, with respect to the trench, realigning of the pipe shall be done to eliminate force
or strain in the pipe by the Contractor at no extra cost to Company.
11.5 If a pup end cannot be avoided for tie-in, the minimum length that shall be added is 1.0
meter and two or more such pups shall not be welded together. All cut-off lengths greater
than 1.0 meter shall be moved ahead in order to be welded into the pipeline at a suitable
location. Tie-in with two or more pups may be used provided that they each have minimum
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INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4

length of 1.0 meter and are separated by an entire length of pipe. In no case more than three
(3) welds shall be permitted on a 10 meter length of pipeline.
11.6 In connecting pipes, special items, fittings and equipment where different wall thicknesses
are to be welded, Contractor shall weld transition piece as per procedures indicated in
ASME B31.8/ ASME B31.4, as applicable. The required tapering shall be done by
Contractor at no extra cost to Company.
11.7 For tie-in of adjacent sections of pipeline already pressure tested, the pup used for tie-in
shall be of single length or off-cuts of pipe, which have already been hydrostatically tested.
Contractor shall take care that sufficient number of pretested pipes with different wall
thicknesses are readily available.
12.0 SPECIAL INSTALLATIONS ON THE PIPELINE
12.1 General
12.1.1 In addition to constructing the pipeline, Contractor shall also install certain other auxiliary
facilities and appurtenances.
Contractor shall do all WORK necessary at each of the installations to provide facilities,
which are complete in all respects and ready for operations.
Without limiting the generality thereof, the WORK required to complete the installations
shall, where applicable, include all site surveys, site preparation, filling, grading, fencing,
foundations, installation of block valves, side valves, pipe work, pipe supports, pressure
gauges, mechanical facilities, civil work, painting, installation of all electrical equipments,
motors, cables, conduit, wiring and fixtures and hooking up of same; installation of all
instruments, piping, valves and fittings; mounting of all instruments and making all piping
and electronic connections, etc.
On completion, all elements of each entire installation shall be checked out and tested for
full and correct operation in the presence of, and to the satisfaction of Company. All WORK
shall be carried out strictly in accordance with the appropriate codes, the approved drawings,
and this and other related specifications.
Contractor shall fabricate all piping and install valves and fittings as required by the detailed
engineering fabrication drawings prepared by him and approved by Company. Piping
fabrication drawings shall be prepared by Contractor based on AFC drawings and approved
by Engineer In charge at site.
Stainless steel lines will he "swaged" using permanent fittings installed with a hydraulic
device.
Cold bending for the fitting of 12 mm NB and 6 mm NB pipes is allowed when special
bending tools are used with guides to prevent flattening. The minimum radius allowed shall
not be less than R=10 D, where D = outside diameter of pipe.
The bending tools shall be subject to Company's approval.
Contractor shall ensure that the piping assemblies are not in a strain prior to the final bolting
or welding. Contractor shall also ensure that all equipment and piping are thoroughly
swabbed clean of all dust, refuse, welding-spatter, scale, or any potentially detachable matter
prior to the tie-in or final bolting.
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ENGINEERS
0:gar 004--67, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
12.1.2 Dimensional tolerances
These tolerances apply to inline items and corrections for other lines. These tolerances can
be exceeded on items such as vents, drains, dummy supports, field supports, temperature and
pressure connections, where the deviation will not affect another spool.
a. General dimensions such as face to face, face or end to end, face or end to centre, and
center to centre: ± 3mm.
b. Inclination of flange face from true in any direction: 4mm per meter.
c. Displacement of branch connection from indicated location: ± 1.6mm. When multiple

branches are involved, the displacement of the branches shall not exceed 3mm from a
common point.
d. Rotation of flange bolt holes shall not exceed 1.6mm.
12.1.3 Flanged connections
Contractor shall ensure that prior to final bolting, all flange faces are parallel and centered,
according to standard practice. Contractor shall not use bolting forces as a means for
attaining alignment. A gasket of required size and quality shall be installed between the
flanges at each joint.
Bolts shall be tightened in diagonal sequence and shall be centered with equal amounts of
thread visible on both sides. Bolts shall be uniformly tightened to produce a leak-proof joint.
Bolts that yield during tightening shall be removed and discarded. It is mandatory that a
torque wrench is used for bolt tightening. Bolt tensioning, wherever applicable, shall be
carried out.
12.1.4 Threaded connections
Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.
Contractor shall properly align all threaded joints. Pipe entering unions shall be true to
centerline so the union will not be forced during make-up. The threaded pipe shall not
project through fittings to cause interference with valves or other operating mechanisms.
PTFE tape shall be used for threaded joints.
Except for the threaded connections of instruments, which will require periodic testing and
maintenance, all threaded joints shall be seal welded. The latter joints shall be made up
without pipe joint compound and with a minimum of oil from the thread cutter. Seal welds
should taper into the pipe with as little discontinuity as possible, and should cover all
threads. All seal welds shall be tested with DP, MP testing.
12.1.5 Welded connections
Where the ends of the piping components being welded have an internal surface
misalignment exceeding 1.6mm, the wall of the component extending internally shall be
trimmed by machining so that the adjoining internal surfaces will be approximately flush.
All welding shall be performed in accordance with EIL Specification No. 6- 77-0006
(Welding specification for onshore pipeline for transportation of Gas), Specification No 6-
77-0007 (Welding specification for onshore pipelines for transportation of liquid
hydrocarbons) and other applicable Jobs Specifications and Welding Specification Chart.
Tie-ins between fixed points shall be made at maximum ambient temperature.
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ENGINEERS
laWer, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
12.1.6 Civil work
Civil work shall be performed in accordance with Specifications issued for the purpose.
12.1.7 Painting
All exposed surfaces like piping, valves, structures, and miscellaneous appurtenances shall
be painted in accordance with the specifications issued for this purpose. The corrosion
coating on pipe surface will end approximately 300 mm above the finish grade and it will be
necessary for Contractor to provide a clean interface at the junction of the protective coating
and the paint.
12.1.8 Coating of buried installations, etc.
All buried valves, insulating joints, flow tees, bends, other in-line fittings and appurtenances
shall be coated with 100% solid high build epoxy (minimum 500 micron thk) or 1.5 mm
thick polyurethane coating or any other equivalent suitable Company approved coating at no
extra cost to Company. For buried pipes and LR bends, heat shrink sleeves/cold applied
tapes conforming to Company's specification for Field Joint Coating (Specification No. 6-
71-0044), shall be used. Contractor shall submit to Company a report regarding the method
of application and the materials used along with all test certificates. Only after obtaining
written approval from the Company, Contractor shall commence the work of coating.
12.1.9 Clean-up
After all required tests have been concluded satisfactorily, Contractor shall clean up the Site
as laid down in the specifications issued for the purpose. The Site shall be graded in
accordance with the approved drawings.
12.2 Installation of Valves and Valve Stations
12.2.1 Block and sectionalising valve stations shall be installed as shown on the approved
drawings. It is Contractor's responsibility to have the units completely assembled, tested and
made fully functional including all related instruments etc.
12.2.2 The civil and structural work shall be carried out in accordance with the relevant
specifications issued for the purpose and in accordance with the approved drawings as
directed by Company. This work as a minimum shall include clearing, grading, fencing,
foundations etc. as required. All above ground structures shall be painted as per the
specification and color code given by the Company.
12.2.3 Suitable concrete foundation as directed by Company shall be constructed on which the
valve shall be firmly installed, after embedding an insulating sheet of hard polyethylene/
neoprene/ teflon with a thickness of at least 5mm or equivalent. Such insulating sheet is also
to be installed under pipe clamps, etc.
12.2.4 Valves with flow arrows shall be installed according to the normal flow in the pipeline.
During welding, the valves shall be in fully open position. In addition, all instructions of the
manufacturer shall be followed.
Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.
12.2.5 For valves and piping installed below ground and/or above ground the anti-corrosion
coating/painting shall be as per the requirements of the relevant specifications issued for the
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eitq ENGINEERS
ligar0153eg INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
tn139217.1 (A Govt kW. Undottoktogl
purpose. The anti-corrosion below ground coating shall extend upto 300mm above grade at
the lowest point.
12.2.6 Sectionalising valves shall be installed on sections of the pipeline in the horizontal position
only or with an inclination not greater than that allowed by the valve manufacturer.
Installation shall be done in such a way that there is no strain in the welded joint while the
pipeline at upstream and downstream side is straight.
12.2.7 All valves shall always be handled using appropriate equipment and methods so as to avoid
impact, shaking and other stresses. In particular, the equipment and tools used for lifting and
handling shall never be hooked through hand wheel, valve stem, flange joints and other
parts, which may suffer damage/misalignment.
12.2.8 All sectionalising valve and any other inline assemblies shall be prefabricated and tested
hydrostatically ex-situ as per applicable specification. All such assemblies shall be installed
at the locations shown in the drawings only after successful completion of the hydrostatic
test and dewatering. Thereafter the ends of the assembly shall be closed off. Contractor shall
carry out necessary excavation, cutting, beveling of pipe ends and welding of the tie-ins
required for the installation of such assembly. The tie-in joints shall be radiographically
examined over 100% length and also 100% ultrasonically examined prior to backfilling. All
works shall be executed in accordance with the relevant specifications issued for the
purpose.
12.3 Installation of Scraper Launchers and Receivers
12.3.1 Scraper stations shall be fabricated and installed as per the approved drawings and whenever
applicable as per the requirements of clause 12.2 of this specification. It is Contractor's
responsibility to have the units completely assembled tested and made fully functional
including all instruments and related piping.
12.3.2 The Civil and structural works for the scraper stations shall be carried out as per the relevant
specifications, in accordance with the drawings and as directed by the Company. The
WORK as a minimum shall include site survey, site preparation, clearing, grading, fencing,
foundations, etc. as required.
12.3.3 It shall be Contractor's responsibility to maintain elevations shown on the approved

drawings and to carry out any pipe work adjustments, necessary for this purpose. Field cuts
shall be square and accurate and field welds shall not be performed under stress of pipe
ends.
12.3 .4 The painting for the scraper stations shall be carried out as per "Specifications for Painting".
The underground sections shall be coated as specified for the pipeline upto at least 300mm
above grade.
12.3.5 The hydrostatic testing of the scraper stations shall be executed after installation in
accordance with the relevant specifications issued for the purpose.
12.4 Installation of Insulating Joints
12.4.1 Insulating joints shall be installed at the locations shown in the drawings. Contractor shall
obtain approval from the Company before installation of the insulating joints.
12.4.2 Handling and installation of the insulating joints shall be carried out with all precautions
required to avoid damage and excessive stresses and that the original pup length is not
reduced.
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eiel ENONEERS
$1g-ar Weg INDIA LIMI I ED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
iOOVOT 7.170377m1,12.1 IO Govt kola Undedolong)
12.4.3 The insulating joints and the welded joints shall be protected by external coating as per
relevant specifications issued for the purpose.
12.4.4 When the in-line inserting is made on the buried pipeline, care shall be taken to weld at an
external temperature as close as possible to the pipeline operating temperature.
The joint shall be inserted on straight sections and laid on a fine sand bed.
12.4.5 During the execution of the in-line connection welding, the propagation of heat shall be
avoided. To achieve this, the joint shall be kept cold by means of rags continuously wetted.
12.4.6 Insulating joints shall be electrically tested before welding into the pipeline. The electrical
resistance/conductance test shall be carried out using a Megger. Measurement of the
insulation resistance across the joint shall be approx. one (1) Mega Ohm. The tests shall be
repeated after installation and welding of the joint into the pipeline to verify that the
assembly is undamaged.
13.0 WORKING SPREAD LIMITATIONS
Contractor shall, in general, observe the following maximum distances between the working
mainline spread:
Between RoU grading, clearing and backfilling 25 km
Between backfilling and final clean-up 05 km
The spread limitations do not apply to point spreads such as rock blasting, river crossing and
bored crossings of roads, railways and canals and HDD crossings.
Any deviations from the above shall meet prior approval of Company. Company reserves
the right to stop the WORK, in case the approved spread limitations are exceeded and
Contractor shall not be paid any compensation for stoppage of WORK.
14.0 CLEAN UP AND RESTOFtATION OF RIGHT OF USE

-
14.1 Contractor shall restore the RoU and all sites used for the construction of pipelines, water
crossings and other structures in accordance with Company's instructions, and deliver them
to the satisfaction of Company.
14.2 Surplus Materials
For Company supplied materials, after completion of WORK, the Contractor shall return all
surplus materials at Company's designated areas.
The reconciliation of surplus free issue line pipes shall be as per the requirement of
commercial condition of contract.
14.3 Disposal
14.3.1 All surplus and defective materials supplied by Contractor and all trash, refuse and spoiled
materials shall be collected and disposed off by Contractor.
14.3.2 The RoU shall be cleared of all rubbish, broken skids, empty cans, card board, sacks,
stumps, trash, and leftover construction material. All burnable matter shall be burned, but
only after obtaining appropriate permits for such burning. If burning is not allowed,
Contractor shall haul the clean-up material to an approved dumping area. All scrap metal
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Mireg INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
and unburnable material shall be disposed of, in an appropriate manner, but never be buried
in the RoU.
14.3.3 Surplus soil can only be removed from the Owner's plot after authorisation by Company.
14.3.4 All dumping fees connected with the disposal of materials shall be to the account of
Contractor.
14.3.5 All loose stones and rock exposed by the construction operations and scattered over the RoU
or adjacent grounds shall be removed by Contractor and be transported to a location
considered suitable by the land-owner and/or tenant, or by authorities have jurisdiction, for
satisfactory disposal. For stones, gravel or other hard material, which may be buried in the
trench the provisions of the specifications shall apply with the understanding that the use of
the land by the land-owner and/or tenant will not be interfered with.
14.4 Temporary Structures
All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which were
erected or installed by Contractor as temporary measure, shall be removed. However, it may
be necessary to remove the fence of RoU during the maintenance period.
14.5 Repair of Damages
Damages to roads, bridges, and private property shall be repaired by Contractor. All fences
and other structures, which are damaged during construction, shall be restored to original.
Slopes, water course sides or banks which have been partially or totally demolished during
the execution of the works shall be properly consolidated and restored (without waiting for
their natural consolidation and settling) complying the requirement of the concerned
Authorities. The bed of water-courses shall be restored to the original level. The banks and
any excavated areas shall be restored to the original levels and contours. The banks shall
also be stabilized.
All boundary stones, which have been moved or removed during the WORK must be reset
in their original location to the satisfaction of the landowner concerned.
14.6 On completion of clean-up, the RoU shall be restored to such stable and usable condition as
may be reasonably consistent with the condition of the RoU prior to laying the pipeline. The
Company shall be completely indemnified and held harmless by Contractor from any and
against all claims, demands, losses, expenses etc. that may arise in this behalf or the
Company may anyway suffer or sustain, relative to, arising out of, or in connection with
same. The Company may require from the Contractor signed Releases from landowners
regarding satisfactory indemnification and restoration of their lands.
14.7 Special precautions shall be taken near steep slopes prone to erosions and landslides. All
necessary steps shall be taken to ensure the rapid growth of grass by providing wicker
barriers and by regulating the drainage of surface waters.
14.8 All cadastral or geodetic markers, which may have been removed during the execution of
the WORKs, shall be restored in their exact position.
14.9 Ditches for which no instructions for their restoration have been issued, or restoration cannot
be done due to absence of banks, shall be restored as instructed by Company. The bed of
ditches crossed by the pipeline shall be cleaned over the full width of the RoU, also outside
the RoU if necessary. This restoration might contain but is not limited to the supply and
installation of proper materials for backfill and protection, the sodding or other precautions
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wawri) ENGINEERS
Igartit5ite-g INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
to prevent erosion or guarantee the stability. All work has to be done after deliberation and
acceptance of the authorities and Company. Other field drains have to be restored over full
width of RoU and if necessary also outside the RoU by hand and/or special equipment as
soon as possible.
14.10 Any subsidence, cave-ins, wash-outs, which have been caused during the pipeline
construction and maintenance, caused by whatever reason within the edge of ditches and
open drains, shall be repaired by Contractor immediately or at first notice given by
Company.
14.11 After the clean-up, the RoU of pastures has to remain fenced considered suitable by the
tenant and to be removed during the maintenance period. When agricultural and other traffic
(requested by tenant) have to cross the RoU the cross-overs have to be fenced with the same
material as the RoU. If necessary, special materials have to be used to allow traffic on the
cross-over. Fencing of the right-of-use as specified shall not be removed until Contractor has
obtained written permission by Company. In general this has to be done during the
maintenance period.
14.12 All openings in or damage to the fences or enclosures shall be repaired by installing new
fencing of a quality, which shall be at least equal to the parts damaged or removed.
Provisional gates shall be removed and replaced with new fencing. All repairs to fences and
enclosures shall be carried out by Contractor to the complete satisfaction of Company,
landowner and/or tenant.
14.13 If, in the opinion of Company, the sod in pasture land has been damaged by vehicles and
wheel tracks are visible, the RoU shall be tilled with a disc-harrow or rotary cultivator
several times. The damaged sod shall be firmly cut up and thoroughly mixed through the
top-soil. In general, the RoU has also to be ripped. After this procedure no closed-in layers
must be found and sufficiently loose top-soil 250 mm to 300 mm thick must be present. The
whole procedure must be approved by Company. Subsequently, the entire RoU, which is
part of pasture land, shall be prepared for seeding and fertilized by Contractor according to
the instructions of Company.
14.14 In crop fields the tillage shall consist of passing over the land several times with a disc
harrow, cultivating with a spading machine, or plow, to a depth of approx. 200 mm. In
general the RoU has also to be ripped. After this cultivation process no closed-in layers must
be found any more in the RoU. The equipment used and methods adopted shall require the
approval of Company. Ripping has to be done with rippers with a distance of 500 mm
between the ripper blades. The type to be used shall be approved by Company.
14.15 Adequate numbers of saplings of any plant/tree uprooted or cut during construction shall be
planted along the route as per the direction of the Company and in accordance with the
requirement of Authorities. The cost of sapling and its plantation shall be to Contractor's
account.
14.16 The RoU and the backfilled trench in particular has to be finished in such a way that after
settlement of the soil the fields are at their original level.
If during the maintenance period certain parts of the RoU are lower than the original level,
Company can order Contractor to bring these parts to the original level.
In cases where heavy damage has occurred to the structure of the subsoil as a result of
adverse circumstances, Company reserves the right to order Contractor to carry out special
restoration work. Said special work can include:
- Spading with dragline (depth 300-800 mm);
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(001,rd) ENGINEERS
INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
Spading with dragline (depth 800-1000 mm);

fertilizing;
cover with sand.
If during clean-up operations soil shortages become apparent outside the trench, Contractor
shall supplement said soil shortage using suitable materials, approved by Company.
If site and/or climatic conditions should render this necessary, Company shall have the right
to order Contractor to suspend certain parts of the work related to the clean-up and postpone
it to a later date.
14.17 Soil Surplus
If on site, as a result of the WORK and after careful backfilling and compacting, a sub-soil
surplus exists, this shall be worked up by grading and compacting below the sub-soil top
layer and as a rule this shall be done in the same plot of land. It shall not be permitted to
remove the surplus from the plot concerned, unless it concerns rejected soil, which has to be
removed. Working up surplus soil or removal of rejected soil shall be considered to pertain
to the WORK.
To work a soil surplus into the ground, Contractor shall remove an additional strip of top
soil beside the trench. Next, the upper layer of sub-soil shall also be removed. Both soil
types shall be stored separately across a width depending on the size of the soil surplus. The
soil surplus shall then be distributed across the trench thus widened, after which it shall be
graded and compacted and subsequently the top layer of sub-soil and the top-soil shall be
replaced in the correct order, in accordance with the Specifications.
In case Company has given prior permission for mixed excavation of the sub-soil as well as
in cases where Company deems mixed excavation permissible, the above provision of
separate storage of the upper layer of sub- soil shall not apply to the working up to the soil
surplus.
In cases where the soil surplus can be worked up in others plots where soil shortages have
arisen due to the WORK, this shall only be done after prior permission by land-owner, land-
user and Company.
14.18 Soil Shortages
If due to unforeseen circumstances during backfilling and compacting there should not be
enough soil to fill the trench properly, or to install the crown height as stipulated, Contractor
shall supply the necessary backfill material.
Soil shortages shall be supplemented and applied before the top-soil is replaced.
The soil to be supplied shall be worked up in those locations and into those layers where a
soil shortage has been established. The quality of the supplemented soil shall be equal to that
of the shortage.
15.0 MAINTENANCE DURING DEFECTS LIABILITY PERIOD
Defects Liability Period (defined as period of liability in the CONTRACT) means the period
calculated from the date certified in the Completion Certificate.
Company reserves the right to carry out instrumented pigging survey of the completed
pipeline.
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ei ENGINEERS
fableri, INDIA LIMITED PIPELINE CONSTRUCTION 6-71-0051 Rev. 4
Contractor shall be responsible for making good with all possible speed at his expense any
defect in or damage to any portion of the Work which may appear or occur during the
Defects Liability Period and which arises either:
a. From any defective material (other than supplied by Company), Workmanship or design
(other than a design made, furnished or specified by Company and for which Contractor
has disclaimed responsibility in writing), or
b. From any act or omission of Contractor done or omitted during the said period.
If such defect shall appear or damage occur, Company shall forthwith inform Contractor
thereof stating in writing the nature of the defect or damage.
If any such defect or damage be not remedied within a reasonable time, Company may
proceed to execute the WORK at Contractor's risk and expense provided that he does so in a
reasonable manner. Such defect or damage can be, but is not limited to:
Clean-up of RoU, including water courses
Sagging or sinking of site level or pipe supports
Sliding of ditch banks
- Repair of fencing or removal of construction fencing
- Repaving of pavements, repair of pavements, repair of Roads
Repair of coating, painting
- Realigning markers, signs
- Leak/burst of pipe, leaking of flanges, washouts
Short-circuit in casings
Construction defects such as dents, ovality, welding offsets/defects, etc. detected during
intelligent pigging survey, etc.
Company reserves the right to have the required Computerised Potential Logging Test
executed during the DEFECTS LIABILITY PERIOD and whenever weather conditions are
more favorable for this job. The work shall (at or as soon as practicable after the expiration
of the Defects Liability Period) be delivered to Company in the conditions required by the
CONTRACT, fair wear and tear excepted, to the satisfaction of Company. Contractor shall
finish the work, if any outstanding, at the date of completion as soon as possible after such
date and shall execute all such work.
Page 403 of 1963

INDI NEERS
(AIM =MOM
ENGIA
LIMIT CONSTRUCTION OF PIPELINES
EDCROSSING ROADS, RAIL ROADS &
(A Govt Inds Undertoking)
MINOR WATER CROSSINGS

6-71-0052 Rev. 3
Page 1 of 11
criztiql1 WEFT
VA* iff‘
1:rriW ?elk
CONSTRUCTION OF PIPELINES
CROSSING ROADS, RAIL ROADS AND
\k-oP
RE-AFFIRMED & REISSUED AS STANDARD
3 09.05.11
SPECIFICATION NR VM DM
2 22-03-06 VJN
SPECIFICATION MKM SK AS
1 28.9.98 SPECIFICATION KKS RK VC AS
0 09.06.89 ISSUED AS STANDARD SPECIFICATION MK GD SA RCPC

Standards Standards
by by
Approved by
Page 404 of 1963

eit'idgith ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
41 en
g
lawn
tmegvir
21■RIAZ0. 3cM.i)
INDIA LIMITED CROSSING ROADS, RAIL ROADS &
(A Govt ot India Undertaking)
MINOR WATER CROSSINGS Page 2 of 11
Abbreviations:

OISD Oil Industry Safety Directorate
RoU Right of Use
US DOT United States Department Of Transportation
Convenor: Mr. Vinay Mittal
Members: Mr. Raj Kumar

Mr. M. S. Gunjiyal
Mr. Atul Chhatwal
Mr. A.K.Chaudhary (PDD)
Mr. M.P.Jain (Projects)
Page 405 of 1963

ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
1W114:31A umnID CROSSING ROADS, RAIL ROADS &
2:11=
Men MOW =WOO IA Govt. el Inch Undated%)
Page 3 of 11
CONTENTS
1.0 SCOPE 4
3.0 GENERAL 5
4.0 ROAD AND RAIL-ROAD CROSSINGS 6
5.0 CROSSING OF BURIED SERVICES 9
6.0 MINOR WATER COURSE CROSSINGS 9
Page 406 of 1963

-

4oi 21 igh ENGINEERS CONSTRUCTION OF PIPELINES
`fgzlf161P-eg WV INDIA LIMITED CROSSING ROADS, RAIL ROADS & 6-71-0052 Rev. 3
lonirrardnn'fril3OrffAi (A Govt of India Undertaking)
1.0 SCOPE
1.1 This specification covers the minimum requirements for the various activities to be carried out
by the Contractor for or about the installation of pipelines crossing roads, railroads, minor
watercourses and other services.
The provisions of this specification are not applicable for pipelines crossing water courses,
which are specifically designated as "Major Water Courses" in the CONTRACT.
documents included in the CONTRACT between Company and Contractor. Unless specified
specification.
of floating the enquiry) of the following codes, standards and specifications.
ASME B 31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids
ASME B 31.8 Gas Transmission and Distribution Piping systems.
API RP 1102 Recommended practice for Liquid Petroleum Pipelines

Crossing Railroads and Highways.
OISD B 141 Design and construction requirements for cross-country

hydrocarbon pipelines
Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line
(US DOT - Pipe Line Safety Standards).
Part 195 Transportation of liquids by Pipe Line

(US DOT - Pipe Line Safety Standards).
g) EIL Standard Specifications:
6-71-0051 Standard Specification for Pipeline Construction (Onshore)
6-77-0006 Welding Specification for Onshore Pipelines for

Transportation of Gas
iii) 6-77-0007 - Welding Specification for Onshore Pipelines for

Transportation of Liquid Hydrocarbons
2.2 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern. In case of conflict
between the requirements of this specification and that of the above referred codes, standards,
specifications and practices, the requirements of this specification shall govern.
the words 'Shall' and 'Must' are mandatory.

the words 'Should', 'May' and 'Will' are non-mandatory, advisory or recommended.
Page 407 of 1963

ENalistraED
fb iN CR OSNSSIT
CO NR CO
GUR TA IPREO
IODNSOF PL LIANDESS
6-71-0052 Rev. 3
&
Page 5 of 11
MIRA PROWMIJAIIIVII (A Goof of MOW Undotaldno
3.0 GENERAL
3.1 Crossing of roads, railroads, buried services, canals and minor water courses with equipment
and/or personnel is allowed only after acquiring approval from the authorities having
jurisdiction and after malting arrangements for safeguarding the roads, etc. and the verges
and/or banks thereof and the buried services with appropriate provisions.
Highways, Main-Roads and Railroads and their verges and banks of water crossings are not
allowed to be used for loading, unloading or stacking of materials and/or equipment. For
secondary roads, such loading/unloading is permitted only after prior approval from the
concerned authorities. Contractor is not allowed to close or divert roads or watercourses
without prior approval from the Company and the concerned authorities. Contractor shall
never unnecessarily hamper the users of the roads, railroads, buried services and/or
watercourses. The water flow shall not be obstructed in any way.
All Civil and Mechanical works associated with or incidental to the installation of pipeline
crossings shall be carried out in accordance with EIL Specification no. 6-71-0051 "Standard
Specification for Pipeline Construction (Onshore)".
3.2 Company reserves the right to demand for individual crossings from the Contractor a separate
detailed report for approval, containing:
Approval letter from concerned authorities
Time Schedule
Execution methodology with details of equipment
Test procedure
Manpower deployment
Calculations/Description of temporary works
Design calculations for crossing
Soil investigations, etc.
Such works shall be without any extra cost to Company.
3.3 Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically pretested
ex-situ, prior to joint coating, whenever,
Crossing is executed by boring of carrier pipe:
Crossing is installed in casing pipe;
River Crossing pipes which are to be continuously concrete weight coated
Whenever, in Company's opinion, the repair of pipeline at crossing, in case of a leak

during final hydrostatic testing, would require inordinate amount of efforts and/or time;
Whenever pretesting is insisted upon by the Authorities having jurisdiction over the
utility crossed.
Page 408 of 1963

401 el MENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
LIIEIVRegw
wen
Mew' =WO INDIA LIMITED CROSSING ROADS, RAIL ROADS &
1A Govt Incite Undertaking)
The section of the pipeline for the crossing shall be tested as a single string. Unless specified
otherwise in the CONTRACT, the test pressure shall be the one resulting in hoop stress
corresponding to 90% of SMYS of pipe material. Test pressure shall be retained in the
pipeline for minimum period of four (4) hours. Test section shall be kept under surveillance by
regular patrols during test and it shall be visually examined for leaks/defects, etc.
4.0 ROAD AND RAILROAD CROSSINGS
4.1 The work under crossings shall include necessary clearing, grading and trenching to required
depths and widths, welding of casing (when required) and carrier pipes, lowering-in, back
filling, clean-up, restoration to the original condition and further strengthening and protective
works, testing, installation of assemblies, insulators and end-seals, and temporary works such
as sheet piling, bridges, etc.
The work shall be carried out in accordance with the approved drawings and job standards, as
directed by Company and to the satisfaction of Company and the authorities having
jurisdiction over the facility crossed. The work carried out for road and railroad crossings shall
meet the minimum requirements of API RP 1102.
Before the installation work of crossings is started, the Contractor shall provide suitable
barricades, temporary bridge/bypass work (especially where roads are open-cut) with railing,
if required by Company for safety of traffic. Adequate traffic warning signals and/or traffic
lights and suitable diversions shall be provided as directed by Company/Authority having
jurisdiction over these areas. Such diversions shall not cross the pipeline where it has already
been installed, unless proper safeguarding at Company's opinion is ensured.
Prior approval from the statutory authorities shall be obtained to lay the pipeline across the
highway/road either by boring or by open-cut method. Installation of the crossing shall be by
the method (i.e., boring/open-cut) approved by Authorities having jurisdiction. Railroad
crossings shall always be bored/jacked.
4.2 Boring/jacking of carrier pipes for crossings is allowed only if the pipes for boring/jacking are
provided with a suitable corrosion coating and Contractor remains liable for the suitability of
the pipe and weld-coating of carrier pipes to be bored and type of coating and method of
application are anyhow to be authorized by Company without prejudice to Contractor's
liability. In all other cases the carrier pipes shall be cased.
Before start of the boring/jacking operation, Contractor shall execute soil investigations and
determine the ground water table. Based on these investigations, Contractor shall prepare a
construction drawing and submit to Company for approval including time schedule and soil
investigation report.
During the execution of the boring, the ground water table over the length of the boring shall
be lowered up to atleast 0.50 m below bottom of the pipeline. This water table is to be
regularly inspected and maintained by Contractor and reported to Company. To safeguard the
stability of the bore pit, Contractor shall, if necessary in Company's opinion, use a closed
sheet piling, which shall extend atleast over 50% of the length in undisturbed soil. The length
of the boring shall be in accordance with the width of the ROU of the crossing (road, railroad,
etc.), with minimum 0 6 m extra on either side.
If the soil conditions and ground water for a particular boring give reasons for this, Contractor
is entitled to suggest to Company for a relaxation of one or more of the following
requirements as defined here forth.
Soil investigation
Page 409 of 1963

ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
WA LMTED CROSSING ROADS, RAIL ROADS &
Page 7 of 11
IA Gout of Ind* Urldlaitivq)
Lowering of ground water table
Sheet piling
Length of boring, etc.
In approaches to the crossing, Contractor shall eliminate unnecessary bending of pipe by

conforming to the contour of the ground by gradually deepening the ditch at such approaches
as directed by the Company.
4.3 The bottom of the trench and/or the pit for at least twelve (12) meters at the approach to each
end of a casing shall be graded and if necessary backfilled with clean sand and compacted
upto atleast 95% Proctor Density to an elevation that will provide sufficient and continuous
support to the pipeline so that the pipeline remains correctly aligned at casing ends during and
after backfilling.
4.4 The diameter of the hole for a bored section shall have a hole diameter as close as practicable
to the outside diameter of the carrier or casing pipe. If excessive void or too large hole results,
or if it is necessary, in the opinion of Company, to abandon the bored hole, prompt remedial
measures such as filling the hole with suitable material shall be taken to the entire satisfaction
of the Company and Authorities having jurisdiction thereof at no extra cost to Company.
Equipment used for installation of casing pipe shall be of the type approved by Company.
An installation consisting of hydraulic jacks shall be provided with easily readable pressure
gauges (in bar) and sealable pressure limits. Their proper operation shall be demonstrated
before the work is started. Company can request that the maximum pressing force be limited.
At the front of the pipe there may be a cutting ring, which may be 12 mm large than the
outside diameter of the pipe or casing. A lubricating pipe can also be used in jacking, the
nipples of which shall not protrude from the cutting ring. Said lubricating pipe shall not be
fixed to the pipe or casing. When jacking, only biologically degradable lubricants shall be
used (e.g. WRC Medlube or an emulsion of bentonite).
Removal of soil from the pipeline during jacking shall be done mechanically by means of a
standard, locked auger, which has to be safeguarded against jacking ahead of the pipe. If, in
the opinion of the Company, fluid sand may arise, an inner pipe with funnel shall be used.
During jacking, the progress of the pipe to be jacked and the cutting capacity of the auger shall
be mutually adjusted, by regulating the speed of auger, to prevent the road from bulging (rpm
too low) or cave-ins (rpm too high). In any case no more soil shall be removed than the
volume of the pipe. The auger drive shall be provided with a clutch.
The progress in the work, the readings of the gauge pipes, the jacking pressures observed, etc.,
shall be recorded in a log book, to be shown to Company upon request. All information shall
be supplied to Company on completion of the work.
If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and plugged
at either end. The diameter of the casing pipe shall be as indicated in the job standards.
Company reserves the right to inspect certain lengths of pipes to assess damages, if any, to the
corrosion coating of the carrier pipe used for boring. Contractor shall weld additional lengths
of pipe and pull the required extra lengths for Company's inspection. If during inspection any
defects are noticed, Contractor, in consultation with Company, shall carry out the remedial
measures, as required.
Page 410 of 1963

4ol ei ifillENGINEERS CONSTRUCTION OF PIPELINES
0?ex latRegilif INDIA LIMITED CROSSING ROADS, RAIL ROADS & 6-71-0052 Rev. 3
0112R 2120,12 .4.710.4) (A Govt of Inda Undertakm)
4.5 While welding of the casing and vent/drain pipes, internal high or low is not allowed.
Welding of casing and vent/drain pipes need not be radiographed, however, only normal
visual checks shall be carried out. Before welding, the single length of pipe shall be inspected
in order to check that there is no out of roundness and dents. When such defects are noticed,
these must be completely removed before joining the pipes. If these defects cannot be
repaired, the defective section shall be cut out.
4.6 In the case of crossings where excavation has been authorised, the welding for the casing pipe
and for a continuous section of the pipeline corresponding to the expected length shall be
carried out in the proximity of the crossing. Casing must be laid immediately after the
trenching. Casing pipe must be laid with a single gradient in order to allow for an easy
insertion and, if necessary at a future date, to allow for the removal or replacement of the
pipeline, leaving the casing undisturbed. The direction of gradient shall be marked in the
crossing drawings for future reference.
4.7 The installation of assembly of vent pipe units as approved by Company shall be carried out
by direct insertion and welding to the ends of the casing pipe before introducing the carrier
pipe to avoid damage to insulators from welding heat. The operation of assembling and
extending the vent pipe shall be carried out in such a way that there is no contact with the
carrier pipe. The painting/coating of the vent pipes shall be applied before backfilling as per
relevant specifications.
4.8 The casing pipe shall be considered ready for installation of the carrier pipe, after careful
inspection and internal cleaning with the removal of soil, mud, stones and other foreign
materials.
4.9 Insulators, as approved by Company, shall be securely fastened to the pipe with all bolts and
fixtures firmly tightened. The number of insulators and spacing shall be as shown in the
drawings or at 2.5 meters center (whichever is more stringent). At the end of both sides of the
casing, a double set of insulators shall be installed.
4.10 Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is aligned
correctly in the casing and that the pushing or pulling force is evenly and constantly applied to
avoid damages to the insulators. A nose piece having a diameter equal to that of the pipe shall
be welded on the front and back end of the carrier pipe to facilitate installation of the carrier
pipe properly in the casing and to keep it dry and clean.
4.11 After installation of the carrier pipe section, the casing and the appurtenances, but prior to
making tie-in welds and backfilling, an electrical test shall be conducted by the Contractor in
the presence of the Company, to determine the resistance between the casing and the carrier
pipe or the carrier pipe and the soil. These tests shall show at least a resistance of 100,000 ohm
M2 . After backfilling and compaction, additional tests shall be conducted to determine if the
casing is electrically shorted to the pipe. If the installation is found to be shorted, Contractor
shall make the necessary corrections and repairs at his cost, unless a test to the satisfaction of
the Company is obtained.
4.12 After successful installation of crossing to the satisfaction of Company/Authorities having

jurisdiction, the nose pieces/pulling head welded to carrier pipe as an installation aid shall be
cut/removed and ends of carrier pipe shall be beveled/prepared for further welding/tie-in with
the balance section of pipeline on either side of crossing. Casing end-seals shall be
installed/fitted prior to back filling.
Page 411 of 1963

• MINERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
Mery PRIORMAPP.1) UMITED CROSSING ROADS, RAIL ROADS &
(A GOVI. of Ind. Undirtiking)
5.0 CROSSINGS OF BURIED SERVICES
5.1 The pipeline under construction may pass above or below the existing buried facilities such as
pipelines, cables, etc. Type of crossing shall be such that a minimum depth of cover as
required in the drawings and specifications are guaranteed. The clearance required between
pipeline and the existing facility shall be 500 mm (min)) as indicated in job standard.
5.2 Whenever buried services in the RoU are to be crossed by Contractor, Contractor shall
safeguard the buried facilities and the required protecting precautions shall be executed as
approved by Owners of the buried services and by Company.
5.3 For buried services to be crossed by boring/jacking, the relevant provisions of Section 4.0
shall apply.
6.0 MINOR WATER COURSE CROSSINGS
6.1 Minor water crossings are crossings of (future) ditches, canals, water courses, rivers, streams
etc., whether the bed(s) contain(s) water or not, and such crossings are not being specified as
"Major Water Crossings" in the CONTRACT.
6.2 For minor water crossings a standard drawing or a separate detailed approved drawing for
individual crossing shall be applicable, and all further specifications are applicable.
6.3 Whenever minor water crossings in the RoU are to be crossed, Contractor shall install bridges
and further comply with the provisions as laid down in this specification.
6.4 In crossings of water courses with either moderate flow rate or of torrential nature with
marked and unpredictable flooding, an adequate survey shall be carried out before starting the
work with the object of determining what precautions are necessary and the most favorable
period for executing the work.
6.5 In case of crossings of water courses for which no special methods of laying are required, a
pipe section of a size as per the approved drawings shall be assembled and subsequently laid.
Bends shall be of cold field type.
Whenever required by Company, Contractor shall, before start of construction, execute soil
investigations. Based on the soil investigations, the Contractor shall prepare a construction
drawing, work method and time schedule for approval by Company.
The depth of the existing bottom of a minor water course crossing shall be determined in
relation to the adjacent ground level by taking the average of four measurements.
Measurements shall be taken with a gauge rod and with dimensions 60x60 mm and having a
flat bottom. The minimum force to be exerted shall be 360N (36 kgf).
Contractor shall take special care to check with the responsible authorities for special
conditions applying to working on, over, under or thorough minor water crossings and
Contractor shall comply with any such conditions. Written arrangements with authorities shall
be drawn up in cooperation with Company.
6.6 The minimum cover over the pipe shall be as specified in the relevant approved drawings and
job standard.
6.7 For crossing beneath the bed of water courses, the pipe section shall be made in such a way
that it conforms to the existing or future bed as indicated in the approved drawings. In
crossings for which an individual drawing has not been prepared, the minimum cover of the
Page 412 of 1963

thENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
fat alegw INDIA
e1keer2 Marken)
LIMITED
IA Govt. Of India Undertaking)
CROSSING ROADS, RAIL ROADS &
pipeline shall not be less than that indicated in the standard drawings for a similar type of
crossing.
6.8 Whenever the crossing requires a straight section of pipe between the lower bends coinciding
with the river bed, this section shall be laid at a single horizontal level.
6.9 For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall be
prepared, laid and tested in accordance with the applicable clauses of Section 4.0 of this
specification.
6.10 The Contractor shall arrange temporary installation of diversions as may be necessary, to
ensure the effective functioning of these watercourses crossed, to the entire satisfaction of the
concerned local Authorities as well as the Company.
6.11 Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by Company and shall be thoroughly compacted to prevent soil and bank erosion as
per the drawings and standards to the satisfaction of authorities having jurisdiction thereof and
the Company. Whenever boulders, rock, gravel and other hard objects are encountered, they
shall not be placed directly on the pipe. Sufficient earth, sand or selected and approved
backfill material shall be backfilled initially around and over the pipe to provide a protective
padding or cushion extending to a minimum thickness of 300 mm around the pipe before
backfilling remainder of the trench with excavated or other material as per approved drawings
and standards.
After the trench has been backfilled and during the clean up works, the minor water crossing
shall be cleaned across the whole width of the ROU.
When specified in the CONTRACT, Contractor shall repair the ditch bank with materials to
be supplied by him as follows:
The excavation shall be backfilled with well compacted solid soil, followed by a
minimum 0 25 m thick layer of properly shaped boulders (75-150 mm) encased in a net
of galvanized iron wire of dia 3 mm spaced at a maximum distance of 50 mm to be laid
over the backfilled, compacted and graded banks.
The lengths of the above protection shall be equal to the bank excavation and damage
and extending 2 m on either side. The width of this protection on the slope shall be
determined by the following:
2 m plus the highest water level
Upto the bottom of the crossing or 20 m below the highest water level
whichever is smaller.
6.12 The crossing of any embankments shall be carried out strictly in accordance with approved
drawings.
No drilling work on embankments shall be permitted without prior written approval from the
competent Authorities.
6.13 When specified in the CONTRACT, the complete river crossing (minor) must be hydrotested
post-installation after the backfilling of the trench. The test procedure shall result in a hoop
stress in pipe corresponding to 90% SMYS of the pipe material. After temperature
stabilisation, pressure shall be retained in the pipeline for a minimum twenty four (24) hours
Page 413 of 1963

gh ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
WV, MOW =MINI) II43IA LIMITED
IA Govt of Incla Undid/icing)
CROSSING ROADS, RAIL ROADS &
and recorded by manothennograph. The hydrostatic testing shall be carried out in accordance
with approved procedures.
Page 414 of 1963

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Page 415 of 1963
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Page 416 of 1963
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Anssaaau sao!nap angoawid nwo pun spoddns jo adAt nwo Au g 2upnwhapun Aniodutat
/Cplownvinumo
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spi 1u lopaguop ;no patina aq qpneupioj Hugs pedal pun lopepuoa atp Aq polonium
aq Heys pauiaauoa Alpownypauneict aw 'mom -op Apigniamptuis Attu 01 aSutunp Aire pings
I3WOOf ale samprui&saptign atp wtp nuuetu n gons ui pun tpdap n o1 91EAEO3C0 Aunnuntu
wig Hugs iolouguop tamptuisisamiln punoanpun nwo 53550.10 atwadul ay; angm
awns alp jo uogoawid pun uognool ao3 alcpsuodsal aq pue sappownv pool prenapi alp wolf
SOOIAJOS punalitnpun pauunid pun SuilsIxa ltn jo spwap linj pun strew! wwqo Hugs lopepuop
spowatc ppads pus samma punoanpuft jo uonanom
asodind atp ioj awntunsuoo pun sintiolnut pun SuWW Ittouidwba latilo pun siapnag
Sw8Spi Aniodtual He 'wow pun Aiddns Hails lopepuoa •adid atp Jo nputew puniut wupnou
341 30 %% 0l tenba laming) n °Aug Hugs Sid 2w8ne2 ays -auiladpi atp tiSnalw Sid 2u!Sna
Suwood Aq aulladW 04430 npumw aw ,anoad, Heys iopuguop '5ugsa1 oiluisawAq 'rug amps 8'01•17
Attedwoj 04 4503 EXIXO ou In
auop aq Hugs S31.10M ild "pomolloj aq 'lugs suopongsw si XtrodtuoD pun uoilon jo asmoo latpinj
asodoad "legs iolonpuoD `pagnump punoj osln Si Iwo(' itp2ual adid puoaas jo Slum° NI ji
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itpSual adid wanbasqns atp Iwo!. /Owl adid wig mg u! papapp an &Copilot' isaSuump 3SE3
til • Suilnoo proof auo pun tpSual adid auo aq 'mammal n se 'Hugs papadsw aq o1 giSual 311
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ilnod pica atp 1e wino!' atp Suilnilow pun op dn uogiod waonfpe atp Sugunnox3 (9
wiod pxa atp le dn pas 8!.1 imam twm appssod wawa atp adid aw Suilind (n
:Aq apetu aq Hugs uoilendo 2ullind Jo uomplumo nun augadtd alp jo uoiloadstu Stump
sSugnoo angoawid panoadde X.IESSOOOU
,Cue XlcidE Hugs pun Suiwoo uotso.uoo atp jo Api2aw! atp Jo; appsuodsai aq Hugs aolouguop L'Olt
-uopongsuoo jo saSnis tin
ssauww of puuosnd s iAundwoD 01 sampan; awnuosnai °amp Jo aag apptoid Hugs nionguop TO I '17
.Suilnoo auilad!d alp Supaawid pun 5u!sdniloo wog item atp Suiluanald 'Nog am owi padwnd
aq Hugs Apsoosp pagpads jo ,Canis °pumas . 0104 atp ui auiladtd alp jo saapj uopopj aonpai
01 law u! Ionqifind Stump 0.19Z o1 aw!ssod su asop se AotteXonq atp uwwww o1 su os spowaw
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Page 424 of 1963
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tuopoauuoo kiwodtual
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-aid Jo; 'mum ampaooid opelsowAq B i naidde s,Auedwo3 loj amdawl gals loweauop g
aanpaaolj ;said £ £ I
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paaoxa lou gums amssakl ;sal pue peat' onws lutpuaq anp aullacIpl atp w ssans majeAmba
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•
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g
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• g
Hugs lowanuop Ism aw Swan( tid iSounatpouretu Aq pap.mow pue smog (qz) moj Awaku
/seal w loj augadp1 aw m pauwwww aq pugs amssaid ay; tazgweis seq annwadwal ay; logy
utualutu adid aquo SANS
g
aw Jo %06 paaoxa wu Hugs amssaid ;sat pu Sullmaq o1 anp augadp1 341 ul ssans walemnba
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&goal apulsoapiCH Hoptqpnsupaid I I 17
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.
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111 '2ulpuaq atp ul AumAuu panwfun wu pue ;Owns aq Hugs wiluai adid wag yo a 3o spua atu g
sampaowd panaMdu si AuudwoD lad se Knaenuop /Cc, pauedal aq 11845 qoppn `saSutuup 948001
Knowap Xemog Aq pue AgEnsvi pawadsw aq pugs s ell(' pawoo wo.g spew spuaq ppg plop p
puaq ay; jo &wind Suunp watuamsuaw Jo Aownoo pue pmpatu g
wid lad aatilap wnuuxew `stpSuai -sdais 134po IsSuoum opiuom pugs ampaowd atu •9014081(1
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pu pancuddu And= pue (paunbaa JO impuutu pu auwouw Stupuaq 8 asn 11245 .10108111103 Zt 1 '17 g
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Page 425 of 1963
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aq hugs spuaq `spuaq wag augadlid ui moo° sawn; anqpi t maimy pauwwoo uogeogpads
Sugnam 3o swawannbat alp lam `nnamoti 'wogs *dal spa -pp leguanjwnono aw nudat
wtpatim JO raj awl sapnpu! Imp adId aug alp jo uogoas a aouplat mtpaqm AuedwoD
ay; jo suogonnsw twm Aidwoo Hugs K4oww03 -AuudtuoD Aq pauptuawp aq hugs nedat jo
potpaw atp swam iuguanjtunano u! .111300 MEN waqm saseo asow uI • smoao amgej JO a2mwal
gowm u! swpf JO Iwo!' wpm jo watuaauplat Aq panedw aq guys weal pugmnBuo! JO HEM
adid atp unwm samITJ pue IIV -alum JO aSuleal jo uoguog ay; 4alE05 auptualap
pegs JoweiwoD to!wpsl nip amssaad ;sal pagpads ay; uwwww sue; uogaas 4831
-uogump ;sal 344 woOnanp claw amssald idruqe
ou Sr waw pue twajja amondwal 01 anp saSuutp Joj Klaaxa togump 4531 aw mot(Bnang
awn wwsuoo e KlaN seq anissaid ji angisod se pazawsuoa aq Hugs pal agulsomAg atu, CE I
-suogoas
adild jo imami ay; wog puusfisru 'alum !gm Ile 9/1011101 01 sdno pue saqswq papuoi Suuds
qww paw/told sSld uwww ne Aq augacnd atp Imp Hugs lowenuop ùogwado 2uwg wojag 9' E I .17
aSurewsplopuum pue sdwnd 511 o4134BM3o aamos wag
wauuoo 04 Asessaaau aq Autu qwww luWW Amodwal Ile Hewn pue gstwnj guys Knowpwa
-aawm 4534 ay; 04 pappe aq 01 sapptiaweq pun slaSuanuos uaXxo tiomptwi wnso.uoa
panatdde Auedwoj apptard guys lowatwoD • 2u14sw Joj pasn nwm Jo spodat 4s34 Amiwoqel
numns guys lowetwoD • gs jo puns U1013 33.1j pu g tawwwuwoo aq 4ou finis `panqg aq guys
past' aq o1 mwm a4.L • .wwwwoD ay; Aq pa2uu.uu aq nium tpag aq guys tunwaw 1531 atu c El
-ow siapuaq 2w220 pug npeaq sal wpA4 lindtd kiwodwante Swpwou!
31.10m Sunumpad zo3 1109E111011111.0SUI 7g watudwba Anssaaau 112 qs!tunj pegs mweiwoo YE! 17
ewp Sugsal atp Sugmoow zo3 suuol
suo!wogpads Sid
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uogeow nays `(sareds Suwnpu!) swarm-Limn pue watudwba pasodwd ge jo uogclinsap
awidwoo u 2wpwou! '2ugsal nip uogoas augadtd aw 2ww4Bmap ales Joj ampaowd
.sNew jo uo!waol pue uwwwap zo3 ampaaatd
sucnwpolea amp ammadwal
anp a2uu4o amssaid pu g suogewowa atunion-nu 2wpwout suogg inowa pd •2
sw amssaid atp Stninp ewp jo 2wpmow pue wwwmasqo
.103 walsAs pasodwd pue `dn-;as pue uo!wool naw `(sands 2wpwou!) swaturtasul pue
luawd!nba pasodwd IIe jo uogdposap awidwoo a 2wpwou! ampaowd Sugsw anssam
uogezqwws annendtual zo3 MOIIB
of pue uoIwz!mssaid Joj pue 2umg mp g uogezqwws pue Suwanal zo3 sampaowd -a
aSuurep sawotpu! SW Sw2na
alp am ul pamogoj aq o4 ampaaard Stnprgatn tampaawd uogoadsu! Sid '5133100d nu
Jo 1EAOU13J pue 2unmap zo3 walsAs Buppen 2K1 ay; pue sSid jo aauanbas pue ad/CT 3q
pue uoguao! natp `(sands Suwnpu!) swawruistn pu g wawd!nba
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Page 426 of 1963
peniassi spa pv -113 p4BuAdoo 0 A sel I3-1000-00-9 oNietwod
woo ten Aug woggm XuedwoD
Aq pawngsw se ioipug uogo!ps!mi spigot' lanuoo uogngod pu g sagpowne Aq panoaddg
Amp suo!wooi w swy dn000fwawuagnua ay; 04 lung Au g wong 04 sr os zoom ;sal pagq!qu!
uo!so.uoo ag X.unis aguowaq puu gos sniclins Ile jo fesodsip aps zo3 attain !lugs .1013E111100
.13113A1 panquipq 110p01.103 2p Annis attuoluag nos snidrns Jo issodsta Sit
-augaWd amp uogetwww/SwAr! lopd
now aw suompuoo wpm wals!suoo Alcpuoseat aq X g tu se suompuoo mum pu g appris yaps
payesal aq !lugs now ow 'cln-uualo jo uogaidwoo up • AuedwoD 04 woo Rex° ou w auop
aq wigs glom lions lid • uogo!pspni Suptuy saggowng pue AuedwoD jo uogoejsges awidtuoo
ow parg alo aq guys ags • wwwoD ay; ty alatimasia paugap ss 1s)pl gA 3f301S paint2wap
s,Augclutoa patutgat aq guys Xuedwoa £q pagddns stp2ual ad!d °mum •spqap
pug lepaletu aougig q ps jo says mg nap gems yflogatiop togorwsuoo jo uogaldwoo lagy
do unap maw List
asn 04 yyld ignaidde siAugdwoD 04
;coigns aq Hugs saSesop puu slogq!qu! uo!somoD • ogongsuoo jo uogaldwoo jo ow wog
stpuotu x!s uue!xew jo popad a zo3 augaWd atp uo!wmasald awg alp! Kg amssaid puu
syn!q!qu! 3o sa2esop pagnbal ay; au!uumap guys pu g sewq!qu! pa/oxide asn guys loweguop
mum pagqww gym% uoguz!mssa yl Xq augad0 3o uo!wmasaid zo3 s3pom ps twopad
pue "ow ` 1.101OPILIOUITUISUI ` SONEA `suogoautioo 2u!d!d pg gusu! guys pug lowsti! pus IOWA%
Su!pniou! agsumsuoo pu g wpm= ile Agldns !legs KnotnuoD louguoD ay; u! pawls os uaqm
aulladm Jo uopwasaaj atuu, aim
luissolo lawm egew /Jams yoga jo sap!s wog uo • d• D Melodtual suoguis Tsal puu
spua ad!d aql punaig ales paw ammo! win% tpq tucz x wit x tug1 az!s jo Supuaj Xgmoas
zluy wetip aim •1. 9 Velum puu spgalutu pe Xyldns guys iworawoD `pagpads aanalaym
Supuag Sit
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pen 'Jana/wog twattniug qwa 0yl uo paguisu! aq dugs saavetu ougaWd agl àggs gaj aanalaym
2w/well) aoualajal lad se gwsu! pug awopqej pug swpawtu lie Aiddns Hugs
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jo uo!wool puu awp 'sump amgej ug g o!pti! Sel a twm 'lured 14!M aq guys sacycl
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tre tight pawoo aq !lugs salt-we; wog 2uginsal gilds pu g siowo try .AuudwoD aw Aq pawawap
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wang patgewoo suogeogpads
ay; wpm aotiepl000g u! auop aq !tugs 'smug; ao gidal àd!d aug 2uguistgal jo 3pom
sampaocud pancuddu ay lad su Inv pawadal
aq gulls 4504 oguisaipAti ay; `sgudai jo uogaglwoo zagy -spuaq jo aositap awes tipm paogiclai
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Page 427 of 1963
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anoqn JO 010Z OSCO10)1 GVDOWV OJEMAJOS Butsn paredard aq Heys autmerp ;lin g -W I1V
'S1011E111 aulladul jo uotwoorr
tspuaq piano °pm pun uomoorr
truauntilyn aullaWd pty2po ay; tuag mod rpca jo
rasjjo pram gym atop 'rpm pun Aiwa jo sa;Sun pun smod rpm pun kqua jo uorwoorr
tsmuarty
repr8ar w adpi jo dot or JOAO° jo tpdap aw pun parmsw su aullaWd ay; jo °mold anal
tauyaWd ay; &top slung pun papaw& rofutu /JOAO amp apjoid mud,
:uouetwom EtymoHoj ay; °mow ummtutu a se Ireqs sSupwwp wnq w -sStusswo
roj s2upsnwp rling-sy yspunj pun andard Heys rowemoD toptursuoo jo uouardwoo rally
'SUM )JJOM pun Boll aturaWd jo uomrowar pun do-unap ktowejsms Stupthar
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Stursar put.; pun 5upsar-aid ounrsowAti jo sprooaa
suompen lanai /went ow gym Sum aroy paHup jo °mold all unid
sirom snopun ay; roj uouowspniStunny sawmill-re wag pawnwo suturad
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Page 428 of 1963
Otilktzett ENGINEERS FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
zg-iartataiegve INDIA LIMITED
tA Gov/ of Ada UM.tiong) OF ONSHORE PIPELINES Page 1 of 20
IN 41440141 * W41 deb acted

cr farT4r
FOR
HYDROSTATIC TESTING OF
ONSHORE PIPELINES
elNP Vil‘v itntA".

3 11.04.12 REVISED & REISSUED AS STANDARD RSB SKJ VM DM
SPECIFICATION
2 31.07.06 REVISED & REISSUED AS STANDARD MKM DD AS VC
SPECIFICATION
1 15.10.98 REVISED & REISSUED AS STANDARD KKS RK VC AS
SPECIFICATION
0 09.06.89 ISSUED AS STANDARD SPECIFICATION MK GD SA RCPC
Standards Standards
Rev. Convenor Chairman
Date Purpose by by
No
Approved by
Page 429 of 1963

00-a-eke-a,l ENGINEERS
1g7 efflegei INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
IA Gan 01 ■ncla Undenakingi OF ONSHORE PIPELINES Page 2 of 20
Abbreviations:

OISD Oil Industry Safety Directorate (of India)
Members : Mr S. K. Jain
Mr. Raj Kumar
Mr. M. S. Gunjiyal
Page 430 of 1963

ENGINEERS
INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
,
sag709-eg IA Govl of loam Undertaking], OF ONSHORE PIPELINES Page 3 of 20
CONTENTS
1.0 SCOPE 4
3.0 GENERAL 4
4.0 HYDROSTATIC TEST PROCEDURE MANUAL 5
5.0 TEST DURATION AND PRESSURE 5
6.0 EQUIPMENT AND INSTRUMENTATION 6

7.0 PROCEDURES 8
8.0 ACCEPTANCE 11
9.0 TERMINATION 11
10.0 TEST REPORT 12

11.0 MEASUREMENTS 12
12.0 CALCULATIONS 14
13.0 PRECAUTIONS DURING THE TEST 15
14.0 PRESERVATION OF PIPELINE 15
FIGURES
FIG.1 WATER COMPRESSIBILITY FACTOR VS PRESSURE AND TEMPERATURE
TABLES
TABLE-1 DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR

AND THE STEEL THERMAL EXPANSION FACTOR

Page 431 of 1963

lolfaelela
ENGINEERS
FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
GigalialitegW INDIA LIMIED OF ONSHORE PIPELINES Page 4 of 20
1.0 SCOPE
1.1 This specification covers the minimum requirements of supply, work and operation to be
performed by Contractor for hydrostatic testing of cross-country steel pipelines transporting
hydrocarbons in liquid or gaseous phase under high pressure.
This specification does not cover the requirements of caliper pigging, drying/
pre-commissioning of the tested pipelines.
documents included in the CONTRACT between Company and Contractor. Unless specified
specification.
of issue of enquiry) of the following codes, standards and specifications.
ASME B31.4 Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids.
ASME B 31.8 Gas Transmission and Distribution Piping Systems.
API RP 1110 Pressure Testing of Steel Pipelines for the
Transportation of Gas, Petroleum Gas, Hazardous
Liquids, Highly Volatile Liquids or Carbon Dioxide.
ASME Sec. VIII Div. 1 : Boiler and Pressure Vessel Code- Rules for
Construction of Pressure Vessels.
e) OISD STD 141 Design and Construction Requirements for Cross
Country Hydrocarbon Pipelines
Company Standard Specifications
6-71-0051 Standard Specification for Pipeline Construction

(Onshore)
6-77-0006 Welding Specification for Onshore Pipeline for
Transportation of Gas.
iii) 6-77-0007 Welding Specification for Onshore Pipelines for
Transportation of Liquid Hydrocarbons
2.2 In case of conflict between the requirements of this specification and that of the above
referred codes, standards, and specifications, the requirement of this specification shall
govern.
The words "Shall" and "Must" are mandatory.

The words "Should', "May" and "Will" are non-mandatory, advisory or
recommended.
3.0 GENERAL
3.1 Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall
be performed in accordance with approved Hydrostatic Test Diagrams clearly indicating the
number of test sections and minimum and maximum test pressures in each test sections. The
maximum length of each test section shall not exceed 50 km.
Format No. 8-00-0001-F1 Rev. 0 Copyright El L — All rights reserved
Page 432 of 1963

PIRITRTIIIA, ENGINEERS
iaOteg WV INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
OF ONSHORE PIPELINES Page 5 of 20
3.2 For pipeline sections which in Company's opinion, once installed would require an
inordinate amount of effort for repair in case of a leak, a provisional pre-test shall be
conducted. However, after installation, such pre-tested sections shall be tested again along
with the entire pipeline.
3.3 Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all
welds have been accepted and the pipeline has been laid and backfilled. Hydrostatic test shall
include those sections which have been previously tested viz. Rail/road crossings, major
water crossings including test on banks and in place after installation, and scraper traps at the
terminals. Contractor shall perform all works required for hydrostatic testing after obtaining
prior written approval from the Company.
4.0 HYDROSTATIC TEST PROCEDURE MANUAL
Contractor shall prepare for Company's approval a hydrostatic test procedure manual. The
procedure shall strictly comply with the requirements of this specification and shall be
submitted to Company for approval well in advance. The procedure manual shall include all
temporary materials and equipment, but not be limited to the following items:
A diagram for the system to be tested, indicating all fittings, vents, valves,
temporary connection, relevant elevations and ratings. The diagram shall also
indicate injection locations and intake and discharge lines.
Estimated amount of test water, water source, including required concentration of

corrosion inhibitors and additives, procedure for inhibitor injection and control of
concentration.
Filling and flushing procedures, including a complete description of all proposed

equipment and instruments (including spares), their location and set-up.
The type and number of pigs to be used, gauging plate parameters, sequence of pigs
to be launched during pig tracking system for cleaning and removal of air pockets.
Pig inspection procedures, including procedure to be followed in case the caliper pig
indicates damage to pipeline in excess of the values specified in governing codes.
Procedure for levelling and stabilization after filling and for pressurization and to
allow for temperature stabilization.
Pressure testing procedure including a complete description of all proposed

equipment and instruments (including spares), their location and set-up and
proposed system for observation and recording of data during the pressure test.
Procedure for detection and location of leaks.
Procedure for dewatering the pipeline section(s) after testing, including a complete
description of all proposed equipment and instruments (including spares), their
location and set-up, the type and sequence of pigs and the pig tracking system along
with the pig specification.
i) Forms for recording the test data.
5.0 TEST DURATION AND PRESSURE
5.1 The duration of hydrostatic test shall be minimum 24 hours after thermal stabilization.
5.2 Unless specified otherwise in the Contract, the hydrostatic test pressure shall be as follows:
Page 433 of 1963

laWleila ENGINEERS
51 F Eardu Mir INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

.Govt of India Undenakirg) OF ONSHORE PIPELINES Page 6 of 20
For pipeline handling hydrocarbon in gaseous phase:

1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 31.8.
1.5 times the design pressure for pipeline located in Class-3 and Class-4 locations as
per ASME B 31.8.
For pipeline handling hydrocarbon in liquid phase:

a) 1.25 times the design pressure for pipeline handling liquids including Liquefied
Petroleum Gas (LPG).
The test pressure, as calculated above, shall be generated at the highest point in the section
under test. At any point in the test section hoop-stress due to test pressure and static head
shall not exceed 95% of the SMYS of pipe material.
6.0 EQUIPMENT AND INSTRUMENTATION

The Contractor shall furnish all necessary equipment for performing the work as stated in
cleaning, flushing, filling, stabilising, testing and dewatering procedures.
This shall include, but not be limited to the following equipment and instruments:
Pigs for cleaning, filling and gauging
Cleaning pigs with spring loaded steel wire brushes. For internally coated
pipes, the pigs shall be provided with nylon/polyurethane brushes.
Four cup batching pigs.
Gauging pigs fitted with gauge plate.
The Contractor shall provide a sufficient number of pigs, including spares.
Fill pumps:
The Contractor shall determine the type and number of fill pumps in order to
guarantee the following:
Differential Head : 20% greater than the maximum required

Flow Rate Minimum 400 m3/h; Maximum 1000 m3/h
If a single pump is used, a standby unit must be available.

Variable speed positive displacement pumps equipped with a stroke counter to
pressurize the pipeline. The pump shall be capable of exceeding the maximum test
pressure by at least 20 bar. Contractor shall also ensure availability of standby
pressurizing pump.
Two positive displacement meters to measure the volume of water used for filling
the line. These meters shall be provided with a calibration certificate not older than
three months.
e) Portable tanks of sufficient size to provide a continuous supply of water to the pump
during filling and pressurizing.
0 Bourdon pressure gauges of suitable pressure range and accuracy.
g) Dead weight testers with an accuracy of 0.01 bar measuring with least count of 0.05
bar provided with a calibration certificate not older than three months.
Page 434 of 1963

1512-a-eqit ENGINEERS
a-iar Weg WW: INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
IA Geri ol India undertaking) OF ONSHORE PIPELINES Page 7 of 20
Two 48 hours recording pressure gauges complete with pressure recording charts
and ink, duly tested with dead weight tester prior to use. These shall be installed at
the test head.
Two temperature recorders for fill water.
Thermocouples duly calibrated for measuring the pipe wall temperature
Two laboratory thermometers of range 0°C to 60°C and with accuracy of ±0.2° C
to be used in thermowells.
I) Means to measure the volume of water necessary to drop the line pressure by 0.5
bar (container on scales or graduated cylinder)
Injection facilities to inject additives into the test medium in the required
proportions.
Communication equipment suitable for a continuous connection between the

beginning and the end of the test section and with the inspection team along the line,
in accordance with the requirements of Local Authorities.
The temporary scraper traps shall be installed according to the test section fixed in
the test procedure manual. Proper piping and valve arrangements shall be available
to allow launching and receiving of each pig independently.
The test heads shall be sized in conformity with ASME specification Section VIII,
Division 2.
Thermocouples for measuring the temperature of the pipe wall and soil shall be
installed at the following locations:
One pair of thermocouples at about 500 m distance from the pumping

head.
One pair of thermocouples every 2500 m of the pipe. The spacing may be
increased to maximum 5000 m depending on the terrain and nature of sub
soil along the alignment of test section.
One pair of thermocouples at about 500 m distance from the terminal head.
Thermocouples shall be attached on the external surface of the pipe after removal of
external coating and shall be adequately protected by padding with minimum 500
mm soil. After successful testing, the thermocouples shall be removed and damaged
coating shall be repaired as per applicable coating repair procedure, approved by
Company. For soil temperature measurements, the thermocouple shall be buried at
pipe centerline depth at a distance of 500 mm from the pipe wall.
q) Digital pressure/ temperature monitoring and chart recording systems can be used in
lieu of the components listed above provided that the individual pressure/
temperature sensors included in the system have a level of accuracy and can be field
calibrated in a manner similar to those instruments listed above. Instruments shall be
portable and rugged in construction with minimum weatherproof rating of IP-66.
They shall display pressure and temperature readings on the screen and shall have
adequate memory for recording the same. The instrument shall have computer
interface to export the stored data after completion of test.
Page 435 of 1963

011taae?0,11 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
a
^fs laWlegW;INDIA LIMITED
Undertaking)
In Gm/ of Inda
FOR HYDROSTATIC TESTING
OF ONSHORE PIPELINES
6-71-0055 Rev. 3
Page 8 of 20
7.0 PROCEDURES
7.1 Equipment and/or parts which need not or must not be subjected to the test pressures or
which must not be tested with water, must be disconnected or separated from the pipeline to
be tested.
7.2 If the difference of minimum and maximum atmospheric temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps and
above ground pipeline shall be properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz.
aerial lengths on piers, suspension bridges, etc. Such sections shall be tested separately.
7.3 The test medium shall be soft non-aggressive water furnished by the Contractor. The water to
be used shall be filtered, shall not be contaminated and shall be free from sand or silt.
Contractor shall submit laboratory test reports of water used for testing. The possible use of
sea water shall be subject to its degree of cleanness, the possibility of obtaining a pre-
determined salinity neutralisation and the use of corrosion inhibitors, this at the sole
discretion of Company. Contractor shall provide Company approved corrosion inhibitors,
oxygen scavengers and bactericides to be added to the test water. The Contractor shall
furnish and install all temporary piping, which may be necessary to connect from source of
water to its pump and manifolds/tankages.
The following products are acceptable for corrosion inhibition of the water used for hydro
testing:
REMIDOL 4000 of M/s Chemtreat India Ltd., Navi Mumbai.

HIBITOL 2000 of M/s Renkal Chemical, Navi Mumbai.
INDION 175 of M/s Ion Exchange India Ltd., Hyderabad.
VISCO 3900 of M/s NALCO EXXON.
Indicative dosage for inhibitor is as follows:
Upto 6 months 500 mg/I

Above 6 months 750 mg/I
However the exact dosage rates shall be as per the hydro test water analysis and manufacturer
recommendation.
Contractor shall note the following:
All chemicals for hydrotesting shall be procured from approved vendors. Chemicals
older than three months shall not be used.
Company representative shall inspect the chemical containers and take random
samples prior to its use. Contractor shall get the samples tested in an EIL nominated
Govt./PSU/other competent laboratories. Testing shall be carried out for accelerated
% corrosion inhibition efficiency, % SRB and TBC killing efficiency test. Company
reserves the right to witness the testing. The test report shall be submitted to Company
for approval prior to undertaking hydro testing works.
Only those chemicals which have passed the above tests shall be used for
hydrotesting.
Chemicals shall be injected by dosing pump only and mixing in open tank shall not be
al lowed
7.4 Before filling operation, the Contractor shall clean the pipeline by air driven pigs provided
with spring loaded brushes and chisels to remove all mill scale, rust, sand, etc. from the
Page 436 of 1963

ONZIE5/01SENGINEERS
s'gff EtfiregS INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
Govt of India Umiertaung) OF ONSHORE PIPELINES Page 9 of 20
inside of pipe section. For this purpose, temporary headers for air cleaning shall be attached
to the pipeline. The number of pig runs depends upon the cleaning results and shall be
determined by the Company at site.
7.5 After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried
out by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter
of the heaviest wall pipe in the test section. While computing the ID of heaviest wall pipe,
pipe manufacturing tolerances shall not be considered. A 10 mm thick aluminium plate shall
be used for making the gauge plate.
After receipt of gauging pig at the other end, the gauge plate shall be inspected in the
presence of Company representative. A deformed, bent or severally nicked plate or damaged
pig shall be evidence of gauging pig run failure and the same shall not be acceptable to
COMPANY. In such cases the Contractor shall repair and rectify the line and repeat the
gauging pig run to the satisfaction and approval of the Company Representative. Any
obstruction and/or faults such as dents, buckles, flat spots, etc. analysed and noted during
gauging pig run shall be located and any necessary repair work shall be performed to rectify
the same to the satisfaction of the Company. A written approval shall be obtained from
Company regarding successful completion of gauging pig run.
After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pigs shall be welded to test section.
The drawing of the test headers shall be submitted along with hydrotest procedure for
approval. All fittings and flanges to be used in the test header fabrication shall be at least one
ANSI rating higher than the line rating. The headers shall be pretested at line hydrotest
pressure for duration of minimum 24 hours. The record shall be kept and shall be part of the
final hydro test report.
Weld joints between test header and pipeline shall be radiographed. Un-inhibited water equal
to 10% of the volume of test section shall be introduced in front of the first pig. The first pig
shall be launched by introducing about 1.5 km un-inhibited water. Then the second pig shall
be launched by pumping the inhibited water till the second pig is received at the other end.
Subsequent to receipt of second pig, the pressurization and thermal stabilization operation
can commence.
7.6 Thermal stabilization
After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, the thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked through the
thermocouples installed on the pipeline and in the soil.
Pipe and soil temperature readings shall be taken at 2 hours-intervals. Thermal stabilization
shall be considered to have been achieved when a difference not higher than 1°C is attained
between the average pipe temperature and average soil temperature. Thermal stabilization
completion shall be approved by Company.
7.7 Pressurisation
7.7.1 The pressurization shall be performed in the presence of Company at a moderate and constant
rate not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel
with the dead weight tester. Volume required to reach the test pressure shall be recorded
periodically throughout the pressurization as follows:
Page 437 of 1963

Ii5ilatre?eft ENCJNEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
5g-9 ielffleg we INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
poll of India undertaking) OF ONSHORE PIPELINES Page 10 of 20
Each 5 bar increments up to 80% of test pressure as recorded by the dead weight
tester;
Each 2 bar increments between 80% to 90% of test pressure as recorded by the dead
weight tester;
c) Each 0.5 bar increments between 90% of the test pressure to full test pressure as
recorded by the dead weight tester.
7.7.2 The pressurisation shall be cycled according to the following sequence:
Pressurise to 50% of test pressure, hold pressure for 1 hour,

Drop pressure to static head of test section at test head,
Pressurise to 75% of test pressure, hold pressure for 1 hour
Drop pressure to static head of test section at the test head
e) Pressurise to test pressure.
During the pressurisation to each test pressure, two tests shall be carried out for the
calculation of air volume in the pipeline under test at 50% and 75% of test pressure.
In case, during the hold pressure periods indicated above, a decrease in pressure in observed,
the above operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the Contractor has isolated and eliminated the cause for the
lack of water tightness.
7.8 Air Volume Calculation.
In order to check the presence of air in the pipeline, two separate consecutive pressure
lowering of 0.5 bar shall be carried out after pressurizing to test pressure.
For calculation of air in the pipeline the second pressure lowering shall be used, and the
relevant drained water shall be accurately measured (V 1 ). This amount measured shall be
compared to the theoretical amount (Vp) corresponding to the pressure lowering that has been
carried out, by using the procedure outlined in clause 12.1 of this specification.
If no air is present in the length under test:
Vt —
1
VP
In order that the above ratio is acceptable, it shall not differ from I by more than 6% (i.e.
1.06). If the air found in the pipeline is within the above established tolerance, then the
pressurising can continue. If the ratio V I Np exceeds 1.06, the hydrostatic testing cannot go
on and additional pig passages shall be performed to remove the air pockets. V i Np ratio less
than 1 shall not be acceptable. In such a case all hydrotest calculations for Vp including pipe
book lengths shall be rechecked.
The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurising can then continue, to reach the value of the test pressure.
7.9 Testing
After the section has been pressurised and the air volume test has given acceptable results the
test pressure shall be held for a minimum of 24 hours after stabilisation. After temperature
and pressure has stabilished, the injection pump shall be disconnected and all connections at
the test heads shall be checked for leakage. The pressure recorders shall then be started with
the charts in a real time orientation for continuous recording throughout the test.
Page 438 of 1963

lairaeleis ENGINEERS
$j1g211 1 INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

During the testing period the following measurements shall be recorded/reported
Every one hour pressure measurements from dead weight testers.

Every two hour the ambient temperature and the pipe temperature at the
thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded. Bleed-off
water shall be accurately measured and recorded.
8.0 ACCEPTANCE
8.1 The hydrostatic test shall be considered as positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such changes shall
be evaluated as described under clause 12.2 of this specification.
The pressure change value as a function of temperature change shall be algebraically added
to the pressure value as read on the meters. The pressure value thus adjusted shall be
compared with the initial value and the test shall be considered as acceptable if the difference
is less than or equal to 0.3 bar. Incase of doubt the testing period shall be extended by 24
hours.
8.2 If test section fails to maintain the specified test pressure after isolation, Contractor shall
determine the location of leakage or failure by suitable means. All leaks and failures within
the pipe wall or weld seams shall be repaired by replacement of entire joint or joints in which
leakage or failure occurs. In those cases where leaks occur in circumferential welds the
method of repair shall be determined by the Company. Contractor shall comply with
instructions of the Company whether to replace a section of the line pipe that includes the
line leak or whether to repair the circumferential weld. This repair should, however, meet the
requirements of applicable welding specification enclosed with the Contract. Where failures
occur in pipeline field bends, bends shall be replaced with same degree of bends. After
completion of repairs, the hydrostatic test shall be repeated in full, as per this specification.
8.3 The cost of repairs or replacements, followed by refilling and repressurising the line, due to
poor workmanship, shall be borne by the Contractor. In the event of leaks or failures
resulting from faulty Company furnished materials, Contractor shall be reimbursed as per the
provisions of Contract. All work of reinstalling line pipe, to replace failures, shall be done in
accordance with the relevant specifications included in the CONTRACT.
8.4 Contractor shall haul and stockpile all damaged and defective pipes to storage location
designated by the Company. All cracks and splits resulting from failure shall be coated with
an application of grease to preserve the characteristics of failures from corrosion. Joint of
failed pipes shall be marked with paint, with a tag indicating failure details, date and location
of failure and pressure at which failure occurred. Failed pipes shall have pipe number and
heat number clearly marked on the outside surface along with warning sign to prevent re-
usage.
9.0 TERMINATION
After the positive result of testing and completion of data gathering, the test shall be
terminated upon written approval given by the Company. The pipeline shall be slowly
depressurised at a moderate and constant rate as instructed by Company. Subsequent
operations such as caliper pigging, swabbing, drying, purging/inertising and commissioning
shall be carried out as per the applicable specifications enclosed with the Contract.
9.1 Contractor shall dewater the tested line as per the following requirement after test acceptance.
Page 439 of 1963

araae? ENGINEERS
0g7 a are G., INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
IA God of India undertaking) OF ONSHORE PIPELINES Page 12 of 20
Dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed
air. The detailed dewatering procedure shall be deployed by the Contractor in such a way as
to provide adequate control of pigs during dewatering. Pigs and equipment required for
dewatering the line shall be furnished by Contractor and shall be approved in advance by the
Company. Four cup pigs shall first be passed through the line to displace the water. Foam
pigs shall then be passed in order to complete the line dewatering. Contractor shall use a
number of foam pigs each in different colours/numbered for this purpose. The line shall be
considered dewatered when a negligible amount of water is flushed out by the last foam pig
and approval is given by the Company.
9.2 Before the start of dewatering and disposal of hydrotest water, a procedure for treatment of
inhibited water to prevent pollution shall be submitted by Contractor to Company for review
and approval. During dewatering, care shall be taken to properly dispose off the discharged
water in order to avoid pollution, damages to fields under cultivation and/or existing
structures and interference with traffic.
9.3 Upon completion of the testing and dewatering operation, any provisional traps for pigs and
all other temporary installation relating to the test shall be removed. Subsequently, the
individual sections of the line already tested shall be joined in accordance with the
requirements of relevant specifications issued for the purpose.
10.0 TEST REPORT
A complete report signed by Contractor and the Company shall be submitted upon
completion of the hydrostatic test for each test section.
This report shall contain as a minimum:
The cleaning, flushing, filling and testing procedures used;

Schematic layout of cleaning, filling and testing facilities;
Instrument calibration certificates;
A profile of the pipeline that shows the test sites, all instrument and injection
connections;
Pipe filling logs and records;
Additive specification, required concentration and additive injection records;
Pig specifications;
Pig inspection records including photographs of the damages;
Records of gauging pig survey and photographs;
Pressurisation and stabilisation records;
Pressure and temperature recording charts with appropriate information inscribed
thereon;
Temperature data along the pipeline;
Dead weight tester logs and recordings;
Air volume calculations;
Pressure change due to temperature change calculations;
Environmental data;
Depressurisation logs and records;
Dewatering procedure and schematic layout of relevant facilities;
Dewatering logs and records;
Records and photographs of all leaks, if applicable.
11.0 MEASUREMENTS
11.1 Water Amount Measurements
Page 440 of 1963

5110-Q3d ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
sgar lafReu VW INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

("""e'"'"?`"anu
A Gent on inow unaenakingi OF ONSHORE PIPELINES Page 13 of 20
The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used).
In the calculation, as per clause 12.1 of this specification, use shall be made of the
geometrical volume of the section in question. The water amount that has been let into the
section shall be measured during the pressurisation stages thorough positive displacement
meters or turbine meters.
11.2 Pressure Measurement
Pressure shall be measured with a dead weight tester that shall permit readings with least
count of 0.05 bar.
During the test, the pressure shall be recorded by means of a recording pressure gauge
featuring the following specifications:
Accuracy ± 0.1% of the full-scale value

Recording Continuous on tape or disk, graph width 100mm
Feed 20mm/h for tape diagrams, 15°/h for disk diagrams
Recording range To be such as to record pressure between 50% and 90% of
the diagram width.
The recording pressure gauge shall be checked by means of dead weight test at the beginning,
and at the end of the hydrostatic test.
11.3 Temperature Measurements
Water temperature shall be taken at every 2 hours through the thermocouples that
have been installed on the pipe wall along the section under test.
Further, the temperature measurement shall be taken:
During the filling operation

During the thermal stabilisation stage
During the hydrostatic test
The thermocouples' sensitivity shall enable temperature readings with the accuracy
of ±0.1°C.
Water temperature shall also be measured on the pump delivery by means of a

recording thermometer throughout the filling stage.
The recording thermometer shall feature the following characteristics:
Accuracy : ± 1% of the scale range

Scale -10° to +40°C
Recording : Continuous on tape or disk, diagram width 100mm
Feed 20mm/h for tape diagrams, 15°/h for disk diagram
Ground temperature shall be taken at every two hours though the thermocouples
that have been installed in the soil along the section under test.
Environmental temperature shall be recorded from the beginning of pressurization

to the end of the test by means of a recording thermometer featuring the following
characteristics:
Page 441 of 1963

•-
OOZE? ENGINEERS
I mac'gINDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

IA Govt of India Undertaingj
Accuracy ± 1% of the scale range

Scale 0° to +60°C
Recording : Continuous on tape or disk, diagram width 100mm
Feed 20mm/h for tape diagrams, 15°/h for disk diagrams.
12.0 CALCULATIONS
12.1 The theoretical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall be calculated
by means of the following formula:
VP = (0.884 + +A) x 10-6 x Vt x AP xK
Where
Vp = computed water amount required to raise the pressure by AP in the section

to be tested (m3)
V, = geometrical volume of the section (m3)
AP = pressure rise (bar)
ri = nominal inner radius of the pipe (mm)
t = nominal pipe thickness (mm)
A = isothermal compressibility value of water at the pressurization temperature
in the P range (bar 1 ) x 106
(Refer water compressibility factor v/s pressure and temperature charts-
Figured , For temperature above 30°C the values may be extrapolated.)
K = a dimensionless coefficient that is equal to a value of 1.02 for welded
pipes.
12.2 The pressure change due to a water temperature change shall be calculated through the
following formula:
B
AP = AT
ri
0.884 +A
where
AP pressure change resulting from a temperature change (bar)

AT algebrical difference between water temperature at the beginning of the
test and water temperature as measured at the end of the test (°C).
Value of the difference between the thermal expansion of water at the
pressure and temperature as measured at the end of the test and that of steel
(°C- ') x 106
(Refer Table 1)
A Isothermal compressibility value of water as estimated at the pressure and
temperature values obtained at the end of test (ban x 106
(Refer Figure 1)
ri nominal inner radius of the pipe (mm)
(in case of the test section having multiple wall thicknesses, "ri" shall
correspond to the wall thicknesses, having the maximum total length in the
given test section).
nominal pipe thickness (mm)
Page 442 of 1963

101 1at5a ENGINEF_RS
LII tafWIegli_V INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
CA Govl of India Undeitaikap/ OF ONSHORE PIPELINES Page 15 of 20
13.0 PRECAUTIONS DURING THE TEST
In addition to all that has been expressly described in the procedures for carrying out the
tests, the following additional requirements shall be complied with:
13.1 Provision shall be made for the installation of no-admittance signs to unauthorised personnel
from the roads to the R.O.U.
13.2 Signs stating 'PIPE UNDER TEST-KEEP OFF" with local language translation shall be
placed where the pipeline is uncovered, and particularly where the provisional traps and
stations are located. Such areas shall be suitably fenced in such a way as to prevent access of
unauthorised personnel. No unauthorised personnel shall be closer than 40M to the pipeline
or equipment under test.
13.3 Provisional scraper traps shall be installed in compliance with methods and suitable location
so that their rupture cannot cause any injuries to the personnel or third parties.
13.4 The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.
13.5 Once dewatering is over the sectionalising valves and other valve assemblies tested
previously, shall be installed at locations shown in the drawings and in accordance with the
procedures contained in the relevant specifications. All thermocouples installed in the
pipeline shall be removed and damaged corrosion coating shall be repaired using Company
approved materials and procedure.
14.0 PRESERVATION OF PIPELINE
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified

duration, Contractor shall completely fill the pipeline with water, with sufficient quantity of
corrosion inhibitors depending upon quality of water and the period of conservation, at a
pressure to be agreed upon with the Company at a later stage. Contractor shall obtain
necessary approval from the Company of the procedure, type and quality and quantity of
inhibitors used before commencement of the works.
Page 443 of 1963

laraaeqeS ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ElPegWINDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

IA Gm/ Mirada Undertaking; OF ONSHORE PIPELINES Page 16 of 20
50
49
48
47
46
45
44
43
18
20
22
42 24
26
20
30
41
40
40 80 120 160 200 240 280 300
PRESSURE (BAR g)
FIG 1. WATER COMPRESSIBILITY FACTOR v/s. PRESSURE AND TEMPERATURE
Page 444 of 1963

Oti=dire? FOR HYDROSTATIC TESTING
51129-e , IA Go v% at India Underwent') OF ONSHORE PIPELINES Page 17 of 20
°C 2 3 4 5 6 7 8
1
bar
.981 -98.62 -79.89 -61.81 -44.34 -27.47 -11.14 +4.66 +19.98
10 -95.55 -76.94 -58.99 -41.65 -24.89 -8.67 +7.02 +22.23
20 -92.15 -73.68 -55.86 -38.64 -22.01 -5.92 +9.65 +24.74
30 -88.74 -70.40 -52.72 -35.63 -19.14 -3.16 +12.29 +27.26
40 -85.32 -67.12 -49.58 -32.62 -16.24 -0.41 +14.93 +29.78
50 -81.90 -63.84 -46.43 -29.60 -13.36 +2.36 +17.57 +32.31
60 -78.47 -60.55 -43.27 -26.58 -10.46 +5.15 +20.23 +34.85
70 -75.03 -57.25 -40.10 -23.54 -7.56 +7.92 +22.89 +37.89
80 -71.60 -53.96 -36.94 -20.51 -4.65 +10.70 +25.55 +39.94
90 -68.16 -50.66 -33.77 -17.47 -1.73 +13.50 +28.23 +42.50
100 -64.72 -47.35 -30.60 -14.43 +1.18 +16.29 +30.90 +45.05
110 -61.28 -44.05 -27.43 -11.38 +4.10 +19.08 +33.58 +47.67
120 -57.84 -40.74 -24.26 -8.34 +7.02 +21.88 +36.26 +50.18
130 -54.40 -37.44 -21.08 -5.29 +9.95 +24.68 +38.94 +52.75
140 -50.96 -34.13 -17.90 -2.25 +12.87 +27.49 +41.63 +55.32
150 -47.53 -30.83 -14.73 +0.80 +15.79 +30.29 +44.31 +57.89
160 -44.10 -27.53 -11.56 +3.85 +18.72 +33.10 +47.00 +60.46
170 -40.67 -24.23 -8.40 +6.89 +21.64 +35.90 +49.69 +63.04
180 -37.24 -20.94 -5.23 +9.94 +24.56 +38.70 +52.37 +65.62
190 -33.83 -17.65 -2.06 +12.98 +27.48 +41.51 +55.06 +68.19
200 -30.42 -14.37 +1.09 +16.01 +30.40 +44.30 +57.75 +70.77
210 -27.02 -11.09 +4.25 +19.04 +33.31 +47.10 +60.43 +73.34
220 -23.63 -7.82 +7.40 +22.06 +36.22 +49.90 +63.12 +75.90
230 -20.24 -4.56 +10.54 +25.08 +39.13 +52.69 +65.80 +78.48
240 -16.87 -1.30 +13.67 +28.10 +42.03 +55.48 +68.48 +81.05
250 -13.50 +1.94 +16.79 +31.11 +44.92 +58.26 +71.15 +83.61
260 -10.14 +5.17 +19.90 +34.12 +47.81 +61.04 +73.81 +86.81
270 -6.80 +8.39 +23.00 +37.11 +50.69 +63.80 +76.48 +88.73
280 -3.48 +11.60 +26.11 +40.09 +53.56 +66.57 +79.14 +91.29
290 -0.17 +14.80 +29.19 +43.07 +56.43 +69.33 +81.78 +93.83
300 +3.13 +17.98 +32.27 +46.03 +59.29 +72.08 +84.83 +96.38
Table 1 : Difference between the water thermal expansion factor and the steel thermal expansion
FACTOR (°C-1) 10-6
Page 445 of 1963

SSW"leia ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
laPege NIP INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

+NTT ereaweauw R) Gort of Indla Uncleftalcingl OF ONSHORE PIPELINES Page 18 of 20
°C 10 11 12 13 14 15
9
bar
.981 +34.82 +49.22 +63.20 +76.78 +89.99 +102.83 +115.34
10 +36.97 +51.26 +65.15 +78.64 +91.75 +104.51 +116.93
20 +39.36 +53.55 +67.33 +80.71 +93.72 +106.39 +118.71
30 +41.76 +55.84 +69.51 +82.79 +95.70 +108.26 +120.49
40 +44.18 +58.14 +71.70 +84.87 +97.68 +110.14 +122.28
50 +46.60 +60.45 +73.90 +86.96 +99.68 +112.04 +124.07
60 +49.02 +62.76 +76.10 +89.07 +102.67 +113.93 +125.88
70 +51.44 +65.08 +78.32 +91.17 +103.68 +115.84 +127.69
80 +53.88 +67.40 +80.53 +93.29 +105.69 +117.76 +129.50
90 +56.32 +69.73 +82.75 +95.41 +107.70 +119.67 +131.32
100 +58.77 +72.07 +84.98 +97.53 +109.73 +121.59 +1333.15
110 +61.21 +74.41 +87.22 +99.66 +111.75 +123.52 +134.98
120 +63.67 +76.74 +89.45 +101.79 +113.79 +125.46 +136.82
130 +66.12 +79.09 +91.69 +103.93 +115.83 +127.39 +138.67
140 +68.58 +81.45 +93.93 +106.07 +117.87 +129.34 +140.51
150 +71.05 +83.80 +96.18 +108.21 +119.90 +131.20 +142.37
160 +73.51 +86.15 +98.43 +110.36 +121.96 +133.74 +144.22
170 +75.97 +88.51 +100.68 +112.51 +124.01 +135.19 +146.08
180 +78.44 +90.87 +102.94 +114.66 +126.06 +137.15 +147.94
190 +80.91 +93.23 +105.19 +116.82 +128.12 +139.11 +149.81
200 +83.37 +95.59 +107.45 +118.97 +130.17 +141.07 +151.68
210 +85.84 +97.95 +109.71 +121.13 +132.24 +143.03 +153.55
220 +88.30 +100.31 +111.97 +123.29 +134.29 +144.99 +155.42
230 +90.67 +102.67 +114.23 +125.45 +136.36 +146.96 +157.30
240 +93.22 +105.03 +116.48 +127.60 +138.42 +148.93 +159.18
250 +95.69 +107.39 +118.74 129.76 +140.48 +150.90 +167.05
260 +98.14 +109.74 +121.00 +131.92 +142.54 +152.87 +162.93
270 +100.60 +112.10 +123.25 +134.08 +144.61 +154.84 +164.81
280 +103.05 +114.44 +125.50 +136.24 +146.67 +156.84 +166.69
290 +105.50 +116.79 +127.75 +138.39 +148.73 +158.78 +168.57
300 +107.94 +119.13 +130.00 +140.54 +150.79 +160.75 +170.45
FACTOR (°C 1) 10-6
Page 446 of 1963

a EVregVif INDIA LIMITED

151fazie?
wart eiewMIJC15.11
ENGINEERS
IA GoN 01 India undetiakingJ
FOR HYDROSTATIC TESTING
OF ONSHORE PIPELINES
6-71-0055 Rev. 3
Page 19 of 20
°C 19 20 21 22 23
16 17 18
bar
.981 +127.52 +139.41 +151.00 +162.31 +173.37 +184.18 +194.75 +205.08
10 +129.02 +140.83 +152.36 +163.58 +174.56 +185.30 +195.79 +206.07
20 +130.71 +142.42 +153.85 +165.00 +175.90 +186.55 +196.96 +207.16
30 +132.40 +144.02 +155.35 +166.42 +177.23 +187.80 +198.14 +208.26
40 +134.10 +145.62 +156.87 +167.85 +178.58 +189.07 +199.33 +209.37
50 +135.80 +147.24 +158.39 +169.29 +179.93 +190.34 +200.52 +210.49
60 +137.51 +148.86 +159.92 +170.73 +181.29 +191.62 +201.72 +211.61
70 +139.22 +150.49 +161.46 +172.18 +182.66 +192.91 +202.93 +212.74
80 +140.95 +152.11 +163.00 +173.64 +184.03 +194.20 +204.14 +213.88
90 +142.67 +153.75 +164.56 +175.10 +185.41 +195.50 +205.36 +215.03
100 +144.42 +155.40 +166.11 +176.58 +186.80 +196.80 +206.59 +216.17
110 +146.15 +157.04 +167.66 +178.05 +188.20 +198.12 +207.82 +217.33
120 +147.90 +158.70 +169.24 +179.54 +189.59 +199.44 +209.06 +218.49
130 +149.65 +160.36 +170.81 +181.02 +191.00 +200.75 +210.31 +219.66
140 +151.40 +162.03 +172.39 +182.51 +192.41 +202.09 +211.56 +220.84
150 +153.16 +163.70 +173.98 +184.00 +193.82 +203.42 +212.81 +222.02
160 +154.93 +165.37 +175.56 +185.51 +195.24 +204.76 +214.08 +223.20
170 +156.69 +167.05 +177.15 +187.02 +196.66 +206.10 +215.34 +224.39
180 +158.47 +168.73 +178.75 +188.53 +198.09 +207.45 +216.61 +225.58
190 +160.24 +170.42 +180.35 +191.05 +199.52 +208.80 +217.89 +226.79
200 +162.01 +172.10 +181.95 +191.57 +200.97 +210.16 +219.17 +227.99
210 +163.80 +173.80 +183.55 +193.09 +202.40 +211.53 +220.46 +229.20
220 +165.58 +175.49 +185.16 +194.62 +203.85 +212.89 +221.74 +230.41
230 +167.36 +177.19 +186.78 +196.14 +205.30 +214.26 +223.04 +231.63
240 +169.16 +178.89 +188.39 +197.68 +206.75 +215.63 +224.32 +232.85
250 +170.94 +180.59 +190.01 +199.21 +208.20 +217.00 +225.63 +234.08
260 +172.73 +182.30 +191.63 +200.75 +209.66 +218.40 +226.93 +235.31
270 +174.53 +184.00 +193.25 +202.29 +211.12 +219.77 +228.24 +236.54
280 +176.32 +185.70 +194.88 +203.83 +212.59 +221.16 +229.55 +237.77
290 +178.11 +187.42 +196.50 +205.37 +214.05 +222.54 +230.86 +239.01
300 +179.90 +189.13 +198.13 +206.92 +215.51 +223.93 +232.18 +240.26
FACTOR (°C') 10-6
Page 447 of 1963

aMzre? eh ENGINEERS
it le151-ctW , INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

ewt,„,..„„nu undenaung)
IA Govt on India OF ONSHORE PIPELINES Page 20 of 20
°C 26 27 28 29 30
24 25
bar
.981 +215.22 +215.14 +234.88 +244.41 +253.79 +263.00 +272.03
10 +216.13 +225.99 +235.66 +245.13 +254.44 +263.59 +272.57
20 +217.15 +226.94 +236.53 +245.94 +255.18 +264.27 +273.18
30 +218.18 +227.88 +237.41 +246.75 +255.93 +264.95 +273.80
40 +219.21 +228.85 +238.30 +247.58 +256.69 +265.64 +274.42
50 +220.25 +229.82 +239.20 +248.40 +257.45 +266.33 +275.07
60 +221.30 +230.79 +240.11 +249.24 +258.22 +267.04 +275.70
70 +222.35 +231.78 +241.02 +250.08 +258.99 +267.75 +276.35
80 +223.42 +232.77 +241.94 +250.93 +259.78 +268.47 +277.01
90 +224.48 +233.76 +242.87 +251.79 +260.57 +269.19 +277.66
100 +225.56 +234.76 +243.79 +252.66 +261.36 +269.92 +278.33
110 +226.64 +235.78 +244.73 +253.53 +262.17 +270.77 +279.01
120 +227.73 +236.79 +245.68 +254.40 +262.98 +271.41 +279.69
130 +228.82 +237.81 +246.63 +255.28 +263.69 +272.16 +280.38
140 +229.92 +238.84 +247.59 +256.18 +264.62 +272.92 +281.08
150 +231.03 +239.87 +248.55 +257.07 +265.44 +273.69 +281.78
160 +232.14 +240.91 +249.52 +257.97 +266.28 +274.46 +282.49
170 +233.26 +241.96 +250.49 +258.88 +267.12 +275.23 +283.20
180 +234.38 +243.01 +251.47 +259.79 +267.97 +276.01 +283.92
190 +235.51 +244.06 +252.46 +260.71 +268.82 +276.80 +284.64
200 +236.64 +245.12 +253.45 +261.63 +269.67 +277.59 +285.37
210 +237.77 +246.18 +254.45 +262.50 +270.54 +278.39 +286.11
220 +238.91 +247.26 +255.45 +263.49 +271.40 +279.19 +286.85
230 +240.06 +248.33 +256.46 +264.43 +272.28 +280.00 +287.59
240 +241.21 +249.41 +257.46 +265.37 +273.16 +280.82 +288.35
250 +242.36 +250.49 +258.48 +266.31 +274.04 +281.63 +289.11
260 +243.52 +251.58 +259.49 +267.27 +274.92 +282.46 +289.86
270 +244.68 +252.66 +260.52 +268.23 +275.82 +283.29 +290.64
280 +245.84 +253.76 +261.54 +269.18 +276.71 +284.12 +291.40
290 +247.01 +254.86 +262.57 +270.15 +277.61 +284.95 +292.18
300 +248.18 +255.96 +263.60 +271.11 +278.51 +285.79 +292.95
FACTOR eC-1) 104
Page 448 of 1963

larazie? ft
in ENGINEERS STANDARD SPECIFICATION
6-71-0057 Rev. 4
oW i :qItgW
n015 . INDIA LIMITED
P17 5rZa S 1) q Goof Inds unlenavng)
FOR PIPELINE MARKERS
Page 1 of 6
1114 Ckch
R, mien flier
FOR
PIPELINE MARKERS
040-12
SPECIFICATION NR MSG VM DM
SPECIFICATION MKM VM AS
SPECIFICATION
1 28.09-98 REVISED & REISSUED AS STANDARD KKS RK
SPECIFICATION VC AS
0 19-07-89 ISSUED AS STANDARD SPECIFICATION MK GD SA RCPC
Standards Standards
by by
Approved by
Page 449 of 1963

OWE'? eh ENGINEERS STANDARD SPECIFICATION FOR
'Wag- VW INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
01,7, enreenawn) I A Govt of India Uncleltak.n9)
Page 2 of 6
Abbreviations:

IP Intermediate Pigging
LPG : Liquified Petroleum Gas
RoU : Right of Use

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Page 450 of 1963

OR-neeENGINEERS STANDARD SPECIFICATION FOR
$11 051eg viir INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
Page 3 of 6
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 GENERAL 4
4.0 AERIAL MARKERS 5
5.0 KILOMETER MARKERS 5
6.0 PIPELINE WARNING SIGN 5
7.0 RoU BOUNDARY MARKER 5
8.0 DIRECTION MARKERS 6
9.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN 6
10.0 SPECIAL MARKERS 6
REFERENCE DRAWINGS
EIL STANDARD DRAWINGS
7-71-0008 K.M. POST
7-71-0009 TYPICAL ROW BOUNDARY MARKER
7-71-0010 AERIAL MARKER
7-71-0011 DIRECTION MARKER
7-71-0012 PIPELINE WARNING SIGN
7-71-0014 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING

SIGN
Page 451 of 1963

002e
efargiINDIA LIMITED
ENGINEERS STANDARD SPECIFICATION FOR
6-71-0057 Rev. 4
IA “thi of Info Undenakiro
PIPELINE MARKERS
Page 4 of 6
1.0 SCOPE
1.1 This specification covers the minimum requirements for supply, fabrication and erection of
pipeline markers to be installed by Contractor at various locations along the route of a cross-
country pipeline.
2.0 REFERENCES
of issue of enquiry) of the following codes:
API RP 1109 : Recommended Practice for Marking Liquid Petroleum Pipeline

Facilities.
Company's Standard Specifications:
6-44-0004 Standard Specification for Shop and Field Painting
Note: In case any Particular Job Specification for Painting is included in the Project
Tender Document, the same shall be applicable in place of Painting specification
mentioned above.
Company's Standards:
7-71-0008 K.M. POST
7-71-0009 TYPICAL ROW BOUNDARY MARKER
7-71-0010 AERIAL MARKER
7-71-0011 DIRECTION MARKER
7-71-0012 PIPELINE WARNING SIGN
7-71-0014 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING

SIGN
3.0 GENERAL
3.1 Contractor shall supply, fabricate and install the Pipeline Markers along the pipeline route.
The location of markers as indicated in the approved drawings shall be treated for guidance
purpose only and the exact location of the markers shall be based on AS BUILT drawings and
as directed by Company.
3.2 The pipeline markers shall be fabricated and installed in accordance with the EIL standard
drawings included herein. Before start of fabrication of the markers, the Contractor shall
prepare and submit for Company's approval, the detailed scheme for the marker plates as
applicable for the project. All the markers shall be painted in accordance with the
requirements of Standard Specification for Shop and Field Painting (Specification No. 6 44
0004). In case of coastal areas the painting on markers shall be suitable for highly corrosive
environment as per Table 10.0, SI. No. 10.2 of specification no. 6 44 0004 and for all other
areas painting shall be suitable for normal corrosive environment as per Table 8.0, SI. No. 8.2
of specification no. 6-44-0004.
Page 452 of 1963

laraael ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
5%-4-,41/a9rg, Pane 5 of 6
3.3 The pipeline markers shall be installed, as far as possible, at locations such that they do not
cause any hindrance to the regular use of the land or to the traffic.
4.0 AERIAL MARKERS

Aerial Markers shall in general be installed along the pipeline at every five (5) kilometers
intervals and at places specified by Company.
Refer EIL Standard Drawing No. 7-71-0010 for details.
5.0 KILOMETER MARKERS

Kilometer Markers shall in general be installed along the pipeline at every one (I) kilometer
interval. Markers shall indicate cumulative distance in kilometers from the reference station,
as directed by Company. A kilometer marker is not required, if the relative distance between
its location and any pipeline warning sign is less than 200 meters.
Refer EIL Standard Drawing no. 7-71-0008 for details.
6.0 PIPELINE WARNING SIGN
Pipeline Warning Sign shall in general be installed at:
National and State Highway crossings 2 Nos. min.
Other Road crossings 1 No. min.
Railway Crossings 2 Nos. min.
Minor Water Crossings (less than 15 m width) 1 No. min.
Minor Water Crossings (above 15 m width) 2 Nos. min.
Major Water crossings 2 Nos. min.
Valve Station & IP Station I No. min.
And or any other location as shown in the approved drawings and as directed by the
Company.
Pipeline Warning Sign shall identify the existence of the pipeline and display the name of the
Company, with an emergency telephone number.
7.0 RoU BOUNDARY MARKER
Right-of-Use boundary markers shall be fabricated as per the drawings and shall be installed
at every 250 meters interval along the entire pipeline route. These shall be installed on either
side of the pipeline alignment to define the RoU boundary limits. These shall also be installed
at pipeline turning points to maintain the continuity of the RoU limits.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —AIL rights reserved
Page 453 of 1963

-,ark a
Pr LE7 ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
T;fen ereetweamnam) (A can of India Undettaingl
Page 6 of 6
8.0 DIRECTION MARKERS
Direction Markers shall be installed to identify the significant Turning Points of the pipeline
during aerial traverse. One direction marker shall be installed at each Turning Point, two more
direction markers shall be installed along the pipeline alignment, one on either side of the
Turning Point at 200 m from the Turning Point.
9.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN
The Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated and installed
one on each bank of navigable water courses at the pipeline crossing location, in lieu of the
Pipeline Warning Sign described in Clause 6.0 of this specification.
10.0 SPECIAL MARKERS
As directed by Company, special markers shall be installed at location where following

changes take place:
Change in pipeline diameter and wall thickness.
Change in type of pipe
Change in class locations for pipelines conveying gas
The above data may be provided on other types of marker (except RoU boundary marker), if
the relative distance between the two does not exceed 100 m.
Page 454 of 1963

If'
e_t ENGINEERS
INDIA LIMITED
Go„ oI Ind i a Undertak m91
FOR DOCUMENTATION
FOR PIPELINE CONSTRUCTION
6-71-0059 Rev. 4
Page 1 of 9
41 4011 ^1 1:1 1-1 1u1 * Cti t N;71

* icrki
FOR
DOCUMENTATION FOR

SPECIFICATION
REVISED & REISSUED AS STANDARD MKM VM AS
3 21-11-06 SPECIFICATION
2 29-10-01 REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
SPECIFICATION
1 09-09-98 REVISED & REISSUED AS STANDARD PKM ASr VC AS
SPECIFICATION
Standards Standards
Approved by
Page 455 of 1963

15122:rei ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
stgzx takies, INDIA LIMITED
„.o„ sind.unde..„ FOR PIPELINE CONSTRUCTION Pane 2 of 9
Abbreviations:
PIMS : Pipeline Information Management System

RoU : Right of Use

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Page 456 of 1963

15dMaeft ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
SigSVS W LNEINtIL
TED
ingi FOR PIPELINE CONSTRUCTION Pa e 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 RECORDS 4
3.0 AS-BUILT DRAWINGS AND PIPE BOOK 6
Format Na 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 457 of 1963

OPIZI-e? cc) ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
21 1 INDIA LIMITED
“ 0„ cond...„,„,„, FOR PIPELINE CONSTRUCTION Page 4 of 9
1.0 SCOPE
1.1 This specification covers the minimum requirements of various records, reports and drawings
for all aspects of pipeline construction to be prepared by the Contractor and submitted to the
Company at intervals as described in this specification and as directed by the Company.
1.2 All documents required to be prepared and submitted by the Contractor as per this
specification shall be in addition to the various reports, records, methodology statements,
calculations, drawings etc. to be submitted by the Contractor for Company's record, review or
approval as per the requirements of all other specifications included in the CONTRACT
between the Company and the Contractor.
1.4 Documentation to be submitted by Contractor to Company is summarized below. Number of

Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.
2.0 RECORDS
The Contractor shall submit to the Company the daily, weekly, monthly reports and after
completion, various other records and reports, for Company's documentation purpose. The
documentation (scheduled reports) shall be submitted progressively during construction. All
às-built' records shall be submitted immediately after the construction. This shall as a
minimum include, but not limited to the following:
2.1 Daily
Separate progress reports of all crews

Daily welding results and repairs
Actual weather conditions
Application for deviations, if any
Accidents
Damages
Activities / approvals required from Company
Materials Receipts
List of urgently required materials
2.2 Weekly
Up-to-date all pipeline data in PIMS

Up-to-date list of confirmed Site Instructions issued by Company
Materials 'taken over' by Contractor
Materials defects and repairs
Outstanding activities of Company
List of installed markers, chainage
Required approval form Company
Progress planned
Page 458 of 1963

laraTle ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
INDIA LJMITED
faoleg, FOR PIPELINE CONSTRUCTION Page 5 of 9
Reports of manning of all crews, equipment and plant

Reports of equipment and plant
Reports of accidents
Reports of damages
Reports of Acquired Releases, Permits etc.
Prices variations
Required materials for next month
2.3 Monthly
Project Progress Report, report of payment, safety report, report of accidents, security
reports, health and environment report, material balance, approved deviations.
2.4 Further, Contractor shall apply for approval, if required, to the Company with document such
as but not limited to:
Organogram for construction of work

BM-data of key personnel (including foremen)
(Revised) list of address of personnel in particular of medical staff, safety and security
officers.
(Revised) list of approved coaters
(Revised) list of approved sub-Contractors
Time schedule
Acquired permits and/or approval from Authorities, if any.
Minutes of meeting with Company with comments, if any.
Material certificates, material receipt.
Guarantees from Vendors and sub-Contractors
Calculations for temporary works, buoyancy, blasting, pipe pulling etc.
Drawings issued by Contractor.
Vendor drawings.
As-built drawing of route maps, alignment sheets, detail drawings and isometric
drawings,
Procedures such as surveying, stacking, fencing.
Welding procedure qualification record, radiographic procedure qualification, welder
qualification
Coating and repair procedure.
Installation of crossings.
Hydrostatic testing Procedure
Blasting Procedure
Radiographic report along with original radiographs
Pipe and welding book
Material records and Accounting book
Page 459 of 1963

ENG INEERS
INDIA LIMITED
FOR DOCUMENTATION
6-71-0059 Rev. 4
Govt FOR PIPELINE CONSTRUCTION Paa e 6 of 9
Reports
Material tests (coating, welding, painting)
Computerised Potential Logging Test
Water samples
Cleaning, Pigging Report before hydrostatic test
Hydrostatic test
Calibration test
Blasting trials
Equipment certificates (dead weight tester, instruments, vessels, equipment)
Manuals
Major water crossings
Waster disposal
Disposal of water after hydrostatic test.
2.5 The Contractor shall submit to Company, colour photographs (hard copy as well as digital
format) taken through digital camera (having resolution >1 mega pixels) of various
construction activities/operations at regular intervals. Size, number and frequency of the
photographs shall be mutually agreed upon between the Contractor and the Company. The
Contractor shall make video recordings of all operations right from the start of construction till
the completion of the work, covering to the extent as instructed by Company and submit to
Company. The recordings shall be made progressively as construction advances. Upon
completion of the work, the Contractor shall submit the recordings in CD / DVD or any other
format specified by the Company. The duration of each video recording shall be of 1/2 hour
(unless specified otherwise) and shall cover all major aspects of the job.
3.0 AS-BUILT DRAWING AND PIPE BOOK
3.1 General
The Contractor shall prepare "As-built' drawings of all the drawings, whether issued by
Company or prepared by Contractor including vendor drawings, such as but not limited to:
For pipeline section:
Route maps
Alignment sheets
Detailed drawings (road, railway, minor water crossings, major water crossing, valley
crossings, utility crossings, cable crossings)
Isometric drawings of installations
Special installation.
Further Contractor shall prepare a pipe book.
If required by the Company, the Contractor shall update the drawings issued for construction
of the job.
Page 460 of 1963

laltre?gth ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
511gar RitegliPINDIA LIMITED FOR PIPELINE CONSTRUCTION
Page 7 of 9
3.2 "As-built" Drawings
The Contractor shall prepare a complete set of "As-built" drawings. From the start of
construction, the Contractor shall, on daily basis, process any changes in two sets of drawings.
Deleted parts shall be indicated in red, new parts in blue, remarks in green and unchanged
parts in yellow. Said drawings shall be kept at site and shall be available to Company at all
times. The Contractor shall prepare "As-built" drawings based on these data. On completion of
the work, revised drawings made "As-built" by Contractor shall be handed over to Company.
The Hard Prints shall be submitted in As-Built Dossier and Soft Copies shall be submitted in
CD / DVD format.
The Contractor shall prepare and submit a specimen of the layout of the drawings for
Company's approval.
The required measurement for "As-built" drawings shall be executed by the Contractor by
experienced and qualified surveyors.
The surveyors shall daily take care of all measurements required such as but not limited to:
Horizontal location of pipeline with regard to deviation and Permanent Grid Pillars.
Vertical level with regard to Mean Sea Level of pipeline and grade.
Location and type of bends, fittings etc. and grades, points of intersection.
Changes of wall thickness, materials.
Location and details of valves, insulating joints, fencing.
Location and details of road, railway, water crossing, suspension bridges.
Location and details of casing pipes, vents.
Location and type of coating.
Location and type of weighing, anchoring.
Location and type of markers.
Location of further appurtenances (Pig-signallers).
Location of RoU and of pipeline with respect of RoU.
Type of soil.
Type of rock.
Type of blasting and ripping
Sand padding.
Type of road pavement.
Details of bank protection, number of insulators, seals.
The Contractor shall also prepare isometric drawings of installation (facilities) etc. for which
the data as mentioned in or required for the Pipe and Welding Book can be identified and these
drawings can also be used for material accounting.
3.3 Name plates of Equipment
All permanent equipment supplied and installed by Contractor shall be provided with plates by
Contractor. All texts shall be submitted to Company for approval before plates may be
manufactured.
Page 461 of 1963

OIIRTAft ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
Sigar laWWW
INDIA LIMITED
(.. FOR PIPELINE CONSTRUCTION Page 8 of 9
3.4 Pipe Book
Every page of the Pipe and Welding Book shall mention:
Data relevant to the project and section thereof

Sequential number
Length brought forward (for pipes and other materials).
Length to bring forward (for pipes and other materials)
Alignment sheet number and at least the location thereon of two welds on every page
of the Pipe Book.
Further, following shall be specified:
Diameter of pipeline
Length of each pipe
Wall thickness
Pipe number
Heat number, certificate number
Cut and re-numbered pipe ends
Coating
Date of stringing
Data of welding
Direction of working
Weld number
Welder number
Type of welding, electrodes, diameter of electrodes etc.
Heat treatment
Equipment used for radiography
Limits of water crossings.
Test pressure and date of test.
In order to achieve this, the Contractor shall identify all pipe elements. Sample format of Pipe
Book shall be submitted for Company approval.
3.5 As-Built Documents
The Contractor shall prepare all documents in the prescribed format as indicated below. In
addition to the hard copy, soft copies of final documents shall also be submitted in electronic
media i.e. CD / DVD format.
Software used for the preparation of these documents shall be as follows:
Type of document Software
Reports MS Word (Office 2007 or above)

Drawings AutoCAD (Release 2010 or above)
Page 462 of 1963

101 e..1 a ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
,,,,wwiANITN■dpsenzED FOR PIPELINE CONSTRUCTION
Stg-istlayeu Page 9 of 9
For the purpose of preparation of As-built drawings, Contractor shall update the "Issued for
Construction" drawings issued by the Company. It shall be the Contractor's responsibility to
convert the drawings furnished by the Company in hard copy into AutoCAD drawings
including scanning, digitising and converting the drawings into a suitable format compatible
with the AutoCAD Release 2010 or above. As-built drawings shall be prepared only on
AutoCAD Release 2010 or above.
Page 463 of 1963

Mae? aa ENGINEERS STANDARD SPECIFICATION
laiegwir WA LIMITED FOR HOT TAPPING 6-71-0062 Rev. 4
coot of hdla undertakung) Pa e 1 of 7
Tr4
*r Trriw *Mu
FOR
HOT TAPPING
ss I—lilt:5
t Of
,--,w
4 08.05.12 REVISED & REISSUED AS STANDARD R SKJ VM DM
SPECIFICATION
3 21.11.06 REVISED & REISSUED AS STANDARD MKM VM AS VC
SPECIFICATION
SPECIFICATION
1 09.11.98 REVISED & REISSUED AS STANDARD SK SJ VC AS
SPECIFICATION
0 08.01.90 ISSUED AS STANDARD SPECIFICATION SK RKD SA
Standards Standards
Approved by
Page 464 of 1963

ISM-CAM ENGINEERS STANDARD SPECIFICATION FOR
ausaplegye INDIA LIMITED HOT TAPPING 6-71-0062 Rev. 4
Page 2 of 7
Abbreviations:

Members : Mr. Raj Kumar

Mr. S. K. Jain
Mr. M. S. Gunjiyal
Page 465 of 1963

Z1f
oraziet INDIA
ENGINEERS
LIMITED
HOT TAPPING
6-71-0062 Rev. 4
Page 3 of 7
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE CODE 4
3.0 MATERIALS 4
4.0 PROCEDURE 4
5.0 WELDING 5
7.0 CUTTING OPERATION 6
8.0 COMPLETION 7
9.0 DOCUMENTATION 7
Page 466 of 1963

antaditit ENGINEERS STANDARD SPECIFICATION FOR
Sigar El5leg VP INDIA LIMITED HOT TAPPING 6-71-0062 Rev. 4
(A GO/ of India undef1710.91
Page 4 of 7
1.0 SCOPE
This specification covers the minimum requirements of safety, procedure and equipment for
hot-tapping work to be carried out on carbon steel pipelines or vessels in service containing
flammable hydrocarbons.
This specification is not intended to be all inclusive, and the use of guidelines set forth herein
does not relieve the Contractor of his responsibility of performing the WORK safely and
completing the WORK capable of performing the intended service.
This specification shall be read in conjunction with the conditions of all specifications and
2.0 REFERENCE CODE
The hot-tapping works shall be carried out in accordance with the latest edition of API RP-
2201 - "Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries" and this
specification. All requirements given in API RP-2201 as "recommendatory" shall be
considered as mandatory requirements.
In case of conflict between the requirements of API RP-2201 and this specification, the
requirements of this specification shall govern.
3.0 MATERIALS
3.1 All materials shall meet the requirements of specification for pipeline and piping materials,
included elsewhere in the CONTRACT between Company and the Contractor and shall be
suitable for the service and applicable Class Rating for which they are to be used. In case, the
Contractor proposes to modify certain requirements of these specifications specifically to suit
the hot tapping procedure to be adopted, he may do so, after obtaining the Company approval
in writing. In any case, prior Company approval is required for all materials supplied by the
Contractor.
3.2 Material of fitting (split tee) shall be compatible with the material of the Run-pipe to be hot-
tapped in terms of metallurgy and weldability.
3.3 Hot-tap welding should not normally be performed on materials, which requires post weld
heat treatment. Therefore, material of split tee shall be selected in such a way, that there is no
requirement of post weld heat treatment.
3.4 Manufacturer shall submit all the test certificates in respect of the materials supplied as
required by the Company specifications.
4.0 PROCEDURE
4.1 The Contractor shall obtain necessary permissions from the concerned authorities for all hot-
works. The Contractor shall ensure that he has requisite permissions from the Competent
Authority as well as valid hot work permit before initiating any work whatsoever.
4.2 All taps shall be made using a full-encirclement fitting having a design suitable for
Contractor's proposed procedure.
4.3 Prior to starting of work, the Contractor shall submit for Company's approval, a detailed
procedure proposed to be adopted for hot tapping. Such procedure shall contain, but not
limited to, the following details:
Page 467 of 1963

ISktaet ENGINEERS STANDARD SPECIFICATION FOR
lafgeg INDIA LIMITED HOT TAPPING 6-71-0062 Rev. 4
A Gent ol India Linden:1,Ni
Page 5 of 7
Preparation for hot works, viz., selection of location on pipe or vessel for hot tap,
ultrasonic testing to check the adequacy of available wall thickness and absence of
laminations, imperfections and out of roundness to ensure that pipe or vessel at the
hot tap location is suitable for welding, pre-heating (if required) and cutting
operations, etc.
Method of ensuring and monitoring recommended minimum and maximum velocity

of fluid in the pipeline.
Method of measurement and maintenance of liquid level in case of hot tapping on

storage tanks.
Connection details.
Detailed welding procedure
Procedure for non-destructive testing of weld and hydrostatic test of assembly

including test pressures, etc.
Details of all materials and equipment
Hot-tapping procedure.
Safety instructions, and safety measures viz., gas detection tests, tests for presence of
toxic environment, etc., and safety measures for installations, equipment, personnel,
etc.
Any additional requirements deemed necessary by Company or by Authorities having

jurisdiction for execution of any or all phases of the work shall be binding on the Contractor.
The Contractor shall proceed with construction only after obtaining approval of the procedure
from Company in writing.
4.4 The Contractor shall carry out all checks as recommended by Hot tapping equipment
manufacturer, before hot-tapping is attempted.
4.5 The exact location of the hot tap on the pipe or vessel shall be carefully identified and marked
in the field and Company's approval shall be obtained.
4.6 All necessary gas detection tests shall be conducted by the Contractor to ensure safe
environment.
4.7 Adequate safety arrangements shall be made for the protection of adjacent installations,
exposed personnel and equipment.
4.8 No hot-tapping work shall be performed in adverse conditions of weather, such as rain, fog,
high dusty winds, etc., which may be detrimental to the quality of the work performed.
5.0 WELDING
5.1 Methods for welding procedure qualification and qualification of welders shall be prepared
and submitted by the Contractor for Company's review and approval in accordance with
Section IX of ASME Boiler and Pressure Vessels Code. Upon receipt of approval from
Company, the Contractor shall prepare for the tests and conduct them in the presence of
Company's representative. Separate qualification tests shall be carried out for each grade of
steel and each size of weld. All welding shall be carried out by qualified welders and qualified
welding procedures.
Page 468 of 1963

Si I fa z e? tat ENGINEERS STANDARD SPECIFICATION FOR
Ifgat faiegvir INDIA LIMITED HOT TAPPING 6-71-0062 Rev. 4
Page 6 of 7
5.2 The manual arc process of welding using shallow penetration low hydrogen electrodes shall
be used.
5.3 Test certificates for each batch of electrodes and other welding materials obtained from the
Manufacturer(s) shall be submitted for the approval of Company. Company reserves the right
to reject such material at any time, in the event these materials do not perform to the
requirements of this specification.
5.4 The weld attaching the fitting to the pipe shall be circumferential to the pipe.
5.5 Welds shall be made in the following sequence - longitudinal welds first, then one end
circumferential weld, then the other.
5.6 The heat input shall be controlled during welding operation to prevent undue overheating of
pressurised pipe or vessel.
5.7 The surface to be welded shall be smooth, uniform, free of fins, laminations, tears, scales,
slag, grease, paint and other deleterious materials, which might adversely affect the welding
and its quality.
5.8 All weld joints shall be cleaned of slag and other irregularities before the deposition of the
next pass. Defective welds shall be completely removed or repaired in accordance with the
qualified welding procedure before further welding and when instructed by Company.
5.9 Tack welds, if allowed, shall be executed as per qualified welding procedure. Defective tack
welds shall be completely removed prior to final welding.
5.10 Prior to commencement of final welding, Contractor shall obtain approval from Company for
proper joint fit-up and alignment.
6.1 Magnetic particle inspection shall be performed for the first pass and after completion of all
welds. In addition, radiographic and/or ultrasonic tests of the welds shall be carried out.
6.2 Before start of the cutting operation, assembly including full bore ball valve/ sandwich valve
kept in open position shall be hydrostatically tested to a pressure equal to or greater than the
operating pressure and not exceeding the internal design pressure of the run pipe. The test
pressure shall be maintained for a minimum period of one hour. Company's representative
shall witness and grant approval on satisfactory completion of the hydrostatic test.
6.3 All welds, which, in the opinion of Company, are found to be defective by hydrostatic testing
or by NDT, shall be repaired or cut and re-welded, as directed by Company, and re-tested.
Repair of a repaired weld is not permitted.
7.0 CUTTING OPERATION
7.1 Instructions given by the Manufacturer of the hot-tapping machine shall be strictly followed
while installing the machine and during the cutting operation.
7.2 Cutting operation shall begin only after all welds have been tested and approved by Company.
7.3 Contractor shall ensure that the full bore ball valve or the sandwich valve is precisely centered
on the tee-connection and is cleaned of all dirt, etc.
Page 469 of 1963

ankletENGINEERS
INDIA LIMITED
6-71-0062 Rev. 4
iLlf HOT TAPPING
Pa e 7 of 7
7.4 Boring bar of the hot tap equipment shall be run several times through the valve to ensure that
the cutter does not jam or drag.
7.5 All bolted joints shall be checked for possible leakage. Packing of hot-tap machine, bleed
valve, bolts of cutter, pilot bit and blank catcher shall be checked before starting the cutting
operation.
7.6 After the cutting operation is complete, the boring bar shall be extracted, the valve closed and
the machine shall be depressurised by opening the bleed valve. Machine shall be dismantled
after these operations have been completed and when authorised by Company.
7.7 A blind flange shall be provided on the valve after removal of hot tap equipment. In the event
sandwich valve is utilised, the end shall be made with a Lock-O-Ring flange.
8.0 COMPLETION
8.1 The hot-tap work shall be considered complete when it has been certified in writing by
Company that all the works have been satisfactorily completed.
8.2 The Contractor shall clear-off the area removing all equipment and left over material, etc.
from the job site after completion of the work.
9.0 DOCUMENTATION
9.1 Documentation to be submitted by Vendor/Contractor to Company is summarized below.

Number of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT
document.
9.2 Following documents shall be submitted:
Hot Tapping Procedure.
General Arrangement Drawings (dimensional drawings)
Sketches of the location (Pipeline KP Point) Owhere hot tapping is performed.
Details/data sheet of components including tees, valves etc. including size, rating and
material details.
Welding Records.
Weld inspection and NDT records.
Page 470 of 1963

ataadhe ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
Igar afilegNIE INDIA LIMITED (ONSHORE)
IA Got 0/ India unleptaxingi Page 1 of 24
*r
TiriaW reitiT
414401§1 Jull
(i 41)
FOR
PIPELINE SURVEYS
(ONSHORE)
3
2
31.08.12
06.11.06
REVISED AND REISSUED AS STANDARD
SPECIFICATION
REVISED AND REISSUED AS STANDARD
SPECIFICATION MKM VM
‘4t AS
DM
VC
1 21.09.91 REVISED AS STANDARD SPECIFICATION ALP AS VC A SONI
0 20.9.91 ISSUED AS STANDARD SPECIFICATION JAY RKD PCR

Standards Standards
Rev. Date Purpose Convenor Chairman
No by by
Approved by

Page 471 of 1963
safrzeigh ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
5'ga Wift INDIA LIMITED (ONSHORE) Page 2 of 24
Abbreviations:
BM Bench Mark
DGPS Differential Global Positioning System
DTM Digital Terrain Modelling
EDM Electronic Distance Measurement
GPS Global Positioning System
GWT Ground Water Table
IP Intermediate Point
NGL Natural Ground Level
ROU Right of Use
SPT Standard Penetration Test
TP Turning Point
UTM Universal Transverse Mercator

Mr. Raj Kumar
Mr. M.S. Gunjiyal
R. Chaudhury (SMMS)
Mr. A. K. Chaudhary (Inspection)
Page 472 of 1963

FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
CONTENTS
1.0 SCOPE
2.0 REQUIREMENTS
3.0 DOCUMENTATION
APPENDIX-A PIPELINE ROUTE CENTRELINE SURVEY

APPENDIX-B DETAILED ROUTE SURVEY
APPENDIX-C SOIL INVESTIGATION SURVEY
APPENDIX-D LOCATION CLASS SURVEY
APPENDIX-E CADASTRAL SURVEY
ANNEXURE-I PIPELINE ROUTE SURVEY DATASHEET

ANNEXURE-II SAMPLE FORMATS
Page 473 of 1963

1.0 SCOPE
This specification covers the minimum requirements for various type of surveys required to be
carried out for an onshore pipeline. The requirements for surveys and investigations related to
locating pipeline route centreline, dumpsites and intermediate station/terminal facilities on
ground, obtaining topographic features, ground profile and soil data along the pipeline route;
collection of revenue maps/ data and preparation of cadastral maps for ROU/Land acquisition
purposes; collection of location class data along the pipeline route are specified in this
specification.
The specification also covers requirements related to construction of survey monuments, field
measurements and presentation of survey data including preparation of maps, drawings,
documents and reports.
2.0 REQUIREMENTS
2.1 All survey works shall be performed by and/or under the direct supervision of a qualified land
SURVEYOR.
2.2 All survey work shall be carried out using modern and well-maintained survey
equipments/instruments such as DGPS, GPS, EDM, Total Station, Theodolite, Inclinometers
and any other equipments/instruments deemed necessary for completion of works as per this
specification.
2.3 Following type of surveys are covered under this specification:
Pipeline route centreline survey as per Appendix-A.
Detailed pipeline route survey as per Appendix-B
Soil investigation surveys as per Appendix-C
Location class survey as per Appendix-D
v) Cadastral survey as per Appendix-E
Specific requirements of surveys for a particular project shall be as indicated in CONTRACT.
2.4 Normally detailed route survey shall be carried out after centreline survey has been completed
and the pipeline route established on ground has been accepted by the Company. In case the
pipeline route has already been identified by the Company and/or the centreline survey is not
required to be carried out by the survey contractor, the SURVEYOR shall make himself fully
aware of the general conditions of the terrain along the pipeline route prior to start of survey
work.
2.5 In case, the pipeline for which the route survey is proposed to be carried out is to be used for
transportation of hydrocarbons in gaseous phase, the location class survey shall be carried out
as per Appendix-D of this specification.
2.6 All major crossings and routing in critical areas shall be finalized by SURVEYOR in
consultation with Company/Engineer-in-Charge. Company may depute its representative
during the survey work to assist the contractor in finalizing such location at its sole discretion
2.7 The SURVEYOR shall avoid major deviations from identified/established route during
detailed survey. Any such major deviation must be approved by Company representative.
Page 474 of 1963

lallaaeg at, ENGINEERS FOR PIPELINE SURVEYS
sign EtWerdif INDIA LIMITED
w, Goys ot YW umertang■ (ONSHORE)
6-71-0071 Rev. 3
Page 5 of 24
SURVEYOR shall clearly specify reasons for such deviations while submitting his proposal
for change in route.
2.8 When so specified in contract document the SURVEYOR shall locate dump site(s), for
storage of line pipe and other pipeline materials, along pipeline route.
Unless specified otherwise in data sheet/ contract document the dumpsite(s) shall be located at
75-100 km interval and shall have an area of 5 — 10 hectares.
Following aspects shall be taken into account while selecting dumpsite location(s):
Dumpsite should preferably be a barren land free from water logging/low lying areas.
The site shall be located in close proximity of identified/established route.
It should be in the vicinity of National/State Highway.
The site should be nearly flat with minimum undulation that might require earth work
(fill-up and earth-cutting).
Site should not be under overhead powerlines.
Site should preferably be on government land.
3.0 DOCUMENTATION
3.1 Maps & Drawings
All maps and drawings shall be made using standard formats enclosed with this specification.
The SURVEYOR shall perform all mapping and drawing work so as to contain all relevant
data consistent with the survey notes and observations. The type of drawings and maps to be
prepared shall be as per requirements specified under Appendix-A to Appendix-E.
3.2 Reports
The reports to be prepared by SURVEYOR shall be exhaustive and shall contain all relevant
information. The report shall describe in brief the survey methodology adopted, equipment
used and tests (if required) conducted for obtaining the details/data presented in the report.
The final results/conclusion shall be based on sound practices and detailed analysis of the data
collected. The report must include recommendations as applicable for the Company's
consideration.
3.3 Drawing/Document Submission
All drawings and document shall be prepared using computers. Hard copies and soft copies of
all required drawings and documents shall be submitted to Company for review/approval. The
Company shall review and comments, if any, shall be passed on to the SURVEYOR. The
SURVEYOR shall incorporate all comments, including carrying out fresh field
works/laboratory testing (when required) and revise the drawing/document to entire
satisfaction of Company. Number/sets of hard copies and soft copies of each drawing and
document (submitted for review/comments by Company) shall be as indicated in
CONTRACT.
Once the drawing/documents have been reviewed by the Company and updated by surveyor to
entire satisfaction of Company, the SURVEYOR shall submit entire documentation
(drawings, maps, reports etc.) both in hard copy as well as soft copies for Company's records
Page 475 of 1963

15Mag e
e ENGINEERS FOR PIPELINE SURVEYS
s'fgar faittgw , WA LIMITED
(ONSHORE)
6-71-0071 Rev. 3
Go„ 01 inch, undersingi Page 6 of 24
(number of copies as specified in CONTRACT). All hard copies shall be signed and stamped
by SURVEYOR. All drawings and sketches shall be prepared using AutoCAD Release 2012
or above. All reports/documents shall be prepared using Microsoft Office Release 2012 or
above. All photographs included in document/reports shall also be in digital format
(JPG/TIFF). Whenever data base is used for presentation of data (location class, ground
profile etc.), the same shall be prepared in Access Data Base Software using Microsoft Office
Release 2012 or above.
Pipeline route maps shall also be furnished with ".KML & .KMZ" files. Additionally, the
complete pipeline route maps in ".KML" file shall be furnished with video files demonstrating
topographical features with limits of ROU & class locations and major crossing such as
Highways, Railways, Canals, Rivers and Forest etc. All crossings shall be linked with
photographs indicating chainage, name of crossing etc. in the video.
Page 476 of 1963

OSillnlaeTa ENGINEERS FOR PIPELINE SURVEYS
7 Emegwi, INDIA LJMITED
salg 6-71-0071 Rev. 3
+wenefeawoonJoom/ IA GoA of M ph lindenalong) (ONSHORE) Page 7 of 24
APPENDIX-A
PIPELINE ROUTE CENTRELINE SURVEY
1.0 Objective
The objective of the centreline survey work is
Physical verification of the identified route and confirm its suitability for pipeline
construction.
Identify restrictive areas and suggest modifications/detours to the identified route
Establish the route on ground.
Collection of development plans along the proposed pipeline route from various agencies
having jurisdiction thereof.
v. Collecting information required for obtaining clearances from various authorities

including environmental clearances.
2.0 Requirements
2.1 General
2.1.1 The Company shall provide the SURVEYOR identified pipeline route details.
2.1.2 The SURVEYOR shall transfer the Company identified route onto Survey of India (Sol)
topographic maps or Satellite imageries (in scale 1:250,000, 1:50,000 or less in case identified
route passes through hilly/ghat areas) for use during field verification and preparation of route
maps. The maps for this purpose shall be arranged by SURVEYOR unless specified otherwise
in contract. For section of the identified pipeline route covered in maps identified/declared by
Sol as "Restricted" maps, Company may arrange such maps and make them available to the
SURVEYOR during field verification. SURVEYOR may also use satellite imagery for
updating of SoI maps, if required, as per provisions of CONTRACT document.
2.1.3 SURVEYOR shall carryout reconnaissance survey as necessary to orient the most practical
alignment along identified route using best judgement and experience of the SURVEYOR to
interpret the needs of pipeline construction. The SURVEYOR shall use Global Positioning
System (GPS) and other survey equipment such as magnetic compass, inclinometer, theodolite
etc. as required during the reconnaissance survey.
2.1.4 The SURVEYOR shall locate and identify all existing features and obstructions along the
route, identified by Company, and within a corridor of 5 km on either side of centreline that
are not shown in the available maps and update the Sol maps to reflect such changes.
SURVEYOR shall collect all development plans from the concerned authorities.
2.1.5 SURVEYOR shall establish stakes/mark flag control points on ground along the centreline of
route. Flag control points shall be clearly identified on the route maps. The flag control points
shall also be established at all major road, rail, canal (lined/unlined), pipeline, river crossings
and terminal locations.
Page 477 of 1963

151012:Re ENGINEERS FOR PIPELINE SURVEYS
sifta kitOlegNie INDIA LIMITED 6-71-0071 Rev. 3
IA Gort of India UndegtWing) (ONSHORE) Page 8 of 24
2.2 Pipeline Route Deviation
221 SURVEYOR in general shall avoid any major deviation from the route identified by
Company. Deviation from route, if considered essential by the Contractor, shall be brought to
the notice of the Company representative for Company's approval.
2.2.2 Contractor shall avoid obvious man made or natural obstructions such as culverts, bridges,
utility poles, building/structures, gorges, plantations, archaeological sites, reserve forest, wild
sanctuaries, environmental sensitive areas, mining sites, future built-up areas etc.
2.2.3 SURVEYOR shall take into account following criteria while selecting pipeline route
alignment in hilly areas/ghat regions etc.
A longitudinal slope along pipeline route shall not exceed 1:5
A transverse slope across pipeline route shall not exceed 1:1
c. As far as possible ridges/spurs should be used to climb up/come down from hill. Side
slopes of hills requiring excessive side billing should be avoided.
Hand held inclinometer shall be used for estimation of slopes
2.2.4 Centreline alignment thus established shall be shown prominently on the route maps. In
addition chainage in km, major turning points, intermediate facilities, planned developments,
existing features/obstructions, flag control points etc. shall also be marked on route maps.
2.3 Field Marking
2.3.1 The entire length of the surveyed route shall be staked on ground along the proposed
centreline. Stakes shall be 8 mm dia. painted twisted rods. Sketches/photographs to facilitate
location of stakes in field shall be furnished giving reference of existing features wherever
major directional change takes place.
2.3.2 Stakes shall be installed at flag control points, major crossings, major turning points and at an
approximate 1.5 to 2.0 km interval as dictated by field conditions.
2.3.3 Consideration shall be given to land use in placing the stakes e.g. stakes placed and left in
cultivated land may not be acceptable to the land owner. Stakes in such areas shall be placed
at boundaries between cultivated areas where necessary.
3.0 Presentation of survey data
Centreline survey data shall be presented in the form of following drawings/documents:
Pipeline route map showing route on SOI Topo sheets or satellite imageries of scale
1:50,000 or 1:25,000 for unrestricted areas. (SOI topo sheets shall be updated for
distance of 5 km on either side of pipeline centreline).
Pipeline route maps showing route on maps developed from SOI topo sheets or
satellite imageries of 1:50,000 or 1:25,000 scale for areas covered in "Restricted" 501
maps.
c. Overall pipeline route map in 1:500,000 scale.
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lgar Ellateg W INDIA LIMITED (ONSHORE) Rape 9 of 24
d. Ground profile drawing and ground elevation v/s pipeline chainages in MicroSoft
Access software (ground elevations to be furnished on an average at every km interval
or at locations where major change in ground elevation occurs).
e) Route report consisting of but not limited to following:
Route Description
Topographic features
Major Crossing details
Extent of reserve forest
Land use pattern and soil strata along route.
Developments plans
Estimates for land cost for RoU acquisition.
General metrological details
Site photographs. (Photographs shall be sufficient in numbers to represent the

entire terrain features).
Dump site locations suitable for pipe storage (when specified)
Ground Profile along the route
(xii) Comparison of alternative routes considered.
Page 479 of 1963

ISIWieg a ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
ltgar Elf5legYe INDIA LIMITED (ONSHORE)
•iRlfrecIASOM)
own IA Goof of inda unentamong) Page 10 of 24
APPENDIX-B
DETAILED ROUTE SURVEY
1.0 Objective
Objectives of detailed pipeline route survey are as follows:
To fix the pipeline alignment on ground.
To determine exact pipeline route length.
Finalize crossing locations and crossing angles.
Establish survey monuments on ground along pipeline route.
To obtain detailed topographic features within 30 m on either side of centreline.
To obtain ground levels and/or contours.
To obtain cross-section details and topographic features at all crossings.
To gather details of land use pattern and soil characteristics
2.0 Requirement
2.1 Pipeline route and turning points (TPs) along the pipeline route shall be located by the
SURVEYOR in consultation with Company/Engineer-in-charge considering the following:
To avoid obstructions along the line, by ranging on ground and shifting the Turning
Points if need be.
Terrain gradient to be checked by using hand held inclinometer.
Ensure proper angle of crossing by keeping as nearly right angle (to road/ canals
(lined/unlined)/ rail/ rivers/ streams, etc.) as possible. The right angle may be laid on
ground by using a chain or string lengths in ratio of 3, 4 and 5.
To check from construction point of view and avoid objects like power, telephone and
telegraph poles, walls, tube wells or such other structures falling in the strip of land,
30m on either side of pipeline alignment.
e. To maintain minimum distance of 100m between two consecutive turning points.
2.2 Staking of pipeline route
2.2.1 The pipeline defining trench centre line shall be staked by placing suitably painted marker
stakes at Turning Points (TPs) and at Intermediate Points (IPs) between consecutive TPs. All
Turning Points (TPs) and intermediate points are referred as Intersection Points.
The pipeline centre line shall be staked on the ground as follows:
First, the Turning Points (TPs) shall be staked on the ground. After locating and marking the
TPs, the intermediate points shall be staked while measuring slack distance. The staking shall
normally be done at intervals of 500 m along the centre line of the pipeline
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sanitzleg e ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
sifga iella4eg Yilif WENA LIMITED (ONSHORE)
e-nmrsidP'"1 (A Gov' of !pima Undenaking) Page 11 of 24
2.2.2 The Intersection Points shall be serially numbered form the starting point. The serial number
of each Intersection Point shall be boldly inscribed on the marker stake. In addition, the
Turning Point (TP) marker stake shall identify the Turning Point reference number from the
starting point.
2.2.3 For Intermediate Points (IPs) letter "P" shall precede the serial number of the intersection
Point marker. For Turning Points, the letters "TP" shall precede the Turning Point reference
number, and the letter "P" shall precede the serial number of the Intersection Point.
2.2.4 The marker stakes at Turning Points (TPs) shall be referred with three reference stakes around
the TP. The reference stakes shall carry the Turning Point reference number and their
respective distance from the TP marker stake. •
2.2.5 Change in direction of line shall be marked on the TP marker stakes. In addition, direction
markers near TPs and other locations shall be placed wherever necessary.
2.3 Stakes and Markers
2.3.1 All marker stakes shall be pre-cast reinforced concrete blocks having dimensions 150 x 200 x
800 mm, and shall be buried to a depth of 500 mm. Stone pillars of similar dimensions can be
used in place of concrete blocks.
The exposed surface of the blocks shall have a smooth finish and shall be painted with 'Post
Office' red paint. All letters and figures shall be paint marked on the surface of the blocks in
white.
2.3.2 On the top surface of the marker stake, a cross inside a circle shall be engraved at the centre or
a nail shall be put centrally inside an engraved circle, to indicate the exact position of the
Intersection Point. The circle shall be of approximately 50 mm diameter.
2.3.3 SURVEYOR can, however, propose to the Company/ENGINEER-IN-CHARGE other types

of stakes/markers which are better suited to site conditions.
2.4 Bench Marks
2.4.1 Permanent Bench Marks (BM) approx. every 5 km or permanent structures on or off the
Right-of-Use (ROU) shall be established and described. Bench marks shall be located in such
a manner that they will not be destroyed when the ROU is cleared for construction.
2.4.2 Additional permanent bench marks shall be established near the major pipeline crossing sites.
2.4.3 Location of Bench Marks shall be established in the field by using reinforced concrete/stone
blocks similar to pipeline marker stakes described in clause 2.3.1 of this specification. Exact
position of BM shall be marked by a cross inside a circle or a nail put centrally inside an
engraved circle on the top surface of the concrete block. The reduced level of the BM shall be
paint marked on the concrete block. Letters "BM" shall precede the reduced level of bench
mark recorded to the second place of decimal.
2.4.4 Accuracy of the reduced levels of the Bench Marks shall be verified wherever possible by
checking levels with the nearest permanent Bench Mark established by Survey of India.
Page 481 of 1963

2.5 Crossings
2.5.1 General
As far as possible, crossings shall be made at right angles. The SURVEYOR shall record the
angles of crossing for all fences, property lines, utilities, roads, railways, canals, streams, etc.
that are crossed. In addition, the true bearings of the centreline of the road, railway, canal, as
well as that of the pipe centre-line shall be recorded. Turning Points (TPs) provided on either
side of crossings shall be located, minimum 50m from the crossing's boundaries, in stable and
firm ground.
2.5.2 Railway Crossings
The angles for all railway crossings shall be as close to 90 degrees as possible, but in no case
less than 85 degrees to the centre-line of the railway.
2.5.3 Primary Road Crossings
Primary roads are the National & State Highways, all-weather roads (paved/unpaved) and
roads providing access to major installations. The angle of crossings shall be as close to 90
degrees as possible, but in no case less than 80 degrees to the centre line of the road.
2.5.4 Secondary Road Crossings
The angles of crossing for secondary roads shall be as close to 90 degrees as possible, but in
no case less than 45 degrees to the centre-line of the roads. All seasonal roads, unpaved
village roads, cart-tracks, etc. come under this category.
2.5.5 River Crossings
These crossings shall be established as close as possible to the locations shown on the route
map. Crossings shall be located in a comparatively straight reach of the river where the banks
are stable and there is sufficient area for construction. Angle of crossing shall be as close to 90
degrees as possible.
2.5.6 Canals (lined/unlined) /Drainage/Stream/Nala/Ditch Crossings
The angle of crossing shall be as close to 90 degrees as possible but in no case less than 60
degrees to the centre-line of the canal/drainage/Stream/ Nala/ditch. Crossings shall be located
where there is no evidence of slumping or erosion of banks, or bed.
2.5.7 Utility Crossings
Utilities crossed shall be located at their centrelines with stakes containing station numbers in
the survey. The angle of crossings shall be measured and locations established relative to their
above ground facilities. The names and sizes of all utility lines shall be included in the survey
notes. In cases of overhead power and telephone lines, the distance to the poles and towers on
each side of the survey line shall be measured, and the numbers of poles or towers noted. Line
voltage shall also be recorded. Where possible, the survey shall be established so that there is
a minimum distance of 50 metres from the survey line to the nearest High Tension (11KV, 33
KV and above) pole or tower.
Underground utilities shall be located as far as possible and staked for a minimum distance of
30 metres on each side of the survey line.
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51g7 ttlaiegNiffi ILIA LIMITED (ONSHORE)
A GoA al Inas Unaerlaknal Page 13 of 24
2.6 Built-up Areas
2.6.1 Monuments and Properties
The pipeline alignment shall run clear of the existing monuments, properties and structures
etc., as indicated in Pipeline Route Survey Data Sheet (Refer Annexure-I for sample).
For congested areas, closer distance may be adopted; however, location shall be approved by
Company/Engineer-in-charge
2.6.2 Parallel Alignment
The pipeline alignment wherever runs parallel to an existing or planned under/over ground
facility will be treated as parallel alignment. For underground facilities SURVEYOR shall
identify and locate them with suitable pipe locator/ cable locator. The following clearances
shall be observed in case of parallel alignment defined above unless specified otherwise:
Between existing/planned electrical power cables/lines and the proposed pipeline - 50.0
metres
Between existing/planned communication cables/lines and the proposed pipeline - 25.0

metres
c. Between existing/ planned pipeline and the proposed pipeline — 50.0 metres
2.6.3 Parallel Encroachment
Unless otherwise stated, when the pipeline alignment runs generally parallel to a road or
railway it shall be kept sufficiently clear of the Right of Way limits of the facility.
2.7 Accuracies in Measurement
2.7.1 SURVEYOR shall incorporate corrections to the linear ground measurement due to standard
errors (and variations from standard temperature and/or pull in case of chain survey, wherever
specifically approved by Company).
2.7.2 The error for angular closure for the work shall not exceed one minute per station and for
linear measurements it shall be read to the nearest 0.001 m.
2.7.3 The error on closure for measurements on vertical distance to establish bench marks shall not
be more that 244K millimetres (where 'IC' is the linear distance in km). The observations for
measurement of vertical distances on bench marks shall be read to accuracy to the nearest 5
mm and for Intersection Points and other points along the pipeline route and at crossings to the
nearest 10 mm. The error of misclosure in vertical distance shall be distributed linearly.
2.7.4 Azimuth control shall be maintained by observations of the Sun or Polaris at intervals of 15-
20 km by closing the traverse on existing control points. These observations of bearings
together with deflection angles shall be recorded in survey notes.
Azimuth misclosure based on bearings with observed angles at Turning Points shall be equally
distributed over the number of stations observed in between. Accuracy of azimuth
observations shall be acceptable if the three deductions agree within one minute when Sun is
used for Azimuth observation. Incase of stars/Polaris observation, computed values should
agree within 10 to 15 secs.
This check is not mandatory when using DGPS system for establishing location/co-ordinates.
Page 483 of 1963

$5iifaeleit ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
Elffleg w INDIA LJMITED
2.8 Chainage
2.8.1 Distance measurement shall be made by Electronic Distance Measurement (EDM) equipment
(or by using 50 m steel tape or 30 m chain if specifically approved by the Company).
However, in case of abrupt slope change the tape/chain shall be used and it shall be
straightened parallel to the probable grading.
2.8.2 Distance between Intersection Points staked along the pipeline route should be measured and
recorded. In addition, distance between level points shall also be measured and recorded.
2.8.3 Chaining, wherever permitted, shall be continuous in the direction of survey.
2.8.4 The true bearing of all straights shall be observed and recorded.
2.8.5 Data on nature of terrain, viz. sandy, stony, vegetation, etc. and type of ground will also be
recorded along with chainages of change points.
2.8.6 Check on distance measurements shall be by Stadia method at the time of levelling.
2.8.7 Standard survey formats shall be used for record keeping.
2.9 Measurement of Horizontal Angles
2.9.1 Horizontal angles are measured to indicate the change in direction of alignment and specify
the horizontal bend at the Turning Points.
2.9.2 Theodolite, reading direct to 10 seconds or better, shall preferably be used. Angles shall be
measured clockwise from back station to fore-station. Mean of two readings-one on face left
and other on face right shall be taken as the horizontal angle.
2.9.3 The line at both ends shall be tied to the grid control system being used for end facilities. True
bearing at the beginning, end and at every 15-20 km shall be observed to keep a check on
errors in angular measurements.
2.10 Profile
2.10.1 Continuous profile of the proposed pipeline route shall be established from the reduced levels
taken.
at the starting point,
at all Turning Points (TPs),
at all Intermediate Points staked on the ground,
at all points on the pipeline route where there is a change in slope.
2.10.2 When the terrain is flat, reduced level shall be additionally recorded along the pipeline route at
100 m interval.
2.10.3 When the terrain is undulating, observation of reduced level shall be made at a sufficient
number of points so as to give an accurate plotting of the ground profile along the route.
2.10.4 For road and railway crossings, the reduced levels shall be recorded at interval of 5 m along
the pipeline alignment and at closure intervals wherever there is a change in slope within the
entire width of the Right-of-Use of the road/railway.
Page 484 of 1963

ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
$ig:ar Mews" INDIA LIMITED
in poi amcu underutngi (ONSHORE) Page 15 of 24
2.10.5 For river/stream/nala/canal crossings, levels shall be taken at intervals of 5 m up to 30 m

beyond the highest banks on both sides. Levels shall be taken at closer intervals, if there is a
change in slope.
2.10.6 In right-of-use having slope across the pipeline alignment, as encountered in hilly areas, Ghat
regions, ravines and other similar areas as directed by Company, cross-sections at 50 m
interval and for a length of 30 m on either side of the pipeline alignment shall be observed and
recorded
2.10.7 For major water crossing sites, cross section as above shall be observed at both banks.
2.10.8 Method of RISE and FALL shall be used to compute reduced levels of various points. Check
on computation shall be made by using the following formula:
Back site - Fore Site = :Rise = First R.L. - Last R.L.
2.10.9 Maximum misclosure shall not exceed 24'dK mm where IC' is the distance in km. Maximum
length of line of sight shall not exceed 100 m.
2.10.10 All levels shall be with respect to Mean Sea Level (MSL).
2.11 Co-ordinates and Grid
2.11.1 Differential Global Positioning System (DGPS) shall be used to determine co-ordinates of all
intersection points and facilities along pipeline route. Accuracy of co-ordinates shall be within
0.5 metre. Non-differential or autonomous GPS are not acceptable.
The following information shall be submitted for DGPS proposed by Surveyor for Company
approval:
GPS Receiver Model used :

Differential Receiver Type :
Guaranteed accuracy in metres :
SURVEYOR shall submit a procedure for setting up & use of DGPS. All co-ordinates shall be
indicated in UTM grid as well as geographic grid. In case more than one survey party is
deployed, each party shall use same reference grid and DGPS system.
2.12 Levels and Contours
2.12.1 In addition to the elevation along center line of route, the SURVEYOR shall obtain, using
Total Station, levels within 30 m wide corridor on either side of route alignment. Co-ordinates
(in UTM grid) of each level point shall also be recorded.
2.12.2 All such level points shall be plotted in the planimetry portion of the alignment sheets. The
levels shall be taken in such a manner that contour can be drawn with a contour interval of 5
m. SURVEYOR shall draw the contours from the data collected.
2.12.3 Electronic data shall be made available in a format compatible with commercially available
Digital Terrain Modelling (DTM) software.
2.13 Seismic Fault lines
2.13.1 Surveyor shall identify the type, chainage and locations seismic fault lines crossings. All the
fault lines within one kilometre on either side of pipeline alignment shall be indicated.
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051PZIete ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
Zigt16i1g1tlil
0 a UMITED
(ONSHORE)
(A Govt of India U ndel amn) Page 16 of 24
Surveyor shall also indicate fault lines are active / non active. In case of parallel fault lines, the
extent of length and distance from the pipeline alignment shall be furnished.
3.0 Presentation of Survey Data
The data collected during survey shall be presented in the form of drawing and document
listed below:
3.1 Drawings
3.1.1 As a minimum following drawings shall be prepared and submitted
S. No. Description Scale

Detailed Route Map 1:50,000
Additional Route Map 1:15,000
(for Hilly, Ghat and ravinous regions)
Alignment sheets covering
- Right-of-Use Planimetry in UTM grid 1:2500 along the line
1:2500 across the line
- Ground Profile 1:2500 Horizontal

1:250 Vertical
Crossing Details 1:100 Horizontal
(Road/Railway/Stream/Nala/Canal/Crossings) 1:100 Vertical
& Utility Crossings
Crossing details (River Crossings)
- Up to 250 m width 1:200 Horizontal
1:200 Vertical
- 250 to 500 m width 1:500 Horizontal

1:500 Vertical
- Greater then 500 m width 1:1000 Horizontal

1:1000 Vertical
Cross Section for sloping Right-of-Use 1:100 Horizontal
1:100 Vertical
Note: Crossing drawings shall be prepared using same horizontal and vertical scales as
indicated above. In case one crossing can not be accommodated in single sheet
additional sheets may be used. Not to scale (NTS) drawings shall be rejected.
3.1.2 Pipeline route map shall show all features including, but not limited to roads and railroads,
canals, streams, lakes, rivers, villages, towns, and cities that are located within a distance of 5
km from the pipeline centre-line on either side of it. For the entire region, contours shall be
plotted on the route map at 20 m contour interval. Additional information like cultivated areas,
barren land, areas prone to flooding, rocky areas and forests including access paths/roads to
Right-of-Use shall also be shown on the route maps.
Additionally for areas which are undulating such as hilly areas, Ghat regions, ravines, and
other areas as directed by Company, Pipeline route map to a scale 1:15,000 shall be drawn
over a distance of 1.0 km from the pipeline centre-line on either side of it. For such areas,
contours shall be plotted at 10 m contour interval.
3.1.3 Right-of-Use Planimetry drawings shall show all objects within 30 metres on either side of the
Pipeline in Plan and shall show spot level & contours at 5m interval.
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1511WPRISENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
a megweINDIA LIMITED
ennt of India Undell*.^91 (ONSHORE) Page 17 of 24
3.1.4 For all rail, road, river, stream, canal and utility crossings, the angle of crossing shall be
mentioned.
3.1.5 For rail, road, river, stream and canal crossings wider than 10 m, the distances at the start and
at the end of the crossing from the nearest IP shall also be mentioned. For crossings less than
10 m, the distance of the centre line of crossing from the nearest IP shall be given.
3.1.6 For all river, stream and nala crossings, the level of water at the time of survey, High flood
level recorded in last 100 years and the approximate surface velocity of the flowing stream
(observed & recorded during survey) shall be reported in the survey drawings. Also, the
general nature of the surface soil (soft/hard, normal soil or rock/boulders) at the bed and banks
of the river/stream/nala shall be observed and mentioned in the drawings.
Ground profile (chainage v/s ground elevation) for the entire pipeline route shall be prepared
and presented in a tabular format using Microsoft Access Database format.
3.2 Documents
In addition to the drawings listed above, the SURVEYOR shall submit a report giving,
Details of survey methodology followed
Details of equipments used
Brief Route Description
Salient features of the route such as
Total length of pipeline
State wise distribution of pipeline route
Terrain details and land use pattern summary
No. of crossings (state wise & chainage wise)
Details of River crossings
State wise extent of forest/reserve forest/environmentally sensitive area
Significant elevation changes along the pipeline route with chainages
Nature of soil (sandy, clay, rocky(hard/weathered), marshy, etc.)
Location of Seismic Fault lines along the pipeline route
Print out of information required to be submitted as data base including
Level & contour information for DTM
Pipeline Profile data
TP detail
Page 487 of 1963

ENGINEERS FOR PIPELINE SURVEYS
azir EfiRegveli, LIMITED 6-71-0071 Rev. 3
lann eWremin) (A Gov/ al India Undetliongl (ONSHORE) Pape 18 of 24
APPENDIX-C
SOIL INVESTIGATION SURVEY ALONG PIPELINE
1.0 Objective
The objective of soil investigation survey is to obtain visual engineering classification of soil
and geotechnical properties of soil for design & engineering of various facilities required
along the pipeline route.
2.0 Requirements
2.1 General
2.1.1 The soil investigation includes boring, collection of disturbed samples from bare holes and
visual engineering classification of soil along the pipeline route, carrying out Standard
Penetration Test (SPT) at specified locations and getting the soil sample collected, from such
bore holes, tested at laboratory for specified engineering properties and submission of detailed
report to Company.
2.1.2 Visual classification of soil shall be in accordance with IS-1498; "IS Classification and
Identification of Soils for General Engineering Purposes". Geotechnical investigation of soil
shall be carried out as per relevant clauses of IS 1892 and other applicable IS standards.
2.2 Location of Bore Holes
2.2.1 Boreholes shall be made at an interval of 250 m along the pipeline route, at all intermediate
points where there is apparently a change in the type of soil and at other places as given below
by Company/Engineer-in-charge.
2.2.2 For canal, stream and river crossings, boreholes shall be made one on either bank and one on
the bed of water crossing. For railroads, state highways and national highways, at least one
bore hole shall be made at each crossing location.
2.2.3 Boring shall be carried out in accordance with the provision of IS: 1892. Minimum diameter
of boring shall be 150mm. Auger boring shall be resorted to above water table, whereas below
water table the boreholes shall be advanced by rotary drilling with mud circulation through all
kinds of soil other then rock. While boring above water table, no water shall be introduced in
boreholes. Casing shall be used to support the sides of boreholes in soft to firm soil.
224 Except for crossing location as defined under clause 2.2.5, the boring shall be either
terminated at a depth of 3 m below NGL or on top of bed rock if rock is encountered at a
depth of less than 3 m.
2.2.5 In case of boring at Highways (National/ State), River and Railways crossings, the boring
shall either be terminated at a depth of 5 m below NGL or on top of bed rock, if rock is
encountered at a depth less than 5 m.
2.2.6 Additionally, bore holes shall be made at all SV stations, IP stations and at all terminal
locations.
3.1 Results of soil investigation survey and laboratory test carried out shall be submitted in the
form of report covering as a minimum the following.
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eh
ri r ENGINEERS FOR PIPELINE SURVEYS
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6-71-0071 Rev. 3
Page 19 of 24
Visual engineering classification of soils encountered along the pipeline route in

borelog form. Depth of Ground Water Table (GWT) below NGL shall also be
mentioned if encountered.
Soil profiles along the pipeline route shall also be prepared and attached with the
report.
Regions along the pipeline route where hard rock is present and special excavation
techniques like blasting, etc. needs to be adopted for excavation of pipeline trench
shall be clearly indicated in the report.
Summary of results obtained from various laboratory tests and their interpretation to
evaluate various soil parameters.
3.2 Visual engineering classification of soils obtained from bore holes shall be shown in
Alignment sheets also, whenever preparations of alignment sheets are included in
SURVEYOR's scope of work.
3.3 Additionally, the undisturbed samples shall be collected (150 mm 0 bore hole up to a depth of
5.0m from NGL) as per clause no. 2.2.5 above, i.e. at location of seismic fault line and one
each at 500m on either side of fault line crossing. The samples shall be laboratory tested for
the following:
Natural Moisture Content
Bulk and Dry density
Grain Size Analysis
Tri-axial shear (unconfined un-drained) test for clayey soil
e. Box shear test for granular soil
With the above tests the following soil data along the route shall be generated:
Type of soil (sand, silt, clay, etc.) up to a depth of 5.0 m
Bulk and dry density of soil
Maximum level of water table
Angle of internal friction (0)
e. Un-drained shear strength in case of clayey soil (c)
Page 489 of 1963

APPENDIX-D
LOCATION CLASS SURVEY
ADDITIONAL REQUIREMENTS FOR GAS PIPELINES
DETERMINATION OF LOCATION CLASS FOR DESIGN AND CONSTRUCTION
1.0 When survey is performed for gas pipelines, the class locations based as per code ANSI B
31.8 "Gas Transmission and Distribution Piping Systems" shall be recorded along with
chainages at change points of each class location.
2.0 Location classes along the pipeline route shall be determined as follows:
A zone, 400m wide (one quarter mile), shall be considered along the pipeline route with the
pipeline in the centre-line of this zone. Then the entire route of the pipeline shall be divided
into lengths of 1600m (one mile) such that the individual lengths will include the maximum
number of dwellings intended for human occupancy. The number of such dwellings which are
intended of human occupancy within each 1600m (one mile) zone shall be counted and
reported along with other survey data.
3.0 Areas shall be classified based on guidelines as given below:
3.1 a) Class 1 Location
A Class 1 Location is any 1600m (one mile) section that has 10 or fewer dwellings
intended for human occupancy.
Class 2 Location
A Class 2 Location is any 1600m (one mile) section that has more than 10 but less
than 46 dwellings intended for human occupancy.
Class 3 Location
A Class 3 Location is any 1600m (one mile) section that has 46 or more dwellings
intended for human occupancy except when a Class 4 Location prevails.
d) Class 4 Location
A Class 4 Location includes areas where multi-storey buildings are prevalent, and
where traffic is heavy or dense and where there may be numerous other utilities
underground.
3.2 In addition to the criteria contained in Clause 3.1, while classifying areas, additional
consideration must be give to possibilities of increase in concentration of population along the
pipeline route such as may be caused by the presence of schools, hospitals, recreational areas
of an organized character, places of assembly, places of worship etc. If one or more of these
facilities are present, the area shall be classified as a Class 3 Location.
3.3 Notwithstanding the provisions of Clause 3.1 and 3.2 above, while determining Class
Location of an area, due consideration shall be given to the possibility of future development
of the area during the design life of the pipeline. If it appears likely that future development
may cause a change in the Location Class, this shall be taken into consideration while
determining its Class Location.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell — All rights reserved
Page 490 of 1963

APPENDIX-E
CADASTRAL SURVEY
1.0 Objective
The objective of cadastral survey is to identify the ownership & land use details and collect
data /all other details sufficient for acquisition of RoU, under the Petroleum and Mineral
Pipelines (Acquisition of Right of User in land) Act 1962 of Government of India and its
amendments, along the pipeline route identified by Company and duly surveyed and
established on ground.
2.0 Requirements
2.1 The SURVEYOR shall be responsible for collecting all revenue and other maps as well as
arranging all necessary forms required for carrying out cadastral survey at his own cost.
Company will assist the SURVEYOR by way of issue authorization letter only. Alignment of
established pipeline route will also be made available to SURVEYOR.
2.2 SURVEYOR shall carry out plane table survey, as may be required, along the pipeline route
covering an area 30 m on either side of centreline to show the following details in cadastral
maps to be prepared on 1:2500 scale.
Pipeline alignment as per details made available.
RoU limit on either side of centreline as per details given in Data Sheet. RoU limit at
turning points shall be marked in a curve having turning radius of 50 times pipe line
outside diameter for pipeline size 18" & above. The pipeline diameter shall be
indicated in data sheet. In case of multiple lines in same RoU, the largest pipe size
shall be considered for this requirement.
Property identification/survey number, Part "Hissas" on survey numbers as per the

latest official revenue records.
Identification of RoU of existing pipelines/utilities/ rail, roads, canal, river and other
pipeline crossings on the Cadastral maps.
Number and type of trees within RoU limits.
Other major features such as given below:
All built up areas.
Religious places, schools, dharamshala, hospitals etc.
Railway lines, National/State Highways and district / village and

Panchayat roads.
Creeks, rivers, canals, drains etc.
Forest land (Reserved/Protected/Social)
Wildlife sanctuaries
Industrial Land.
Page 491 of 1963

Quary/mining and other prohibited areas.
Over-head/underground utility crossings
The above information shall be adequate in all respect for RoU acquisition and obtaining
forest clearance (if any).
2.3 Arrange for and furnish VII and XII extracts in duplicate of all land areas covered/ shown in
cadastral map as per clause 2.2 above. The extracts are required to be duly certified by the
local concerned authorities. Expenses in obtaining these extracts shall be borne by the
SURVEYOR.
2.4 In respect of the map at 2.2 above, marking of part "Hissas" as per the latest revenue records
shall be checked/ verified by the local concerned authorities. SURVEYOR shall ensure that
the land records are submitted to Company for checking and verifications as work proceeds.
2.5 SURVEYOR shall also prepare a schedule, as per format to be approved by Company/
Engineer-In-Charge, showing information on part "Hissas" and details of ownership (to be
extracted from map at para 2.2 above for obtaining pipeline Right of Use (ROU).
2.6 SURVEYOR shall prepare a summary of ownership details of land covered within 30 m on
either side from the centreline of pipeline giving all relevant details village wise including
land cost and crop cost supported by the relevant documents from respective Tehsil/ District
head quarters.
2.7 SURVEYOR shall furnish requisite Performa (number of copies as specified in the
CONTRACT) duly completed on proper schedule form, including of procurement of all
revenue maps and forms required from revenue department, submitting all proposal village
wise and Tehsil vise.
The SURVEYOR shall submit all survey data in the form of following drawings /documents:
3.1 Cadastral maps in scale 1:2500 as per clause 2.2 above.
3.2 Cadastral Survey Report including summary of ownership details, land and crop cost detail
and other documents as per clause 2.5 & 2.6 as above.
3.3 All revenue maps collected by the SURVEYOR from various authorities
3.4 All forms/performas necessary for estimation of land cost.
3.5 Any other detail as specified by Company.
Page 492 of 1963

a-at-mitaENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
lig arraweger INDIA UMITED
ANNEX1LTRE-I
PIPELINE ROUTE SURVEY DATASHEET
Gradient (RoU) 1:5 (max.) Along pipeline alignment (see note-5)
1:10 (max.) Across pipeline alignment
Bend Radius 30 D for pipeline size up to 16"
40 D for pipeline size greater then 16"
(D= Out side diameter of pipeline)
Minimum Distance between TP's 100 m
Maximum Deflection Angle at TP 90°
RoU width 20 m (5 m in left and 15 m in right side of pipeline

centreline while viewing in the direction of flow)
unless specified otherwise.
Minimum distance
from existing Habited dwellings 15 m
from Buildings/structures/monuments : 50 m
Co-ordinates of starting point To be filled by Survey Contractor
Notes:
Number of TP's along the pipeline route shall be kept to a minimum. Additional traversing
required for TP optimization shall be carried out by the Contractor prior to finalisation of TPS.
Chainages for pipeline shall start with 0.0 chainage in the direction of flow.
At road/rail/canal crossing locations, nearest TP on either side shall be located at a distance

not less than 50 m from the RoU of the facility being crossed, unless instructed otherwise by
In case of major river crossings, no TP shall be located within 150 m from the defined bank on
either side, unless instructed otherwise by Company Representative.
5. Slope up to 1:5 can also be acceptable for hill section.
Page 493 of 1963

OW:Ate ENGINEERS FOR PIPELINE SURVEYS
ItgarEVIegl
e INDIA LIMITED 6-71-0071 Rev. 3
(A GoN a A is undertsung) (ONSHORE) Page 24 of 24
ANNEXURE-II
SAMPLE FORMATS
SURVEYOR shall prepare all drawings as per the enclosed formats. Soft copies of formats will be
provided at appropriate time.
Alignment Sheets
Pipeline Route Maps*
River Crossings
Nala/CanaUOther water body Crossings
Railway Crossings
Road Crossings
*Pipeline route maps shall be furnished in ".KML & KMZ" file also.
Page 494 of 1963

~zit4 ENGINEERS FOR FABRICATION AND
$1g-ar 0154- g w INDIA LIMITED ERECTION OF PIPING
6-44-0012 Rev. 4
1.~ cYrTK M13,4.1 Ift Govt of Incha Unclertaking)
Page 1 of 15

FABRICATION AND ERECTION OF
PIPING
REVISED AND ISSUED AS STANDARD

4 30.07.14
SPECIFICATION AK ATD SC
3 31.03.09
SPECIFICATION RN VKB SC ND
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03
STANDARD SPECIFICATION RN DM BN SKG
REAFFIRMED AND ISSUED AS STD.
1 15.09.98 SH BRB NS AS
SPECIFICATION
0 14.04.93 ISSUED AS STANDARD SPECIFICATION AKG BPV GRR AS
Standards Standards
Rev. Committee Bureau
Prepared Checked
No by by
Approved by
Page 495 of 1963

ENGINEEFZS
RLJI £;Mes o INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1~1 C-1,9,1, 051 3W1,) (A Govt ol Indo Undertakngt
OF PIPING Page 2 of 15
Abbreviations:
A.S. : Alloy Steel

ASME : American Society of Mechanical Engineers
C.I. : Cast Iron
C.S. : Carbon Steel
HMTD : Heat & Mass Transfer Division
IBR Indian Boiler Regulations
LTCS : Low Temperature Carbon Steel
NACE : National Association of Corrosion Engineers
NB Nominal Bore
NDT : Non Destructive Testing
P&ID : Piping and Instrumentation Diagram
PMI Positive Material Identification
S.S. Stainless Steel
SMMS : Specialist Material & Maintenance Services
Piping Standards Committee
Convenor : Mr. R. Nanda
Members : Mr. M. Ismaeel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.J. Harinarayanan (HMTD)
Mr. P P Lahiri / Mr. S. Ghoshal (SMMS)
Mr. S. Mukherjee (Construction)
Page 496 of 1963

zig ENGINEERS
OgLar INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1>ffeR IA Tool ol Ind2 Undertakin)
CONTENTS
1.0 SCOPE 4
2.0 SCOPE OF WORK OF CONTRACTOR .4
3.0 BASIS OF WORK 7
4.0 FABRICATION 8
5.0 ERECTION 11
Page 497 of 1963

ENGNEERS
fffl it—
eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
.1"2-, 21,1,1,
151,41,411 IA Govt of India Undertalong)
1.0 SCOPE
This specification covers general requirements of fabrication and erection of above ground
and trench piping systems at site. The specification covers the scope of work of Contractor,
basis of work to be carried out by Contractor and standards, specifications and normal
practice to be followed during fabrication and erection by the Contractor.
2.0 SCOPE OF WORK OF CONTRACTOR
Generally the scope of work of Contractor shall include the following:
2.1 Transportation of required piping materials (as described in C1.2.1.1), pipe support (material
as described in Cl. 2.3) and all other necessary piping materials from Owner's storage point
or Contractor's storage point (in case of Contractor's scope of supply) to work site/shop
including raising store requisitions for issue of materials in the prescribed format &
maintaining an account of the materials received from Owner's stores.
2.1.1 Piping materials include the following but not limited to the same.
a. Pipes (A11 sizes and schedule)
b. Flanges (A11 sizes, types & Pressure ratings).
c. Fittings (All sizes, types and schedule)
d. Valves (A11 sizes, types and Ratings)
e. Gaskets (All sizes, types & Ratings)
f. Bolts, Nuts or M/C Bolts (All types)
g. Expansion Joint/Bellows (All types)
h. Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air
traps, springs, silencers, snubbers, steam and condensate manifolds, injection nozzles,
MOVs, sight glass, spray nozzles, integrated steam traps, hoses, hose couplings, etc.
i. Online instruments like control valve, orifice flange, rotameter, safety valves,
restriction orifice, rupture disc, de-super heaters, corrosion probes, annubar, magnetic
flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi PG/PT/ Flow
transmitter, ejectors, static mixers, flame arrestors, thermal flow switches, pre-
fabricated hook-ups etc.
j. Shut Down Valves with and without fire box.
2.2 Shop & field fabrication and erection of piping in accordance with documents listed under
C1.3.0 i.e. 'BASIS OF WORK' including erection of all piping materials enumerated above.
2.3 Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips,
cradles, hangers, turn-buckles, supporting fixtures, bracket cantilevers, struts, tee-posts
including erection of spring supports, sway braces, dummy pipes, corrosion pads/protection
shields, low friction pads, clamps, special support, expansion bellows, steam and condensate
manifolds supports etc. Corrosion Pads/Protection shields, stiffeners and stiffening rings, if
not covered in the specifications/standards, shall be of the same material as of parent pipes.
Page 498 of 1963

ENGINEEFZS
dg INDIA LIMITED
Odi FABRICATION AND ERECTION 6-44-0012 Rev. 4
.R27T 0,
1 J~1,
A
GoN of Ind,a Underta«.9) OF PIPING Page 5 of 15
2.4 Site fabrication of Piping items
Site fabrication of Piping items shall include but not be limited to the following
2.4.1 Fabrication of piping specials like special radius bends, reducers, mitres etc.
2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3 Fabrication of swage nipples as and when required.
2.4.4 Fabrication of odd angle elbow like 60°, 30° or any other angle from 90°/45° elbows as and
when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
2.4.6 Fabrication of stub-in connection with or without reinforcement.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/different
thickness wherever required.
2.4.8 Fabrication of circular pipe for steam rings, fire water lines, utility lines.
2.4.9 Threading of all small bore piping as per piping material specifications.
2.4.10 Drilling on blind flange for inserting / joining small bore lines.
2.4.11 Fabrication and welding of reinforcement pads at branch pipe locations wherever required.
2.4.12 Equipment nozzle reinforcement with pads, jacket & stiffeners wherever required.
2.4.13 Fabrication of injection nozzles as per details provided wherever required.
2.4.14 Fabrication of chain operation arrangement for valves, wherever required. A11 material
required for this modification shall be supplied by Contractor.
2.4.15 Fabrication and erection in position of funnels required for OWS/ SS/ Condensate blow
down system as per direction of Engineer-in-charge.
2.4.16 Grinding/ finishing of uneven surfaces/ joints after welding. Internal grinding of welds of
orifice flanges to render smooth surface.
2.4.17 Tapping and drilling of holes in flanges, blind flanges, piping connections for jack screw, if
required.
2.4.18 Providing bird screens at the outlet of lines open to atmosphere.
2.5 Modifications like providing additional cleats, extension of stem of valve, locking
arrangement of valves etc. as and when required.
2.6 Piping isometrics for main process/utility lines shall be provided to the Contractor.
Preparation of miscellaneous small bore isometrics with bill of materials for process and
utility lines (up to 11/2" size) like instruments & pump flushing / cooling, sample connection,
purging, pump casing vents & drains, pump Base plate drains, control valve drains / vent to
flare, instrument drains & vents, steam tracing (non-IBR) from steam supply stations up to
condensate recovery station, and lines specified as field routed within the Unit battery limit
Page 499 of 1963

ry s ENGINEERS
Ogz-drr 2fal-egI INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1.1r7R Crt-LISTC 2/513,721,) IA Govl o■ Indu UnclettakIng)
as and when required are in Contractor's scope of work. Approval for these isometrics
prepared by the Contractor shall be taken from Engineer-in-charge before erection.
Small bore piping isometrics given by Owner shall be rechecked by Contractor before
erection and installation.
2.7 Obtaining approval for drawings prepared by Contractor from statutory authority, if
required.
2.8 Spun concrete lining of the inside of pipes 3" NB & above including fittings and flanges as
required in accordance with specification.
2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specification.
2.11 Performing PMI using alloy analyzers as per `Standard Specification for Positive Material
Identification at Construction Sites, 6-82-0002'.
2.12 Casting of concrete pedestals and Fabrication and erection of small structures/ platforms for
pipe supports and valve operation / attending some instruments, spectacle blinds etc.,
providing brackets, modification / extension of platforms, providing additional platforms /
ladders for improving / providing accessibility.
2.13 Providing insert plates with anchor fasteners in concrete structures / paved floors and repair
of platform gratings around pipe openings and providing suitable members for support
under the platform grating.
2.14 Making material reconciliation statement and return of Owner's supply left over materials to
Owner's storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection,
flushing and testing of piping systems (Specification No. 6-44-0013). The accessories
required for blinding the line like flange, blind flange, gasket (all sizes, type and rating),
stud-bolts, flexible hoses etc. are to be arranged by the Contractor. During flushing the
discharged water / air shall be drained / routed as directed by the Engineer — In Charge.
2.16 Contractor shall prepare welding specifications for all weld joints where dissimilar welding
will be performed, and obtain approval from EIL.
2.17 Contractor to ensure meeting all requirements for carrying out work in shutdown/running
plant.
2.18 Pickling (as and when applicable) as per Job specification(s) for chemical cleaning of CS
suction piping of compressors, SS Piping, Weldments etc, as applicable.
2.19 Chemical Cleaning/ Hydro jet cleaning as per marked-up P&IDs with supply of chemicals,
consumables, DM water, equipments, boilers, coupons, tools & tackles and other testing
equipments required for the same.
Page 500 of 1963

■31 ENGINEERS
FABRICATION AND ERECTION
ar 1.1W1 <9,741 451 ,1,1~)
in Govt ot India Undertaloow
3.0 BASIS FOR WORK
3.1 The complete piping work shall be carried out in accordance with the following:
3.1.1 "Approved for Construction" drawings and sketches issued by EIL to the Contractor - Plans
and/or Isometrics.
3.1.2 "Approved for Construction" drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
3.1.3 Approved Process Licensor's standards and specifications.
3.1.4 Drawings, sketches and documents prepared by Contractor duly approved by Engineer-in-
Charge (such as isometrics of small bore piping and offsite piping etc.).
3.1.6 EIL specifications/documents as below:
a. Process and Instrument Diagram.
b. Job Piping Materials Specification (****-6-44-0005). **** denotes job number.
c. Piping support, engineering standards.
d. Line list
e. Piping support indices (only in offsite), if supports are not shown in plan.
f. Job specification of Non-destructive Requirement of Piping (****-6-44-0016)
g. Job Welding Specification Charts for Piping Classes (****-6-77-0005)
h. Job Welding specification for fabrication of piping (****-6-77-0001).
i. Any other EIL or OTHER specifications attached with Piping Material Specification
or special condition of contract (such as standard for cement lining of pipe, standard
ofjacketed piping, standard for steam tracing, Dimensional Tolerances etc.)
j. Standard specification for positive material identification (PMI) at construction sites,

6-82-0002
k. Standard Spec for application of torque & hydraulic bolt tension for flange joints (6-
76-0002) and its addendum, if any.
3.1.7 Following codes, standards and regulations
a. ASME B 31.3 Process Piping
b. ASME Sec. VIII Code for unfired pressure vessel.
c. IBR Regulations
d. ASME Sec. IX Qualification standard for welding and brazing

procedures, welders, brazers and welding and
brazing operators.
Page 501 of 1963

ENGINEERS
Og-ar fa2es
I è-117R C4c,7>r, ,Lq .~11
INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
IA Govt 01 India UndetaMing)
e. NACE Std. Code for Sour Services material requirements

MR-0175/MR0103/Job spec(NACE), as applicable
Note : A11 codes referred shall be latest edition, at the time of award of contract.
3.2 Deviations
Where a deviation from the "Basic of Work" and approved job procedure described above is
required or where the basis of work does not cover a particular situation, the matter shall be
brought to the notice of Engineer-in-Charge and the work carried out only after obtaining
written approval from him in each case.
4.0 FABRICATION
4.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system
shall be strictly as per the "Piping Material Specification" for the "Pipe Class" specified for
that system. To ensure the above requirement, all piping material supplied by the Owner /
Contractor shall have proper identification marks as per relevant standards / EIL
specifications / Licensors specification. Contractor shall provide identification marks on left
over pipe lengths wherever marked up pipe lengths have been fabricated/erected. Material-
traceability is to be maintained for A.S., S.S., NACE, LTCS, material for Hydrogen service
and other exotic materials by way of transferring heat number, etc. (hard punching) as per
approved procedure. This shall be in addition to colour coding for all piping materials to
avoid mix-up.
For the purpose of common understanding the construction job procedure, to be submitted
by the Contractor, shall include proposal for
- Maximizing prefabrication, inspection and testing at fabrication shop with minimum

field joints.
- Positive material identification, handling, storage & preservation.
4.2 Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per EIL Standard No. 7-44-0486.
The Contractor shall be responsible for working to the dimensions shown on the drawings.
However, the Contractor shall bear in mind that there may be variations between the
dimensions shown in the drawing and those actually existing at site due to minor variations
in the location of equipments, inserts, structures etc. To take care of there variations "Field
Welds" shall be provided during piping fabrication. An extra pipe length of 100 mm over
and above the dimensions indicated in the drawing may be left on one nide of the pipe at
each of the field welds. During erection, the pipe end with extra length at each field weld,
shall be cut to obtain the actual dimension occurring at site. Isometrics, if supplied may have
the field welds marked on them. However, it is the responsibility of the Contractor to
provide adequate number of field welds. In any case no extra claims will be entertained
from the Contractor on this account. Wherever errors / omissions occur in drawings and
Bills of Materials it shall be the Contractor's responsibility to notify the Engineer-in-Charge
prior to fabrication or erection.
4.3 IBR Piping
4.3.1 Contractor shall obtain approval for the piping systems falling under purview of IBR from
the statutory Indian Boiler Regulations (IBR) authority of the state where the plant is
Page 502 of 1963

ENGINEERS
5gU Offl— g
1.1WR Govt of UnOettaking)
situated. The Owner shall provide documentation for the IBR System. The Contractor shall
carry out the fabrications, erection and testing of this piping as per requirements of Indian
Boiler Regulations and to the entire satisfaction of the Local Boiler Inspector. The
Contractor shall also get the approval of IBR inspector for all fabrication and testing done
by him at his own cost. All certificates of approval shall be in proper IBR forms.
4.3.2 IBR Package for residual, field routed and site modified steam lines shall be prepared by the
Contractor. IBR approval for the same shall be in Contractor's scope, at his own cost.
4.4 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general,
joining of lines 2" and above in process and utility piping shall be accomplished by butt-
welds. Joining of lines 1-1/2" and below shall be by socket welding/butt welding/threaded
joints as specified in "Piping Material Specifications". However, in piping 1-1/2" and below
where socket welding/ threaded joints are specified butt - welds may be used with the
approval of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only
applicable for non-galvanized piping without lining.
Flange joints shall be used at connections to Vessels, Equipment's, Valves and where
required for ease of erection and maintenance as indicated in drawings.
4.5 Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating,
post-heating and heat treatment shall be as described in the Job welding specification
(****-6-77-0005) and NDT specification (****-6-44-0016).
4.6 Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.1 NPT as
required to match threads on fittings, valves etc. All other piping shall have threads as per
ANSI B2.1, tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed.
Threading of pipes shall be done preferably after bending, forging or heat treating
operations. If this is not possible, threads shall be gauge checked and chased after welding
heat treatment etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly
cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated
with thread sealant and the joint tightened sufficiently for the threads to seize and give a
leakproof joint. Threaded joints to be seal-welded shall be cleaned of all foreign matter,
including sealant and made up to full thread engagement before seal welding.
4.7 Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation
is shown in the drawing.
Wherever jack screws are to be provided, drilling and tapping for the jack screws in the I
flange, shall be done as per EIL Standard before welding it to the pipe.
4.8 Branch Connections
Page 503 of 1963

■
31 ENGINEERS
fg-r;Ir fa2e5 INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
14.2R ar a,
W,7,1~1) IA GoN of Indo Underfaon9)
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using
forged tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
4.9 Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be
used.
Cold bends for lines 1-1/2" and below, with a bend radius of 5 times the nominal diameter
shall be used as required in place of elbows wherever allowed by piping specifications.
Bending of pipes 2" and above may be required in some cases like that for headers around
heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles,
bulges, flat spots and other serious defects. They shall be true to dimensions. The flattening
of a bend, as measured by the difference between the maximum and minimum diameters at
any cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal
and external pressure respectively.
4.10 Forging and Forming
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2" and
below, shall be as per ASME B 31.3.
4.11 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabricated reducers shall be governed by
the Piping Material Specifications. Reducers shall be fabricated as per directions of
Engineer-in-Charge. The radiographic requirements shall be as per Material Specifications
for process and utility systems and NDT Specification for steam piping under IBR,
radiographic requirements of IBR shall be complied with.
4.12 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per drawings
and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight
length piping.
4.13 Galvanized Piping
Galvanized carbon steel piping shall be completely cold worked, so as not to damage
galvanized surfaces. This piping involves only threaded joints and additional external
threading on pipes may be required to be done as per requirement.
Page 504 of 1963

ENGINEERS
r Êtral
fg--a,- -g
e INDIA LJMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
oloo,r1.,om, IA Go, ol lnO. Undellaking)
4.14 Jacketed Piping
The Jacketing shall be done in accordance with EIL Specification or Licensors specification
as suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at

shop by Contractor. Position of jump-over and nozzles on the jacket pipes, fittings etc. shall
be marked according to pipe disposition and those shall be prefabricated to avoid damaging
of inner pipe and obstruction of jacket space. However, valves, flow glasses, in line
instruments or even fittings shall be supplied as jacketed.
4.15 Shop Fabrication / Prefabrication
The purpose of shop fabrication or pre-fabrication is to minimize work during erection to

the extent possible. Piping spool, after fabrication, shall be stacked with proper
identification marks, so as facilitate their withdrawal at any time during erection. During this
period all flange (gasket contact faces) and threads shall be adequately fabricated by coating
with removable rust preventive. Care shall also be taken to avoid any physical damage to
flange faces and threads.
4.16 Miscellaneous
4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler,
supporting elements like turn-buckles, extension of spindles and interlocking arrangement of
valves, operating platforms as required by Engineer-in-Charge.
4.16.2 Spun Concrete Lining
The work of inside spun concrete lining of pipes and specials of diameter 3" and above shall
be done as per material specifications and special condition contract.
4.16.3 Fabrication of pipes from plate
Pipes shall be fabricated at site as and when required as per the specifications and the actual
Piping Material Specification.
5.0 ERECTION
5.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing
with compressed air/or flushing out with water. Special cleaning requirements for some
services, if any, shall be as specified in the piping material specification or isometric or line
list. S.S jacketed piping requiring pickling shall be pickled to remove oxidation and
discolouring due to welding.
5.2 Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without the
consent of Engineer-in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings
shall be strictly followed as these clearances may be required for the free expansion of
Page 505 of 1963

ENGINEERS
$1gul8M--eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1.117R +1,13,70,) (A Govt ol roma Undertalong)
piping / equipment. No deviations from these clearances shall be permissible without the
approval of Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall be
brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his
instructions.
5.3 Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as
indicated in the drawing. Confirmation in writing shall be obtained by the Contractor from
the Engineer-in-Charge, certifying that the gap between the pipes is as indicated in the
drawing, before drawing the cold pull. Stress relieving shall be performed before removing
the gadgets for cold pulling.
5.4 Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the
Contractor. Corrective action shall be taken by the Contractor in consultation with Engineer-
in-Charge wherever the Contractor is not able to maintain the specified slope.
5.5 Expansion Joints / Bellows
Installation of Expansion Joints/Bellows shall be as follows:
5.5.1 Al1 Expansion joints / Bellows shall be installed in accordance with the specification and
installation drawings, supplied to the Contractor.
5.5.2 a. Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the
case(s) and check for any damage occurred during transit.
b. The Contractor shall bring to the notice of the Engineer-in- Charge any damage done
to the bellows / corrugations, hinges, tie-rods, flanges/ weld ends etc.
c. Each Expansion Joint / Bellow shall be blown free of dust / foreign matter with
compressed air or cleaned with a piece of cloth.
5.5.3 a. For handling and installation of Expansion Joints, great care shall be taken while
aligning. An Expansion Joints shall never be slinged from bellows corrugations/
external shrouds, tie / rods, angles.
b. An Expansion Joints / Bellow shall preferably be slinged from the end pipes / flanges
or on the middle pipe.
5.5.4 a. All Expansion Joints shall be delivered to the Contractor at "Installation length",
maintained by means of shipping rods, angles welded to the flanges or weld ends or
by wooden or metallic stops.
b. Expansion Joints stop blocks shall be carefully removed after hydrostatic testing.
Angles welded to the flanges or weld ends shall be trimmed by saw as per
manufacturer's instructions and the flanges or weld ends shall be ground smooth.
5.5.5 a. The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned
or shall have specified lateral deflection as noted on the relevant drawings.
b. The pipe ends / flanges shall be spaced at a distance specified in the drawings.
Page 506 of 1963

■31 ENGINEERS
r 02-
$1g-a,ffum eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
IA Go, ol Underlaking)
5.5.6 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall be
tack welded/bolted. The mating pipes shall again be checked for correct alignment.
5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged Expansion
Joint, the mating flanges shall be bolted.
5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes and
Expansion Joints are in correct alignment and that the pipes are well supported and guided.
5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain
parallelism of restraining rings or bellows convolutions.
5.5.10 Precautions
a. For carrying out welding, earthing lead shall not be attached with the Expansion Joint.
b. The Expansion bellow shall be protected from arc weld spot and welding spatter.
c. Hydrostatic Testing of the system having Expansion Joint shall be performed with
shipping lugs in position. These lugs shall be removed after testing and certification
is over.
5.6 Flange Connections
While fitting up mating flanges, care shall be exercised to properly align the pipes and to
check the flanges for trueness, so that faces of the flanges can be pulled together, without
inducing any stresses in the pipes and the equipment nozzles. Extra care shall be taken for
flange connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange
connections to these equipments shall be checked for misalignment, excessive gap etc. after
the final alignment of the equipment is over. The joint shall be made up after obtaining
approval of Engineer-in-Charge.
Hydraulic bolt tensioning & torque tensioning shall be performed on flange joints as per the
requirements specified in "Standard Specification for application of Torque & Hydraulic
Bolt Tension for flange joints," 6-76-0002 and its addendum, if any.
Temporary protective covers shall be retained on all flange connections of pumps, turbines,
compressors and other similar equipments, until the piping is finally connected, so as to
avoid any foreign material from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between these
flange faces is uniformly compressed. To achieve this, the bolts shall be tightened in a
proper sequence. A11 bolts shall extend completely through their nuts but not more than 1/4".
Steel to C.I. flange joints, if any, shall be made up with extreme care, tightening the bolts
uniformly after bringing flange flush with gaskets with accurate pattern and lateral
alignment.
5.7 Vents and Drains
High point vents and low point drains shall be provided as per the instructions of Engineer-
in-Charge, even if these are not shown in the drawings. The details of vents and drains shall
be as per piping material specifications / job standards.
Page 507 of 1963

ENGINEERS
Og'-ar Ofd i gw
2,22F1? 461 34.--,1
IA Govt of Ind‘a Undenak,n9)
5.8 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. In case of any difficulty in doing this or if the spindle orientation / position is not
shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his
instructions. Care shall be exercised to ensure that globe valves, check valves, and other uni-
directional valves are installed with the "Flow direction arrow "on the valve body pointing
in the correct direction. If the direction of the arrow is not marked on such valves, this shall
be done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking arrangements of

valves (if called for), shall be carried out as per drawings/ instructions of Engineer-in-
Charge.
5.9 Instruments
Installation of in-line instruments such as control valve, orifice flange, rotameter, safety
valves, restriction orifice, rupture disc, de-super heaters, corrosion probes, annubar,
magnetic flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi PG/PT/
Flow transmitter, ejectors, etc. and Shut Down Valves with fireboxes shall form a part of
piping erection work.
Fabrication and erection of piping upto first block valve / nozzle / flange for installation of
offline Instruments for measurement of level, pressure, temperature, flow etc. shall also
form part of piping construction work. The limits of piping and instrumentation work will be
shown in drawings / standards / specifications. Orientations / locations of take-offs for
temperature, pressure, flow, level connections etc. shown in drawings shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above and the
precautions to be taken are covered in flushing, testing and inspection of piping (EIL Spec.
6-44-0013). Care shall be exercised and adequate precautions taken to avoid damage and
entry foreign matter into instruments during transportation, installation, testing etc.
5.10 Line Mounted Equipments / Items
Installation of line mounted items like filters, strainers, steam traps, air traps,
desuperheaters, ejectors, samples coolers, mixers, flame arrestors, light glasses etc
including their supporting arrangements shall form part of piping erection work.
5.11 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise
specified in piping classes) all bolts and nuts during storage, after erection and wherever
flange connections are broken and made-up for any purpose whatsoever. The grease and
graphite powder shall be supplied by the Contractor within the rates for piping work.
5.12 Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal effects
of the piping system and to prevent its vibrations. Location and design of pipe supports will
be shown in drawings for lines 2" NB & above. For lines 11/2"NB & below Contractor
shall locate and design pipe supports in line with EIL Stds. In case of IBR Lines 1 1/2"NB &
below only indicative supporting shall be provided & detailing of such supports is in
Contractor's scope. Contractor shall obtain approval of Engineer - in - Charge on drawings
prepared by Contractor, before erection. However, any extra supports desired by Engineer-
in-Charge shall also be installed.
Page 508 of 1963

ENGINEERS
1~1 ,i,cmtJ9-0,-.1) IA Govt of InOla Undertaxng)
No pipe shoe / cradle shall be offset unless specifically shown in the drawings.
Hanger rods shall be installed inclined in a direction opposite to the direction in which the
pipe move during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and
insulation is over. Springs shall be checked for the range of movement and adjusted if
necessary to obtain the correct positioning in cold condition. These shall be subsequently
adjusted to hot setting in operating condition. The following points shall be checked after
installation, with the Engineer-in-Charge and necessary confirmation in writing obtained
certifying that:
- A11 restraints have been installed correctly.

- Clearances have been maintained as per support drawings.
- Insulation does not restrict thermal expansion.
- A11 temporary tack welds provided during erection have been fully removed.
- All welded supports have been fully welded.
Page 509 of 1963

if ENGINEERS INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
$1g-ar f8151e-
rlecne m,
1.17R
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INDIA LIMITED
TESTING OF PIPING SYSTEMS Page 1 of 9
-crr-4Wr 19-*7-41 flzIT

f-49-k7

INSPECTION, FLUSHING AND
TESTING OF PIPING SYSTEMS
C 1
,1„1
REVISED & ISSUED AS STANDARD RN TD DM
4 01.07.13
SPECIFICATION
REVISED & ISSUED AS STANDARD RN ATD DM VC
3 27.08.07
SPECIFICATION
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03 RN DM BN SKG
REAFFIRMED AND ISSUED AS STD. BRB NS AS
1 15.09.98 SH
SPECIFICATION
0 06.04.83 ISSUED AS STANDARD SPECIFICATION DB DB SLG RSB

Standards Standards
Committee Bureau
No by by
Approved by
Page 510 of 1963

ENGINEERS
rtg-ar tt154-- eg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
eietnre 0,7 JT7.11 IA Govt of India Undeilak.9) TESTING OF PIPING SYSTEMS Page 2 of 9
Abbreviations:
ASME : The American Society of Mechanical Engineers
IBR : Indian Boiler Regulations
PMI : Positive Material Identification
ppm Parts per million
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. Ajay Shrivastava
Mr. G.K. Iyer (Construction)

Page 511 of 1963

■
31 ENGINEERS
fg-a(.77nr taf*reg INDIA LIMITED TESTINGINSPECTION, FLUSHING AND 6-44-0013 Rev. 4
G" °"'" Unde"'"g) OF PIPING SYSTEMS Page 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 INSPECTION 4
4.0 FLUSHING 4
5.0 PRESSURE TESTING 5
Page 512 of 1963

ENGINEERS
INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
NIRY1 esreM7F 3,10.1)
G" '11"" Unde"") TESTING OF PIPING SYSTEMS Page 4 of 9
1.0 SCOPE
This specification covers the general requirements for inspection, flushing and testing of
piping systems. However, testing of steam lines falling under IBR shall also be governed by
Indian Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.
2.0 REFERENCES
ASME B31.3 Process Piping
EIL SPEC 6-82-0002 : Standard Specification for Positive Material Identification

(PMI) at Construction Sites
3.0 INSPECTION
During various stages and after completion of fabrication and erection, the piping system shall
be inspected by the Engineer-In-Charge to ensure that:
Proper piping material has been used.
PMI has been performed as per EIL specification '6-82-0002'.
Piping has been erected as per drawings and instructions of Engineer-In-Charge.
All supports have been installed correctly.
Test preparations mentioned in this specification have been carried out.
4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by 'fresh potable water' or by 'dry compressed air wherever water
flushing is not desirable to clean the pipe of all dirt, debris or loose foreign material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing, the line/system shall be pressurized by compressed air at the
required pressure which shall be 3.5 kg/cm2g maximum. The pressure shall then be released
by quick opening of a valve, already in line or installed temporarily for this purpose. This
procedure shall be repeated as many times as required till the inside of the pipe is fully
cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and other
instruments like thermowells which may interfere with flushing shall not be included in
flushing circuit.
The screens/meshes shall be removed from all permanent strainers before flushing.
Screens/meshes shall be reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall be removed, cleaned and
reinstalled after flushing, but, before testing.
Page 513 of 1963

ENGINEERS
faf5reg
1.11R, ti,Prel>1393,1)
INDIA LIMITED INSPECTION, FLUSHING AND
6-44-0013 Rev. 4
G" In Unde"")
Page 5 of 9
In case any equipment such as column, vessel, exchanger etc. form part of a piping circuit
during flushing, this shall be done with the approval of Engineer-In-Charge. However,
equipments thus included in the circuit shall be completely drained and dried with compressed
air after flushing is completed.
During flushing discharged water/air shall be drained to the place directed by the Engineer-In-
Charge. If necessary, proper temporary drainage shall be provided by the contractor.
Care shall be taken during flushing so as not to damage/spoil work of other agencies.
Precautions shall also be taken to prevent entry of water/foreign matter into equipments,
electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed.
The contractor shall carry out all the activities required before, during and after the flushing
operation, arising because of flushing requirements, such as but not limited to the following:
Dropping of valves, specials, distance pieces, inline instruments and any other piping part
before flushing. The flanges to be disengaged for this purpose shall be envisaged by the
contractor and approved by the Engineer-In-Charge. These flanges shall be provided with
temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve distance pieces, piping specials etc. shall
be reinstalled by the contractor with permanent gaskets. However, flanges at equipment
nozzles and other places where isolation is required during testing, only temporary gaskets
shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each piping system
for the flushing done in the proforma provided/approved by the Engineer-in-Charge.
5.0 PRESSURE TESTING
Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless otherwise
specified, herein. Lines carrying highly hazardous/poisonous fluids must have a sensitive leak
test. For IBR lines, ÌBR Regulations' shall also be followed.
5.1 Extent of Testing
With the exclusion of instrumentation, piping systems fabricated or assembled in the field
shall be tested irrespective of whether or not they have been pressure tested prior to site
welding or fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be included in
the system with the prior approval of Engineer-In-Charge if the test pressure specified is equal
to or less than that for the vessels and other equipments.
Pumps, compressors and other rotary equipments shall not be subjected to field test pressure.
Lines which are directly open to atmosphere such as vents, drains, safety valves discharge
need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines
shall be tested by continuous flow of fluid to eliminate the possibility of blockage. However,
such lines if provided with block valve shall be pressure tested up to the last block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working
pressure of the valve. Test pressure applied to valves shall not be greater than the
manufacturer's recommendation nor less than that required by the applicable code. Where
allowable seat pressure is less than test pressure, test shall be made through an open valve.
Page 514 of 1963

0 ENGINEERS
fg-zir tif5leg
rirane as ,sr...
(>172R
INDIA LIMITED INSPECTION, FLUSHING AND
6-44-0013 Rev. 4
Page 6 of 9
Instruments in the system to be tested shall be excluded from the test by isolation or removals,
unless approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting, draining such as orifice plates etc. shall not
be installed unless testing is complete.
Control valves shall not be included in the test system. Where bypasses are provided test shall
be performed through the bypass and/or necessary spool shall be used in place of the control
valve.
Pressure gauges which are part of the finished system, but cannot withstand test pressure shall
not be installed until the system has been tested. Where piping systems to be tested are
directly connected at the battery limits to piping for which the responsibility rests with other
agencies, the piping to be tested shall be isolated from such piping by physical disconnection
such as valve or blinds.
5.2 General Requirements / Test Preparation for Testing
Testing shall be carried out with permanent gaskets installed unless specified otherwise or
instructed by the Engineer-in-Charge.
No pressure test shall be carried out against closed valve unless approved by the
Engineer-in-Charge
The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence
and programme, to enable him to be present for witnessing the test. The Contractor shall be
fully responsible for making arrangements with the local boiler inspector to witness the tests
for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the
relevant IBR forms and furnished to the Engineer-in-Charge.
Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale,
debris and other loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points and the
systems purged of air before the test pressure is applied.
Wherever in the line any void exists due to any reasons, like absence of control valves, safety
valves, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the test.
Before pressurizing the lines, each weld joint shall be cleaned by wire brush to free it from
rust and any other foreign matter.
Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted

between the companion flanges. Minimum thickness of the blank shall be designed in
accordance with applicable design code.
Open ends of piping system where blanks cannot be used, such as pumps, compressors,
turbines or wherever equipment or pipe spools have been recovered or disconnected prior to
hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the
piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest point in the
piping system to be tested, to avoid overstressing of any of the lower portions of the system.

Page 515 of 1963

ENGINEERS
ligaf fdWeg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
afIR'n ,eant „Ng.) Govt ol India uncieriakm) TESTING OF PIPING SYSTEMS Page 7 of 9
For longer lines and vertical lines, two or more pressure gauges shall be installed at locations
decided by the Engineer-in-Charge.
For lines containing check valves any of the following alternatives shall be adopted for
pressure testing:
Whenever possible pressurize up-stream side of valve.
Replace the valve by a temporary spool and reinstall the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. At these flanges, temporary gaskets shall
be provided during testing and shall be replaced by permanent gaskets subsequently.
For check valves in lines PA" and below flapper or seat shall be removed during
testing (if possible). After completion of testing the flapper/seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary supports
during testing as directed by the Engineer-in-Charge.
Piping which is spring or counter-weight supported shall be temporarily supported, where the
weight of the fluid would overload the support. Retaining pins for spring supports shall be
removed only after testing is completed and test fluid is completely drained.
When testing any piping system, air or steam of approximately 2 kg/ cm2g may be used as
preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the line
to make repairs. However, steam shall not be used for this purpose, if the steam temperature is
more than the design temperature of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is
continuously jacketed, before it is jacketed. The outer jacket shall be tested separately as a
system. For piping with discontinuous jacketing the core pipe and the jacket shall be tested as
separate continuous systems.
5.3 Testing Media, Test Pressure and Test Pressure Gauges
5.3.1 Testing Media
In general all pressure tests shall be hydrostatic using iron free water, which is clean and free
of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 15-
20 ppm.
Air shall be used for testing only if water would cause corrosion of the system or overloading
of supports etc. in special cases as directed by Engineer-in-Charge.
If operating fluid in the line is much lighter than testing fluid, the additional weight of testing
fluid may render piping supports (as designed) inadequate. This will call for additional
temporary supports. The typical examples are flare and vapor lines. It is preferable that
hydrostatic testing is avoided in such systems and instead pneumatic testing may be specified.
Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc.
shall be used as the testing medium, with due consideration to the hazards involved. These test
fluids shall be specified in the line list given to the contractor.
Page 516 of 1963

ara_it.-7 ENGINEERS
INSPECTION, FLUSHING AND
fg-zrr lafj4-d-
'g
1.17",eiecnIe SW{1,141
INDIA LIMITED
°""d' Uncle"") TESTING OF PIPING SYSTEMS
6-44-0013 Rev. 4
'A 6" Page 8 of 9
5.3.2 Test Pressure
The hydrostatic/ pneumatic test pressure shall be as indicated in the line list or as per the
instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the following:
Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress, maximum length
of piping shall be included in each test.
5.3.3 Test Pressure Gauge
All gauges used for field testing shall have suitable range so that the test pressure of various
systems falls in 35% to 65% of gauge scale range. Pressure gage dial shall be minimum of 150
mm. Size of Bourdon shall not be less than 75% of nominal diameter of dial range. Gauge
shall be of a good quality and in first class working condition.
Prior to the start of any test or periodically during the field test programme, all test gauges
shall be calibrated using a standard dead weight gauge tester or other suitable approved testing
apparatus. Any gauge showing an incorrect zero reading or error of more than ± 2% of full
scale range shall be discarded .The Engineer-in-Charge shall check the accuracy of master
pressure gauge used for calibration. Calibration certificate shall be furnished for the pressure
gages.
5.4 Testing Procedure
5.4.1 Hydrostatic Test
All vents and other connections used as vents shall be left open while filling the line with test
fluid for complete removal of air. In all lines for pressurizing and depressurizing the system,
temporary isolation valves shall be provided if valved vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved by the Engineer-in-
charge.
Pressure shall be applied by means of a suitable test pump or other pressure source which shall
be isolated from the system as soon as test pressure is reached and stabilized in the system.
A pressure gauge shall be provided at the pump discharge for guidance in bringing the system
to the required pressure.
The pump shall be attended constantly during the test by an authorized person. The pump shall
be isolated from the system whenever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time not less than 10minutes. Test
pressure shall be released only after physical checking of all the joints and attachments are
completed, to permit thorough inspection of all joints and connections for leakage or signs of
failure. Any joint found leaking during a pressure test shall be retested to the specified
pressure after repair.
The pump and the piping system to be tested are to be provided with separate pressure
indicating test gauges.

Page 517 of 1963

` It1-s
- w ENGINEERS
$/tgal taWreg l INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
WWI eic,
tal 451 Jgsr.) IA Govt of India Undertaking)
TESTING OF PIPING SYSTEMS Page 9 of 9
Care shall be taken to avoid increase in the pressure due to temperature variation during the
test.
5.4.2 Pneumatic Test
When testing with air, pressure shall be supplied by means of a compressor. The compressor
shall be portable type with a receiver, after cooler and oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so that the
joints can be examined for leaks.
All other details shall be same as per hydrotesting procedure (specified above).
5.5 Completion of Testing
After the hydrostatic test has been completed, pressure shall be released by opening the vents,
in a manner and at a rate so as not to endanger personnel or damage equipments.
All vents shall be opened before the system is to be drained and shall remain open till all
draining is complete, so as to prevent formation of vacuum in the system. After draining, lines
/ systems shall be dried by air. In services like dry air, ethylene etc., small traces of water can
cause problem. For such lines hot air drying is to be done after hydro-test.
After testing is completed the test blinds shall be removed and equipment / piping isolated
during testing shall be connected using the specified gaskets, bolts and nuts. These
connections shall be checked for tightness in subsequent pneumatic tests to be carried out by
the contractor for complete loop / circuit including equipments (except rotary equipments).
Pressure test shall be considered complete only after approved by the Engineer-in-Charge.
Defects, if any, noticed during testing shall be rectified immediately and retesting of the
system / line shall be done by the contractor at his cost.
5.6 Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping system,
for the pressure test done in the proforma provided/approved by the Engineer-in-Charge.
Records shall also be submitted for the PMI undertaken as per EIL Std. Specification No.
6-82-0002.
Page 518 of 1963

ENGINEERS FOR NON DESTRUCTIVE
0`-ar 2Ws INDIA LIMITED
IA Govt of indo Undertaking)
EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
9igrki41 aTteik:r~ trftur

aTr-
g~ra#

NON DESTRUCTIVE EXAMINATION
REQUIREMENTS OF PIPING
7 28.01.14 REVISED & ISSUED AS STD. SPECIFICATION PsgoyUK àH K N SC
6 20.10.10 REVISED & ISSUED AS STD. SPECIFICATION RN ATD SC DM ND
5 23.07.07 REVISED & ISSUED AS STD SPECIFICATION RN ATD DM VC
4 15.01.02 ISSUED IN CONFORMITY WITH STD PMS REV-4 RN AKG BN GRR
3 18.04.95 ISSUED IN CONFORMITY WITH STD PMS REV-2 MP AKG NS AS

Standards Standards
Committee Bureau
No by by
Approved by
Page 519 of 1963

k31 ENGINEERS FOR NON DESTRUCTIVE
fgW la2"
4,1R 2320,12 ,151,1QPI
INDIA LIMITED
IP Govt of lntlia Undertakmg) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
Abbreviations:
AS Alloy Steel
ASME : American Society of Mechanical Engineers
ASTM : American Society for Testing & Materials
CS Carbon Steel
DP/LP : Dye/Liquid Penetrant
IBR : Indian Boiler Regulations
MP Magnetic Particle
PMS : Piping Material Specification
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. Ajay Shrivastava
Page 520 of 1963

ENQNEERS FOR NON DESTRUCTIVE
$"g-alaWs INDIA LIMITED
1.11,n 21~ fuLttivn.t, IA Govt of lorlo Unclertalong) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
CONTENTS
1.0 GENERAL 4
2.0 VISUAL EXAMINATION 4
3.0 NON DESTRUCTIVE EXAMINATION 6
4.0 TABLE-1 (with applicable Notes to Table-1) 7
Page 521 of 1963

51g, ;
131
2[41
e
_g ENGINEERS FOR NON DESTRUCTIVE
I ~71 0.100,0 0/1300.0 A Go. 01 0100 Unde1101000 ) EXAMINATION REQUIREMENTS
1.0 GENERAL
1.1 Scope
This specification covers the general requirements for non destructive examination of
shop & field fabricated piping.
1.2 Related Codes & Engineering Standards
Referred codes / standards are as follows. Latest editions of the Codes/Standards referred
to shall be followed.
a) ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div.1) including
addenda.
b) ASME B31.3
c) ASME B16.5
d) ASME B16.34
e) Standard Piping Material Specification, 6-44-0005
f) Welding Specification Charts for Piping Classes, 6-77-0005
g) Standard Specification for Fabrication & Erection of Piping 6-44-0012
h) ASTM EIO
i) Welding Specification for Fabrication of Piping, 6-77-0001
j) Design Guide for Radiography Requirements, 8-77-0010
k) Indian Boiler Regulations (IBR)
2.0 VISUAL EXAMINATION
2.1 Weld shall be visually inspected wherever accessible in accordance with the following
requirements:
a) Internal misalignment 1.5 mm or less
b) Cracks or lack of fusion not permitted
c) Incomplete penetration Depth shall not exceed the Lesser of 0.8mm or 0.2
times thickness of thinner component joined by
butt-weld. The total length of such imperfections
shall not exceed 38 mm in any 150 mm of weld
length.
d) Surface porosity and not permitted

exposed slag inclusions
(For nom. wall thickness
4.7 mm and less)
Page 522 of 1963

2f5le'g w
1~1 a-1,cnr1.,.TRIs.
INDIA LIMITED
I A Govt of Incha Undettaiong1 EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
e) Concave root surface For single sided welded joints, concavity of the
root surface shall not reduce the total thickness
(Suck up) of joint, including reinforcement, to less than the
thickness of the thinner of the components being
joined.
Weld ripples irregularities 2.5 mm or less.
Lack of uniformity in bead 2.5 mm or less.

width
Lack of uniformity of leg 2.5 mm or less.

length
Unevenness of bead 2.0 mm or less.
Weld undercutting 0.8 mm or 1/4 thickness of thinner components

joined by butt weld, whichever is less. (shall be
smooth finished)
Overlap 1.5 mm or less
Bead deflection 2.5 mm or less
External weld reinforcement and internal weld protrusion (when backing rings are
not used) shall be fused with and shall merge smoothly into the component
surfaces. The height of the Lesser projection of external weld reinforcement or
internal weld protrusion from the adjacent Base material surface shall not exceed
the following limits:
Wall thickness of thinner Weld reinforcement or internal weld protrusion

component joined by butt (mm) max
weld (mm)
6.4 and under 1.6

Over 6.4 -12.7 3.2
Over 12.7 -25.4 4.0
Over 25.4 4.8
n) Throat thickness of fillet welds:
Nominal thickness of the thinner component x 0.7 or more.
o) Flattening
Flattening of a bend, as measured by difference between the nominal outside

diameter and minimum or maximum diameter at any cross section shall not
exceed 5 % of the nominal outside diameter of pipe.
P) Reduction of wall thickness
Reduction of wall thickness of a bend, as measured by difference between the

nominal thickness and minimum thickness shall not exceed 10 % of the nominal
wall thickness of pipe.
Page 523 of 1963

$'1g-af la2es INDIA LIMITED 6-44-0016 Rev. 7
IA Govl ol Indo Undertalfing) EXAMINATION REQUIREMENTS
2.2 Welds having any of imperfections which exceed the limitations specified in various
clauses of 2.1 shall be repaired by welding, grinding or overlaying etc. Number of times
of repair welding for the same weld, however shall conform to applicable notes to Table
1- Note 6(b)b.5.
3.0 NON DESTRUCTIVE EXAMINATION
3.1 The type and extent of weld examination shall be in accordance with Table-1. A11 visual
and supplementary methods of girth weld examination shall be in accordance with ASME
B31.3 & the requirements of this standard specification.
3.2 Welds between dissimilar materials shall be examined by method & to the extent required
for the material having the more stringent examination.
Page 524 of 1963

■
311 ENGINEEFZS FOR NON DESTRUCTIVE
22— eg INDIA LIMITED 6-44-0016 Rev. 7
■
~1,-xcrwan,rem) 1A Gov1 of Irwha Undellaiong) EXAMINATION REQUIREMENTS
4. TABLE-1 (with applicable notes)
TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION
INSPECTION CLASS: 1
INSPN. SERVICE MATERIAL P.NO. TEMP. PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) DEG.0 CLASS PIPING EXAMINATION
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACH- FAB. FAB.
BUTT WELD MENT BRANCH WELDS
WELD (NOTE 2) WELD WELD OF
(NOTE 1) MITRES /
REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
I CATEGORY 'D' CARBON 1 0 A3A, A3Y,

FLUID STEEL TO J2A, J3A,
SERVICE 186 A4Y, A5Y
AUSTENIC 8 - 29 150# A3K a)

UPTO 100% 100% 100% 100% 100%
S.S. TO VISUAL
186 10 55
KG/CM2
HDPE - 20 A1Z, A4Z,
TO ASZ. b)
--- 5°o 10%
50 LP (NOTE 4, 6,9,) —
CURPO 34 - 29
NICKEL TO
60
REMARKS FOR ABOVE TABLE :
1. LP TEST NOT APPLICABLE TO NON-METALLIC CLASSES.
2. MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 525 of 1963

Og-ar fddi-eg
I .R71,,,crt +1,1344.11
INDIA LIMITED
IA GoA Ot incha Undmi.kIn9) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)
INSPECTION CLASS: II
INSPN. SERVICE MATERIAL P. TEM PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) NO. P. CLASS PIPING EXAMINATION
DEG. B16.5/ CLASS
C B16.34 GIRTH SOCKET ATTACH FAB. FAB.
BUTT WELD -MENT BRANCH WELDS
WELD (NOTE 2) WELD WELD OF
(NOTE 1) MITRES/
REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
II a) ALL SERVICES
COVERED UNDER CARBON 1 - 29 I50# TO AIA, BIA, DIA
INSPECTION STEEL TO 600# A6A, B6A,
CLASS-I, BUT, 427 A7A, A8A,
EXCEEDING A9A, B9A, D9A,
CATAGORY 'D' AIOA, AllA,
PR /T EMP A13A, BI3A,
LIMITATIONS. A15A, A20A,
A32A, B32A.
b) ALL SERVICES
OTHER THAN a) 100% I 00% 100% 100% 100%
THOSE COVERED VISUAL
UNDER
INSPECTION b)
CLASS-I BUT RADIOGRAPHY 5% --- --- 20%
NON-TOXIC, NOT (NOTE 5,6)
SUBJECTED TO
SEVERE CYCLIC c)
CONDITIONS. MP / LP (NOTE --- 5% -- 5% 20%
4,6,10,11)
c) TOXIC, NON-
LETHAL & LTCS -45 A4A, B4A, D4A d)
FLAMMABLE. TO HARDNESS NOTE 7 NOTE 7 NOTE-7 NOTE-7 NOTE-7
204
d) FLAMMABLE /
NON FLAMMABLE
& TOXIC / NON-
TOXIC; NOT
SUBJECT TO
SEVERE CYCLIC
CONDITIONS
AUSTENITIC 8 -29 AlK, BIK,DIK,

STAINLESS TO A6K, B6K,
STEEL 500 AlM, B1M,B3M,
AlN, 131N, B6N,
1. EXTENT OF HARDNESS TEST FOR Al 1A IS 100%..
2. MITRES & FABR1CATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
3. NOTE- 7 FOR HARDNESS IS NOT VALID FOR P. NO. 8.
Page 526 of 1963

ENGINEEFZS FOR NON DESTRUCTIVE
1~71 C.1~21,61~) IA Govt Undertffitvv31 EXAMINATION REQUIREMENTS
INSPECTION CLASS: III
INSPN. SERVICE MATERIAL P. TEMP. PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) NO. DEG.0 CLASS PIPING EXAMINATION
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACH FAB. FAB.
WELD (NOTE 2) WELD WELDS OF
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III FIRE WATER CARBON I - 29 150# A33A, A33Y, a) 100% 100% 100%
100% 100%
AND IBR STEEL (FIRE TO TO VISUAL
SERVICES. WATER) 427 600#
b)
10% -- --- 50%
CARBON A2A, B2A, RADIOGRAPHY
STEEL (IBR) D2A. (NOTE 5,6)
c) 10%. --- 10% ---

LP / MP (NOTE
4,6,11)
d) NOTE 7 NOTE 7
NOTE 7 NOTE 7 NOTE 7
HARDNESS
FOR IBR SERVICE A2A, B2A & D2A NOTE- 8 IS ALSO APPLICABLE.
3. FOR A33A & A33Y FIRE WATER SERVICE, NOTE-12 IS ALSO APPLICABLE.
Page 527 of 1963

$1g-ar 2a-eg INDIA LIMITED 6-44-0016 Rev. 7
1.11Z71 2.1~ LIA 3,121.41 IA Govl o7 Indo Undertaking) EXAMINATION REQUIREMENTS
INSPECTION CLASS: III (CONTD.)
B16.5/ CLASS
B16.34
GIRTH SOCKET ATTACH FAB. FAB.
(NOTE 1) MITRES /
REDUC.)
I 2 3 4 5 6 7 8 9 10 11 12 13
III ALL GENERAL C - 0.5 Mo

(CONTD) SERVICES STEEL. 3 a) 100% 100% 100% 100% 100%
EXCEPT THOSE 0.5 Cr _ 0.5 mo VISUAL
SUBJECT TO STEEL
SEVERE b)
ABOVE 150# 20% --- --- --- 50%
CYCLIC I TO 3 Cr Mo. 4 5A A1D, B1D, D1D RADIOGRAPHY
CONDITIONS. ' -29 TO (NOTE 5,6)
STEEL. BlE
600#
c)
C - 0.5 Mo 3 LP / MP (NOTE --- 20% --- 20% ---
STEEL (IBR). 4,6,11)
I - 3 Cr Mo 4,5A D2D d)
STEEL (IBR) HARDNESS NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
FOR IBR SERVICE D2D NOTE- 8 IS ALSO APPLICABLE.
Page 528 of 1963

$'1 gar 22- eg INDIA LIMITED
IHRn e,cnr, 451 IA Govl ol Incha Undenakbng) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III ALL GENERAL 3 5 Ni STEEL 9B - 80 150# 100% 100% 100% 100% 100%
a)
(CONTD) SERVICES TO TO
VISUAL
EXCEPT THOSE 120 600#
SUBJECT TO
b)
SEVERE 10% --- -- 50%
RADIOGRAPHY
CYCLIC
(NOTE 5,6)
CONDITIONS.
c)
10% --- 10% --
LP / MP (NOTE
4,6,10,11)
d)
NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
HARDNESS
REMARKS FOR ABOVE TABLE:
1. NOTE- 7 FOR HARDNESS IS NOT VALID FOR P. NO. 9B.
Page 529 of 1963

Offleg INDIA LIMITED 6-44-0016 Rev. 7
(~, ofrovt IA Govl of loOla Undenalmg) EXAMINATION REQUIREMENTS
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III ALL GENERAL ALUMINIUM 21 ALL 150#

(CONTD) SERVICES & TO
EXCEPT THOSE ALUMINIUM 25
SUBJECT TO BASE ALLOY a)
100% 100% 100% 100% 100%
SEVERE CYCLIC VISUAL
CONDITIONS. COPPER & 31
COPPER
BASE ALLOY
b) 20% --- --- -- 50ò
RADIOGRAPHY
(NOTE 5,6)
ALUMINIUM 35
BRONZE
-- 20% --- 20% ---

c)
LP / MP (NOTE
OTHER NON -- 4,6,10,11)
FERROUS
ALLOYS
Page 530 of 1963

.311 L.1 ENGINEERS FOR NON DESTRUCTIVE
22-eg
1,117",r-fraw a.,~1)
INDIA LIMITED
IA Govt o11n0ia Undellakong) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACdFAB. FAB.
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III SPECIAL CARBON 1 ALL 150# A16A, B16A,

(CONTD) SERVICES STEEL TO D16A, a) 100% 100% 100% 100% 100%
(NACE, 600# A19A, B19A, VISUAL
CAUSTIC) D19A
b)
RADIOGRAPHY 20% --- --- 50%
(NOTE 5,6)
c)
CARBON 150# A5A, B5A Lp / mp -- 20% 10% 20% --
SPECIAL STEEL TO (NOTE
SERVICES 300# 4,6,10,11,13)
( 0, H)
d) NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7

HARDNESS
SPECIAL AUSTENITIC 8 150# -

SERVICES STAINLESS TO
(NACE, STEEL 600#
CAUSTIC)
EXTENT OF HARDNESS TEST FOR CLASSES A5A & B5A IS 10% & FOR CLASSES A 1 6A, B 16A, D16A, A 1 9A, B19A & D19A IT
IS 100%.
Page 531 of 1963

71n ENGINEEFZS FOR NON DESTRUCTIVE
fg-ar faae5
lèvRN JOtTolt
INDIA LIMITED
IA Govt ot Indo Undettalong) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
INSPECTION CLASS: IV
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
I 2 3 4 5 6 7 8 9 10 11 12 13
IV ALL SERVICES CARBON I ALL ABOVE E1A, F1A, a) 100%

100% 100% 100% 100%
OTHER THAN STEEL 600# E9A, F9A, VISUAL
SPECIAL E19A, Fl9A
SERVICES (O,H) b)
RADIOGRAPHY 100%
CARBON E2A, F2A. 100% --- - ---
(NOTE 5,6)
STEEL (IBR)
c)
LP / MP
100% 10% 100%
(NOTE 4,6,10,11) ---
d) NOTE 7
NOTE 7 NOTE 7 NOTE 7 NOTE 7
HARDNESS
1. FOR IBR SERVICE E2A & F2A NOTE- 8 IS ALSO APPLICABLE.
2. EXTENT OF HARDNESS TEST FOR CLASSES El 9A, FI9A IS 100% .
Page 532 of 1963

IA Govt 01 inolta Undettaktog) EXAMINATION REQUIREMENTS
INSPECTION CLASS: IV (CONTD.)
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
IV ALL GENERAL C - 0 5 Mo 3 ALL ABOVE

(CONTD) SERVICES. STEEL 600# a)
100% 100% 100% 100% 100%
VISUAL
5 Cr - 9 Cr Mo 5B 150# TO A4F, A4G, B3F,
STEEL 600# B4F, B4G.
b)
100% --- --- -- 100%
RADIOGRAPHY
(NOTE 5,6)
13 Cr (TYPE- 6 ALL --
410 SS)
c)
--- 100% 1 0% 100% --
KILLED 1 UPTO ABOVE -- LP / MP
CARBON - 45 600# (NOTE 4,6,10,11)
STEEL
4,5A ALL F2D d)

I TO 3 Cr NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
STEEL (IBR) HARDNESS
FOR IBR SERVICE F2D NOTE- 8 IS ALSO APPLICABLE..
MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 533 of 1963

fg-ar dj-eg
1.1,771 ?:1721512" L151,1-05-41,
INDIA LIMITED
Iff GON of Incha Uncleflak,ng) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 I1 12 13
SPECIAL CARBON 1 ALL ABOVE D5A, E5A, FSA 100%

IV SERVICES (O, H) STEEL 300#
(CONTD)
SERVICES 0 5 TO 9 CR 3, ALL ALL
SUBJECT TO Mo STEEL 4, —
100%
SEVERE CYCLIC 5A,
CONDITIONS 5B
SPECIAL 135D, D5D,
SERVICES D5E, ESE
(NACE, O, H, 100% 100% 100% 100%
VISUAL
CAUSTIC)
SERVICES 13 CR 6 —
SUBJECT TO STEEL b)
SEVERE CYCLIC (TYPE RADIOGRAPHY
CONDITIONS 410SS) 100% -- --- ---
(NOTE 5,6) NOTE 7
SERVICES 3 5 NI 9B —
SUBJECT TO STEEL c)
SEVERE CYCLIC LP / MP
CONDITIONS. --- 100% 10% 100%
(NOTE
SPECIAL — 4,6,10,11,13)
SERVICES
(NACE, O, H,
CAUSTIC) d)
NOTE 7 NOTE 7 NOTE 7 NOTE 7
SPECIAL NI ALLOYS 41, — HARDNESS
SERVICES 42,
(NACE, O, H, 43
CAUSTIC)
45 —
ALL SERVICES
1. NOTE-7 FOR HARDNESS IS NOT VALID FOR P.NO.9B.
2. EXTENT OF HARDNESS TEST FOR CLASS D5A, E5A AND F5A IS 10%.
Format No. 8-00-0001-F1 Rev. 0 Copyright — All rights reserved
Page 534 of 1963

ENQNEERS FOR NON DESTRUCTIVE
IA GoA of Indo Underlakong) EXAMINATION REQUIREMENTS
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
I 2 3 4 5 6 7 8 9 10 11 12 13
SERVICES AUSTENITIC
IV SUBJECT TO STAINLESS 8 ALL ALL --
(CONTD) SEVERE STEEL
CYCLIC a)
CONDITIONS 100% 100% 100% 100% 100.%0
VISUAL
LOW TEMP. BELOW 150# A2K, B2K,
SERVICE - 45 300# & D2K
600# b)
100% - -- -- 100%
RADIOGRAPHY
GENERAL ALL ABOVE -- (NOTE 5,6)
SERVICES 600#
c)
-- 100% 10% 100%
HIGH TEMP. > 500 ALL B4K, BSK LP / MP (NOTE
SERVICES 4,6,10,11)
SPECIAL ALL ALL B5M d)

- -
SERVICES (0,H) HARDNESS -
Page 535 of 1963

fèrffleg INDIA LIMITED 6-44-0016 Rev. 7
Ivozn ASI Ja-4.1) IA Govt of Incha Undertaking) EXAMINATION REQUIREMENTS
Applicable Notes to Table-1
Branch welds shall consist of the welds between the pipe & reinforcing element (if any),
nozzles & reinforcing element and the pipe & nozzle under the reinforcing element.
Reinforcing element to be interpreted as pads, saddles, weldolets, sockolets etc.
2. Seal welds of threaded joints shall be given the same examination as socket welds.
3. Unless specifically stated, all materials shall be for "Non-IBR" service.
4. Magnetic Particle & the Liquid Penetrant method of examination shall be in accordance
with Section V of the ASME Boiler and Pressure Vessel Code, Article VII and VI
respectively. The entire area of the accessible finished weld surface shall be examined.
Selected root runs, subject to a maximum of 10%, before finished weld, may also be
examined, at the discretion of the engineer-in-charge.
a) Wherever MP / LP testing is specified, either MP or LP test may be used. But

wherever only MP test is specified, LP method of examination may be used only
if MP examination is impracticable in the field as concurred by EIL site-in charge.
b) "Random 5%" of Liquid Penetrant / Magnetic Particle test shall mean testing, by
applicable test, one weld for each twenty welds or less made by the same welding
procedure. "Random 10%" shall mean testing, by applicable test, one weld for
each ten welds or less made by the same welding procedure. Similarly "Random
20%" shall mean testing, by applicable test, one weld for each five welds or less
made by the same welding procedure.
c) When Liquid Penetrant examination is specified, the surface shall be free of

peened discontinuities.
d) Inspection shall be performed in the welds excluding those for which radiography
has been done.
e) Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni steel shall
be Liquid Penetrant tested only when welded with austenitic material where MP
test has been specified.
5. Radiography:
a) "Random 5%, 10% or 20% radiography" shall mean examining not less than one
from each 20 welds or less in case of "Random 5% radiography", 10 welds or less
in case of "Random 10% radiography", one from each five welds or less in case of
"Random 20% radiography" made by the same welding procedure. Irrespective of
percentage, no. of welds to be radiographed shall be minimum 1. However first
two welds made by each welder shall also be radiographed in case of "Random
radiography". Welds selected for examination shall not include flange welds and
shall be radiographed for their entire length. However, where it is impossible or
impracticable to examine the entire weld length of field welds for either random
or 100% radiography, and if the same impossibility is agreeable to EIL site-in-
charge, then a single 120 deg. exposure of the weld length may be given a
Magnetic Particle test or Liquid Penetrant test. However in such cases for
ferro-magnetic materials, only MP test shall be acceptable for classes higher than
600#.
b) In-process examination shall not be substituted for any required radiographic

examination.
Page 536 of 1963

,31 ENGINEERS FOR NON DESTRUCTIVE
fgzTr g INDIA LIMITED 6-44-0016 Rev. 7
,~n a,rort a,~) IA Govt ol Incha Undettak.g) EXAMINATION REQUIREMENTS
c) Number of radiography per one circumferential weld shall be as per ASME Sec.V
Articles 2 and 22.
6. When radiography or other non destructive inspection is specified, acceptance criteria for
repairs or defects shall be as follows:
a) In case of 1 00eY0 examination, any unacceptable weld shall be repaired and

reinspected.
b) If required random examination reveals a defect requiring repair, then:
b. 1 Two additional examinations of same type shall be made of the same kind
of item (if welded joint, then by the same welding procedure or operator
or both).
b.2 If the group of items examined as required by b.1 above is acceptable, the
items requiring repair shall be repaired or replaced and reexamined as
required and all items represented by this additional examination shall be
accepted.
b.3 If any of the items examined as required by b.1 above reveals a defect
requiring repair, two further comparable items shall be examined for each
defective item found by examination.
b.4 If all the items examined as required by b.3 are acceptable, the items
requiring repair shall be repaired or replaced and reexamined as required,
and all items represented by this further examination shall be accepted.
b.5 Number of times repair welding could be done for the same weld before
acceptance shall be as follows:
Material No. of times repair welding is allowed
C.S. upto 300 # 3 or less
C.S. above 300 # 2 or less
Killed steel 2 or less
Low alloy steel 2 or less
Austenitic S.S. 2 or less
3.5 Ni steel 2 or less
Al & Al base alloy 2 or less
Cu & Cu base alloy 2 or less
Others 2 or less
b.6 Welds not found acceptable for allowed number of times of repair as per
b.5 above shall be replaced and reexamined.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — AII rights reserved
Page 537 of 1963

Ilf ENGINEERS FOR NON DESTRUCTIVE
$Rz-1~1ir2TlQT7 +151~1) INDIA LIMITED 6-44-0016 Rev. 7
IA GoA ol Intha UndeAolongI EXAMINATION REQUIREMENTS
b.7 If any of the items examined as required by b.4 above reveals a defect
requiring repair, all items represented by these examinations shall be
either :
- repaired or replaced and reexamined as required.
- fully examined and repaired or replaced as necessary, and

reexamined as necessary.
7. Hardness Test:
a) Hardness test shall be in accordance with ASTM specification E10.

Hardness tests of the heat affected zone shall be made at a point as near as
practicable to the edge of the weld. One test per weld shall be performed.
b) Hardness test where specifically called out in Table-1 of this specification

or in PMS, shall be carried out irrespective of thickness and to the extent
(%age) as mentioned therein.
c) A11 welds which are given heat treatment shall be hardness tested.
Hardness test shall be performed after final heat treatment.
d) A minimum of 10% of welds, hot bends, and hot formed components in

each furnace heat treated batch and 100% of those which are locally heat
treated shall be hardness tested.
e) Hardness test requirement not covered in this specification shall be as per

ASME B31.3.
f) The hardness limit applies to the weld and heat affected zone. Following
hardness values shall be maintained:
Base Metal Group Maximum

Hardness
(BHN/RC)
CS 238BHN/RC22
CS (NACE) , Caustic, 200BHN

Amine, H2
Cr Upto 2% 225BHN
Cr 2.25%-10% 241BHN
18/8 SS (NACE) RC22
g) In case hardness values are mentioned in both Welding Specification

Charts for Piping Classes, (6-77-0005) & table given in Note-7(f), the
lower of the two values shall be applicable.
8. For IBR service lines, following IBR requirements shall apply in addition to the notes 4, 5, 6,
7, 12 and Table 1. In case of conflict between above notes and these requirements, the more
stringent ones shall apply. IBR piping shall be erected of IBR inspector approved material and
Page 538 of 1963

/01 ENGINEERS FOR NON DESTRUCTIVE
OgL
ar 2e5 INDIA LIMITED 6-44-0016 Rev. 7
■awrt vtevort tol,rosvi) IA Govt of InO. Uneef taking) EXAMINATION REQUIREMENTS
construction procedure. Erected piping shall be hydrotested, inspected and approved by IBR
inspector.
a) Piping over 102 mm (4") bore:
10')/0 of welds made by each welder on a pipeline with a minimum of two welds per
welder, selected at random, shall be subjected to radiography.
b) Piping 102 mm (4") bore and under, but not less than 38 mm (1-1/2") bore:
Two percent of welds made by each welder on a pipeline with a minimum of one weld
per welder, selected at random, shall be subjected to radiography or may be cut for
visual examination and tests.
c) Piping less than 38 mm (1.5") bore:
Special tests are not normally required but 2% of welds by each welder on a pipe line
may be cut out from the pipeline for the visual examination and bend tests.
d) Retests:
If any test specimen is unsatisfactory, two further weld specimens for retests shall be
selected from the production welds and subjected to tests. In the event of failure of
any retest specimens, the production welds carried out by this welder subsequent to
the previous test shall be given special consideration.
9. For fabricated fittings LP test shall be done on the final pass of welding only, in addition to
visual examination.
10. For mitres and fabricated reducers, LP / MP test shall be done on root pass in addition to
radiography applicable to circumferential joint of respective piping class.
11. For branch connections, LP/MP test shall be done on root pass and final pass.
12. 10% of the butt weld joints shall be radiographed, however, 50% of these butt weld joints
shall be field weld joints.
13. All joints including butt weld joints for Al 6A, B16A and D16A classes shall be wet
fluorescent magnetic particle tested. Percentage of wet fluorescent magnetic particle testing of
butt weld joints shall be 100% and this testing shall be in addition to radiography.
14. For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.
Page 539 of 1963

ENGINEERS TECHNICAL NOTES FOR
5fg-ar I~-3
dg INDIA LIMITED PIPES 6-44-0051 Rev. 6
IA GoN of Indo Undeflakng)
Page 1 of 10
lebri ch i•JA
TECHNICAL NOTES
FOR PIPES

6 25.09.14
SPECIFICATION SH' K ATD(‘'\:' SC
5 31.12.13
SPECIFICATION UK SH AK RN SC
4 04.07.08
SPECIFICATION RN SC DM VC
3 15.03.00 RN BRB NS AS
SPECIFICATION
HYDROTEST & I.G.C. TEST CLAUSES
2 04.04.94 AKG BPV GRR AS
REVISED
Standards Standards
Committee Bureau
No by by
Approved by
Page 540 of 1963

INDIA LIMITED PIPES 6-44-0051 Rev. 6
rivvottt.1.5trool, IA Govt ot Intha Undertalfing)
Page 2 of 10
Abbreviations:
ANSI American National Standards Institute

ASTM American Society for Testing & Materials
BHN Brinell Hardness Number
BIS Bureau of Indian Standards
E.FS.W Electric Fusion Weld
E.R.W Electric Resistance Weld
HIC Hydrogen Induced Cracking
IGC Inter Granular Corrosion
IS Indian Standard
LT Low Temperature
MR Material Requisition
NACE MR National Association of Corrosion Engineers : Material Requirement
NB Nominal Bore
NPT Nominal Pipe Thread
PMI Positive Material Identification
PR Purchase Requisition
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. S. Mukherjee (Construction)
Page 541 of 1963

$;fgW 2154- INDIA LIMITED PIPES 6-44-0051 Rev. 6
1+fV7R rwnrt ,151,70541, IA Govl of lodia Undeftalong)
Page 3 of 10
CONTENTS
1.0 GENERAL 4
2.0 IBR PIPES 6
3.0 ACCEPTABLE DEVIATIONS 7
4.0 HYDROSTATIC TEST 7
5.0 MARKING AND DESPATCH 10
6.0 REFERENCES 10
Page 542 of 1963

2f5le'g INDIA LIMITED
IA Govl ol lnaia Undertakog)
PIPES 6-44-0051 Rev. 6
Page 4 of 10
1.0 GENERAL
1.1 A11 pipes and their dimensions, tolerances, chemical composition, physical properties, heat
treatment, hydrostatic test and other testing and marking requirements shall conform to the
latest codes and standards specified in the material requisition (MR). Supplier shall strictly
comply with MR/PR stipulations and no deviations shall be permitted. Post Order
Concession/Deviation Permit 5-0000-0180-F1 as mentioned in Cl. 5.18 of Specification for
Quality Management System Requirements from Bidders (6-78-0001) is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the MR & Clauses 1.10 & 1.11.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the pipes supplied.
1.2.3 PMI shall be performed as per the scope and procedures as defined in the spec for PMI at
Supplier's Works (6-81-0001).
1.2.4 Refer to specification nos. 6-81-0002 and 6-81-0003 for Inspection & Test plans for welded
pipes and seamless pipes respectively.
1.3 Manufacturing Processes
1.3.1 Steel made by acid Bessemer process shall not be acceptable.
1.3.2 A11 longitudinally welded pipes should employ only automatic welding.
1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters
respectively.
1.5 a. Seamless and E.R.W. pipes shall not have any circumferential seam joint in a random
length. However, in case of E.FS.W pipe, in one random length one welded
circumferential seam of same quality as longitudinal weld is permitted. This weld
shall be at least 2.5 m from either end. The longitudinal seams of the two portions
shall be staggered by 90°. Single random length in such cases shall be 5 to 7 m.
b. Unless otherwise mentioned in the respective material code, E.FS.W pipes < 36" shall
not have more than one longitudinal seam joint and E.FS.W pipes 36" shall not
have more than two longitudinal seam joints.
1.6 Pipe with screwed ends shall have NPT external taper pipe threads conforming to
ASME/ANSI B1.20.1 up to 1.5" NB & IS 554 for 2" to 6" NB.
Page 543 of 1963

INDIA LIMITED PIPES 6-44-0051 Rev. 6
wlrrT t,vcrtV ItISOIstt ) IA Govt ol Intlia Gott000k,o9)
Page 5 of 10
1.7 Pipe with beveled ends shall be in accordance with ASME B16.25. Weld contours shall be as
follows:
Material Wall Thickness Weld Contour

Up to 22 mm Figure 2 Type A
Carbon Steel (Except
Low Temp. Carbon Steel) > 22 mm Figure 3 Type A
Up to 10 mm Figure 4
Alloy Steel,
Stainless Steel & > 10 mm & Up to 25 mm Figure 5 Type A
Low Temp. Carbon Steel
> 25 mm Figure 6 Type A
1.8 Galvanized pipes shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM
A 153.
1.9 All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types
of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to the normal solution annealing. Soaking time
& holding temp. for stabilizing heat treatment shall be 4 hrs & 900°C respectively.
1.10 I.G.C. Test for Stainless Steels
1.10.1 For all austenitic stainless steel pipes inter-granular corrosion test shall have to be conducted
as per following:
ASTM A262 Practice "B" with acceptance criteria of "60 mils/year (max.)".
OR
ASTM A262 Practice E with acceptance criteria of no cracks at 20X magnification and
microstructure to be observed at 250X magnification shall ensure the absence of any cracks/
fissures. When testing is conducted as per practice 'E' photograph of microstructure shall be
submitted for record.
1.10.2 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (eg.SS 309, 310, 316, 316H etc.) ASTM A262 Practice "C" with
acceptance criteria of "15 mils/year (max.)" shall have to be conducted.
1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from each
solution annealing lot; one set corresponding to highest carbon content and the other set
corresponding to the highest pipe thickness.
All welded pipes indicated as `CRY0' & `LT' in MR shall be impact tested per requirement
& acceptance criteria of ASME B31.3. The impact test temperature shall be -196°C & -45°C
for stainless steel and carbon steel respectively unless specifically mentioned otherwise in
MR.
1.12 NACE/HIC Requirements
1.12.1 Pipes under "NACE" category and those designated as "HIC1" shall meet the requirements
given in NACE MR-0103 unless mentioned otherwise.
1.12.2 Pipes made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless mentioned otherwise.
Page 544 of 1963

`51
1 ENGINEEFZS TECHNICAL NOTES FOR
5fga 02-eg INDIA LIMITED PIPES 6-44-0051 Rev. 6
1.11UR ertcnt ,TR,1-4.1) Ift Govt of UnciertaNingf
Page 6 of 10
1.13 Specified heat treatment for carbon steel and alloy steel and solution annealing for stainless
steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot
shall be restricted to maximum two by approved repair procedure.
1.14 For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be
20%.
1.15 All 1Cr-V2Mo and 11/4Cr-1/4Mo seamless pipes shall be normalised and tempered.
1.16 For all welded alloy steel pipes with mandatory requirement of heat treatment and
radiography, radiography shall be performed after heat treatment.
1.17 For Hydrogen service pipes following special requirements shall also be met:
1.17.1 All carbon steel pipes having wall thickness 9.53 mm (0.375") and above shall be normalised.
Cold drawn pipes shall be normalised after the final cold draw pass for all thicknesses.
1.17.2 All alloy steel (Cr-Mo) pipes shall be normalised and tempered. The normalising and
tempering shall be a separate heating operation and not a part of the hot forming operation.
The maximum room temperature tensile strength shall be 100,000 psig.
1.17.3 For carbon steel Pipes, hardness of weld and HAZ shall be 200 BHN (max.). For alloy steel
Pipes, hardness of weld and HAZ shall be 225 BHN (max.).
1.17.4 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
Ferrite No.(FN) not less than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by Ferritescope prior to post
weld heat treatment.
1.17.5 For all Carbon steel and Alloy steel pipes with wall thickness over 20mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-1 for weld metal and base metal from the thickest item per heat of material and per
heat treating batch. Impact test specimen shall be in complete heat treated condition and
accordance with ASTM A370. Impact energies at 0°Celsius shall average greater than 27J (20
ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).
1.18 For dual grades of SS where specified, chemical composition and mechanical properties of
both grades specified shall be ensured.
2.0 IBR PIPES
2.1 IBR Documentation
2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form III-A
duly approved and countersigned by IBR authority/local authority empowered by the Central
Boiler Board of India(Photocopy of the original certificate duly attested by the local boiler
inspector where the supplier is located is the minimum requirement for acceptance) or Form
III-D [for well known pipe manufacturers as per IBR] signed by Manufacturer's authorized
representative. Well known pipe manufacturers, as recognized by IBR, shall submit a duly
attested copy of Form XVI-G along with Form
2.1.2 For materials 11/4Cr - V2Mo (ASTM A335 Gr.P11 / A691 Gr.11/4Cr), 21/4Cr - 1Mo (ASTM
A335 Gr.P22 / A691 Gr.21/4Cr) & 9Cr -1Mo-V (A335 Gr.P91/A691 Gr.91), Form III-A
approved by IBR shall include the tabulation of Et, Sc & Sr values for the entire temperature
range given below. Et, Sc & Sr values shall be such that throughout the temperature range
Page 545 of 1963

$R-ar 22-eg
1.177, rrmrr an s~›
INDIA LIMITED
IA Govt ot India Undertalfingt
PIPES 6-44-0051 Rev. 6
Page 7 of 10
E,/ 1.5
Sr / 1.5 SA
Sc
where ,
SA Allowable stress at the working metal temperature.

Yield point (0.2% proof stress at the working metal temperature)
S, The average stress to produce elongation of 1%(creep) in 100000 hrs at the
working metal temperature.
Sr The average stress to produce rupture in 100000 hrs at the working metal
temperature and in no case more than 1.33 times the lowest stress to produce
rupture at this temperature.
SA (psi)
Temp(°F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
Material
A335 Gr.P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
A691 Gr.11/4Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
A335 Gr.P22 /
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A691 Gr.21/4Cr
A335 Gr.P91/
28100 27700 27300 26700 25900 24900 23700 22300 20700 18000 14000 10300
A691 Gr.91
Note : SA values shall be as per the latest edition prevai ing.
2.2 For carbon steel pipes under IBR the chemical composition shall conform to the following:
Carbon (max) 0.25%

Others (S, P, Mn) As prescribed in IBR.
The chemical composition as indicated in this clause is not applicable for pipes other than IBR
services.
3.0 ACCEPTABLE DEVIATIONS
3.1 Pipes to IS 3589 Gr.410 are acceptable in place of IS 3589 Gr.330.
3.2 Pipes of Grades SS317 of corresponding material are acceptable in place of Grades SS316 or
SS316(2.5 Mo min.).
3.3 Pipes of Grades SS317L of corresponding material are acceptable in place of Grades SS316L
or SS316L(2.5Mo min.).
3.4 Seamless pipes are acceptable in place of welded pipes except in the case of welded
SS321/SS321H pipes with nominal thickness greater than 9.53mm.
4.0 HYDROSTATIC TEST
4.1 A11 pipes shall be hydrostatically tested.
Page 546 of 1963

~_le7 ENGINEERS TECHNICAL NOTES FOR
• e5 INDIA LIMITED
IA Govt of Incha Undertalting)
PIPES 6-44-0051 Rev. 6
Page 8 of 10
4.2 The mill test pressure shall be as follows:
4.2.1 Seamless, E.R.W. & Spiral Welded
a) Carbon Steel
Material Std. Test Pressure Std.
ASTM A106 Gr.B ASTM A530
API 5L Gr.B, Seamless API 5L
API 5L, E.R.W. API 5L
API 5L, Spiral API 5L
ASTM A333 Gr.3 & 6, Seamless ASTM A530
ASTM A333 Gr.3 & 6, E.R.W. ASTM A530
b) Seamless Alloy Steel
ASTM A335 Gr.P1, P12, P11, P22, P5, P9 ASTM A530
ASTM A268 TP 405, TP410 ASTM A530
c) Seamless Stainless Steel

ASTM A312 Gr.TP 304, 304L, 304H, 316, ASTM A999
316L, 316H, 321, 347
d) Seamless Nickel Alloy
ASTM B161 UNS No. 2200 ASTM B161
e) Welded Nickel Alloy
ASTM B725 UNS No. 2200,4400 ASTM B725
Page 547 of 1963

0141
-eg INDIA LIMITED
IA Govt of Indo UnclertaNngt
PIPES 6-44-0051 Rev. 6
Page 9 of 10
4.2.2 Electric Fusion Welded
a) Carbon Steel & Alloy Steel E.FS.W (16" & above)

API 5L Gr.B P = 2ST/D
ASTM A671 Gr.CC65, 70 (C1.32) S = 90% of SMYS
ASTM A672 Gr.C60, 65, 70 (CI.12,22) Except for API 5L Gr.B
ASTM A671 Gr.CF60, 65, 66, 70 (C1.32) S = 85% of SMYS
ASTM A691 Gr.V2Cr, 1Cr, 11/4Cr, 21/4Cr, For API 5L Gr.B
SCr, 9Cr (C1.42) T = Nominal Wall Thickness
D = O.D of Pipe
b) Stainless Steel E.FS.W (2" to 6")
The hydrostatic test pressure in kg/cm2 for the following materials shall be as given
below :
Material Gr.1 :ASTM A312 TP 304 / 304H / 316 / 316H / 321 / 347 welded.
Material Gr.2 :ASTM A312 TP 304L / 316L welded.
Size Pipe Schedule : 10S Pipe Schedule : 40S Pipe Schedule : 80S
Material Material Material Material Material Material
Gr. 1 Gr.2 Gr.1 Gr.2 Gr.1 Gr.2
2" 100 80 155 130 230 190
3" 80 60 155 130 230 190
4" 80 50 155 130 230 190
6" 65 35 90 75 155 130
c) Stainless Steel E.FS.W (8" and above).

ASTM A358 TP 304L, 304, 304H, 316L, P = 2ST/D
316, 316H, 321, 347 (Classes 1, 3 & 4) S = 85% of SMYS
T = Nominal Wall Thickness
D = O.D of Pipe
ASTM A358 TP 304L, 304, 304H, 316L, P = 2ST/D
316, 316H, 321, 347 (Classes 2 & 5) S = 72% of SMYS
T = Nominal Wall Thickness
D = 0.D of Pipe
4.2.3 Carbon Steel Pipes to BIS Standards

IS 1239 IS 1239
IS 3589 IS 3589
4.3 Hydrostatic pressure testing shall be performed using iron free water, which is clean and free
of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 50
ppm.
Page 548 of 1963

OrcRes
1
.1,P+,,
M11 J457,01/
INDIA LIMITED
IA GoN ol India UnclettaMing)
PIPES 6-44-0051 Rev. 6
Page 10 of 10
5.0 MARKING AND DESPATCH
5.1 All pipes shall be marked in accordance with the applicable codes, standards and
specifications. In addition the purchase order number, the item code & special conditions like
"IBR", "CRY0", "NACE", "H2" etc. shall also be marked.
5.2 Pipes under "IBR","CRY0", "NACE" & "H2" shall be painted with one circumferential
stripe of colour red, light purple brown, canary yellow & white respectively for easy
identification. Width of stripe shall be 12mm for pipe sizes lens than 3" and 25mm for pipes
3" and above.
5.3 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead
or copper which cause corrosive attack on heating.
5.4 Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
5.5 Pipes shall be protected from rust & corrosion.
5.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a
petroleum solvent and the same shall not be harmful to welding.
5.7 Both ends of the pipe shall be protected with the following material:
Plain end Plastic cap

Bevel end Wood, Metal or plastic cover
Threaded end Metal or plastic threaded cap
5.8 Pipes may be provided with plastic push-fit type end caps/ steel caps without belt wire.
5.9 Steel end protectors to be used on galvanized pipes shall be galvanized. Plastic caps can also
be used as end protectors for galvanised pipe ends.
6.0 REFERENCES
6.1 6-81-0001: Specification for Positive Material Identification (PMI) at Supplier's Works.
6.2 6-81-0002: Inspection & test plan for welded pipes.
6.3 6-81-0003: Inspection & test plan for seamless pipes.
6.4 6-79-0013: Material requirements for carbon steel components used in sour service for
petroleum refinery environments
Page 549 of 1963

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Page 569 of 1963
Oa&
+rpm kgronre akrantl)
INDIA LIMITED
IA GovI of India Undertaking)
GASKETS 6-44-0056 Rev. 4
Page 1 of 5
Clcfri I 14) I I duLI
TECHNICAL NOTES
FOR GASKETS
REVISED & ISSUED AS STANDARD

4 21.03.13 '(
„yr UK yrSH z RN kTD DM
SPECIFICATION
3 23.07.07
SPECIFICATION RN ATD DM VC
REAFFIRMED & ISSUED AS STANDARD
2 15.06.98 SH BRB BN AS
SPECIFICATION
1 30.12.92 AKG BPV GRR AS
SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared
Date Purpose Checked by Convenor Chairman
No by
Approved by
Page 570 of 1963

Ogaf Rae
lg INDIA LIMITED GASKETS 6-44-0056 Rev. 4
anen efetpre ftst 3,70,1 IA Govt of India Undettatongt
Page 2 of 5
Abbreviations:
AARH : Average Arithmetic Root Height
BHN : Brinnel Hardness Number
CS Carbon Steel
RTJ Ring Type Joint
Members : Mr. Harish Chander

Mr. M. Ismaeel
Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.V.K Naidu (Projects)
Page 571 of 1963

fgar fafgeg
,ania riroreaw+i,
INDIA LIMITED
IA Goof of India Undertaking)
Page 3 of 5
CONTENTS
1.0 GENERAL 4
2.0 REFERENCES 5
Page 572 of 1963

$14-ar 051-eg
wren erecore 4513405141
INDIA LIMITED
(A Goer of India Undertaking)
Page 4 of 5
1.0 GENERAL
1.1 All gaskets shall conform to the codes/standards and specifications given in the
requisition. Supplier shall strictly comply with MR/PR stipulations and no deviations shall
be permitted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as mentioned in Cl.
5.18 of Specification for Quality Management System Requirements from Bidders (6-78-
0001) is not applicable.
1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall be in
accordance with the requirements of the manufacturer's standards.
1.3 Testing
1.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the standards
specified in the requisition.
1.3.2 Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of
test reports on samples.
1.3.3 For Spiral wound material following shall be furnished:
a. Manufacturer's test certificate for filler material and spiral material as per the relevant
material specifications.
b. Manufacturer's test certificate for raw materials and tests for compressibility/ seal-
ability & recovery as per the relevant material specifications.
1.3.4 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001) for ring type joint gaskets.
1.3.5 Refer Specification no 6-81-0008 for 'Inspection & Test Plan for Gaskets'.
1.4 Full face gaskets shall have bolt holes punched out.
1.5 Filler material for spiral wound gaskets shall not have any colour or dye.
1.6 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall
be CS unless otherwise specified in the MR.
1.7 For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip
material. In addition to the requirements as per code and as specified in the MR, inner
rings shall be provided for the following:
a. Sizes 26" and above.
b. Class 900 and above.
1.8 Hardness of metallic RTJ gaskets shall not exceed the values specified below unless
otherwise specified in MR:
Ring Gasket Material Maximum Hardness (BHN)
Soft Iron 90
Carbon steel 120
Page 573 of 1963

ligar 215ieg
rrecryrens,mn.,
NIVM
INDIA LIMITED
IA G0A of Incha Uncterlaiong)
Page 5 of 5
5 Cr. 1/2 Mo 130
Type 304, 316, 321, 347 140
Type 304L, 316L 120
1.9 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.
1.10 Gaskets of different types and sizes shall be placed in separate shipping containers and
each container clearly marked with the size, rating, material specification and item code.
1.11 All items shall be inspected and approved by EIL Inspector or any other agency
authorized by EIL.
1.12 Any additional requirements specified in the requisition, shall be fully complied with.
1.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto
24" (except 22" size) and to ASME B16.47B above 24" unless specified otherwise. For
22" size, the matching flange standard shall be MSS-SP44 unless specified otherwise.
1.14 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto
24"(except 22"size) and to ASME B16.47B above 24" unless specifically mentioned
otherwise. For 22" size, the matching flange standard shall be MSS-SP44 unless specified
otherwise.
1.15 The following abbreviations have been used in the Material Requisition for Spiral Wound
Gaskets :
(I) Inner Ring

(0) • Outer Ring
GRAFIL : Grafoil Filler
2.0 REFERENCES
6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works
6-81-0008 Inspection & Test Plan for Gaskets
6-78-0001 Specification for Quality Management System Requirements from

Bidders
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved
Page 574 of 1963

6-44-0057 Rev. 4
Igar tif5leg INDIA LIMITED
IA Govt of India Undettatongf
BOLTS AND NUTS
Page 1 of 5
64vd,N*1 -R-
47 7-
4‘k:r *
ocn i criI Idui 'J ig'
TECHNICAL NOTES
FOR BOLTS AND NUTS

9'°1A-)-
4 21.03.13 4, UK 4.7t5(H RN STD DM
SPECIFICATION
3 23.07.07
SPECIFICATION RN ATD DM VC
REAFFIRMED & ISSUED AS STANDARD
2 15.06.98 SH BRB BN AS
SPECIFICATION
REVISED & ISSUED AS STANDARD AS
1 30.12.92 AKG BPV GRR
SPECIFICATION
Standards Standards
Committee Bureau
No by by
Approved by
Page 575 of 1963

tg-ar 054-eg
1.71217 2T2a+re OP J73,A)
INDIA LIMITED
(A Govt of India Undertaking)
BOLTS AND NUTS 6-44-0057 Rev. 4
Page 2 of 5
Abbreviations:
ASME : The American Society of Mechanical Engineers
ASTM : The American Society for Testing and Materials
MR : Material Requisition
SS Stainless Steel
Members : Mr. Harish Chander

Mr. M. Ismaeel
Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.V.K Naidu (Projects)
Page 576 of 1963

INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 4
I ,lecnr, am award) (A Govt Of India Undertaking)
Page 3 of 5
CONTENTS
1.0 GENERAL 4
2.0 ACCEPTABLE DEVIATIONS 5
3.0 REFERENCES 5
Page 577 of 1963

Ogar 0144-eg
1.417M el,a,Je
INDIA LIMITED
IA Govt of India Undeilaking)
BOLTS AND NUTS 6-44-0057 Rev. 4
Page 4 of 5
1.0 GENERAL
1.1 The process of manufacture, heat treatment, chemical & mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the
codes/standards and specifications given in the requisition. The applicable identification
symbol in accordance with the material specification shall be stamped on each bolt and
nut. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as mentioned in Cl. 5.18
of Specification for Quality Management System Requirements from Bidders (6-78-0001)
is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
1.2.2 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and
Mechanical Requirement)
1.2.3 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001).
1.2.4 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453
bolting material irrespective of the temperature.
1.2.5 Refer Specification no 6-81-0007 for 'Inspection & Test Plan for Bolting Material'.
1.3 All bolting shall be as per ASME B 18.2.1 for studs, M/c bolts and jackscrews and ASME
B18.2.2 for nuts.
1.4 Threads shall be unified (UNC for 1" dia and 8UN for > 1" dia) as per ASME B1.1 with
class 2A fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.
1.5 Stud bolts shall be threaded full length with two heavy hexagonal nuts unless otherwise
specified. Length tolerance shall be in accordance with the requirement of Table D2 of
Annexure-D of ASME B 16.5.
1.6 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be
made by the hot forged process and stamped as per respective material specification.
1.7 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be
rounded.
1.8 Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in separate
containers marked with size and material specifications. `CRY0' shall be marked
additionally in case `CRY0' is specified in the requisition.
1.9 All items shall be inspected and approved (stagewise) by EIL inspector or any other
agency authorized by EIL.
1.10 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
1.11 All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed
condition unless specified otherwise in the material specification.
1.12 Any additional requirements specified in the requisition shall be fully complied with.
Page 578 of 1963

■
31 ENGINEERS TECHNICAL NOTES FOR
$2-al faReg INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 4
Govt 01 India Undenaking)
Page 5 of 5
1.13 Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material
specification and also where the material specification is indicated as "CRYO". For S.S.
nuts and bolts minimum impact energy absorption shall be 27 Joules and test temperature
shall be -196°C unless mentioned otherwise. For other materials impact energy and test
shall be as per respective code.
1.14 Bolts/nuts of material of construction B7M/2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A193.
1.15 When specified as galvanized, the studs, M/C bolts and nuts shall be 'hot dip zinc coated'
in accordance with requirements of 'class C' of ÀSTM A 153'. As an alternative, electro-
galvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable.
1.16 All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts
irrespective of whatever has been specified elsewhere in the MR.
1.17 Bolting shall be protected by non-corrosive oil or grease before dispatch to prevent
rusting.
2.0 ACCEPTABLE DEVIATIONS
2.1 'Nuts' to ASTM A194Gr.7 are acceptable in place of ASTM A194Gr.4.
3.0 REFERENCES
6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works
6-81-0007 Inspection & Test Plan for Bolting Material
6-78-0001 Specification for Quality Management System Requirements from

Bidders
Page 579 of 1963

STANDARD SPECIFICATION STANDARD SPECIFICATION
siitaet5 (Cr) ENGINEERS FOR SURFACE PREPARATION NO. 6-79-0020
Keg INDIAN.LIMITED
RI AQFIV CA , IA GOO Of Undeflangl AND PROTECTIVE COATING Rev. 0
PAGE 1 OF 59
tin a K4
1-49-br
(7q. Wu! tg)
FOR
SURFACE PREPARATION
AND PROTECTIVE COATING
(NEW CONSTRUCTION)
6-44-0004 REV. 3 REVISED, RE-

0 30.08.12 NUMBERED 8 ISSUED AS STANDARD A.SRIDHAR R.CHAUDHURY P.P.LAHIRI D.MALHOTRA
SPECIFICATION
Standards Standards
Rev. Prepared Committee Bureau
No Date Purpose by Checked by Convenor Chairman
Approved by
Page 580 of 1963

02-zieLa ENGINEERS NO. 6-79-0020
$1?-eir la Me ear INDIA LIMITED FOR SURFACE PREPARATION
HIM eknillcIAJAA.M IA GNI al India LInderlaIm9/ AND PROTECTIVE COATING Rev. 0
PAGE 2 OF 59
Abbreviations:
AS Alloy Steel
CS Carbon Steel
DFT : Dry Film Thickness
DM De-mineralized
GI Galvanized Iron
ID Internal Diameter
IRN Inspection Release Note
LTCS : Low Temperature Carbon Steel
MS Mild Steel
NB Nominal Bore
OD Outside Diameter
RCC : Reinforced Cement Concrete
SS Stainless Steel
TSAC : Thermally Sprayed Aluminium Coating
WFT : Wet Film Thickness
SMMS Standards Committee
Convener : Mr. P.P. Lahiri
Members : Mr. A. Amin (SMMS)

Mr. S. Ghosal (SMMS)
Mr. G.S. Hegde (SMMS)
Mr. P. Saha (SMMS)
Mr. R Nanda (Piping)
Mr. Raj Kishore (Pipeline)
Mr. A.K. Gupta (HMTD)
Mr. S. Mukharjee (Construction)
Mr. A.R. Purushottam (POSD)
Mr. R. Muthulingam (Inspection)
Page 581 of 1963

OfteituvaNEERs STANDARD SPECIFICATION STANDARD SPECIFICATION
FOR SURFACE PREPARATION NO. 6-79-0020
laiReedi INDIA LIMITED Rev. 0
PIM FRW ZIRJR140 IA Go.4 ei India unden.lono AND PROTECTIVE COATING PAGE 3 OF 59
CONTENTS
SL. DESCRIPTION PAGE

NO NO.
1.0 General 4
2.0 Scope 4
3.0 Reference Codes & Standards 6
4.0 Equipment 7
5.0 Surface Preparation, Shop Primer,Coating Application & Repair and Documentation 7
6.0 Paint Materials 16
7.0 Coating Systems 21
8.0 Coating System for Gratings, Rolling & Stationery Ladders, Spiral Stairways and
Hand Rails in All Location 23
9.0 Coating System for Offsite Area (Inland Plants) 24
10.0 Coating System For Unit Areas as well as DM, CPP, Cooling Tower of Inland Plants
and for All Areas (Unit, Offsite, DM, CPP, etc.) of Coastal Plants 25
11.0 Coating System for Effluent Treatment Plant (ETP) 27
12.0 External Coating Systems for Uninsulated Carbon Steel and Low Alloy Steel Storage
Tanks (For All Plant Locations, Coastal or Inland) - All Process Units & Off-Sites 28
13.0 Internal Coating Systems for Carbon Steel and Low Alloy Storage Tanks - All
Process Units & Off-Sites 30
14.0 Coating Systems for External Side of Underground Carbon Steel Plant Piping and
Underground Vessels 32
15.0 Coating Under Insulation (Coastal Or Inland Plants) All Units Areas & Off-Sites 33
16.0 Coating System for Carbon Steel Components of Coolers / Condensers (Internal
Protection) for Fresh Water Service 34
17.0 Coating System (Internal Protection) for Galvanized or Non Ferrous or Stainless
Steel/ Duplex Stainless Steel Components of Coolers/ Condensers for Fresh Water
Service 35
18.0 Storage 35
19.0 Colour Code 35
20.0 Identification of Vessels, Piping etc 42
21.0 Painting for Civil Defence Requirements 42
22.0 Quality Control, Inspection and Testing 42
23.0 Guarantee 46
24.0 Qualification Criteria of Painting Contractor/Sub-Contractor 46
25.0 Qualification/Acceptance Criteria for Paint Coating System 46
26.0 Method of Sampling & Dispatch for Laboratory Testing 48
Annexure-I Specification For TSAC 50
Page 582 of 1963

StilMziet- ENONEERS
Oar iiiRtg Ter INDIA LIMITED Rev. 0
own ARAW/INJOSA) /A Govt a htha Unden•ingi AND PROTECTIVE COATING PAGE 4 OF 59
1.0 GENERAL
1.1 This technical specifications shall be applicable for the work covered by the contract, and
without prejudice to the provisions of various international codes of practice, standard
specifications etc. It is understood that contractor shall carry out the work in all respects with
the best quality of materials and workmanship and in accordance with the best engineering
practice and instructions of Engineer-In-Charge.
1.2 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor.
Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
1.3 This specification coven the requirement for protective coating for new construction.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the
following.
2.1.1 This specification defines the requirements for surface preparation, selection and application
of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts,
steel structures, external & internal protection of storage tanks for all services and chimneys
if any. The items listed in the heading of tables of paint systems is indicative only, however,
the contractor is fully responsible for carrying out all the necessary painting, coating and
lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting:
All uninsulated Carbon Steel & Alloy Steel equipments like vessels, Columns, storage
Tanks, Exchangers if any, parts of boilers etc.
All uninsulated carbon steel and low alloy plant and related piping, fittings and valves
(including painting of identification marks), furnace ducts and stacks.
All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping and if
any other insulated items present.
All items contained in a package unit as necessary.
All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms etc.
Flare lines, external surfaces of MS chimney with or without refractory lining and
internal surfaces of MS chimney without refractory lining. (If present)
Page 583 of 1963

0a-zetaENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
51gar fatilegW INDIA WIRD Rev. 0
laiRrIMENVOIMBIll (A GoN ot India undertaiongi AND PROTECTIVE COATING PAGE 5 OF 59
Identification of colour bands on all piping as required including insulated aluminium

clad, galvanized, SS and nonferrous piping.
Identification lettering/ numbering on all painted surfaces of equipment/piping insulated

aluminium clad, galvanized, SS and non-ferrous piping.
Marking / identification signs on painted surfaces of equipment/piping including

hazardous service.
Supply of all primers, paints and all other materials required for painting (other than
Owner supplied materials)
Over insulation surface of equipments and pipes wherever required.
Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
Painting of pre-erection/fabrication and Shop primer.
Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the
field/site before and after erection as required.
All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP
plant.
Quality control, testing and inspection during all stages of work (surface preparation,
application of coating and testing of furnished coating).
2.2.2 The following surfaces and materials shall not require painting in general. However, if there
is any specific requirement by the owner, the same shall be painted as per the relevant
specifications:
Uninsulated austenitic stainless steel.
Plastic and/or plastic coated materials
c. Non-ferrous materials like aluminum, Cu-Ni alloy, galvanized steel.
2.3 Documents
2.3.1 The contractor shall perform the work in accordance with the following documents issued to
him for execution of work.
Bill of quantities for piping, equipment, machinery and structures etc.
Piping Line List.
c. Painting specifications including special civil defence requirements.
2.4 Unless otherwise instructed, final paint coating (i.e., application of field primer,
wherever required, intermediate and top coats) on pre-erection/ shop primed
Page 584 of 1963

151fraeLA ENGINEERS
Itgar 'Matt INDIA umnB) FOR SURFACE PREPARATION NO. 6-79-0020
(NM Fletifie Maga,/ IA Gobi al India uncienaton9/ AND PROTECTIVE COATING Rev. 0
PAGE 6 OF 59
equipments shall be applied at site, only after all welding, testing on systems are
completed as well as after completion of steam purging wherever required .
2.5 Changes and deviations required for any specific job due to clients requirement or otherwise
shall be referred to E1L for deviation permit.
3.0 REFERENCE CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, latest editions of the following codes and standards are applicable for the work
covered by this contract.
IS-5 : Colour coding

RAL DUTCH : International Standard for colour shade (Dutch Standard)
IS-101 : Methods of test for ready mixed paints and enamels
IS-2379 : Indian Standard for Pipe line identification-colour code
ISO-12944 : Corrosion Protection of steel Structures by Protective Paint
System
ASTM-Vol 6.01&6.03 : American standard test methods for Paints and Coatings.
ANSI A 13.1 : Scheme for identification of piping systems: American
National Standards Institution
SSPC : Steel Structures Painting Council
3.2 Surface Preparation Standards
The latest editions of any of the following standards shall be followed for surface
preparation:
3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for Preparation of steel substrates before
application of paints and related products. This standard contains photographs of the various
standards on four different degrees of rusted steel and as such is preferable for inspection
purpose by the Engineer-In-Charge.
3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).
3.2.3 National Association of Corrosion Engineers, U.S.A., (NACE).
3.2.4 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
3.4 The paint manufacturer's instructions shall be followed as far as practicable at all times for
best results. Particular attention shall be paid to the following:
Instructions for storage to avoid exposure as well as extremes of temperature.
Surface preparation prior to painting shall be followed as per Table 8.0 to 16.0 of
this standard shall be followed.
Page 585 of 1963

oga1511teTa
naleuw ENONEERS
INDIA umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
Men KROP7m3R6311 IA GOY/ India Undatalang/ AND PROTECTIVE COATING
PAGE 7 OF 59
Mixing and thinning.
Application of paints and recommended limit on time intervals in between coats.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all
equipments, scaffolding materials, shot & grit blasting equipments & air compressors etc.
required to be used shall be suitable for the work and all in good order and shall be arranged
by the contractor at site and in sufficient quantity. The manufacturer's test certificates / data
sheets for all the above items shall be reviewed by Engineer-in-charge at site before start of
work.
4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack systems
except that the Engineer-In-Charge may allow the hand mixing of small quantities at his
discretion in case of specific requirement for touch up work only.
5.0 SURFACE PREPARATION, SHOP PRIMER COATING APPLICATION & REPAIR

AND DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed, depending on condition of surface to be painted and as
instructed by Engineer-In-Charge. Adhesion of the paint film to surface depends largely on
the degree of cleanliness of the metal surface. Proper surface preparation contributes more to
the success of the paint protective system.
Abrasive blast cleaning
Mechanical or power tool cleaning
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and
dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per
provisions of relevant tables given elsewhere in this specification. The minimum acceptable
standard, in case of thermally sprayed metal coatings, in case of mechanical or power tool
cleaning it shall be St. 3 or equivalent. In case of blast cleaning it shall be Sa 2-1/2 as per
Swedish Standard SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning
shall be Sa 3 as per Swedish Standard in case thermally sprayed metal coatings.
Before surface preparation by blast cleaning, the surface shall be degreased by aromatic
solvent to remove all grease, oil etc.
5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning shall not be
performed where dust can contaminate surfaces undergoing such cleaning or during humid
weather conditions having humidity exceed 85%. In case of internal coating of storage tanks,
dehumidifier shall be used, to control humidity level below 60%. Dehumidifier should
depress the dew point of air in the enclosed space, sufficient enough so as to maintain it 3°C
Page 586 of 1963

Oa ft ENGINEERS STANDARD SPECIFICATION
FOR SURFACE PREPARATION
NO. 6-79-0020
Og a 'Meg INDIA LIMITED
Rev. 0
MON FIXOW COIORFM /A Govt kW Undertaking) AND PROTECTIVE COATING PAGE 8 OF 59
below the metal substrate temperature during centre period of blasting and coating
application. During the interval time between application of primer coat and subsequent
intermediate and top coats or between blast cleaning completion and start of application of
primer coat, dehumidifier unit should be in continuous operation to ensure that no
condensation occurs on substrate.
Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25
grains per pound of air per hour. Dehumidifier should have capacity of at least 2 air changes
per hour of the enclosed space. All necessary psychometric data should be collected by
contractor for the given site conditions before starting operation of dehumidifier to ensure
that desired values of dew point, moisture content in enclosed scope is achieved.
Dehumidification to be maintained round the clock for surface preparation and painting till
the total coating application is over.
Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed
to the satisfaction of the technical representative of the paint manufacturer interested with
quality assurance for the work. In case the dehumidifier breaks down in middle of the job, the
same shall be replaced at the risk and the cost of the contractor and the entire unfinished
work shall be repeated.
5.1.4 The Engineer in-charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances the
contractor shall remove the equipment and replace the same with another equipment to
provide satisfactory results without any additional cost to the owner.
5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray/ air assisted conventional spray if recommended by the paint manufacturer on
dry surface. This should be done immediately and in any case within 4 hours of cleaning of
surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall
have the liberty to control the time period, at his sole discretion and/or to insist on re-
cleaning, as may be required, before primer application is taken up. In general, during
unfavorable weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose
particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush.
Acid etching with 10-15% HCL solution for about 15 minutes shall be carried and surface
must be thoroughly washed with water to remove acid & loose particles and then dried
completely before application of paint.
5.2 Procedure for Surface Preparation
5.2.1 Air Blast Cleaning with abrasives
The surfaces shall be blast cleaned using one of the abrasives like angular chilled cast iron or
steel grit, copper slag or Nickel slag, Al 203 particles at pressure of 7kg/cm 2 at an appropriate
distance and angle depending of nozzle size maintaining constant velocity and pressure.
Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16 — G42
conforming to SSPC AB I and 5250 grade size of steel shots (maximum) to obtain a desired
surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the
Page 587 of 1963

aielMENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Iguemegwir INDIA LIMITED Rev. 0
Men AMR =MOM (A GS of India UndedaIngl AND PROTECTIVE COATING PAGE 9 OF 59
range of G16 — G24. The combination of steel grits and shots shall be normally in the ratio of
3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet
the requirements of SSPC AB I . Compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the
materials for liners. Nozzles orifice may vary from 3/16" to %". On completion of blasting
operation, the blasted surface shall be clean and free from any scale or rust and must show a
grey white metallic luster. Primer/first coat of paint shall be applied within 4 hours of surface
preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible
vacuum collector shall be installed for collecting the abrasives and recycling.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding
wheels or rotating steel wire- brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and /or washed by water or steam and thoroughly dried with
compressed air jet before application of paint.
5.3 Non-Compatible Shop Coat Primer
For equipments on which application of total protective coating (Primer + Intermediate + top
coat) is carried out at shop, compatibility of finish coat with primer should be checked with
paint manufacturer. If the shop coat is in satisfactory condition showing no major defect upon
arrival at site, the shop coat shall not be removed.
5.4 Shop coated equipments (coated with Primer & Finishing coat) should not be repainted unless
paint is damaged. Repair shall be carried out as per Table 7.2 of paint systems depending
upon compatibility of paint.
5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means
of power tool brush cleaning or hand tool cleaning and.then spot primed before applying one
coat of field primer unless otherwise specified. If shop primer is not compatible with field
primer then shop coated primer should be completely removed before application of selected
paint system for particular environment.
5.6 For Package units/equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer's standard can be followed after review.
As mentioned in section 2.4, all coating application at field (field primer, intermediate and
top coat) on equipments, structures, piping, etc, shall be carried out only after its erection and
all welding, testing, steam purging (wherever carried out) have been completed.
5.7 Coating Procedure and Application
All paint coatings shall be applied by airless spray excepting at the following special
cases where application can be carried out by brush subject to suitability of the
application of the paint product by brush.
Spot repair
Stripe coating on edges
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — MI rights reserved
Page 588 of 1963

samzEift. ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
51?eg faitegW: INDIA LIMITED Rev. 0
MUT fIRIVOIMIPM (A Ga.( al Oda undenakm AND PROTECTIVE COATING PAGE 10 OF 59
- Small bore parts not suitable for spray application.

Irregular surfaces such as sharp edges, welds, small brackets, and interstices may stripe
coated to ensure specified DFT is achieved. Paint manufacturer recommendation
should be followed before deciding for brush application.
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
exists, when the steel surface temperature is less than 5°F above dew point when the relative
humidity is greater than 85% or when the temperature is below 40°F and when the
ambient/substrate temp is below the paint manufacturer's recommended temperature of
application and curing. De-humidifier equipment shall be used to control RH and Dew point.
The paint application shall not be done when the wind speed exceeds 20km per hour.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous
film uniform thickness free of probes. Any spots or areas missed in application shall be
recoated and permitted to dry before the next coat is applied. Applied paint should have the
desired wet film thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding
coat. Material shall be considered dry for recoating when an additional coat can be applied
without the development of any detrimental film irregularities, such as lifting or loss of
adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval.
5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage
of the surface. The tinting material shall be compatible with the material and not detrimental
to its service life and shall be recommended by the original paint manufacturer.
5.7.6 Airless spray application shall be in accordance with the following procedure: as per steel
structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An air compressor or
electric motor is sued to operate a pump to produce pressures of 1000 to 6000 psi. paint is
delivered to the spray gun at this pressure through a single hose within the gun, a single paint
stream is divided into separate streams, which are forced through a small orifice resulting in
atomization of paint without the use of air. This results in more rapid coverage with less over
spray. Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks
paint from any container, including drums. The unit shall have in built agitator that keep the
paint uniformly mixed during the spraying. The unit shall consist of in built strainer. Usually
very small quantity of thinning is required before spray. In case of high build epoxy coating
(two pack). 30:1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern.
Ideally fluid hoses should not be less than 3/8" ID and not longer than 50 ft to obtain
optimum results.
In case of gun choking, de-choking steps shall be followed immediately.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —AI rights reserved
Page 589 of 1963

ada INGINEERS
#ar1512-
epeow INDIA umirED
NO. 6-79-0020
OfferleIRPRIM3aqi/ IA Gov1 a/ India UnclettSagl AND PROTECTIVE COATING Rev. 0
PAGE 11 OF 59
5.7.7 Brush application of paint shall be in accordance with the following:
Brushes shall be of a style and quality that will enable proper application of paint.
Round or oval brushes are most suitable for rivets, bolts, irregular surface, and
rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they
shall not have width over five inches.
Paint shall be applied into all corners.
Any runs or sags shall be brushed out.
There shall be a minimum of brush marks left in the applied paint.
Surfaces not accessible to brushes shall be painted by spray, doubers, or sheepkin.
5.7.8 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be
ensured in the qualification trial.
5.8 Drying of Coated Surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered
dry for re-coating when another coat can be applied without the development of any film
irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat
should not exceed maximum specified for it as a first coat; if it exceeds the paint material has
possibly deteriorated or maxing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling,
blistering formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturer's
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry
to the fullest extent practicable.
5.9 Spot Repair of Damaged Primer
5.9.1 Where pre erection shop primer has been damaged at isolated localized spots during handling
and transportation, or after erection / welding, the repair of damaged coating of pre-erection /
pre-fabrication or shop primer shall be done as given below and as per the Table 7.2 of this
specification.
5.9.2 Repair of damaged inorganic zinc silicate pre-erection / pre-fabrication or shop primer
(F9) after erection / welding in the design temperature of -90°C to 400°C and damaged
silicone aluminium (F-12) pre-erection / pre-fabrication or shop primer after erection /
welding for design temperature range of 401 — 550 °C.
Surface Preparation: Quickly remove the primer from damaged area by mechanical scraping
and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the
Page 590 of 1963

0R-4:Aft ENGINEERS
Siga tilaiegel INDIA LIMITED Rev. 0
11412712013Valgarff / IA Gott of Ha undertaking) AND PROTECTIVE COATING PAGE 12 OF 59
surface, if possible. Feather the primed surface over the intact adjacent surface surrounding
the damaged area by emery paper.
Primer coating: One coat of F-9 shall be applied wherever damage was observed on pre-
erection / pre fabrication or shop primer of inorganic zinc silicate coating (F-9). Similarly
one coat of F-12 shall be applied wherever damage observed on pre-erection / pre-
fabrication shop primer of silicone aluminium (F-12).
5.9.3 Wherever if damaged areas are found extensive and spread over large areas, then entire pre-
erection / pre-fabrication or shop primer shall be removed by blasting to achieve SSPC-SP-
10 then entire blasted surface shall be primed again with F-9 or F-12 as applicable for the
intended design temp. (See note under table 7.2).
5.10 Paint Application
5.10.1 Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface
(SSPC-SP-10)
5.10.2 Shop priming / pre-erection priming with F9 or F 12 shall be done only with airless spray.
5.10.3 Assessment of Painting Requirement
The paint system to be applied for a specific job shall be arrived at sequentially as given
below:
- Identify the environment from area classification details and chose the appropriate table.
- Identify the design temperature from the technical documents
- Identify the specific field paint system and surface preparation requirement from the above
identified table and temperature range.
- Identify the shop priming requirement from Table 7.1 based on compatibility of the above
paint system.
- Identify the need of repair of shop primer and execute as per Table 7.2.
5.11 Documentation / Records
5.11.1 A written quality plan with procedure for qualification trials and for the actual work
including test and inspection plan & procedure for approval before start of work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no of
coats and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness,
holiday detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
Page 591 of 1963

02zielt. ENGINEERS
I@Tif WeVITIV INDIA LIMITED Rev. 0
INIPPIFIRINVMMICID (A Gov of Inda Underliong) AND PROTECTIVE COATING PAGE 13 OF 59
5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
The coating applicator must maintain a job record consisting of all the information as per
5.11.2 -5.11.7 above as well as the approved procedure of work (5.11.1 above). The job
record consisting of information as required in accordance to 5.11.2 — 5.11.7 shall be entered
on daily basis and should be daily signed by Engineer-in-charge.
Page 592 of 1963

1515036a ENGINEERS
KiegW WA LIMITED FOR SURFACE PREPARATION NO. 6-79-0020
l aildleRzer7013Rdill Cdd d India Underldm9) AND PROTECTIVE COATING Rev. 0
PAGE 14 OF 59
TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL
SI. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Manual or hand tool
cleaning
Removal of loose rust, loose ST.2 SSPC-SP-2 --

1 mill scale and loose paint,
chipping, scrapping, This method is
standing and wire brushing. applied when the
Surface should have a faint surface is exposed to
metallic sheen normal atmospheric
Mechanical or power tool conditions when
cleaning other methods cannot
be adopted and also
Removal of loose rust loose ST.3 SSPC-SP-3 -- for spot cleaning
mill scale and loose paint to during maintenance
2 degree specified by power painting.
tool chipping, de-scaling,
sanding, wire brushing and
grinding, after removal of
dust, surface should have a
pronounced metallic sheen.
Dry abrasive Blast cleaning
3
There are four common
grades of blast cleaning
White metal
Blast cleaning to white metal Where extremely

cleanliness. Removal of all clean surface can be
3.1 . SA 3 SSPC-SP-5 NACE#1
visible rust. Mill scale, paint expected for prolong
& foreign matter 100% life of paint system.
cleanliness with desired
surface profile.
Near white metal The minimum
requirement for
Blast cleaning to near white chemically resistant
metal cleanliness, until at paint systems such as
least 95% of each element of epoxy, vinyl,
surface area is free of all polyurethane based
visible residues with desired and inorganic zinc
3.2 SA 21/4 SSPC-SP-10 NACE#2 .
surface profile. silicate
licate paints, also
for conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
Page 593 of 1963

Isdozesk -r ENGINEERS
fatalegwv INDIA mem FOR SURFACE PREPARATION NO. 6-79-0020
laiRn FRaW !N W) GoA a/ India Undenaly.91 AND PROTECTIVE COATING Rev. 0
PAGE 15 OF 59
VARIOUS INTERNATIONAL
SI. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Commercial Blast For steel required to
be painted with
Blast cleaning until at least conventional paints
two-third of each element of for exposure to
3.3 SA 2 SSPC-SP-6 NO.3
surface area is free of all mildly corrosive
visible residues with desired atmosphere for longer
surface profile. life of the paint
systems.
Brush-off Blast
Blast cleaning to white metal

3.4 cleanliness, removal of all SA 1 SSPC-SP-7 NO.4
visible rust, mill scale, paint
& foreign matter. Surface
profile is not so important
Page 594 of 1963

15illtea ENGINEERS
Itgai Bakst INDIA map FOR SURFACE PREPARATION NO. 6-79-0020
Men eiMEORMCFM (A Govt of India Undertalung) AND PROTECTIVE COATING Rev. 0
PAGE 16 OF 59
6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on original printed
literature, alongwith the test certificate for all specified characteristics given in this
specification. All the paint materials shall be of first quality and conform to the following
general characteristics as per the tables 6.1, 6.2, 6.3 and 6.4.
PAINT MATERIALS
TABLE No. 6.1 PRIMERS
SI. DESCRIPTION P-2 P-4 P-6 P-7

No.
Chlorinated Etch Epoxy zinc ZINGA,
rubber Zinc primer/wash phosphate primer LOCKTITE or
1 Technical name
Phosphate primer. primer ZRC
cold galvanizing
Single pack, air Two pack Two component One pack
drying chlorinated polyvinyl butyral polyamine cured Synthetic Resin
rubber based resin medium epoxy resin based zinc
medium cured with medium, galvanizing
2 Type and composition plasticised with phosphoric acid pigmented with containing min
unsaponifiable solution zinc phosphate. 92% of electrolytic
plasticizer, pigmented with zinc dust of
pigmented with zinc tetroxy 99.95% purity.
zinc phosphate. chromate.
3 Volume Solids % 40±3 10±1 50±1 37%
DFT (Thy Film
4 thickness) per coat in 40-45 8-10 40-50 40-50p
microns
Theoritical covering
5 8-10 8-10 8-10 4m2/kg
capacity in M2/coat/ litre
Weight per litre in
6 1.3±0.05 1.2±0.05 1.4±0.05 2.67 kg at 15°C
kgs/litre
Touch dry at 30°C
7 30 minutes 2 hrs. After 30 min. 10 minutes
(minimum)
Hard dry at 30°C
8 8 hrs. 24 hrs. 8 hrs 24 hrs.
(maximum.)
9 Overcoating interval Min.: 8 hrs Min: 4-6 hrs. Min.:Shrs. Min.:4 hrs
Pot life at 30°C for two Not
10
component paints Applicable
Not applicable 6 - 8 hrs. Unlimited
Temperature (Resistance 60 °C NA 80°C 50°C
11
(minimum) Dry service Dry service Dry service Dry service
Page 595 of 1963

15ifiziEgftENIONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
star taRegWINDIA LIMITED
011iTIF01112451W1, (A GM al Se Undertab19) AND PROTECTIVE COATING Rev. 0
PAGE 17 OF 59
PAINT MATERIALS
TABLE No. 6.2 FINISH PAINTS
SI. DESCRIPTION F-2 F-3 F-6A/I3 F-6C F-7

No
Acrylic Chlorinated
1 Technical name Polyurethane rubber based Epoxy-High
. Build Solvent less High build coal
finish paint finish paint coati ng epox coating tar
coating.
epoxy
Single pack F-6A Two-pack Two pack, Two

plasticised Aromatic amine cured pack
with polyamide
Two-pack chlorinated cured epoxy resin Amine
aliphatic rubber based medium suitably Adduct; cured epoxy
2 Type and isocynate medium with resin blended
composition pigmented. with
cured acrylic chemical and F-6B: polyamide catalyzed
epoxy resin
coaltar
finish paint. weather cured epoxy resin suitably medium,
resistant .
medium suitably pigmented suitably
pigments. pigmented pigmented
3 Volume Solids % 40 ± 3 38±2 60±3 99+1 65±3
DFT (Dry Film
4 thickness) per coat in 30-40g 30-40 100-125g 200-500 100-125g
microns
5 capacity in 11-15 11-15 5-6 2-3 5.2-6.5
M2/coat/litre
6 Weight per liter in 1.15±0.03 1.150.03 1.41+0.03 1.40+0.03 1.40±0.03
kgs/litre
7 Touch dry at 30°C 30 minutes 30 minutes. 3 hrs. 3 hrs. 4 hrs.
Hard dry at 30°C
(max) 16 hrs
8 hrs 48 hrs
8 Full cure at 30°C (for 8 hrs 16 hrs
immersion/ high 5 days
5 days
temperature service)
9 Over-coating
at 30°C
interval Min.12 hrs. Min.: Min.: Overnight Min.: 8 hrs. Min.: 24 hrs
Overnight Max.: 5 days Max.: 48 hrs. Max.: 5 days.
Pot life (approx.) at
10 30°C for two 6-8 hrs. ot 4-6 hrs 30 minutes
applicable 4-6 hrs.
component paints
Temperature 120°C(Diy
Resistance 80 °C 60 °C service), 125°C
11 (minimum) Dry service Immersion 80°C 50°C Immersion
min service Dry service
(Immersion service
service)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — NI rights reserved
Page 596 of 1963

ogesOwes
kveg
ENGINERS
INDIA Limo) FOR SURFACE PREPARATION NO. 6-79-0020
Wien diereer eagatale deort d India Undertaking) AND PROTECTIVE COATING Rev. 0
PAGE 18 OF 59
PAINT MATERIALS
SI.
DESCRIPTION F-8 F-9 F-11 F-12
No
Self priming type Heat resistant
Heat resistant
surface tolerant synthetic medium
silicone
high build epoxy Inorganic zinc based two pack
1 Technical name Aluminium paint
coating (complete silicate coating Aluminium paint
suitable upto
rust control suitable upto
500 ° C dry temp.
coating). 250°C dry temp.
A two pack air
Two pack epoxy drying self curing
resin based solvent based
Heat resistant
suitable inorganic zinc Single pack
synthetic medium
pigmented and silicate coating with silicone resin
based two pack
2 Type & composition capable of minimum 80% zinc based medium
Aluminium paint
adhering to content on dry film. with Aluminium
suitable upto
manually The final cure of flakes.
250°C.
prepared surface the dry film shall
and old coating. pass the MEK rub
test.
3 Volume Solids % 7813 60±3 3810.03 2012
DFT (Dry Film
4 thickness) per coat in 100-125 65-75p 15-20g 15-20g
microns
5 capacity in M2/coat/ 6.0-7.2 8-9 10-12 8-10
litre
Weight per liter in
6 1.4110.03 2.310.03 0.95±0.03 1.0010.03
kgs/litre
Touch dry at 30°C
7 3 hrs. 30 minutes. 3 hrs. 30 minutes.
(maximum)
Hard dry at 30°C
(maximum) 24 hrs 12 12 hrs 24 hrs
8 Full cure 30°C (for
immersion thigh 5days NA NA NA
temperature service)
Mb. 12 hrs . at 20°C
Mm.:
9 Over-coating interval Min.: 10 hrs 24 lin Mb.: 24 hrs
& 50 % RH
Pot life at 30°C for two
10 90 minutes. 4-6 hrs. Not applicable Not applicable
component paints
Temperature 80 °C 400 °C 250°C 500°C
11
Resistance (minimum) Dry service Dry service Dry service Dry service
Page 597 of 1963

ate ENGINEERS
azir Wear INDIA LIMITED
Rev. 0
NOM MN ?AMMO (A GS of kola tAlerlicing) AND PROTECTIVE COATING PAGE 19 OF 59
PAINT MATERIALS
SI. F-16
DESCRIPTION F-14 F-15 F-17
No
Ambient temperature
curing Poly Siloxane
Two-component Two component
coating/High build
Epoxy phenolic solvent free type
cold applied inorganic
coating cured with high build epoxy
copolymer based
Polyamine cured Polyamine adduct phenolic/novalac
1 Technical name aluminium coating
coal tar epoxy hardner system epoxy phenolic
suitable for under
(primer + . coating cured with
Insulation coating of
intermediate coat Polyamine adduct
CS and SS piping for
+ finish paint) hardner system
high temperature
service.
Two pack ambient Two component
Specially
temperature curing Amercoat 738 from solvent free type
formulated
epoxy phenolic PPG Protective & high build epoxy
polyamine cured
coating system Marine Coatings or phenolic/novalac
2 Type & composition coal tar epoxy
suitable for Intertherm 751 CSA of epoxy phenolic
suitable for
application under International (Akzo coating cured with
application under
insulation of Nobel). Note: 6 Polyamine adduct
insulation
CS/SS piping hardner system
3 Volume Solids % 70±3 70±3 60±2 98-100
DFT (Dry Film
4 thickness) per coat in 100-125 75-100 75-100 125- 150
microns
5 capacity in M2/coat/ 5-8 4-5 7.0- 9.0 6.5 - 8
litre
Weight per liter in
6 1.4540.03 1.650.03 1.3 1.7
kgs/litre (mix paint)
Touch dry at 30°C
7 4 hrs 3 hrs 1 hr 2 hrs
(maximum)
Hard dry at 30°C
(maximum) 24 hrs 24 hrs 16 hrs 24 hrs
8 Full cure 30°C (for
immersion Thigh 168 hrs (7 days) 168 hrs (7 days) - 168 hrs (7 days)
temp. service)
Over-coating interval Min. 6 hrs Min. 36 hrs Min.16 hrs Min. 16 hrs
9
Max.S days Max.21 days Max. Not applicable Max.21 days
Pot life at 30°C for
10 two component 4 hrs 4-6 hrs 1 hr 1 hr
paints
Temperature upto 400 °C for C.
Resistance Steel & S. Steel for
-45°C to 150°C
-45°C to 125°C Intertherm 751 CSA
under insulation & -45°C to 150°C for
11 under insulation upto 480 °C for C.
immersion immersion service
And immersion Steel & upto 600 °C
(Note: 5)
for S. Steel for
Amercoat 738
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell. —All rights reserved
Page 598 of 1963

0151-43-eta ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Igtlf Emegw INDIA LIMIIID Rev. 0
IMWIFIRMFM WD IA Gobi of Incl. Unded*V AND PROTECTIVE COATING PAGE 20 OF 59
NOTES (for tables 6.1 to 6.4):
Covering capacity and DFT depends on method of application. Covering capacity

specified above are theoretical. Allowing the losses during application, min specified
DFT should be maintained.
All primers and finish coats should be cold cured and air drying unless otherwise
specified.
All paints shall be applied in accordance with manufacturer's instructions for surface
preparation, intervals, curing and application. The surface preparation, quality and
workmanship should be ensured. In case of conflict between this specification and
manufacturer's recommendation, the same shall be clarified through EIL SMMS
department.
Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
F-15: Two-component Epoxy phenolic coating cured with Polyamine adduct hardner
system (primer + intermediate coat + finish paint) suitable upto 225°C (Intertherm 228
from M/s Akzo Nobel Coatings India Pvt Ltd. Bangalore). For all other companies, the
temperature resistance shall be a maximum of 150°C.
F-16: Ambient temperature curing epoxy poly siloxane Coating or high build cold
applied inorganic co-polymer based aluminium coating.
Amercoat 738 from PPG Protective & Marine coatings. Mumbai, is suitable up to
480°C for CS surfaces and 600°C for SS surfaces.
Intertherm 751 from Akzo Nobel Coatings India Pvt Ltd. Bangalore, Inorganic co-
polymer cold applied Aluminium spray coating is suitable upto 400°C of CS & SS
surfaces.
Page 599 of 1963

fit ENGINEERS
ligar ta2eg e INDIA LIMITED
i
Rev. 0
1 11101.124112=3WRI■ IA Gen a/ Ind4a Undertalng) AND PROTECTIVE COATING PAGE 21 OF 59
7.0 COATING SYSTEMS
The coating system should be selected based on the Plant location as given below:
Classification based on Plant Location:
a) Plant located in Inland area (more than 50 km from coast);

Environment Classification — Industrial
For offsite areas: Table 9.0 to be followed
For all unit areas including DM,CPP and Cooling Tower: Table 10.0 to be
followed
b) Plant located on sea coast or within 50 km from sea coast;

Environment classification- Industrial marine
- For offsite area, as well as all unit area including DM, CPP, Cooling Tower:
Table 10.0 to be followed
c) For external surface of above ground tanks, table 12.0 to be followed for all
locations (Inland or coastal)
Notes:
Coating systems (Primers, Finish Paints etc.) based on Area

classification/environments/Applications are tabulated in Table 8.0 to Table 17.0
Primers & Finish paints covered in Tables 8.0 to 17.0 are listed in Table 7.1.
3. Repair of Pre-Erection/Pre-Fabrication & Shop priming after erection/ welding shall be

done as per Table 7.2.
Page 600 of 1963

el ENGINEERS NO. 6-79-0020
Raft
litaimeneRanuoim INDIA LIMITED
IA GNI d Undertakng)
AND PROTECTIVE COATING Rev. 0
PAGE 22 OF 59
TABLE 7.1: LIST OF PRIMERS & FINISH COATS COVERED IN TABLE NOS. 8 to 18.0
PRIMERS
P-2 Chlorinated rubber zinc Phosphate Primer
P-4 Etch Primer/Wash Primer
P-6 Two component Epoxy Zinc Phosphate Primer cured with polyamine hardener
Single pack, cold galvanizing compounds containing minimum 92% electrolytic zinc in dry film.
P-7
make ZINGA, LOCKTITE (of HENKEL) or ZRC
FINISH COATS / PAINTS

F-2 Two component Acrylic — Polyurethane finish paint
F-3 Chlorinated Rubber finish paint
F-6A High Build Epoxy finish coating cured with polyamine hardener
F-6B High Build Epoxy finish coating cured with polyamide hardener
F-6C Solvent less Epoxy Coating cured with poly amine hardener
F-7 High. build Coal Tar epoxy coating cured with polyamine hardener
F-8 Self priming surface Tolerant High Build epoxy coating. cured with polyamine hardener
F-9 Two component Inorganic Zinc Silicate coating
F-11 Heat resistant synthetic medium based Aluminium paint
F-12 Two component Heat resistant Silicone Aluminium paint.
F-14 Specially formulated coal tar epoxy coating. cured with polyamine hardener
F-15 Two component Epoxy phenolic coating cured with Polyamine adduct hardener system
Engineered Epoxy poly Siloxane Coating or high build cold applied inorganic co-polymer based
F-16
aluminium coating
Two component solvent free type high build epoxy phenolic/novalac epoxy phenolic coating cured
F-17
with Polyamine adduct hardener system
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — NI rights reserved
Page 601 of 1963

latrazieLre ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
lgaf Efieg NDIA LIMITED
Rev. 0
lageR21201701JMAI (A Govt Lea Undertakin) AND PROTECTIVE COATING PAGE 23 OF 59
TABLE 7.2 REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER

AFTER ERECTION/WELDING
For all un-insulated CS, LTCS & low allow steel items in all Environments
Total DFT
SI. Surface Coating System in Microns Remarks
No.
Design Temp. in °C Preparation
(min.)
7.2.1 -90 to 400 SSPC-SP-3 1 coat of F-9 65-75 See note
below and
7.2.2 401 to 550 SSPC-SP-3 1 coat of F-12 20 clause 5.9.3
NOTES
1 The application and repair of pre-erection/pre-fabrication or Shop Primer given in above tables
shall be done for all the items to be painted. In case the damages of primer are severe and spread
over large area, entire primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces
to be primed again with F-9 or F-12 as applicable.
TABLE 8.0 COATING SYSTEM FOR GRATINGS, ROLLING & STATIONERY

LADDERS, SPIRAL STAIRWAYS AND HAND RAILS IN ALL LOCATION
Design
SI. Total DFT
No.
Temp. in Coating System in Microns (min.)
°C
Hot Dip Galvanizing to 80-85 microns (600-610
80 microns of finish coat
gm/m2)as per IS 4759, 2629, 4736, 2633 +
8.1 Up to 60 (excluding the thickness of
1 coat of P-6 @ 40u DFT/coat + 1 coat of F-2 @ 40
)
microns DFT/coat
NOTES:
1 No galvanized specimen shall have thickness less than 80 microns.
2 Repair of the damaged area of galvanized coatings due to welding during erection shall be
carried out as per recommended practice IS 11759 using cold galvanizing spray process.
Organic Paint systems are not acceptable for repair.
3 After repair of damaged galvanized coating by Cold Galvanized, the repaired area shall be top
coated with paint system as given in Table 8.0 above (i.e., 1 coat of P-6 @ 40g DFT/coat + 1
coat of F-2 @ 40g DFT/coat).
4 Approved Cold Galvanizing manufacturers are ZINGA, LOCKTITE or Z.R.C.
Page 602 of 1963

PlitiegaENONIEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Oga ft W INDIA UMITED Rev. 0
lam mewl:limn.) IA Gal of w. undmanno AND PROTECTIVE COATING PAGE 24 OF 59
TABLE 9.0 COATING SYSTEM FOR OFFSITE AREA (INLAND PLANTS)

For external surfaces of Un-insulated & aboveground (atmospheric exposure)
Structures, Piping, Vessels, Equipments, Pumps, etc. (Note-1); (For Carbon Steel,
LTCS & Low Alloy Steel). See Note Below*
Surface Coating System Total Final

Design
SI. Preparation & (Post-erection / Field) DFT
Temp. in Remarks
No. Pre-erection/Shop in Microns
°C Primer Finish Coat
Primer (min.)
SSPC-SP-10; No over-
9.1 -90 to -15 lcoat of F-9 @ None None 65-75 coating to be
65-75p DFT/coat done on
SSPC-SP-10; F-9 as it will
I coat of F-2 @
9.2 -14 to 60 1 coat of F-9 @ None 105-115 lead to mud
40p DFT/coat cracking.
65-75p DFT/coat
SSPC-SP-10;
1 coat of F-2 @
9.3 61 to 80 lcoat of F-9 @ None 105-115
40g DFT/coat
65-75g OFT/coat
2 coats of F-11
SSPC-SP-10;
20p
9.4 81 to 250 I coat of F-9 @ None 105
DFT
@/coat;
65-75p DFT/coat
(2x20=40)
2 coats of F-12
SSPC-SP-10;
@ 20p
9.5 251 to 400 1 coat of F-9 @ None 105-115
DFT/coat
65-75p DFT/coat F-12 shall be
(2x20=40)
ambient
SSPC-SP-10; 2 coats of F-12 temperature
9.6 401 to 550 lcoat of F-12 @ None @20g DFT/coat 60 curing type
20g DFT/coat (2x20=40)
* Flare line within unit or offsite areas shall be coated as per Clause 10.3 of Table 10.0, but
having finish coat of 2 coats of F-12.
NOTES:
1 The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2 If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
3 In case of Paint systems as per SI. Nos. 9.5 and 9.6, the color bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
4 All coating system including surface preparation, primer, and finish coat for piping shall be done
at field only.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —NI rights reserved
Page 603 of 1963

15Naeg a- ENGNEERS
NO. 6-79-0020
5litaf talateltli INDIA LMTED
Rev. 0
eRternorni IA God al Indo Undenalogl AND PROTECTIVE COATING
PAGE 25 OF 59
TABLE 10.0 COATING SYSTEM FOR UNIT AREAS AS WELL AS DM, CPP,
COOLING TOWER OF INLAND PLANTS AND FOR ALL AREAS (UNIT,
OFFSITE, DM, CPP, etc.) OF COASTAL PLANTS
For external surfaces of un-insulated and above ground (atmospheric exposure)

structures, piping, vessels, equipments, external surface of MS chimney/stacks,
RCC chimney, internal surface of MS chimney without refractory lining, towers,
columns, pumps, compressors, blowers etc. of carbon steel, LTCS & low alloy
steels (note-1)
Surface Preparation & Coating System Total DFT

Design Pre-erection/Shop (Post-erection / Field) in
SI. Remarks
Temp. in °C Primer Microns
No. Primer Finish Coat
(min.)
SSPC-SP-10; No over-
10.1 -90 to -15 lcoat of F-9 @ None None 65-75 coating to be
65-75g DFT/coat done on
F 9 as it will
2 coats of F-6A lead to mud
@ 100 g cracking.
DFT/coat + 1
SSPC-SP-I 0; 1 coat of P-6
coat of F-2 @ 345_355 F-12 shall
10.2 -14 to 80 lcoat of F-9 @ @ 40 p
4 0p DFT/coat; be ambient
65-75p DFT/coat DFT/coat
(2x100 + 40= temperature
240) curing type
c) Finish coat
including
2 coats of F-12 primer
SSPC-SP-10; @ 20p compatible
10.3 81 to 400 lcoat of F-9 @ None DFT/coat 105-115 with finish
65-75p DFT/coat 2x20=40 coat (i.e. field
primer) shall
be applied at
site only.
Finish
2 coats of F-12 coating is not
SSPC-SP-10; permitted at
@ 20p
10.4 401 to 550 lcoat of F-12 @ None 60 equipment
DFT/coat;
20p DFT/coat manufacture
(2x20=40)
shop.
NOTES:
The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
Page 604 of 1963

ail-ileaENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Eififtw INDIA LIMITED
imprriWREM3001411 (A GS of In& Undertalargl
AND PROTECTIVE COATING
NO. 6-79-0020
Rev. 0
PAGE 26 OF 59
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
For external surface of MS chimney with or without refractory lining and for internal surface
without refractory lining, paint system as per 10.3 above shall be followed.
For external surface of RCC Chimney, 2 coats of F-6 @ 10012 DFT/coat to obtain total DFT of
200 p. shall be applied after proper surface preparation as per guidelines in 5.1.6.
In case of paint systems as per SI. Nos. 10.3 and 10.4, the colour bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
All coating system including surface preparation, primer, finish coat for piping shall be done at
site/field only.
Page 605 of 1963

OWIETte. ENONEERS
1ga fa2e3 WV INDIA LIMITED Rev. 0
Olen eiROIMMICR)A GM a/ Incia Undertalong) AND PROTECTIVE COATING PAGE 27 OF 59
TABLE 11.0 COATING SYSTEM FOR EFFLUENT TREATMENT PLANT (ETP)
Coating System Total

SI. Design Temp. DFT in
Surface Preparation Remarks
No. in °C Primer Finish Coat Microns
(min.)
For Extemal Surfaces of C.S./M.S. items: Screens, Walk way bridges, Baffles, Dual media filters,
11.1 Vertical pumps, piping in treated effluent sump, bio sludge pump, Screw pump and pump house, CS
tanks, sumps and vessels.
2 coats of
F-6A @100g
DFT/coat + 1
1 coat of F-9
coat40g
of F-2 @
-14 to 80 SSPS-SP-10 @ 65-75g 305-315 -
DFT/coat
DFT/coat;
(2x100+40=2
40)
For Internal Surfaces of CS/MS Items: Bio-sludge sump, Fil er feed sump, Process sump, Sanitary
11.2
sump, Transfer ump, Sludge, Slop oil tank, scrapping mechanism in Clarifier
3 coats of
1 coat of F-9
F-6A @100g
-14 to 80 SSPS-SP-10 @ 65-75g 365-375 Note:1
DFT/coat
DFT/coat.
(3x100=300)
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc. in
11.3 Process sump, TPI separator (Process and Oil), Aeration Tank and Transfer sump etc.
Epoxy screed
lining shall be
Blast cleaning to SSPC-SP
applied as per
guide lines and Acid
specific
-14 to 80 etching with 10-15% HCI Epoxy Screed lining 3mm
manufacturer
acid followed by thorough
and Engineer-
water washing.
in-Charge
instructions
C.S/M.S Dual media filters (Internal), Chemical dosing tanks(intemal such as Di-Ammonium
11.4
Phosphate (DAP) and Urea
Natural
Rubber lining
shall be
Natural Rubber Lining applied as per
Up to 60 SSPC-SP-10 (As per IS 4682, Part 1) 4.5mm specific
manufacturer
and Engineer-
in-Charge
instructions
NOTES
1. The paint /coating manufacturers shall provide their Quality control test certificate of coating
materials (F-6A) for immersion service of the exposed effluent given in 11.2.
Page 606 of 1963

azdZICS ENGNEERS
Oa' 111e W INDIA LIMITED Rev. 0
(02,121POIRCOMWM (A Sort el In& Undeftm g ) AND PROTECTIVE COATING PAGE 28 OF 59
TABLE 12.0 EXTERNAL COATING SYSTEMS FOR UNINSULATED CARBON STEEL

AND LOW ALLOY STEEL STORAGE TANKS (For all plant locations, coastal
or inland)
All Process Units & Off-sites
Total
Surface Coating system (Field) DFT
SI. Design Temp. Preparation (see note 1 below) in Remarks
No. in °C (Field)
Microns
Primer Finish Coat (min.)
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tank including top
12' 1 . of external and internal floating roof and associated external structural works.
side
F-6 should
2 coats of F-6A @
lcoat of F-9 @ 65-75p be suitable
100p DFT /coat + 1
SSPC-SP-10 DFT/coat + lcoat of P-6 for
12.1.1 -14 to 80 coat of F-2 @ 40p 345-355
@ 40p DFT/ coat ; occasional
DFT/ coat;
water
immersion
1 coat of F-15 primer @ 1 coat of F-15 finish

SSPC-SP-10 80p DFT/ coat + 1 coat coat @80p DFT/ coat +
12.1.2 81 to 150 280 -
of F-15 intermediate lcoat of F-2 @ 40p
coat @ 80p DFT/coat ; DFT/ coat;
2 coats of F-12 @20 p

105
DFT/ coat
lcoat of F-9 @ 65-75p or or
12.1.3 151 to 500 SSPC-SP-10 -
DFT/coat 115
1 coat of F-16 @ 50 p
DFT / coat
12.2 External surfaces of bottom pla e (soil side) for all storage tanks.
F-7 should
be suitable
for
SSPC-SP-10 1 coat of F-9 @ 3 coats of F-7@ 100p 365_375 immersion
12.2.1 -14 to 80
65-75p DFT/ coat DFT/coat (3x100=300) service of
the
products
given
1 coat of F-15 primer @
80p DFT/ coat + 1 coat
SSPC-SP-10 1 coat of F-15 finish
12.2.2 81 to 150 of F-15 intermediate 240 -
coat @ 80p DFT/ coat
coat @ 80p DFT/coat ;
(80+80=160)
1 coat of F-16 @ 125 p 1 coat of F-16 @ 125 p
12.2.3 151 to 550 SSPC-SP-10 250 -
DFT /coat DFT /coat
12.3 For underside of the bottom plate (in case tank is not lifted during PWHT) (see Note 2c)
Page 607 of 1963

5Rizth ft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
1@U Elffleg NDIA LIMITED
Rev. 0
leiarr FIROIMIWII IA Gut d India Undedalung) AND PROTECTIVE COATING PAGE 29 OF 59
For CS Products
SSPC SP-6 from
JOTUN or
Commercial
Blast HI-TEMP
2 coats of inert
-180 to 650 1 coat of inert polymeric coatings or
12.3.1 polymeric matrix 350-400
For SS matrix coating @ 125 u SK
coating @ 125 Ft
SSPC SP-1 FORMULA
with non- TIONS are
chloride
chlo recommend
solvent ed.
NOTES
All paint coating application including primer for tankage shall be carried out at field after
erection and completion of all welding.
For underside of bottom plate :

Painting shall be carried out before laying of bottom plate for tanks with Non-Post Weld
Heat Treatment (PWHT).
For tanks with PWHT, painting shall be carried out after PWHT.
c) In case tank is not lifted during PWHT then painting shall be applied before laying of bottom
plate, clause no. 12.3.1 shall be followed.
Caution: PWHT temperature shall not exceed 650°C.
Page 608 of 1963

151fizieta ENCINEERS
Oga tiRegs INDIA LMTED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
INF 212(INVINMER) (A Gout of kb Undettiong) AND PROTECTIVE COATING
PAGE 30 OF 59
TABLE 13.0 INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY
STORAGE TANKS
All Process Units & Off-sites
Coating system (Field) Total

Surface DFT
SI. Design Preparation (see note 1 below)
in Remarks
No. Temp. in °C (Field) Microns
Primer Finish Coat
(min.)
CRUDE OIL, ATF, TURPENTINE OIL, LUBRICAT NG OIL AND VEGETABLE OIL
Underside of floating roof, internal surface of cone roof, inside of bottom plate, Internal surfaces of Shell
13.1
- including wetted and free board height, oil side surfaces of deck plates, oil side surfaces of pon oons,
roof structures, structural steel, ladders and other CS internals
1 coat of F-15
intermediate coat @
13.1. 1 coat of F-15 primer a -
-14 to 90 SSPC-SP-10 — 800 DFT/coat + 1 coat 240-300
1 800 DFT/ coat
of F-15 finish coat @
80p DFT/ coat,
PETROLEUM PRODUCTS & INTERMEDIATES like LDO, HSD , GAS OIL, FEEDS of
FCC-PC, FCC-LCO, VGO-HDT, ISOM, DHDT, REFORMATE, DCU, NHT & GASOLINE,
NAPHTHA, ISOMERATE AND KEROSENE.
13.2
Underside of Floating roofs, internal surface of cone roof, inside of bottom plate, internal surfaces of
Bare shell for full height, underside of floating roof, oil side surfaces of deck plates, oil side surfaces of
pontoons, support structures and ladders etc.
13.2. I coat of F-9 @
-14 to 45 SSPC-SP-10 - 75 Note 2
I 75 0 DFT/coat
1 coat of F-15
intermediate coat @
13.2. 1 coat of F-15 primer @
46 to 90 SSPC-SP-10 80p DFT/coat + 1 coat 240-300 -
2 80p DFT/ coat
of F-15 finish coat @
800 DFT/ coat;
POTABLE AND FIRE WATER
13.3 All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
2 Coats of F-6A @
13.3. 1 Coats of P-6 @ Note-4
-14 to 60 SSPC-SP-10 1000 DFT/ Coat; 300-350
1 100 0 DFT/coat;
(2x100=200)
DE-MINERALIZED (DM) WATER
2 coats of F-6C @
13.4. 1 Coats of P-6 @
-14 to 60 SSPC-SP-i0 200p DFT/ coat; 400-450 -
1 1000 DFT/coat;
(2x200=400)
1 coat of F-15
intermediate coat @
13.4. 1 coat of F-15 primer @ 800 DFT/coat + 1 coat
61 to150 SSPC-SP-10 240-300
2 800 DFT/ coat of F-15 finish coat @
800 DFT/ coat;
(80+80=160)
HYDROCHLORIC ACID (HCI) 10 %
13.5
All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
13.5. 4.5 mm -
-14 to 60 SSPC-SP-10 None Natural Rubber Lining
1
Page 609 of 1963

ofteiftENGINEERS
ogaiEgRegewr INDIA um-rED FOR SURFACE PREPARATION NO. 6-79-0020
114M MK,'"UMR0 IA GS of Undertaiong) AND PROTECTIVE COATING Rev. 0
PAGE 31 OF 59
AGGRESSWE SOLVENTS LIKE HEXANE, HEXENE, BENZENE, XYLENE AND TOLUENE

13.6. 1 coat of F-9 @ 75p

-14 to 65 SSPC-SP-10 --- 75
1 DFT/ coat
ETHYLENE GLYCOL (EG) TANKS

13.7 Internal shell-full height, bottom plate, underside of roof and all accessories
3 coats of vinyl
chloride co-polymer
13.7. AMERCOAT 23 @ 225 -
All SSPC-SP-10 None
1
75p /Coat;
(3x75=225)
13.8 Inside pontoon and inside of double deck of all floatingroofs
13.8. 1 coat of F-8 @ 100p 1 coat of F-8 @ 100p
- 14 to 80 SSPC-SP-3 200
1 DFT/coat DFT/coat
WET SLOPS, AMINE soluCons, SOUR WATER , WATER DRAW OFF
13.9
1 coat of F-15
intermediate coat @
13.9. 1 coat of F-15 primer @ 80p DFT/coat + 1 coat
-14 to 90 SSPC-SP-]0 240
1 80p DFT/ coat of F-15 finish coat @
80p DFT/ coat;
(80+80=160)
VACUUM RESIDUE, FUEL OIL , DRY SLOP, BITUMEN AND OTHER HIGH TEMPERATURE
HYDROCARBON LIQUIDS
13.10 Underside of floating roof, internal surface of cone roof, bottom plate, inside of bare shell — including
wetted and non wetted surfaces, oil side surfaces of deck plates, oil side surfaces of pontoons, roof
structures, structural steel and ladders
1 coat of F-17
intermediate coat @
13.10 1 coat of F-17 primer 125p DFT/coat + 1 coat 375 .. N.. _
Up to 150°C SSPC-SP-10 ote:3
.1 @ 125p DFT/ coat of F-17 finish coat
@125p DFT/ coat.
(125+125=250)
ALKALIS UP TO 50 % CONCENTRATION
13.11
2 Coats of F-6 A @
13.11 1 coat of F-15 primer
mer @
Up to 60°C SSPC-SP-10 100p DFT/coat; 280-100 -
1 80p DFT/ coat
(2x100=200)
NOTES
I. All paint coating application including primer shall be carried out after erection and completion
of all welding work at site.
F-6A should be suitable and resistant for immersion service for the respective Hydrocarbons.
This system can be used where maximum operating temperature is below 150°C and design
temperature is upto 200°C. Cases of operating temperature > 150°C are not covered in this spec,
such cases shall be covered in the job specifications.
4 F-6 A shall be suitable for drinking water service and should have competent authority
certification.
Page 610 of 1963

ateaftINGINEERS
Igar fitileuW WA LIMITED Rev. 0
Iiik717421191PONAZIPI) IA GM al Ma Undslasn91 AND PROTECTIVE COATING PAGE 32 OF 59
TABLE 14.0 COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND

CARBON STEEL PLANT PIPING AND UNDERGROUND VESSELS
Surface Coating system (Field) Total Final

Design Preparation
SI. Surface DFT
Temp. in & Remarks
No. Preparation & Finish Coat in Microns
°C Shop Primer
(min.)
min.)
14.1 Underground carbon steel plant piping
I layer of coaltar tape

The primer
coating @ 2mm +1
DFT is not
coat of synthetic fast
SSPC-SP-10; measurable.
drying primer 25 @u
Reconciliation
OFT/ coat + 1 layer of
14.1.1 25 to 65 --- 1 coat of synthetic 4 mm primer shall
coal tar tape coating @
fast drying primer be done by
2mm /layer as per
25 @it DFT/ coat coverage of
EIL Standard
maximum 10
Specification No
sq.m/litre
6-79-0011
SSPC-SP-10; 1 coat of F-17

intermediate coat @
14.2.1 66 to 150 --- 1 coat of F-17 125u DFT/coat + I 375 -
primer @ 125u coat of F-17 finish
DFT/ coat coat @125u DFT/ coat
SSPC-SP-10;
1 coat of F-16 finish
14.2.2 151 to 400 ---
1 coat of F-I6 250 -
coat @125u DFT/ coat
primer @l25µ
DFT/ coat
14.3 External side of un-insulated underground storage vessels
SSPC-SP-10;
I coat of F-9 3 coats of F-7 @ 100u

14.3.1 -40 to 80 -- 365-375 -
@ DFT/coat
65-75u DFT/
coat
SSPC-SP-10;
I coat of F-17
intermediate coat @
1 coat of F-17
14.3.2 81 to 150 --- 125u DFT/coat + 1 375 -
primer @
coat of F-17 finish
125u DFT/
coat @12512 DFT/ coat
coat
SSPC-SP-10;
I coat of F-16 1 coat of F-16 finish

143.3 151 to 400 --- 250 -
primer @ coat @125u DFT/ coat
125u DFT/
coat
Page 611 of 1963

azosfillteifitENONEERS
eies INDIA utsiTED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
IMIPWd3,0111 IA GOA d loan Undeglaan9) AND PROTECTIVE COATING
PAGE 33 OF 59
TABLE 15.0 COATING UNDER INSULATION (COASTAL OR INLAND PLANTS). ALL

UNITS AREAS & OFF-SITES
For insulated Piping, Equipments, Storage vessels, tanks, Columns etc of Carbon
Steel, LTCS, Low Alloy Steel & Stainless Steels

Surface
(Post-erection / Field) Final
Preparation &
SI. Design DFT
Pre- Remarks
No. Temp. in °C Primer/ in
erection/Shop Finish Coat
Intermediate Microns
Primer
(min.)
15.1 Carbon steel, LTCS and low Alloy steel Piping
SSPC-SP-10; 2 coats of F-15 @
1 coat of F-15 @
15.1.1 -45 to 120 'coat of F-15 @ 75p DFT/coat; 225- 250 -
75p DFT/coat
75p DFT/coat (2x75= 150)
SSPC-SP-10; 2coat of F-I2 @
15.1.2 121-540 'coat of F-12 @ None 20p DFT/coat; 60 -
20p DFT/coat (2x20=40)
15.2 Carbon steel, LTCS and low Alloy steel - Storage vessels, Reactors, Columns & Equipments
SSPC-SP-10; 2 coats of F-15 @
1 coat of F-15 @
15.2.1 -45 to 120 'coat of F-15 @ 75p DFT/coat; 225- 250 -
75p DFT/coat
75p DFT/coat (2x75= 150)
Temporary oil
based varnish Thermally Sprayed Aluminium coating
121 to 540 coating to be (TSAC)
15.2.2 - -
provided for Refer ANNEXURE-I
transport and
storage
153 Stainless Stee (SS) including Alloy-20 piping (Note:2)
For CS
SSPC SP-6 Products from
Commercial Blast JOTUN or HI-
1 coat of inert 2 coats of inert
-180 to Zero TEMP coatings or
15.3.1 polymeric matrix polymeric matrix 350-400
For SS SK
coating @ 125 p coating @ 125 p
SSPC SP-1 with FORMULATIONS
non-chloride are recommended.
solvent
If the piping &
equipments are
already erected
then surface shall
SSPC-SP-10
1 coat of F-15 be prepared by
(15-25p surface 1 coat of F-15
cleaning with
15.3.2 0 to 125 profile) intermediate coat finish coat@ 80 240
emery paper and
1 coat of F-15@ @80 p DFT/coat p DFT/coat; wash/flush with
80 p DFT/coat
chloride free DM
water followed by
wiping with
organic solvent
SSPC-SP-10 Not recommended
1 coat of F-16 @
15.3.3 126 to 400 1 coat of F-16 @ None 250 for operating
125 0 DFT/coat
125 g DFT/coat temperature
Page 612 of 1963

laizEtha ENGINEERS FOR SURFACE PREPARATION
NO. 6-79-0020
Glg a tiOtegmv INDIA UNITED Rev. 0
1011PFT 21R077 ttUatf 0 IA Govl of Yea Undetlicingi AND PROTECTIVE COATING PAGE 34 OF 59
SSPC SP-10; between

I coat of
1 coat of 60 - 120 °C
15.3.4 401 to 600
Amercoat 738@
None Amercoat 738@ 250
125 it DFT/coat 125 g DFT/coat
15.4 Coating system for Cyclic Service of Carbon Steel, LTCS, Low Alloy Steel & Stainless Steel
SSPC-SP-10 Apcothem EPN
(15-25g surface 1 coat of F-15 1 coat of F-15 200 of M/s Asian
15.4.1 - 40 to 150 profile) intermediate coat finish coat @ 240 Paints Ltd
1 coat of F-15 @ @ 80g DFT/coat 80m DFT/coat; OR
80 p DFT/coat Equivalent
For CS
Products from
SSPC SP-6
JOTUN or HI-
Commercial Blast 1 coat of inert 2 coats of inert
-180 to 650 TEMP coatings or
15.4.2 For SS polymeric matrix polymeric matrix 350-400
SK
SSPC SP-1 with coating @ 125 g coating @ 125 g FORMULATIONS
non-chloride are recommended.
solvent
15.5 No painting is required for insulated Monel, Incoloy and Nickel lines.
NOTES
"Cyclic Service" is characterized by rapid temperature fluctuation.

The blast cleaning abrasives for SS and Alloy steel surfaces shall be Aluminium oxide
grits/shots or garnet.
3. In case of overlapping of temperature ranges as mentioned in 15.4.1 and 15.4.2, clause 15.4.1
shall be followed.
TABLE 16.0 COATING SYSTEM FOR CARBON STEEL COMPONENTS OF COOLERS /

CONDENSERS (INTERNAL PROTECTION) FOR FRESH WATER SERVICE
Fresh Water boxes, channels, partition plates, end covers and tube sheets etc.

Surface Preparation Final DFT
SI. Design (Post-erection / Field)
& Pre-erection/Shop Remarks
No. Temp. in .C in Microns
Primer Primer Finish paint (min.)
1 coat of F-15 2 coats of F-15 @
16.1 Up to 80 °C SSPC-SP-10 240
@ 80 microns 80p DFT/coat;
1 coat of Glass
Fibre Reinforced
16.2 80 to 140 SSPC-SP-10 1500 -
Novolac epoxy of
1.5 mm DFT
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL - All rights reserved
Page 613 of 1963

laitairiENONEERS
5fgaitameni, INDIA umiTED FOR SURFACE PREPARATION NO. 6-79-0020
MR" eleanSFM (A Gm 0/ India Undertiongi AND PROTECTIVE COATING Rev. 0
PAGE 35 OF 59
TABLE 17.0 COATING SYSTEM (INTERNAL PROTECTION) FOR GALVANIZED OR

NON FERROUS OR STAINLESS STEEL/ DUPLEX STAINLESS STEEL
COMPONENTS OF COOLERS/ CONDENSERS FOR FRESH WATER
SERVICE
Coating System Total Final

Surface Preparation
SI. Design (Post-erection / Field) DFT Remarks
& Pre-erection/Shop in Microns
No. Temp. in °C
Primer Primer Finish paint
(min.)
1 coat of F-15 @ 1 coat of F-15 @
17.1 Up to 80 Sweep Blasting 160 -
80g DFT/coat; 80g DFT/coat;
I coat of Glass
Fibre Reinforced
17.2 80 to 140 Sweep Blasting --- 1500 -
Novolac epoxy of
1.5 mm DFT
18.0 STORAGE
18.1 All paints and painting materials shall be stored only in rooms to be arranged by contractor
and approved by Engineer-in-charge for the purpose. All necessary precautions shall be
taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word "PAINT STORAGE - NO NAKED LIGHT -
HIGHLY INFLAMABLE" shall be clearly displayed outside. Manufacturer's
recommendation shall be followed for storage of paint materials.
19.0 COLOUR CODE
The following colour coding system shall be followed. However alternate colour coding may
also be followed as per Owner's colour coding practice/scheme.
19.1 IDENTIFICATION
The system of colour coding consists of a ground colour and secondary colour bands
superimposed over the ground colour. The ground colour identifies the basic nature of the
service and secondary colour band over the ground colour distinguishes the particular service.
The ground colour shall be applied over the entire length of the un-insulated pipes. For
insulated lines ground colour shall be provided as per specified length and interval to identify
the basic nature of service and secondary colour bands to be painted on these specified length
to identify the particular service. Above colour code is applicable for both unit and offsite
pipelines.
Page 614 of 1963

,S RS STANDARD SPECIFICATION STANDARD SPECIFICATION
0?atitatuvoy INDIA LIMITED
Rev. 0
Sifflirel3qtall IA Govt d Irda Undenkr9) AND PROTECTIVE COATING PAGE 36 OF 59
COLOUR CODING
SR. SERVICE RECOMMNDED COLOUR FOR RAL COLOUR CODE

No. PAINT SYSTEM
BASE BAND
COLOUR COLOUR
HYDROCARBON LINES (UNINSULATED)
1 CRUDE SOUR Dark Admiralty grey with 1 orange band 7012 2011
2 CRUDE SWEET Dark Admiralty grey with I red band 7012 3001
3 LUBE OILS Dark Admiralty grey with 1 green band 7012 6010
4 FLARE LINES Heat Resistant Aluminium 9006
5 LPG Orange with 1 oxide red band 2011 3009
6 PROPYLENE Orange with 2 blue bands 2011 5013
7 NAPTHA Orange with 1 green band 2011 6010
8 M.S. Orange with 1 dark admiralty grey band 2011 7012
9 AV.GASOLINE (96 RON) Orange with 1 band each of green, white 2011 6010 9010 3001
and red bands
10 GASOLINE (regular, leaded) Orange with 1 black band 2011 9005
11 GASOLINE (premium, Orange with 1 blue band 2011 5013
leaded)
12 GASOLINE (white) Orange with 1 white band 2011 9010
13 GASOLINE (Aviation Orange with 1 red band 2011 3001
100/130)
14 GASOLINE (Aviation Orange with 1 purple band 2011 4006
115/145)
15 N-PENTANE Orange with 2 blue bands 2011 5013
16 DIESEL OIL (White) Oxide red with 1 white band 3009 9010
17 DIESEL OIL (Black) Oxide red with 1 yellow band 3009 1023
18 KEROSENE Oxide red with 1 green band 3009 6010
19 HY.KEROSENE Oxide red with 2 green bands 3009 6010
20 DISUFIDE OIL (EX- Oxide red with 1 black band 3009 9005
MEROX)
21 M.T.0 Oxide red with 3 green bands 3009 6010
22 DHPPA Oxide red with 2 white bands 3009 9010
23 FLUSHING OIL Oxide red with 2 black bands 3009 9005
24 LAB FS Oxide red with 2 dark admiralty grey 3009 7012
bands
25 LAB RS Oxide red with 3 dark admiralty grey 3009 7012
bands
26 LAB (Off. Spec) Oxide red with 1 light grey band 3009 7035
27 N-PARAFFIN Oxide red with 1-blue band 3009 5013
28 HEAVY ALKYLATE Oxide red with red band 3009 3001
29 BLOW DOWN, VAPOR Off white / Aluminum with 1-Brown 9006 8004
LINE band
30 SLOWDOWN Off white / Aluminum with 2 brown 9006 8004
bands
31 A.T.F. Leaf brown with 1 white band 8003 9010
32 TOULENE Leaf brown with 1 yellow band 8003 1023
33 BENZENE Leaf brown with 1 green band 8003 6010
34 LAB PRODUCT Leaf brown with 1 blue band 8003 5013
35 FUEL OIL Black with 1 yellow band 9005 1023
Page 615 of 1963

ogegOfrae
liftENGINEERS NO. 6-79-0020
gaituw INDIA umn-ED FOR SURFACE PREPARATION
INIMMER1101MOR0 IA GOA d India Undedakingl AND PROTECTIVE COATING Rev. 0
PAGE 37 OF 59
36 FULE OIL (Aromatic rich) Black with 2 yellow bands 9005 1023
37 ASPHALT Black with 1 white band 9005 9010
38 SLOP AND WASTE OILS Black with 1 orange band 9005 2011
39 SLOP AROMATICS Black with 2 orange bands 9005 2011
CHEMICAL LINES
40 TRI-SODIUM PHOSPHATE Canary yellow with 1 violet band 1012 5000

41 CAUSTIC SODA Canary yellow with 1 black band 1012 9005
42 SODIUM CHLORIDE Canary yellow with 1 white band 1012 9010
43 AMMONIA Canary yellow with 1 blue band 1012 5013
44 CORROSION INHIBITOR Canary yellow with 1 Aluminum band 1012 9006
45 HEXAMETA PHOSPHATE Canary yellow with 2 black bands 1012 9005
46 ACID LINES Golden Yellow with 1 red band 1004 3001
47 RICH AMINE Canary yellow with 2 blue bands 1012 5013
48 LEAN AMINE Canary yellow with 3 blue bands 1012 5013
49 SOLVENT Canary yellow with 1 green band 1012 6010
50 LCS Canary yellow with 1 smoke grey 1012 7031
WATER LINES
51 RAW WATER Sky blue with 1 black band 5015 9005

52 INDUSTRIAL WATER Sky blue with 2 signal red band 5015 3001
53 TREATED WATER Sky blue with 1 oxide red band 5015 3009
54 DRINKING WATER Sky blue with 1 green band 5015 6010
55 COOLING WATER Sky blue with 1 light brown band 5015 1011
56 SERVICE WATER Sky blue with 1 signal red brown 5015 3001
57 TEMPERED WATER Sky blue with 2 green bands 5015 6010
58 DM WATER Sky blue with 1 aluminum band 5015 9006

59 DM WATER ABOVE 150°F Sky blue with 2 black bands 5015 9005
60 SOUR WATER Sky blue with 2 yellow bands 5015 1013

61 STRIPPED WATER Sky blue with 2 blue bands 5015 5013
62 ETP TREATED WATER Sky blue with 2 oxide red bands 5015 3009
FIRE PROTECTION SYSTEM (ABOVE GROUND)
63 FIRE WATER FOAM & Post office red 3002

EXTINGUISHERS
AIR & OTHER GAS LINES (UNINSULATED)
64 SERVICE MR Sea green with 1 signal red band 6018 3001

65 INSTRUMENT AIR Sea green with 1 black band 6018 9005
66 NITROGEN Sea green with 1 orange band 6018 2011
67 FREON Sea green with 1 yellow band 6018 1023
68 CHLORINE Canary yellow with 1 oxide band 1012 3009
69 SO2 Canary yellow with 2 white bands 1012 9010
70 H2S Orange with 2 red oxide bands 2011 3009
71 GAS (Fuel) Orange with 1 aluminum band 2011 9006
72 GAS (Sour) Orange with 2 aluminum bands 2011 9006
Page 616 of 1963

ogatimever
ol
gra14 ENGINEERS
NA UNITED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
1 4*Vi MeRnm agara) (AGutsneauncleilaking) AND PROTECTIVE COATING PAGE 38 OF 59
73 GAS (Sweet) Orange with 2 signal red band 2011 3001

74 HYDROGEN Orange with 1 light green band 2011 6021
STEAM AND CONDENSATE LINES (UNINSULATED)
75 HP STEAM Off white / Aluminum with 1 yellow band 9006 1023

76 MP STEAM Off white / Aluminum with 1 red band 9006 3001
77 MLP STEAM Off white / Aluminum with 1 orange band 9006 2011
78 LP STEAM Off white / Aluminum with 1 light green 9006 6021
band
79 CONDENSATE Sky blue with 1 white band 5015 9010
80 CONDENSATE ABOVE Sky blue with 3 oxide red band 5015 3009
150°F .
81 BFW Sky blue with 2 red bands 5015 3001
Note: For all insulated steam lines, the colour coding shall be follow as given for un insulated lines with the
specified length of color bands.
INSULATED HYDROCARBON PIPING
82 IFO SUPPLY 1Black ground colour with 1 yellow band

9
9005 1023
in centre
83 IFO RETURN Black ground colour with 1 green band in 9005 6010
centre
84 HPS Black ground colour with 1 red band in 9005 3001
centre
85 BITUMEN Black ground colour with 2 red bands in 9005 3001
centre
86 CLO Black ground colour with 1 brown band 9005 8004
in centre
87 VB TAR Black ground colour with 2 brown bands 9005 8004
in centre
88 VR AM (BITUMEN / VBU 1 Black ground colour with 1 blue band 9005 5013
FEED) in centre
89 VR BH 1 Black ground colour with 2 blue bands 9005 5013
in centre
90 VAC. SLOP 1 Black ground colour with 1 white band 9005 9010
in centre
91 SLOP 1 Black ground colour with 1 orange band 9005 2011
in centre
92 CRUDE SWEET 1 Dark admiralty grey ground colour with 7012 3001
1 red band in centre
93 CRUDE OUR 1 Dark admiralty grey ground colour with 7012 2011
1 orange band in centre
94 VGO / HCU 1 Oxide red ground colour with 2 steel 3009 7011
grey bands in centre
95 OHCU BOTOM / FCCU 1 Oxide red ground colour with 2 steel 3009 7011
FEED grey bands in centre
UNINSULATED EQUIPMENTS, TANKS AND STRUCTURES
96 HEATER STRUCTURE Steel grey 7011

97 HEATER CASING Heat resistant aluminium 9006
98 VESSELS & COLUMNS Aluminium 9006
Page 617 of 1963

15ilfraq t ENGINEERS
igeg Eveglief INDIA um iTED FOR SURFACE PREPARATION NO. 6-79-0020
INA/ 2ROWMACNI) IA Cal el India Undertaking) AND PROTECTIVE COATING Rev. 0
PAGE 39 OF 59
99 HYDROGEN BULLETS Pink 3014

100 LPG VESSELS Oxide red 3009
101 SO2 VESSEL Canary yellow 1012
102 HEAT EXCHANGER Heat resistant aluminium 9006
103 FO TANK AND HOT Black 9005
TANKS
104 ALL OTHER TANKS Aluminum / Off white 9006
105 CAUSTIC / AMINE / ACID Golden yellow 1004
TANKS
106 SOUR WATER Sky Blue 5015
107 OUTER SURFACE IN Heat resistant aluminum 9006
BOILER HOUSE
108 COMPRESSORS AND Dark admiralty grey 7012
BLOWERS
109 PUMPS Navy blue 5014
110 MOTORS & SWITCH GEAR Bluish green 5024
111 HAND RAILING Signal red 3001
112 STAIRCASE, LADDER Black 9005
AND WALKWAYS
113 LOAD LIFTING Leaf brown 8003
EQUIPMENT AND
MONORAILS ETC
114 GENERAL STRUCTURE Black 9005
PIPES AND FITTINGS OF ALLOY STEEL AND SS MATERIAL IN STORE
115 IBR Signal red 3001

116 9Cr-lMo Verdigris green 6021
117 5Cr-0.5Mo Satin blue 5012
118 2 1,4 Cr-1 Mo Aircraft yellow 1026
119 1,,4Cr- 1/2 Mo Traffic Yellow 1023
120 SS-304 Dark blue grey 5008
121 SS-316 Dark violet 4005
122 SS-321 Navy blue 5014
SAFETY COLOUR SCHEMES
123 DANGEROUS Black and alert orange band 9005 2008

OBSTRUCTION
124 DANGEROUS OR Alert orange 2008
EXPOSED PARTS OF
MACHINERY
Note: All LPG service PSVs shall be painted Deep Blue.
All drains & Vents shall be painted in Main line colour.

The colour code scheme is for identification of piping service group, It consists of a ground
colour and 1 / 2 colour bands.
19.2 Ground Colour

On uninsulated pipes, the entire pipe has to be painted in ground colour., and on metal cladded
insulated lines, minimum 2M long portion should be painted.
Page 618 of 1963

el ENGNERS NO. 6-79-0020
lazir faiatowNDIAumn-ED FOR SURFACE PREPARATION
O
7R W ,a MOM g
IA God d Ada Undertakin / AND PROTECTIVE COATING Rev. 0
PAGE 40 OF 59
19.3 Colour Bands

Location of colour bands:
At Battery Limits
Intersection points & change of direction points in piping
Midway of piping section, near valves, across culverts
At 50 M interval on long stretch pipes
At starting and termination points.
Minimum width:
NB Width
3" and below 75 mm
Above 3" to 6" NB X 25 MM II! Note:
Above 6" to 12" NB X 18 MM For insulated pipes, NB indicates
Above 12" NB X 15 MM OD of the insulation
Sequence :
Colour bands shall be arranged in sequence showing Table above and the sequence follows the
direction of flow. The width of the l st Band to 2nd band is 4:1,
!!! Note : Wherever deemed required by Process Department or Safety, pipes handling hazardous
substances will be given hazard marking of 30 mm wide diagonal stripes of Black and Golden Yellow
as per IS : 2379.
19.4 Special Camouflage Painting for Uninsulated Crude and Product Storage Tanks.
Paint specification shall be as per standards.
Camouflage painting scheme for Defense requirement in irregular patches will be applied with
3 colours
Dark Green Light green Medium Brown

5 3 2
The patches shall be irregular and asymmetrical and inclined at 30 to 60 Degrees.
Patches should be continuous at surface meeting lines / points.
Slits / holes shall be painted in dark green shade.
Width of patches shall be 1 to 2 meters.
19.5 Identification Markings on Equipment / Piping
Equipment tag Numbers shall be Stenciled / neatly painted using normal 'Arial' Lettering
Style on all equipment and piping (Both insulated & uninsulated) after completion of all paint
works. Lettering colour shall be either BLACK or WHITE, depending upon the background,
so as to obtain good contrast.
Page 619 of 1963

02zieLft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
NO. 6-79-0020
-
IgZIT gate* WA LIMITED FOR SURFACE PREPARATION

IMEAMIIInM 3AIFAI IA GoN d India Undeoliongl AND PROTECTIVE COATING Rev. 0
PAGE 41 OF 59
Operations Group shall specify location.
Sizes shall be:

Columns, Vessels, Heaters: 150 mm
Pumps and other M/c 50 mm
Piping OD / 2 with Maximum 100 MM.
Storage Tanks (As per Drawings)
19.6. Colour Coding for Control Valve
Carbon steel body - Light grey
Alloy steel body - Canary yellow
Stainless steel body - Natural
The actuator of the Control valve shall be painted as :
Direct action (open on air failure) valves - Green
Reverse acting (close on air failure 1 valves - Red
The painting Status shall be comprehensively updated every 6 months for compliance
19.7 Colour Coding for Structural & Others
SI Item Color Indicative

No
1 Pipe rack structurals Dark Admiraltry Grey
2 Chequered Plate ( Both faces) Black
3 Grating Black
4 Ladder Rungs & Railing Vertical Posts Black
5 Hand Rail, Middle rail, Toe Plate Signal Red
6 Ladder Verital Posts Signal Red
7 Building Structurals, Steel Columns; brackets,
beams, bracings, roof trusses, purlings, side Dark Admiratry Grey
girts, louvers, stringers
8 OverHead Monorail Signal Red
9 Gantry Girder & Monorail Dark Green
10 Monorail Stopper Plates Signal Red.
11 Coke Cutting System Signal red
12 EOT / HOT Cranes Canary Yellow
13 Transformers, & Battery room structurals Dark Admiraltry Grey
14 Electrical Motors Dark Blue
Page 620 of 1963

OWES ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
Sga €10e3W INDIA LIMITED
a
Rev. 0
PRA panne an) IA Govt Crl hda Undertakng ) AND PROTECTIVE COATING PAGE 42 OF 59
20.0 IDENTIFICATION OF VESSELS, PIPING ETC
20.1 Equipment number shall be stencilled in black or white on each vessel, column, equipment &
machinery (insulated or uninsulated) after painting. Line number in black or white shall be
stencilled on all the pipe lines of more than one location as directed by Engineer-In-Charge;
Size of letter printed shall be as below:
Column & Vessels 150mm (high)

Pump, compressor & other machinery 50mm (high)
Piping 40-150 mm
20.2 Identification of Storage Tanks
The storage tanks shall be marked as detailed in the drawing.
21.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
21.1 Following items shall be painted for camouflaging if required by the client.
All Columns
All tanks in Offsites
Large Vessels
Spheres
21.2 Two coats of selected finishing paint as per defense requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
21.3 Method of Camouflaging
21.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all
matte finish).
Dark Green Light Green Dark Medium Brown

5 3 2
21.3.2 The patches should be asymmetrical and irregular.
21.3.3 The patches should be inclined at 30° to 60° to the horizontal.
21.3.4 The patches should be continuous where two surfaces meet at an angle.
21.3.5 The patches should not coincide with corners.
21.3.6 Slits and holes shall be painted in dark shades.
21.3.7 Width of patches should be 1 to 2 meters.
22.0 QUALITY CONTROL, INSPECTION AND TESTING
22.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and shall be
Page 621 of 1963

OPzEtt, ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
NO. 6-79-0020
laatuilir INDIA UMITED
1142710IROW WWI/ IA Gait pi India Uadettiong)
AND PROTECTIVE COATING Rev. 0
PAGE 43 OF 59
accompanied by manufacturer's test certificates. Paint formulations without certificates are

not acceptable (see section 24.0).
22.2 The contractor must produce Test Certificate from Pre Qualified Paint Manufacturer for
various tests as detailed out in section 25.1 of this document, for each batch & for each
category of product. The Engineer-in-Charge shall have the right to test wet samples of paint
from each batch at random for verifying quality of paint supplied. Contractor shall arrange to
have such tests, when called for by Engineer-in-Charge, performed at his cost any one of the
independent laboratories listed in the 25.1 of this document.
Samples for the test will be drawn at random in presence Engineer-in-Charge or his
representations. Following tests to be carried out if called for by Engineer-in-Charge:
Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
Drying time (touch dry & full curing)
- Adhesion
Flexibility
- Hardness
Storage stability (pot life)
Test methods for above tests shall be as per relevant ASTM or ISO Standard.
22.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as follows:
Surface preparation
Primer application
(c) Each coat of paint
During surface preparation, following tests are to be carried out:
Test for absence oil & grease after degreasing before blasting as per procedure given in
sec 6.7 of Annexure-I of this specification (specification for thermally sprayed
Aluminium Coating).
Tests for surface finish of blasted surface shall be done by visual inspection using SSPC-
VISI. Clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of
dust on blasted surface. Checks shall be done on each component atleast once per 200 m2
of blasted surface and minimum of 3 checks per shift.
Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt
content shall be considered 20 mg/m 2 (2 mg/cm 2). Checks shall be done on each
component atleast once per 200 m2 of blasted surface and minimum of 3 checks per shift.
In case salt exceeds specified limit, the contaminated surface shall be cleaned by method
as per Annexure-C of IS 12944-4 (water cleaning). After cleaning surface shall be
retested for salt after drying.
Blast profile measurement — This shall be done as described in sec 6.2 of Annexure-I of
this specification (Specification for thermally sprayed Aluminium).
Test for blasting Media and Blasting air- this shall be done as described in sec 6.6 of
Annexure-I of this specification (Specification for thermally sprayed Aluminium).
Page 622 of 1963

w ENGINEERS
161daelela,
Ogzir tapeg NDR FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
Mien FIRM WWI) LID
IA Gad of Nu Uncle/01V AND PROTECTIVE COATING PAGE 44 OF 59
In addition to above, record should include type of shop primer already applied on equipment
e.g. zinc silicate, or zinc rich epoxy, or zinc phosphate.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be responsible
for making good any defects found during final inspection/guarantee period/defect liability
period as defined in general condition of contract. Dry film thickness (DFT) shall be checked
and recorded after application of each coat and extra coat of paint should be applied to make-
up the DFT specified without any extra cost to owner, the extra coat should have prior
approval of Engineer-in-charge.
22.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
22.5 The shades of successive coats should be slightly different in colour in order to ensure
application of individual coats, the thickness of each coat and complete coverage should be
checked as per provision of this specification. This should be approved by Engineer-In-
Charge before application of successive coats.
22.6 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required for
checking in case of immersion conditions.
22.7 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The thickness of
paint on test panels shall be determined by using gauge such as 'Elkometer'. The thickness of
each coat shall be checked as per provision of this specification. This shall be approved by
Engineer-In-Charge before application of paints on surface of chimney.
22.8 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and without
any obligation to the owner, as it would be in the interest of the manufacturer to ensure that
both surface preparation and application are carried out as per their recommendations. The
contractor is responsible to arrange the same.
22.9 Final inspection of finished coating shall consist of measurement of:

Paint dry film thickness (DFT),
Adhesion, and,
3) Holiday detection check as well as for finish and workmanship.
1) Coating DFT measurement shall be as per ISO 2808. Type II electromagnetic gauges
should be used for ferrous substrates. DFT gauge calibration, number of measurement
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — M rights reserved
Page 623 of 1963

agraes STANDARD SPECIFICATION STANDARD SPECIFICATION
ENGINEERS NO. 6-79-0020
azit ta5tegWV INDIA LIMITED FOR SURFACE PREPARATION
ilMweg awo (A GM of Inda Undertalcmg) AND PROTECTIVE COATING Rev. 0
PAGE 45 OF 59
shall be as per SSPC-DA 2. Measured DFT shall be within + 10% of the dry film
thickness, specified in the specifications.
Adhesion of the primer to the steel substrate and intercoat adhesion of the subsequent
coat(s) after curing for at least a week after application of the topcoat shall be examined by
a knife test in accordance with ASTM D 6677. For the knife test, if the rating is better than
8, the adhesion is considered acceptable. The adhesion is destructive and tested areas shall
be repaired afterward using the spot repair procedure. Alternatively, the applicator may
perform the adhesion test on a steel coupon coated using the same surface preparation and
coating application procedure as the work piece. Adhesion testing shall be carried out for
each component at least once per 200 m2 (2000 ft2) of coated surface.
Holiday testing shall be conducted in accordance with NACE SP 0188. For immersion
services, 100% of coated area shall be inspected for holidays. For atmospheric exposure,
10% of coated area which must include weld seams, corners and edges to be holiday
tested. Voltage at which test is to be carried out will depend upon DFT of coating being
tested and shall be as per NACE SP 0188. Any holiday is unacceptable and should be
marked and repaired immediately.
22.10 The contractor shall arrange for spot checking of paint materials for Specific gravity, glow
time (ford cup) and spreading rate.
22.11 Final Inspection of coating system
A final inspection shall be conducted prior to the acceptance of the work. The coating
contractor and the facility owner shall both be present and they shall sign an agreed inspection
report. Such reports shall include:
General
Names of the coating contractor and the responsible personnel
Dates when work was performed
Coating Materials
- Information on coating materials being applied
- Condition of coating materials received
Environmental Conditions
- Weather and ambient conditions
- Coating periods
Surface Preparation
Condition of surface before preparation
Tools and methods used to prepare surface
Condition of surface after preparation
Coating Application
- Equipment used
- Mixing procedure prior to application
- Coating application techniques used
Page 624 of 1963

15i1frita ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
V_IF INDIA UNITED Rev. 0
le FROWCPWO (A Gpi of Irda usertakm9) AND PROTECTIVE COATING
PAGE 46 OF 59
Testing
Type and calibration of inspection instruments used
Type of quality control tests performed, and results
23.0 GUARANTEE
23.1 The contractor shall guarantee that the chemical and physical properties of paint materials used
are in accordance with the specifications contained herein/to be provided during execution of
work.
24.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR
Painting contractor who is awarded any job for EL, Projects under this standard must have
necessary equipments, machinery, tools and tackles for surface preparation, paint application
and inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor supervisor, inspector,
surface preparator and paint applicator must be conversant with the standards referred in this
specification.
25.0 QUALIFICATION/ACCEPTANCE CRITERIA FOR PAINT COATING SYSTEM
25.1 Pre-Qualification of Paint Coating Manufacturer and his Products
Paint Coating manufacture meeting the following requirements shall be considered for supply
of their products. Contractor is advised to select coating manufacturer. Only after obtaining
prequalification from EL for the manufacturer based on following requirements. Even those
manufacturers, whose names are appearing elsewhere in the tender document, under the list of
"EIL's Recommended or Approved Vendors", will also be required to meet the following
prequalification requirements.
Manufacturer should have been in continuous business of paint coating formulation and
manufacturer for at least past 5 years.
Manufacturer should posses past experience of supplying his products to hydrocarbon

processing industry or offshore platforms in the past 5 years.
- Coating manufacturer should have supplied at least 10000 litre of an individual product
to hydrocarbon processing industry or offshore platform.
The manufacturer's manufacturing procedure & QA/QC system shall meet ISO 9001
requirements and preferably should posses ISO 14000 certificate.
The Quality control set up should be manned by qualified paint technologists whose bio
data should be sent along with quality control organization chart.
Pre-Qualification Testing:
Manufacturer should have got his products tested at least one time in last 3 years at a
reputed independent laboratory for the following test items. Test certificates which are
more than 3 years old will not be considered.
Page 625 of 1963

OFEET STANDARD SPECIFICATION STANDARD SPECIFICATION
ENONEERS NO. 6-79-0020
Iariaffleg41, INDIA UNITED FOR SURFACE PREPARATION
iwnewa.mgarm IA Gart Inda Undertaar0 AND PROTECTIVE COATING Rev. 0
PAGE 47 OF 59
Test Test Method

Specific gravity ASTM D 1475
Dipping properties ASTM D 823
Film characteristics -
Solids content by weight ASTM D 2369
Drying time ASTM D 1640
Flexibility ASTM D 1737/ D 522
Hardness ASTM D 3363
Adhesion ASTM D 2197
Abrasion resistance ASTM D 968/ D 1044
DFT/coat As per SSPC guidelines
Storage Stability ASTM D 1849
Resistance to moisture vapour permeability for 2000 hrs ASTM D 2247
Cyclic Test for the duration of 4200 h (25 cycles a 168 ISO 7253, ASTM G53
hours)
% Zn in Dry film for Inorganic Zinc -
Silicate primer
Chemical Resistance test ASTM D 543
- 10% & 40% NaOH (applicable only for F-6 & F-15)
- 10% H2SO4 (applicable only for F-6 & F-15)
- 10 % Nitric Acid test (applicable only for F-6 & F-15)
- Benzene / Toluene (applicable only for F-6 & F-15)
- Kerosene (applicable only for F-6 & F-15)
- Sea water (applicable only for F-6 & F-15)
- MIBK test (applicable only for F-6 & F-15)
Resistance to water using water immersion (applicable ASTM D 870
only for F6-, F-7, F-8, F-14 & F-15)
Dry Heat Resistance test
(applicable only for F-9, F-6A/B, F-2, F-15, F-16,
polysiloxane, heat resistance Al silicone)
Thermal shock resistance test ASTM D2485 - 91
(only for F-9, F-6, polysiloxane)
Each coating product to be qualified shall be identified by the following
An infrared scan (fingerprint), for Part A and B, each component as per ASTM
D 2621
Specific gravity of Base and curing agent (Ref. ISO 2811)
3) Ash content (ASTM D1650), volatile and non-volatile matters (ISO 3251) of each
component
The identification shall be carried out on the batch, which is used for the Pre-
qualification testing. Pre-qualification of the products shall be carried out at an
independent laboratory.
Test shall be carried out at any one of the following laboratories and tests to be witnessed &
certified by third party inspection agency (TUV, BV, DNV).
Page 626 of 1963

000:eftENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
siges eg W: WA LIMITED
Rev. 0
men eeteRtel3AARI (A God d( Undell/A1A) AND PROTECTIVE COATING PAGE 48 OF 59
IICT, Hyderabad
HBTI, Kanpur
DMSRDE, Kanpur
BIS Laboratories
UICT, Matunga, Mumbai
RITES, Kolkata
PDIL, Sindri
NTH, Kolkata
Contractor shall furnish to EIL for approval/ acceptance of all necessary

documents/information including test certificates to prove that the paint manufacturers, from
whom he intends to procure paint products, meet the various requirements for fulfilling the
pre-qualification criteria as given under section 25.1 above. The paint manufacturer shall be
qualified and approved for supply after review/assessment of the submission made by the
contractor.
25.2 Information to be furnished during delivery of coating system:
Contractor along with delivery of paint material has to furnish following information from
paint manufacturer to EIL for acceptance/approval of products.
Batch test certificates (Batch Testing)
Along with delivery to site of the paint products from pre-qualified coating manufacturer.
Contractor has to produce test certificate from paint manufacturer for each batch and for
each category of product for the following test items. Test to be witnessed & certified
by third party inspection agency. All test results must mention clearly the batch no. and
category of product tested. Tests to be conducted for following properties:
Infrared scan for Part A and B, each component

- Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
Product information sheet/ technical data sheet for each category of product.
26.0 METHOD OF SAMPLING & DISPATCH FOR LABORATORY TESTING

(Pre-Qualification tests (sec. 25.1), Batch testing (sec. 25.2) and Inspection testing (sec.
22.0))
26.1 Samples of coating materials should be submitted to the Govt. laboratory in sealed containers
with batch no. and test certificate on regular format of manufacturer's testing laboratory. The
sampling shall be certified and sealed by a certifying agency.
26.2 All test panels should be prepared by Govt. testing agency coloured photographs of test
panels should be taken before and after the test and should be enclosed along with test report.
Sample batch no. and manufacturer's test certificate should be enclosed along with the
report. Test report must contain details of observation and rusting if any, as per the testing
code.
Page 627 of 1963

Oftieta ENGINEERS
Tif Ell5leg4TV WA LIMITED Rev. 0
Mien a21017 ./L7RIM IA GM of India Undeddimal AND PROTECTIVE COATING PAGE 49 OF 59
26.3 Manufacturers should intimate the company, details of sample submitted for testing, name of
Govt. testing agency, date, contact personnel of the govt. testing agency. At the end of the
test the manufacturer should submit the test reports to the company for approval.
26.4 Coating systems for panel test shall be decided after discussion with EIL
Page 628 of 1963

151Rat ENGINEERS
71E1071ft%, INDIA LIMITED
NO. 6-79-0020
11;4 Rev. 0
MM.'MOWS° g
IA GM India Underlim ) AND PROTECTIVE COATING PAGE 50 OF 59
ANNEXURE-I
SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM (TSA) COATING
1.0 SCOPE
The following sections outlines the requirement of supply, application and testing of thermally
sprayed aluminum coatings (TSAC) for corrosion protection of insulated carbon steel piping
and equipments with design temperature not exceeding 540 ° C.
2.0 ITEMS TO BE THERMALLY SPRAYED
Steel Structures/equipments to be protected by TSAC shall be as per Tables 15.0 of this

standard specification. Structures, components thermally sprayed shall not have any uncoated
area or shall not be in mechanically connected by flanges etc to any uncoated bare steel work.
Such adjacent areas to TSA coated areas, if not coated by TSA shall have suitable paint
coating system as per the standard specification.
3.0 TSAC REQUIREMENTS
3.1 Surface Preparation
All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and
grease after degreasing shall be tested by method given elsewhere in the specification (Refer
Sec. 6.7). Thereafter the surface to be abrasive blasted to white metal finish as per NACE
1/SSPC-SP 5 for marine and immersion service. Using SSPC VIS 1, it is to be visually
assessed that the blast cleaned surface meets requirement of SSPC-SP 5. Thereafter clear
cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust on the blasted
surface Finally blasted surface shall be tested for presence of soluble salts as per method ISO
8502-9. Maximum allowable salt content shall be considered 50mg/m 2 . (5 micrograms/cm2)
.In case salt content exceeds specified limit. The contaminated surface shall be cleaned by
method as per Annex C of IS 12944-4 (Water Cleaning). After cleaning the surface shall be
retested for salt content after drying. Testing shall be carried out at least on each component,
once per 200 m2 and a min of 3 times per shift during progress of work.
The blasting media shall be either chilled iron or angular steel grit as per SSPC-AB-3 of mesh
size G-16 to G-40. Copper, Nickel slag, Garnet or Aluminum Oxide as abrasives will also be
suitable having mesh size in the range of G16 to G24 (10-30 mesh), conforming to SSPC-AB-
1. Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and
blasting equipment used. The blasted surface should be having angular profile depth not less
than 65 microns with sharp angular shape but shall not exceed 85 microns. The profile depth
shall be measured according to NACE standard RP 0287 (Replica Tape) or ASTM D 4417
method B (Profile depth gauge).
For manual blasting one profile depth measurement shall be taken every 10-20 m 2 of blasted
surface.
Surface preparation shall be completed in one abrasive blast cleaning operation wherever
possible.
Page 629 of 1963

agraift ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
$1g a fifReall INDIA UNITED Rev. 0
(NMI MIRMIARI/ (A Gout al lita Underlakin3) AND PROTECTIVE COATING PAGE 51 OF 59
If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal
spraying, the affected area shall be reblasted to achieve specified degree of cleanliness after
which only thermal spraying shall commence.
Air blasting pressure at nozzle shall be normally maintained at 100 psi. Air pressure and
media size should be reduced and adjusted to preclude damage/distortion to thin gauge
materials. Blasting time on work piece should be adjusted to only clean the surface and cut
required anchor tooth with minimum loss of metal. Blast angle should be as close to
perpendicular as possible but in no case greater than ± 30 ° from perpendicular to work
surface. Blasting media must be free of debris, excessive fines, and contaminants such as
NaCI and sulfur salts (Ref. SEC 6.0 of this Spec). Blast cleaning shall not be performed when
the surfaces to be blasted are wet or less than 5°C above dew point temperature or when the
relative humidity in the vicnicity of the work is greater than 90%.
3.1.1 Blasting Equipment
The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning
equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall be
used to validate clean and dry air.
3.1.2 Feed Stock
The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminum of
commercial purity grade, its composition shall be in accordance with requirement of BS 1475
or ASTM B833 or ISO 209-1 type Al (wrought aluminum and aluminum alloys, wire). Wire
shall be supplied in protective wrapping indicating batch number and other details.
3.1.3 Thickness Requirement
The nominal thickness of finished TSAC shall be 250 microns having minimum value of 225
microns at low thickness areas (valleys) and not more than 275 microns at peak areas.
The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge
(Magnetic Gauge).
3.1.4 Coating Bond Strength Requirement
The TSAC coating shall have a minimum individual tensile-bond strength value of 1000 psi
for flame sprayed and 1500 psi for arc sprayed coating with an average of 2000 psi for arc
sprayed coatings. Minimum tensile bond strength should be achieved by proper anchor tooth
profile of blasted surface, laying down the TSA thickness in multiple passes and carrying out
TSA application under controlled environment
3.1.5 Porosity
All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum
coatings porosity shall not exceed 15% of total surface area for flame sprayed coating and 8%
for arc spray coating.
Page 630 of 1963

lafteleENIONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
es iiptew INDI A umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
(MRPI FRaRVINJWMil IA GO. Dna Wean) AND PROTECTIVE COATING Rev. 0
PAGE 52 OF 59
4.0 THERMAL SPRAY APPLICATION PROCEDURE
Items in the atmospheric zone to be coated by TSA shall be applied by either Flame
spray or Arc spray method only. For coating under insulation, application shall be by
arc wire method.
4.1 Equipment Set Up
4.1.1 Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer
instructions/technical manuals and also TSAC applicators refinement thereto and (2) as
validated by Procedure Qualification (Sec 7.0 of this specification).
4.1.2 Spray Parameters
Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall
be validated with bend test (See 6.5 of this Spec).
4.1.3 Spray Parameters
Spray Parameters Method of Application

Arc wire Spray Flame Wire Spray
Arc voltage 27 V -
Air pressure 80 psi 80 psi
NACE-1 white metal /
Steel surface cleanliness NACE-1 white metal
or Near white metal
Steel surface profile 75 microns (minimum) 75 microns (min.)
Arc current 250-280A -
Coating thickness 225 microns (nominal) 225 microns(Nominal)
Coating adhesion > 1500 psi (Total coating),see 3.1.4 >1000 psi
Coating porosity Less than 8% Less than 15%.
Spray distance (spray Gun 5-7"
6-8"
work piece)
Spray Pass width 40mm 20 mm
The above parameters to be validated with a bend test by the contractor before start of work
(for details of bend test see Sec 6.5 of this Spec).
4.2 Post Blasting Substrate Condition and Thermal Spraying Period.
4.2.1 The steel surface temperature shall be at least 5°C above dew point of ambient air temperature.
Steel substrate surface temperature shall be recorded by with a contact pyrometer.

Thermal spraying should commence within 15 minutes from the time of completion of blasting
4.2.2 Holding Period
Time between the completion of final anchor tooth blasting and completion of thermal
spraying of blasted surface should be no more than four hours. If within this period rust bloom
appears Sec 4.4.1of this specification will apply.
Format No. 8-00.0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 631 of 1963

az
dzieft ENGINEERS NO. 6-79-0020
1&11€151erilV INDIA LIMITED FOR SURFACE PREPARATION
imerreRaRtitM11711 IA Gat al InCia UNIeltaking) AND PROTECTIVE COATING Rev. 0
PAGE 53 OF 59
4.3 Pre-Heating
For flame spraying, the initial starting area of 1-2 square feet to be preheated to approx.120°C
to prevent condensation of moisture in the flame on the substrate. For arc spraying the
preheating is not required.
4.4 Thermal Spraying
Spraying should commence only after validation of equipment set up by procedure

qualification test and spray parameter validation tests described in Sec 7.0 and 6.5
respectively. Thermal spraying must commence within 15 minutes from the time of
completion of blast cleaning
The specified coating thickness shall be applied in several crossing passes. The coating bond
strength is greater when the spray passes are kept thin. Laying down an excessively thick spray
pass increases the internal stresses in TSAC and decreases the bond strength of total TSAC.
The suitable thickness for crossing passes shall be determined by procedure qualification test
described in Sec 7.0 of this specification.
For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin
spots in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.
The surface geometry of the item or area to be sprayed should be inspected before application.
The spraying pass and sequence shall be planned according to following.
Maintain Gun as close to perpendicular as possible and within ± 30° from perpendicular to
the substrate.
Maintain nominal standoff distance and spray pass width as given below:
Spray pass width

Spray method Standoff (Inches)
(Inches)
Arc Wire 6-8 1 'A( 40mm )
Flame wire 5-7 %( 20mm )
4.4.1 Rust Bloom (Visual appearance of rust or Discoloration)
If Rust bloom appears on the blasted surface before thermal spraying, the affected area shall be
reblasted to achieve the specified level of cleanliness.
If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at any
time during application of TSAC, then spraying shall be stopped and acceptable sprayed area
shall be marked off. The unsatisfactory areas shall be repaired to the required degree of surface
cleanliness and profile.
Blast the edges of the TSAC to provide for 2-3" feathered area overlap of the new work into
existing TSAC.
Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the extent
of feathered edge so that overlap is a consistent thickness.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell. —AI rights reserved
Page 632 of 1963

latazidie ENGINEERS FOR SURFACE PREPARATION
NO. 6-79-0020
sigtaReW INDIA LIMITED Rev. 0
2174WZAJWIRD .
(A Go .4 Inda Undedalungl AND PROTECTIVE COATING PAGE 54 OF 59
4.4.2 Masking
Masking all those parts and surfaces which are not required to be thermally sprayed as
instructed by purchaser should be inspected by applicator to ensure that they are properly
marked and covered by purchaser.
Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator to

minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to substrate
distance and spray angle).
4.4.3 TSAC Finish
The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed steel
as examined with 10 X magnification.
5.0 SEALER
Sealant shall be applied after satisfactory application of TSAC and completion of all testing
and measurements of the finished TSAC as per Sec 6.0 of this specification.
For shop workSealer shall be applied immediately after thermal spraying and for field work
sealer shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the
body of TSAC.
The sealant shall be Silicone Alkyd Aluminium paint having DFT not more than 35-40 micron.
Typically seal coat shall be applied at a spreading rate resulting in theoretical 38 microns DFT.
The seal coat shall be applied in accordance with SSPC-PA 1 and the paint manufacturer
instruction for sealing.
6.0 TESTING AND MEASUREMENT SCHEDULE
6.1 Surface Finish
That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5) shall be
visually inspected using SSPC-VIS 1. The clear cellophane-tape test as per ISO 8502-3 shall
be used to confirm absence of dust or foreign debris on the cleaned surface. Checks shall be
done on each component at least once per 200 m2 of blasted surface and minimum of 3 checks
per shift.
6.2 Blast Profile Measurement: (In-Process testing during actual production before application
of TSA coating)
The angular profile depth measurement shall be done by profile tape as per method NACE
Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot
measurement shall be carried out every 15m 2 of blasted surface. At each spot three
measurements shall be taken over an area of 10 cm 2 and average of measurements to be
recorded and reported.
If profile is <65 microns blasting shall continue till grater than 65 microns depth profile is
achieved.
Page 633 of 1963

Oftela ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
felliteCe INDIA LIMITED Rev. 0
awn maw nem) (A Gem al inda Underlikog AND PROTECTIVE COATING PAGE 55 OF 59
6.3 TSAC Thickness (In-Process Testing For finished coating during regular production)
6.3.1 TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.
6.3.2 For flat surfaces, measurements shall be taken along a straight measurement line, one
measurement line for every 15 m2 of applied TSAC shall be selected along which 5
measurements to be taken at 25 mm internal and average to be reported.
6.3.3 For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring
10 cm2 in area. One spot to be taken for every 15 m2 of applied TSAC area.
6.3.4 The TSAC thickness in surface changes or contour changes, welds and attachments shall be
also measured and reported.
6.3.5 If TSAC is less than specified minimum thickness, apply additional TSAC until specified
thickness range is achieved.
6.3.6 All locations and values of TSAC thickness measurements shall be recorded in Job Record
(JR).
6.4 Tensile Bond Testing (In-Process testing for finished coating during regular production)
Tensile Bond strength of the TSAC finish coat shall be determined according to
ASTM D 4541 using a self-aligning adhesion tester.
One measurement shall be made every 50 m2. If tensile bond at any individual spot
is less than 1000 psi for flame sprayed coating and 1500 psi for arc sprayed coating
the degraded TSAC shall completely removed and reapplied.
The tensile bond portable test instrument to be calibrated according to ASTM C 633
6.5 Bend Tests
Bend test shall be carried out at beginning of each work shift. Bend tests shall also be
conducted on sample coupons before start of thermal spraying work to qualify the following as
mentioned earlier in this specification.
To qualify spray parameters and thickness of each crossing pass.
6.5.1 Test Procedure
Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm

thk. to be prepared.
Surface shall be prepared by dry abrasive blast cleaning as per this specification.
TSAC shall be applied as per specified thickness range. TSAC should be sprayed in
crossing passes laying down approx. 75-100 microns in each pass.
TSAC applied coupons shall be bent 180 ° around a 13 mm diameter mandrel.
Page 634 of 1963

g,, STANDARD SPECIFICATION STANDARD SPECIFICATION
(gal etiregw ENGINEERS
INDIA LMTED FOR SURFACE PREPARATION NO. 6-79-0020
1411MeRePWW) IA Govt al India Undertiong) AND PROTECTIVE COATING Rev. 0
PAGE 56 OF 59
e) Bend test shall be considered passed if on bend radius there is
- No cracking or spalling or lifting by a knife blade from the substrate

- Only minor cracking that cannot be lifted from substrate with a knife blade.
Bend test fails if coating cracks with lifting from substrate.
6.6 Tests for blasting media, blasting air
6.6.1 Blasting Media (For every fresh batch of media and one random test during blasting)
Blasting Media shall be visually inspected for absence of contamination and debris using 10 X
magnification.
Inspection for the absence of oil contamination shall be conducted using following
procedure :
Fill a small clean 200 ml bottle half full of abrasive.
Fill the bottle with potable water, cap and shake the bottle.
Inspect water for oil film/slick. If present, the blasting media is not to be used.
Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If

present, media to be replaced.
c) Clean blasting equipment, especially pot and hoses, and then replace blasting media
and retest.
6.6.2 Test for Blasting Air (Once Daily before start of blasting and once at random during blasting)
The air for blasting shall be free from moisture and oil. The compressor air shall be checked
for oil and water contamination per ASTM D 4285.
6.7 Test for presence of oil/grease and contamination
The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following
procedure to validate absence of oil and grease contamination.
Visual inspection - Continue degreasing until all visible signs of contamination are removed.
Conduct a solvent evaporation test by applying several drops or a small splash of residue-free
trichloromethane on the suspect area especially pitting, crevice corrosion areas or depressed
areas. An evaporation ring formation is indicative of oil and grease contamination.
Continue degreasing and inspection till test is passed.
7.0 TSAC APPLICATOR QUALIFICATION
Following tests to be carried out as part of procedure qualification test for the applicator.
Thickness measurement
Coating bond strength
Porosity test
Page 635 of 1963

loi
rif&JelitENIGINERS
gtIf WegNEW INDIA LIMITED Rev. 0
MDR [111,3M11/ IA Gael d hdia Underlain)) AND PROTECTIVE COATING PAGE 57 OF 59
Bend strength
TSAC applicator's surface finishing and application process and equipment set up, calibration
and operation shall be qualified by application of TSA on a reference sample which shall be
used as a comparator to evaluate the suitability of application process. Only that applicator will
be permitted to carry out the work when test specimens coated by the applicator meets the
desired requirements as cited below.
The sample shall be made of a steel plate measuring approx. 18"x 18" x Vo" thick. If the actual
work is less than 1/4" thick then the sample to be made from material of representative
thickness.
The surface preparation, TSAC application shall be made with actual field equipments and
process/spray parameters and procedures as per the specification. The depth profile of blasted
surface, TSAC coating thickness for each cross pass and total thickness range shall be as per
specification.
The surface preparation and thermal spraying shall be carried out in representative
environmental conditions spraying with makeshift enclosure.
7.1 After application of coating, thickness and tensile bond measurements shall be made in
following manner.
Divide the sample piece into four quadrants.
Measure thickness along the diagonal line of each quadrant.
Four each quadrant five in-line thickness measurements at 1" interval shall be done
using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four "five in line"
thickness measurements to be done for the whole sample.
One tensile bond measurement using ASTM D 4541 type III or IV portable self
aligning test instrument to be done at centre of each quadrant. Total of 4 measurements
for the sample.
One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be
prepared for Metallographic examination as per ASTM E — 3.
The procedure shall be considered qualified if thickness and tensile-bond strength and
porosity values meet the specification requirement.
7.2 Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification.
Applicators thermal spray equipment set-up, operation and procedure of application including
in-process QC checkpoints adopted during procedure qualification as described above should
be always subsequently followed during entire duration of work.
8.0 DOCUMENTATION
The following information shall be provided by TSAC applicator before award of work.
Page 636 of 1963

S ilOzeift ENONEERS
f
NO. 6-79-0020
gaf 215leg e INDIA WAITED
li ir
Rev. 0
1411PMFIRFROMPI) IA &vet Incha Undertaang/
AND PROTECTIVE COATING PAGE 58 OF 59
TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.
Detailed application procedure and in-process quality control check points for (a)
surface preparation (b) thermal spraying (c) seal coats.
Type and specification of instruments to be deployed for measurement of blast profile

depth, TSAC thickness and tensile bond.
Paint manufacturer data sheet for the selected sealing coat to be applied.
9.0 RECORDS
The TSAC applicator shall maintain job record to record production and QC
information. All the results of the tests and quality control checks shall be entered in
the record for each component/part thermally sprayed. All the result of tests
(thickness, tensile bond, bend tests) and other validation tests (e.g. procedure
qualification test, test for surface cleanliness after abrasive blasting, test for
cleanliness of abrasives and air) shall also be recorded and duly signed by owner.
All the information mentioned in Sec 8.0 above should also form part of the Job
record.
Any modification affected after procedure qualification in the procedure, QC, spray
parameter, equipment spec to the original information (submitted before award of the
work) must also form part of Job record.
10.0 WARRANTY
The TSAC applicator shall warrant the quality of material used by providing the purchaser
with a certificate of materials used to include
Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical
analysis, name of supplier, manufacturer.
Sealant: Name of manufacturer, application data sheet.
11.0 SAFETY
The TSAC applicator shall follow all safety procedures required by the purchaser/owner.
Owner shall also give compliance requirement to be followed by applicator. The applicator
shall follow all appropriate regulatory requirements.
12.0 CODES AND STANDARDS
This specification shall apply in case of conflict between specification and following
applicable standards:
Page 637 of 1963

(3i1tael4t ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
5gaia2egwiNDIA umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
t
Wen FRaW ',AMER) IA Govi al India Undeltalang l AND PROTECTIVE COATING Rev. 0
PAGE 59 OF 59
AWS C. 2.17 Recommended Practice for Electric arc Spray.

ASTM C 633 Test Method for Adhesive/Cohesive Strength of Flame Sprayed Coatings.
ASTM D 4285 Method for indicating Oil or Water in Compressed Air.
ASTM D 4417 Test Method for Field Measurement of Surface Profile of Blasted Steel.
BS 2569 Specification for Sprayed Metal Coating.
NACE Standard RP Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel
0287 Surfaces Using a Replica Tape.
Test method for Pull-Off Strength of Coating Using Portable Adhesion
ASTM D 4541
Testers.
Guide for the Protection of Steel with Thermal Spray Coatings of
ANSI/AWS C2.18
Aluminum, Zinc and Their Alloys and Composites.
NACE No. 12/AWS Specification for the application of thermal spray coatings (Metallizing) of
C2.23M/SSPC-CS aluminum, zinc, and their alloys and composites for the corrosion
23.00 protection of steel.
The inspection of coatings and linings: A Handbook of Basic practice for
SSPC Publication
Inspectors, Owners, and Specifiers.
SSPC-AB 1 Mineral and Slag Abrasives.
SSPC-AB 3 Ferrous Metallic Abrasives.
SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel.
SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages.
NACE No. 1/SSPC- White Metal Blast Cleaning.
SP 5
NACE No. 2/SSPC- Near —White Metal Blast Cleaning.
SP 10
Guide and Reference Photographs for Steel Surfaces Prepared by Dry
SSPC-VIS 1
Abrasive Blast Cleaning.
Page 638 of 1963

401 el ENGINEERS
Igar laigtft INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
wren riercure 011,Cr.1) Govt of Indla Unde,lak ■ NI
BOLT TENSION FOR FLANGE JOINTS Page 1 of 33
tfflq. ‘711 icrR

- 4ff-37V (tr4) 14ifeict) ealgt
- 4 argErITT 4itian 1-4r9tT

APPLICATION OF TORQUE AND
HYDRAULIC BOLT TENSION
FOR FLANGE JOINTS
cek ,c0
2 04-05-2616 Issued for Implementation
PG SVRS RP RN
1 26-05-2008 Issued for Implementation PG KPS AA VC
0 15-05-2003 Issued for Implementation PG KPS VC SKG

Standards Standards
Committee Bureau
No by by
Approved by
Page 639 of 1963

if ENGINEERS
tiPteg
(Wen' eirage c7,1,maqq,
INDIA LIMITED
(A Gaut at indta Undettakalq;
APPLICATION OF TORQUE AND HYDRAULIC
BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 2 of 33
Abbreviations:

PMS Piping Material Specification
General Engineering Standards Committee
Convenor : Ms. R. Priyamvada
Members : Mr. R.K. Trivedi

Mr. B.R. Bhogal
Mr. Rajanji Srivastava
Mr. R.B. Bhutda
Mr. Amrendra Kumar
Ms. N.P. Guha
Format No. 8-00-0001-F1 Rev. 0 Copyrights EIL — All rights reserved
Page 640 of 1963

ENGINEERS
ligar 051--eg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
IOWA CleCPIdITIJ,ILITA) IA Govt of India undeltak,n1
CONTENTS
1.0 PURPOSE 4
2.0 SCOPE 4
3.0 REFERENCES 4
4.0 DEFINITIONS 4
5.0 METHODOLOGY AND CONTROL 4
6.0 RESPONSIBILITIES / APPROVALS 11
ANNEXURE-I 32
ANNEXURE-II 33
Page 641 of 1963

-

k1 u ENGINEERS
Ifgof INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
Nreff ele4n2 051.1.70,-.11
1.0 PURPOSE
The purpose of this specification is to describe the methodology for preparation of bolted flange
joints by controlled bolt tightening during construction and commissioning stage of process plant
piping. This specification shall be used in conjunction with the special process/project
requirements and the licensor/vendor recommendations.
2.0 SCOPE
This specification covers ASME B16.5 and ASME B16.47 Series B bolted flanged joints,
involving identical pair of flanges, which are tightened by means of either hydraulic bolt
tensioning or calibrated torque wrenches.
3.0 REFERENCES
EIL Spec no. 6-44-0005 Rev 5 Standard Piping Material Specification

EIL Doc no. 5-7700-0120 Procedure for identification and boxing up of flange joints
not subjected to hydrostatic test at site
ASME B 16.5 Pipe Flanges and Flanged Fittings (1/2" to 24" NPS)
ASME B 16.47 Series B Pipe Flanges and Flanged Fittings (26" to 60" NPS)
ASME B31.3 Process Piping
BP RP 42-2 British Petroleum Recommended Practice: Bolting for
flange joints
ASME Section VIII Division 1 - Boiler and Pressure Vessel Code
and Division 2, 2013
4.0 DEFINITIONS
None.
5.0 METHODOLOGIES AND CONTROL
5.1 Identification of joints for controlled bolt tightening
Controlled bolt tightening can be done either by application of calculated bolt tension with
hydraulic tensioner or by application of calculated bolt torque with calibrated torque wrenches.
The criteria for selection of joints for these two application procedure are given below.
5.1.1 Hydraulic Bolt tensioning
Hydraulic bolt tensioning shall be applied for all joints where the bolt sizes match the criteria
outlined in Table 1, except those in the category 'ID' services. Category 'ID' service is defined in
ASME B31.3.
Page 642 of 1963

lotei ENGINEERS
Zgar weg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
IfirerrelecroecTI.FRIm) IA Gavt Indta Undertakirp) BOLT TENSION FOR FLANGE JOINTS Page 5 of 33
Table 1: Criteria for Bolt Tensioning —

Not applicable for flange joints in category 'D' services
Nominal Bolt
Condition Remarks
diameter
When specified by the Process licensor/
All
vendor / project specifications
50 mm and above All joints
Class 600 and above
Hydrogen service (See Note-1 below)
38 mm and above, Refer ASME B31.3
Category 'M' fluid services
but less than 50 mm
Joints with leakage potential (See Note-2 below)
Critical joints with equipments (See Note-3 below)
25 mm and above, Joints with leakage potential (See Note-2 below)
but less than 38 mm Critical joints with equipments (See Note-3 below)
Note-1: Hydrogen Service
Hydrogen service is defined as service in contact with Hydrogen or gaseous mixtures
containing Hydrogen in which the partial pressure of Hydrogen is 7 bar (100 psi) abs. or
more.
Note-2: Joints with leakage potential shall include
a) Joints involving tapped holes.
b) Joints not subjected to hydro test e.g. joints for equipment manholes,
equipment mounted temperature, pressure and level instruments, line mounted
temperature connections, on line instrument joints like control valves and
safety valves, compressor volume bottles.
c) Items involving two sets of gaskets with one set of bolt e.g. orifice flange
joint, joints with spectacle blind, spacer, flangeless wafer check valve, wafer
type butterfly valves.
d) Tie-in joints with other contractors and package vendors.
e) High temperature (above 371°C) joints in hydrocarbon services.
Note-3: Critical joints with the equipments shall include the inlet and the outlet flanges of
pumps, compressors and turbines.
5.1.2 Application of torque
Controlled bolt torque, with calculated torque values, shall be applied using calibrated torque
wrench. Joints those qualify for hydraulic bolt tensioning per 5.1.1 shall not be considered for
torque application. Controlled bolt torque should be applied for the joints meeting the criteria
given in Table 2. Joints fulfilling the criteria for Hydraulic bolt tensioning need not be checked
for these criteria
Table 2: Criteria for Bolt Torque application
Service Joints
Hydrogen service All joints (Note-1)
Category 'M' services All joints (Note-1)
Other services Class 600 and above
Note-1: Joints, those qualify for hydraulic bolt tensioning as per cl. 5.1.1, shall not be
considered for torque application.
Page 643 of 1963

ENGINEERS
Ifgar fad& INDIA LIMITED APPLICATION
IA GOVI of Indla
OF TORQUE AND HYDRAULIC
Undertaking,
6-76-0002 Rev. 2
Page 6 of 33
5.2 Pre-bolting Operations
5.2.1 Design
a) Flange connection with bolting of nominal diameter 25mm and above shall have sufficient
clearances and access to allow the use of hydraulic tensioning equipment (wherever
hydraulic bolt tensioning is being used).
b) Stud bolts shall be longer by one diameter to suit the bolt tensioners for hydraulic bolt
tensioning. Excess threads shall be protected by using nut, threaded cap etc. On bolts at
ambient temperature duty the cap should have a grease nipple.
c) All flanges on hydrogen service must be left exposed unless otherwise agreed.
d) Interface joints shall be system pressure tested as per the relevant code to ensure their
integrity.
5.2.2 General
a) Use of right type of Gasket, Fasteners etc. conforming to the specifications as per Design and
Drawings should be ensured.
b) The Vickers hardness number of ring joint gaskets should be 30 to 40 less than that of the
mating face of the flange.
c) All non-ring joint gaskets shall be replaced with the new ones whenever an opened joint is to
be re-closed during construction and commissioning stage. Ring joint gaskets normally can
be re-used provided they are inspected and are free from any damage
d) Shop tested flange joints should not be disturbed at site. In case the joint is opened, the
Contractor shall be responsible for final hook-up joints including bolt tensioning if
applicable.
5.2.3 Visual inspection
a) Condition of flange faces should be checked. Those shall be free from dirt, scale, remnant
gasket, and protrusions. Faces with pitting, indentations or radial tool marks, or scratches are
not desirable. Surface finish should conform to specifications.
b) Flanges should be aligned properly. Flange faces shall be parallel and boltholes shall match
so that the studs can be inserted freely.
c) Visual examination of gaskets should be carried out prior to installation to ensure that these
are free of any defects such as bends, crease or loose spiral windings etc.
d) Gasket position should be checked.
e) Studs and nuts shall be free from dirt, nicks, burrs and chips. Studs shall be straight and nuts
shall turn freely on the stud.
f) No external load shall be used to align the flanges.
Page 644 of 1963

ENGINEERS
laOleg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
(.11-effereiMMWrirm (A Govt of Ind a Undertaktngi
5.2.4 Corrective measures
a) Faces with pitting, indentations or radial tool marks, or scratches that form leakage paths or
with the surface finish not in accordance with design requirements shall be replaced or re-
machined to specified surface finish.
b) If necessary, gasket-seating face should be cleaned using wire brush (SS bristles on alloy
components) and/or suitable solvent.
c) Damaged gaskets shall be replaced.
d) If holding gasket in place after installation is a problem, a thin adhesive tape should be used
along the outside edge of gasket.
5.2.5 Lubrication/anti-seize compound
a) Threads and nuts to flange contact face should be lubricated with suitable lubricant. Thread
compound or lubricant, suitable for line temperature, may be used.
b) Gaskets should not be lubricated.
c) Lubricant shall not be applied on bolts, used in oxygen services.
d) Some of the types of lubricants used are as follows:
Molybdenum Lead oxide (graphite based)

Molykote G-n plus
Molykote P37
Molykote HSC Plus / Never Seez nickel special
API SA2
Molykote 1000
Machine oil
Graphite grease
5.2.6 Assembly
a) Suitable lubricant (refer cl. 5.2.5) to be applied to the threads and the face of the nut that
contacts the flange.
b) Four studs should be placed in positions 1, 2, 3 and 4 according to "Stud Tightening Pattern"
in Fig.1, as centring guides for the gasket.
c) Balance studs should be inserted next.
d) Nuts should be run down by hand in such a way that an equal number of threads project at
each end.
5.2.7 Torque/tension calculation
a) EIL software FLTRQ16.5 is used for calculation. The stress analysis part of this software
primarily follows the procedure outlined in ASME Section VIII Division 1/ Division 2.
b) Basic formulae used for torque calculation takes care of friction between bolt threads and nut
threads as well as that between nut and back face of flange.
Format No. 8-00-0001-F1 Rev. 0 Copyrights EIL—All rights reserved
Page 645 of 1963

/6iiia4-1t4 ENGINEERS
faateg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
m1071'411
etra,re fA
Gavt of Indta Uncle!takalgi
c) A frictional co-efficient of 0.15 is assumed for calculation of torque values for the lubricant -
graphite grease. When a lubricant with different co-efficient of friction (ii) is used, the
calculated values get multiplied by the ratio 11/0.15. The approximate IA values of some of the
lubricants are as follows:
Type of Lubricant Co-efficient of friction (pt)

Molybdenum lead oxide + graphite based 0.085
Molykote G-n plus 0.09
Molykote P37 0.10
Molykote I ISC Plus / Never Seez nickel special 0.11
API SA2 0.117
Molykote 1000 0.13
Graphite grease / Machine oil 0.15
However, it is advisable to obtain the appropriate co-efficient of friction (.t) value from the
lubricant manufacturer.
5.2.8 The piping classes included in this specification are given in Table 3
Table 3: Piping classes included
SI. Piping SI. Piping SI. Piping SI. Piping

no class no class no class no class
From Standard PMS (6-44-0005 rev 5)
A1A 26 A4Y 51 B5M 76 F9A
2 A2A 27 A33Y 52 B1N 77 F19A
3 A4A 28 BIA 53 B6N 78 F2D
4 A5A 29 B2A 54 D1A
5 A6A 30 B4A 55 D2A
6 A7A 31 B5A 56 D4A
7 A8A 32 B6A 57 D5A
8 A9A 33 B9A 58 D9A
9 AIOA 34 B13A 59 D16A
10 Al IA 35 B16A 60 D19A
11 A13A 36 B19A 61 D1D
12 A 15A 37 B32A 62 D2D
13 AI6A 38 BM 63 D5D
14 AI9A 39 B5D 64 D5E
15 A20A 40 B1E 65 D1K
16 A32A 41 B3F 66 D2K
17 A33A 42 B4F 67 E1A
18 AID 43 B4G 68 E2A
19 A4F 44 BIK 69 E5A
20 A4G 45 B2K 70 E9A
21 AlK 46 B4K 71 El9A
22 A2K 47 B5K 72 E5E
23 A6K 48 B6K 73 F1A
24 A1M 49 B1M 74 F2A
25 AIN 50 B3M 75 F5A
Page 646 of 1963

dafaei ENGNEERS
Etigieg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
wrent-...r.wrmr,0 (A Govt of Indw Undeltak.ngl
5.2.9 Torque and tension values
Table 4 contains the tension and torque values to be used for bolt tightening using hydraulic bolt
tensioner and torque wrench respectively. These values are listed piping class and size wise. The
tension values specified are the target load per bolt intended after the bolt tensioning
operation is complete. This means any allowance inherent in bolt tensioning equipment (viz.
backlash etc.) shall also to be taken care of as recommended by the equipment manufacturer.
5.2.10 Notes to Torque and tension values in Table 4
a) The maximum allowed design pressure & temperature combination and test pressure
values are listed in Table 4. These values corresponds to PMS rating table values, except
as stated in c) below. Recalculation of torque and tension is necessary if design
condition exceeds these limits.
b) Values in the table are not valid if the design conditionfor pipe wall thickness calculation
is lower than 80% of the class rating condition. Recalculation of torque and tension is
necessary in such cases.
It may be noted that for the sizes above 24" and rating class above 150 (except B1A), the
calculations are carried out for 80% of the pressure used for sizes up to 24".
d) Torque / tension computation of sizes and pipe thickness, which are not covered in the
respective classes of the standard PMS, are carried out based on approximate calculated
pipe thickness for the specified pressure and temperature condition.
e) Suffixes to the rating class numbers denote the flange dimensional standard and are as
follows:
S - ASME B16.5 B - ASME B16.47 Series B
f) The values in the tables are not valid for other flange dimensional standards, e.g., ASME
B 16.47 Series A, AWWA(American Water Works association) etc.
g) All pressure values are in kg/cm2 and all temperature values are in °C
5.3 Bolting Operation
5.3.1 General
a) Categorisation of joints for tension or torque application shall be as per cl. 5.1.
b) Bolt tightening tension or torque value shall be as per cl. 5.2.8.
c) Guidelines and safety requirements provided by the manufacturer bolt tightening equipment
should be followed.
5.3.2 Hydraulic bolt tension application
a) Hydraulic pressure adequate to get the target bolt load can be calculated dividing the bolt
load by the load cell hydraulic seal area. This pressure should be applied simultaneously to
all load cells.
b) 4 load cells equally spaced should be used.
Page 647 of 1963

,511Peit4 ENGINEERS
51geir lat5Itg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
(7112K era:7:V 0,13M177:11
c) Nuts should be run down to flange surface manually.
d) Load cells should be shifted following the Criss-cross Pattern shown in Fig. 1 but in-groups
of 4 bolts each (i.e. 1-2-3-4, 5-6-7-8, 9-10-11-12 etc.) and the tensioning of all bolts should
be completed.
e) Tensioning operations should be repeated once again applying the same pressure.
5.3.3 Stud bolt torque application
a) Bolt torque application sequence shall be in accordance with "Criss-cross Stud Tightening
Pattern" (Fig. 1).
b) Properly calibrated torque wrenches should be used.
c) Torque wrench should be held perpendicular to the axis of the bolt and if hydraulic wrench is
used, it has to be ensured that it reacts against a rigid support parallel to the axis of bolt.
d) Torque should be applied using a minimum of following five steps:
i. All the nuts should be made snug tight with a short wrench (Criss-cross Pattern — Fig.1).
Flange should be bearing uniformly on the gasket (Distance between mating flanges
shall be uniform).
ii. Tightening to 30% of the final torque value (Criss-cross Pattern — Fig. 1).
shall be uniform).
iii. Tightening to 60% of the final torque value (Criss-cross Pattern — Fig.1).
shall be uniform).
iv. Tightening to the final torque value (Criss-cross Pattern — Fig. 1).
Flange should be bearing uniformly on the gasket (Distance between mating flanges shall
be uniform).
v. Tightening should be continued with the final torque in a clockwise manner (bolt to bolt)
until no further rotation is observed.
e) In the event of nut seizure, the nut should be backed off and additional lubricant should be
applied or the nut or/and bolt should be replaced, if necessary.
5.3.4 Testing of joints
Checking up of the individual joints for any leak during system pressure testing should be carried
out using special tapes, soap solutions.
Page 648 of 1963

ENGINEERS
zga fiVeg
I iireK clew/2 MIJMI111)
INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC
6-76-0002 Rev. 2
(A G.rt of Inca Undertaking)
Page 11 of 33
6.0 RESPONSIBILITIES / APPROVALS
6.1 All procedures/documents to be used during Construction should be submitted by the Contractor
to Engineer-in-charge at site in advance.
6.2 The equipment supplier shall be subjected to EIL/Owner approval.
6.3 The details of hydraulic tensioner equipment to be used for tightening shall be intimated to
Engineer-in-charge before application.
6.4 Boxing up and tightening of flange joints shall be done by skilled technicians, qualified and
approved by Contractor and EIL/Owner.
6.5 Any conflict between the requirements of this standard and related codes, standards, data sheets,
drawings, requisitions etc. shall be referred to client / consultant. Agency carrying out bolt
tightening shall list and describe all the deviations from this specification and the related codes
7.0 DOCUMENTATION
7.1 History sheet for flange joints shall be maintained as per Annexure-I.
7.2 Sequence of the activities involved for reopening/ making/ blinding/ de-blinding/ wedge opening
of flange joints shall be as per Annexure-II.
7.3 All joints shall be boxed-up and the record shall be maintained of salient points and names of the
persons involved in the execution/inspection of boxing-up operation.
7.4 All critical joints shall be boxed-up under the supervision of the Contractor's representative and
EIL's Engineer-in-charge or his representative and separate records shall be maintained for such
joints.
7.5 Box up records of interface joints and on-line instrument joints, like control valves, safety valves,
turbine flow meters etc., which are not subjected to hydrotest shall be maintained separately.
7.6 If mentioned in project specification, complete set of bolt Tensioning Equipment/ Torque
Wrenches shall be supplied by Contractor to the Owner after commissioning of the plant, as
mandatory spares.
Page 649 of 1963

ENGINEERS
ligulag6 INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
IfiRR'rieerot andwnwl (A Govt of Intha Undettakingl
4 BOLT FLANGE 8 BOLT FLANGE
12 BOLT FLANGE / 16 BOLT 1 FLANGE
20 BOLT FLANGE
24 BOLT FLANGE
Figure 1 Typical "Criss-cross" Bolt tightening/Torque application pattern
Page 650 of 1963

afa_lei ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
Oges Rift NDIA LIMITED 6-76-0002 Rev. 2
(awn eiwb2 dada.) IA Govt d India Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 13 of 33
Table 4:Bolt Tension and Torque Values

Refer cl. 5.3.8, 5.3.9 and 5.3.10 for applicability of these tables
PMS data Calculation Data

-
Tem perature, pressure, size range and materials Flange Bolt No .
Piping 1 Des Des Test Flange Tension Torque
size ia( of
Class Pr. Temp Pr. Std kg kg-m
Flange Bolt Gasket Pipe In In Bolts
LIST A-1
PMS rated Temperature / Pressure 371 / 7.73 Up to 48" 7.73 371 30.05 150S 1/2 1/2 4 684 2.1
A1A A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150S 3/4 1/2 4 855 2.6
A672 Gr. B60 7.73 371 30.05 150S 1 1/2 4 1027 3.1
PMS rated Temperature / Pressure 300 / 10.44 Up to 36" 7.73 371 30.05 150S 1-1/2 1/2 4 1597 4.8
A2A A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150S 2 5/8 4 2562 9.4
A672 Gr. B60 7.73 371 30.05 150S 3 5/8 4 3020 11.1
PMS rated Temperature / Pressure 260 / 11.95 Up to 24" 7.73 371 30.05 150S 4 5/8 8 2471 9.1
A672 Gr. B60 7.73 371 30.05 150S 8 3/4 8 4931 21.3
A672 Gr. B60 7.73 371 30.05 150S 14 1 12 6249 35.2
PMS rated Temperature / Pressure 371 / 7.73 Up to 24" 7.73 371 30.05 150S 16 1 16 5999 33.8
A7A A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150S 18 1-1/8 16 8583 53.7
A672 Gr. B60 7.73 371 30.05 150S 20 1-1/8 20 8583 53.7
PMS rated Temperature / Pressure 371 / 7.73 Up to 36" 7.73 371 30.05 150S 24 1-1/4 20 11379 78.3
A9A A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150B 26 3/4 36 4111 17.7
A672 Gr. B60 7.73 371 30.05 150B 28 3/4 40 4111 17.7
PMS rated Temperature / Pressure 260 / 11.95 Up to 48" 7.73 371 30.05 150B 30 3/4 44 4385 18.9
AlOA A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150B 32 3/4 48 4522 19.5
API 5L GR.B PSL1 7.73 371 30.05 150B 34 7/8 40 6274 31.2
PMS rated Temperature / Pressure 371 / 7.73 Up to 36" 7.73 371 30.05 150B 36 7/8 44 6274 31.2
AVIA A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150B 38 1 40 7750 43.7
A672 Gr. B60 7.73 371 30.05 150B 40 1 44 7750 43.7
PMS rated Temperature / Pressure 371 / 7.73 Up to 24" 7.73 371 30.05 150B 42 1 48 7750 43.7
A13A A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150B 44 1 52 7750 43.7
A672 Gr. B60 7.73 371 30.05 150B 46 1-1/8 40 11230 70.3
Format No. 8-00-0001-F7 Rev. 0 Copyrights EIL - All rights reserved
Page 651 of 1963

don
- ei ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
215reg
1.112ff eleaRt
INDIA LIMITED
IA Govt of India undertaking) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 14 of 33

- -
Temperature, pressure, size range and materials Flange Bolt No.
Piping Des Des Test Flange Tension Torque
size Dia( of
PMS rated Temperature / Pressure 371 / 7.73 Up to 36" 7.73 371 30.05 150B 48 1-1/8 44 10570 66.2
A19A A105 A193 Gr. B7 Spiral wound SS A106 Gr. B 7.73 371 30.05 150B 50 1-1/8 48 10570 66.2
API5L Gr.BPSL1 7.73 371 30.05 150B 52 1-1/8 52 10240 64.1
7.73 371 30.05 150B 54 1-1/8 56 10240 64.1
7.73 371 30.05 150B 56 1-1/8 60 10240 64.1
■ 7.73 371 30.05 150B 58 1-1/4 48 13488 92.8
7.73 371 30.05 150B 60 1-1/4 52 13488 92.8
LIST A-2
A4Y A105 A307 GR.B BUTYL RUBBER API 5L GR.B PSL1 10.55 186 15.80 150S 3/4 1/2 4 855 2.6
10.55 186 15.80 150S 1 1/2 4 1027 3.1
10.55 186 15.80 150S 1-1/2 1/2 4 1255 3.8
10.55 186 15.80 150S 2 5/8 4 2013 7.4
10.55 186 15.80 150S 3 5/8 4 2013 7.4
IS- _ 186 15.80 150S 4 5/8 8 2013 7.4
10.55 186 15.80 150S 6 3/4 8 3014 13.0
10.55 186 15.80 150S 8 3/4 8 3014 13.0
10.55 186 15.80 150S 10 7/8 12 4184 20.8
10.55 186 15.80 150S 12 7/8 12 4184 20.8
10.55 186 15.80 150S 14 1 12 5499 31.0
10.55 186 15.80 150S 16 1 16 5499 31.0
10.55 186 15.80 150S 18 1-1/8 16 7263 45.5
10.55 186 15.80 150S 20 1-1/8 20 7263 45.5
10.55 186 15.80 150S 24 1-1/4 20 9272 63.8
LIST A-3
A4A A 350 GR.LF2 CL.1 A320 GR.L7 Spiral wound SS A 333 GR.6 14.06 204 27.95 150S 3/4 1/2 4 855 2.6
A 671 GR.CC60 CL.32 14.06 204 27.95 150S 1 1/2 4 1027 3.1
14.06 204 27.95 150S 1-1/2 1/2 4 1597 4.8
14.06 204 27.95 150S 2 5/8 4 2562 9.4
14.06 204 27.95 150S 3 5/8 4 3020 11.1
14.06 204 27.95 150S 4 5/8 8 2471 9.1
14.06 204 27.95 150S 6 3/4 8 3972 17.2
Page 652 of 1963

IN
II .21 ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
ligar Etreg LJMITED
INIEW (A Gov( of (Ma Undertaking) Page 15 of 33

j
Flange Bolt No.
Piping Temperature, pressure, size range and materials Des Des Test Flange Tension Torque
--
size Dia( of
14.06 204 27.95 150S 8 3/4 8 4931 21.3
14.06 204 27.95 150S 10 7/8 12 5135 25.5
14.06 204 27.95 150S 12 7/8 12 5326 26.5
14.06 204 27.95 150S 14 1 12 6249 35.2
14.06 204 27.95 150S 16 1 16 5999 33.8
14.06 204 27.95 150S 18 1-1/8 16 8583 53.7
14.06 204 27.95 150S 20 1-1/8 20 8583 53.7
14.06 204 27.95 150S 24 1-1/4 20 11379 78.3
14.06 204 27.95 150B 26 3/4 36 4111 17.7
14.06 204 27.95 150B 28 3/4 40 4111 17.7
14.06 204 27.95 150B 30 3/4 44 4385 18.9
14.06 204 27.95 150B 32 3/4 48 4522 19.5
14.06 204 27.95 150B 34 7/8 40 6274 31.2
14.06 204 27.95 150B 36 7/8 44 6274 31.2
LIST A-4
A8A A105 A193 GR.B7 BS7531 GR X A 106 GR.B 10.44 300 30.05 150S 3/4 1/2 4 855 2.6
10.44 300 30.05 150S 1 1/2 4 1027 3.1
A15A A105 A193 GR.B7 BS7531 GR X A 106 GR.B 10.44 300 30,05 150S 2 5/8 4 2562 9.4
A672 Gr. B60 10.44 300 30.05 150S 3 5/8 4 3020 11.1
A20A A105 A193 GR.B7 BS7531 GR X A 106 GR.B 10.44 300 30.05 150S 6 3/4 8 3972 17.2
A672 Gr. B60 10.44 300 30.05 150S 8 3/4 8 4931 21.3
A32A A105 A193 GR.B7 BS7531 GR X A 106 GR.B 10.44 300 30.05 150S 12 7/8 12 5326 26.5
10.44 300 30.05 150S 14 1 12 6249 35.2
PMS rated 65 / 16.00 Up to 48" 10.44 300 30.05 150S 16 1 16 5999 33.8
A33A A105 BS7531 GR X IS-1239 (BLACK) 10.44 300 30.05 150S 18 1-1/8 16 8583 53.7
IS-3589 GR.410 10.44 300 30.05 150S 20 1-1/8 20 8583 53.7
A33Y A105 A193 GR.B7 BS7531 GR X IS-1239 (BLACK) 10.44 300 30.05 150B 26 3/4 36 4111 17.7
IS-3589 GR.410 10.44 300 30.05 150B 28 3/4 40 4111 17.7
Page 653 of 1963

IMPTI-e? ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
ttiji-au INDIA LIMITED
,A Govt of Inds Undertaking) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 16 of 33
PMS data_ __Calculation Data
Piping
Class
Temperature, pressure, size range and materials Des
Pr.
Des
Temp
i Test
Pr.
Flange
Std
Flange
size
Bolt
Dia(
No.
of
Tension
kg
Torque
kg-m
A 106 GR.B 10.44 300 30.05 150B 30 3/4 44 4385 18.9
10.44 300 30.05 150B 32 3/4 48 4522 19.5
10.44 300 30.05 150B 34 7/8 40 6274 31.2
10.44 300 30.05 150B 36 7/8 44 6274 31.2
10.44 300 30.05 150B 38 1 40 7750 43.7
10.44 300 30.05 150B 40 1 44 7750 43.7
10.44 300 30.05 150B 42 1 48 7750 43.7
7.73 300 30.05 150B 44 1 52 7750 43.7
7.73 300 30.05 150B 46 1-1/8 40 11230 70.3
7.73 300 30.05 150B 48 1-1/8 44 10570 66.2
7.73 300 30.05 150B 50 1-1/8 48 10570 66.2
7.73 300 30.05 150B 52 1-1/8 52 10240 64.1
7.73 300 30.05 150B 54 1-1/8 56 10240 64.1
7.73 300 30.05 150B 56 1-1/8 60 10240 64.1
7.73 300 30.05 150B 58 1-1/4 48 13488 92.8
7.73 300 30.05 150B 60 1-1/4 52 13488 92.8
LIST A-5
A16A A105 A193 Gr. B7M Spiral wound SS A106 Gr. B 7.73 371 30.05 150S 3/4 1/2 4 855 2.6
A672 Gr. B60 7.73 371 30.05 150S 1 1/2 4 1027 3.1
7.73 371 30.05 150S 1-112 1/2 4 1597 4.8
7.73 371 30.05 150S 2 5/8 4 2562 9.4
7.73 371 30.05 150S 3 5/8 4 3020 11.1
7.73 371 30.05 150S 4 5/8 8 2471 9.1
7.73 371 30.05 150S 6 3/4 8 3972 17.2
7.73 371 30.05 150S 8 3/4 8 4931 21.3
7.73 371 30.05 150S 10 7/8 12 5135 25.5
7.73 371 30.05 150S 12 7/8 12 5326 26.5
. 7.73 371 30.05 150S 14 1 12 6249 35.2
7.73 371 30.05 150S 16 1 16 5999 33.8
7.73 371 30.05 150S 18 1-1/8 16 8583 53.7
7.73 371 30.05 150S 20 1-1/8 20 8583 53.7
7.73 371 30.05 150S 24 1-1/4 20 11379 78.3
Page 654 of 1963

t31 .2.J ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
fai5Vdg INDIA LIMITED 6-76-0002 Rev. 2
1>WW elETIR2 0510112.1) IA Govt of India Undertaiong) BOLT TENSION FOR FLANGE JOINTS Page 17 of 33
PMS data _ ___ Calculation Data

size Dia( of
LIST A-6
AID A182 Gr.F11 CL.2 A193 Gr.B16 Spiral wound SS A335 Gr.P11 7.73 371 30.57 150S 3/4 1/2 4 970 2.9
A691 Gr.1.25Cr CL.42 7.73 371 30.57 150S 1 1/2 4 1141 3.4
PMS rated 371 / 7.73 Up to 24" 7.73 371 30.57 150S 1-1/2 1/2 4 1540 4.6
A4F A182 Gr.F5 A193 Gr.B16 Spiral wound SS A 335 GR.P5 7.73 371 30.57 150S 2 5/8 4 2745 10.1
A 691 GR.5Cr CL.42 7.73 371 30.57 150S 3 5/8 4 3020 11.1
7.73 371 30.57 150S 4 5/8 8 3020 11.1
7.73 371 30.57 150S 6 3/4 8 5205 22.5
7.73 371 30.57 150S 8 3/4 8 5274 22.8
7.73 371 30.57 150S 10 7/8 12 6277 31.2
7.73 371 30.57 150S 12 7/8 12 6277 31.2
7.73 371 30.57 150S 14 1 12 8249 46.5
7.73 371 30.57 150S 16 1 16 7249 40.9
7.73 371 30.57 150S 18 1-1/8 16 11885 74.4
7.73 371 30.57 150S 20 1-1/8 20 11554 72.4
7.73 371 30.57 150S 24 1-1/4 20 14751 101.5
7.73 371 30.57 150B 26 3/4 36 4109 17.7
7.73 371 30.57 150B 28 3/4 40 4383 18.9
7.73 371 30.57 150B 30 3/4 44 4520 19.5
7.73 371 30.57 150B 32 3/4 48 4794 20.7
7.73 371 30.57 150B 34 7/8 40 6847 34.0
7.73 371 30.57 150B 36 7/8 44 7037 35.0
7.73 371 30.57 150B 38 1 40 8748 49.3
7.73 371 30.57 150B 40 1 44 8748 49.3
7.73 371 30.57 150B 42 1 48 8498 47.9
LIST A-7
A4G A182 Gr.F9 A193 Gr.B16 Spiral wound SS A 335 GR.P9 7.73 371 30.57 150S 3/4 1/2 4 970 2.9
A 691 GR.9Cr CL.42 7.73 371 30.57 150S 1 1/2 4 1255 3.8
7.73 371 30.57 150S 1-1/2 1/2 4 1825 5.5
7.73 371 30.57 150S 2 5/8 4 3203 11.8
7.73 371 30.57 150S 3 5/8 4 3386 12.4
Page 655 of 1963

=i) ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
Igar Et154- g NDIA LIMITED 6-76-0002 Rev. 2
I Wen ereS2 ansornair (A Govt of India Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 18 of 33
PMS data ____ ________ ______ _____ _____ Calculation Data

--- Flange Bolt -'-- No.
size Dia( of
7.73 371 30.57 150S 4 5/8 8 3386 12.4
7.73 371 30.57 150S 6 3/4 8 5342 23.1
7.73 371 30.57 150S 8 3/4 8 5342 23.1
7.73 371 30.57 150S 10 7/8 12 7037 35.0
7.73 371 30.57 150S 12 7/8 12 6847 34.0
7.73 371 30.57 150S 14 1 12 8748 49.3
7.73 371 30.57 150S 16 1 16 7999 45.1
7.73 371 30.57 150S 18 1-1/8 16 12215 76.5
7.73 371 30.57 150S 20 1-1/8 20 11885 74.4
7.73 371 30.57 150S 24 1-1/4 20 15594 107.3
7.73 371 30.57 150B 26 3/4 36 4383 18.9
7.73 371 30.57 150B 28 3/4 40 4589 19.8
7.73 371 30.57 150B 30 3/4 44 4726 20.4
7.73 371 30.57 150B 32 3/4 48 5137 22.2
7.73 371 30.57 150B 34 7/8 40 7132 35.5
7.73 371 30.57 150B 36 7/8 44 7132 35.5
7.73 371 30.57 150B 38 1 40 9123 51.4
7.73 371 30.57 150B 40 1 44 9123 51.4
7.73 371 30.57 1508 42 1 48 8998 50.7
LIST A-8
A2K A 182 GR.F304 A320 GR.B8CL.2 Spiral wound SS A 312 TP304 15.32 120 29.00 150S 3/4 1/2 4 855 2.6
A 358 GR.304 15.32 120 29.00 150S 1 1/2 4 1141 3.4
15.32 120 29.00 150S 1-1/2 1/2 4 1597 4.8
15.32 120 29.00 150S 2 5/8 4 2379 8.7
15.32 120 29.00 150S 3 5/8 4 3203 11.8
15.32 120 29.00 150S 4 5/8 8 2837 10.4
15.32 120 29.00 150S 6 3/4 8 4383 18.9
15.32 120 29.00 150S 8 3/4 8 5068 21.9
15.32 120 29.00 150S 10 7/8 12 5516 27.4
15.32 120 29.00 150S 12 7/8 12 5896 29.3
15.32 120 29.00 150S 14 1 12 7499 42.3
15.32 120 29.00 150S 16 1 16 6749 38.1
Page 656 of 1963

In ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
Ifgar tlatu
ranenevemean.yerm)
INDIA LIMITED
(A Goof of India Undertaking) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 19 of 33
PMS data __________ Calculation Data

------------ ----------- ---
size Dia( of
15.32 120 29.00 150S 18 1-1/8 16 9574 59.9
15.32 120 29.00 150S 20 1-1/8 20 9574 59.9
15.32 120 29.00 150S 24 1-1/4 20 12644 87.0
15.32 120 29.00 150B 26 3/4 36 4109 17.7
15.32 120 29.00 150B 28 3/4 40 4246 18.3
15.32 120 29.00 150B 30 3/4 44 4383 18.9
15.32 120 29.00 150B 32 3/4 48 4520 19.5
15.32 120 29.00 150B 34 7/8 40 5896 29.3
15.32 120 29.00 150B 36 7/8 44 5991 29.8
LIST A-9
A1K A 182 GR.F304 A193 GR.B7 Spiral wound SS A 312 TP304 7.73 371 29.00 150S 3/4 1/2 4 798 2.4
A 105 A 358 GR.304 7.73 371 29.00 150S 1 1/2 4 913 2.7
A6K A 182 GR.F304L A193 GR.B7 Spiral wound SS A 312 TP304L 7.73 371 29.00 150S 2 5/8 4 2562 9.4
A 105 A 358 GR.304L 7.73 371 29.00 150S 3 5/8 4 3020 11.1
7.73 371 29.00 150S 4 5/8 8 2471 9.1
7.73 371 29.00 150S 6 3/4 8 3972 17.2
7.73 371 29.00 150S 8 3/4 8 4931 21.3
7.73 371 29.00 150S 10 7/8 12 5135 25.5
7.73 371 29.00 150S 12 7/8 12 5326 26.5
7.73 371 29.00 150S 14 1 12 6249 35.2
7.73 371 29.00 150S 16 1 16 5999 33.8
7.73 371 29.00 150S 18 1-1/8 16 8583 53.7
7.73 371 29.00 150S 20 1-1/8 20 8583 53.7
7.73 371 29.00 150S 24 1-1/4 20 11379 78.3
LIST A-10
AIM A 182 GR.F316 A193 GR.B7 Spiral wound SS A 312 TP316 7.73 371 29.00 150S 3/4 1/2 4 798 2.4
A 105 A 358 GR.316 7.73 371 29.00 150S 1 1/2 4 913 2.7
7.73 371 29.00 150S 1-1/2 1/2 4 1141 3.4
7.73 371 29.00 150S 2 5/8 4 2562 9.4
7.73 371 29.00 150S 3 5/8 4 3020 11.1
Format No. 8-00-0001-F7 Rev. 0 Copyrights EIL - An rights reserved
Page 657 of 1963

46-11 ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
Ogar 18154ft WA LIMITED
10,1?ff el:2MP 051.3.10.1) IA Govl of India Undertaking) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 20 of 33
PMS data ___ ____ ___ ________ Data __ _ _

----- Flange Bolt No .
size Dia( of
7.73 371 29.00 150S 4 5/8 8 2471 9.1
7.73 371 29.00 150S 6 3/4 8 3972 17.2
7.73 371 29.00 150S 8 3/4 8 4931 21.3
7.73 371 29.00 150S 10 7/8 12 5135 25.5
7.73 371 29.00 150S 12 7/8 12 5326 26.5
7.73 371 29.00 150S 14 1 12 6249 35.2
7.73 371 29.00 150S 16 1 16 5999 33.8
7.73 371 29.00 150S 18 1-1/8 16 8583 53.7
7.73 371 29.00 150S 20 1-1/8 20 8583 53.7
7.73 371 29.00 150S 24 1-1/4 20 11379 78.3
LIST A-11
A1N A 182 GR.F316L A193 GR.B7 Spiral wound SS A 312 TP316L 7.73 371 24.26 150S 3/4 1/2 4 798 2.4
A 105 A 358 GR.316L 7.73 371 24.26 150S 1 1/2 4 913 2.7
7.73 371 24.26 150S 1-1/2 1/2 4 1426 4.3
7.73 371 24.26 150S 2 5/8 4 2562 9.4
7.73 371 24.26 150S 3 5/8 4 3020 11.1
7.73 371 24.26 150S 4 5/8 8 2471 9.1
7.73 371 24.26 150S 6 3/4 8 3972 17.2
7.73 371 24.26 150S 8 3/4 8 4931 21.3
7.73 371 24.26 150S 10 7/8 12 5135 25.5
7.73 371 24.26 150S 12 7/8 12 5326 26.5
7.73 371 24.26 150S 14 1 12 6249 35.2
7.73 371 24.26 150S 16 1 16 5999 33.8
7.73 371 24.26 150S 18 1-1/8 16 8583 53.7
7.73 371 24.26 150S 20 1-1/8 20 8583 53.7
7.73 371 24.26 150S 24 1-1/4 20 11379 78.3
LIST B-1
B1A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 28.82 427 79.10 300S 3/4 5/8 4 1373 5.0
A 672 GR.B60 CL.12 28.82 427 79.10 300S 1 5/8 4 1647 6.0
B2A
A105 A193 GR.B7 S.iral wound SS A 106 GR.B 28.82 427 79.10 300S 2 5/8 8 2105 7.7
Page 658 of 1963

ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
IgarownEtiteg
eiewz MIJR11.1
NDIA LIMITED
IA Govt d India UndertMonco BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 21 of 33

- Flange Bolt No.
Piping Temperature, pressure, size range and materials Des j Des Test Flange Tension Torque
s esine D ia ( of
A 672 GR.B60 CL.12 28.82 427 79.10 300S 3 3/4 8 3972 17.2
B5A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 28.82 427 79.10 300S 6 3/4 12 5205 22.5
A 672 GR.B60 CL.12 28.82 427 79.10 300S 8 7/8 12 7608 37.8
B6A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 28.82 427 79.10 300S 12 1-1/8 16 11554 72.4
A 672 GR.B60 CL.12 28.82 427 79.10 300S 14 1-1/8 20 8913 55.8
B9A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 28.82 427 79.10 300S 18 1-1/4 24 11801 81.2
A 672 GR.B60 CL.12 28.82 427 79.10 300S 20 1-1/4 24 14330 98.6
B13A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 28.82 427 79.10 300B 26 1-1/4 32 13065 89.9
A 672 GR.B60 CL.12 28.82 427 79.10 300B 28 1-1/4 36 13065 89.9
A 672 GR.B60 CL.12 28.82 427 79.10 300B 34 1-1/2 36 18168 147.5
A 672 GR.B60 CL.12 28.82 427 79.10 300B 40 1-5/8 40 24392 213.2
28.82 427 79.10 300B 42 1-3/4 36 29631 277.5
LIST B-2
B4A A350 Gr.LF2 CL.1 A320 Gr.L7 Spiral wound SS A333 Gr.6 28.82 427 79.10 300S 3/4 5/8 4 1373 5.0
A671 Gr.CC60 CL.32 28.82 427 79.10 300S 1 5/8 4 1647 6.0
B16A A105 A193 Gr.B7M Spiral wound SS A106 Gr.B 28.82 427 79.10 300S 2 5/8 8 2105 7.7
A672 Gr.B60 CL.12 28.82 427 79.10 300S 3 3/4 8 3972 17.2
28.82 427 79.10 300S 4 3/4 8 5205 22.5
28.82 427 79.10 300S 6 3/4 12 5205 22.5
28.82 427 79.10 300S 8 7/8 12 7608 37.8
28.82 427 79.10 300S 10 1 16 8748 49.3
28.82 427 79.10 300S 12 1-1/8 16 11554 72.4
28.82 427 79.10 300S 14 1-1/8 20 8913 55.8
Page 659 of 1963

ENGINEERS
sirINRK
teg
al
el2X412 COIJMIRI)
INDIA LIMITED
(A Govt d helm Undertaking)
6-76-0002 Rev. 2
Page 22 of 33
PMS data _ __ ______ _ Data _._

size Dia( of
28.82 427 79.10 300S 16 1-1/4 20 10958 75.4
28.82 427 79.10 300S 18 1-1/4 24 11801 81.2
28.82 427 79.10 300S 20 1-1/4 24 14330 98.6
28.82 427 79.10 300S 24 1-1/2 24 17849 144.9
28.82 427 79.10 3008 26 1-1/4 32 13065 89.9
28.82 427 79.10 300B 28 1-1/4 36 13065 89.9
28.82 427 79.10 300B 30 1-3/8 36 15197 114.0
LIST B-3
B1 D A182 Gr. F11 Cl. 2 A193 Gr. B16 Spiral wound SS A335 Gr. P11 15.11 538 79.10 300S 3/4 5/8 4 1007 3.7
A691 Gr.1.25Cr CI.42 15.11 538 79.10 300S 1 5/8 4 1647 6.0
B5D A182 Gr. F11 Cl. 2 A193 Gr. B16 Spiral wound SS A335 Gr. P11 15.11 538 79.10 300S 2 5/8 8 2196 8.1
• A691 Gr.1.25Cr C1.42 15.11 538 79.10 300S 3 3/4 8 4794 20.7
B3F A 182 GR.F5 A193 GR.B16 Spiral wound SS A 335 GR.P5 15.11 538 79.10 300S 6 3/4 12 5205 22.5
A 691 GR5CR CL.42 15.11 538 79.10 300S 8 7/8 12 7228 35.9
B4F A 182 GR.F5 A193 GR.B16 Spiral wound SS A 335 GR.P5 15.11 538 79.10 300S 12 1-1/8 16 11885 74.4
A 691 Gr. 5CR CL.42 15.11 538 79.10 300S 14 1-1/8 20 9574 59.9
15.11 538 79.10 300S 16 1-1/4 20 11801 81.2
15.11 538 79.10 300S 18 1-1/4 24 12222 84.1
15.11 538 79.10 300S 20 1-1/4 24 14751 101.5
15.11 538 79.10 300S 24 1-1/2 24 17849 144.9
12.09 538 63.28 300B 26 1-1/4 32 10958 75.4
12.09 538 63.28 3008 28 1-1/4 36 10958 75.4
12.09 538 63.28 300B 30 1-3/8 36 12577 94.3
12.09 538 63.28 3008 32 1-1/2 32 15937 129.4
12.09 538 63.28 300B 34 1-1/2 36 15299 124.2
12.09 538 63.28 300B 36 1-5/8 32 19819 173.2
12.09 538 63.28 300B 38 1-5/8 36 22105 193.2
12.09 538 63.28 300B 40 1-5/8 40 21343 186.5
12.09 538 63.28 300B 42 1-3/4 36 26937 252.3
Page 660 of 1963

laReiel ENGINEERS
Oges Etwelg w.- INDIA LIMITED
APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
(awn efiesfr MIJR1H11 IA Gout of India Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 23 of 33
PMS data ___ ' Calculation Data

-----
size Dia( of
LIST B-4
B1E A 182 GR.F22 CL.3 A193 Gr. B16 Spiral wound SS A335 Gr. P22 18.63 538 79.10 300S 3/4 5/8 4 1098 4.0
A691 Gr.2.25Cr C1.42 18.63 538 79.10 300S 1 5/8 4 1830 6.7
PMS rated Temperature / Pressure 538 / 17,92 Up to 24" 18.63 538 79.10 300S 1-1/2 3/4 4 3287 14.2
B4G A 182 GR.F9 A193 GR.B16 Spiral wound SS A 335 GR.P9 18.63 538 79.10 300S 2 5/8 8 2288 8.4
A 691 GR9CR CL.42 18.63 538 79.10 300S 3 3/4 8 4931 21.3
18.63 538 79.10 300S 4 3/4 8 5342 23.1
18.63 538 79.10 300S 6 3/4 12 5342 23.1
18.63 538 79.10 300S 8 7/8 12 7418 36.9
18.63 538 79.10 300S 10 1 16 9748 55.0
18.63 538 79.10 300S 12 1-1/8 16 12215 76.5
18.63 538 79.10 300S 14 1-1/8 20 10234 64.1
18.63 538 79.10 300S 16 1-1/4 20 12644 87.0
18.63 538 79.10 300S 18 1-1/4 24 13065 89.9
18.63 538 79.10 300S 20 1-1/4 24 15173 104.4
18.63 538 79.10 300S 24 1-1/2 24 18487 150.1
14.90 538 63.28 300B 26 1-1/4 32 11801 81.2
14.90 538 63.28 300B 28 1-1/4 36 11801 81.2
14.90 538 63.28 300B 30 1-3/8 36 13625 102.2
14.90 538 63.28 300B 32 1-1/2 32 17212 139.8
14.90 538 63.28 300B 34 1-1/2 36 16574 134.6
14.90 538 63.28 300B 36 1-5/8 32 21343 186.5
14.90 538 63.28 300B 38 1-5/8 36 23630 206.5
14.90 538 63.28 300B 40 1-5/8 40 22868 199.9
14.90 538 63.28 300B 42 1-3/4 36 28733 269.1
LIST B-5
B6K A 182 GR.F304L A193 GR.B7 Spiral wound SS A 312 TP304L 24.25 427 63.27 3008 3/4 5/8 4 915 3.4
A 358 TP304L CL.1 24.25 ' 427 63.27 300S 1 5/8 4 1281 4.7
24.25 427 63.27 300S 1-1/2 3/4 4 2192 9.5
24.25 427 63.27 300S 2 5/8 8 1464 5.4
24.25 427 63.27 300S 3 3/4 8 2466 10.6
Page 661 of 1963

/gar INDIA LIMITED 6-76-0002 Rev. 2
1 Wen 2122072 0.11 01i7.) IA Govt of India Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 24 of 33
PMS data ________ _____ ..... _ Data _

-------- -- Flange Bolt No.
size Dia( of
24.25 427 63.27 300S 4 3/4 8 2740 11.8
24.25 427 63.27 300S 6 3/4 12 3150 13.6
24.25 427 63.27 300S 8 7/8 12 4945 24.6
24.25 427 63.27 300S 10 1 16 5249 29.6
24.25 427 63.27 300S 12 1-1/8 16 7263 45.5
24.25 427 63.27 300S 14 1-1/8 20 6933 43.4
24.25 427 63.27 300S 16 1-1/4 20 8851 60.9
24.25 427 63.27 300S 18 1-1/4 24 9694 66.7
24.25 427 63.27 300S 20 1-1/4 24 11379 78.3
24.25 427 63.27 300S 24 1-1/2 24 14662 119.1
LIST B-6
B1K A 182 GR.F304 A193 GR.B7 Spiral wound SS A 312 TP304 5.97 704 75.93 300S 3/4 5/8 4 1281 4.7
A 358 TP304 CL.1 5.97 704 75.93 300S 1 5/8 4 1464 5.4
B2K A 182 GR.F304 A320 GR.B8CL.2 Spiral wound SS A 312 TP304 5.97 704 75.93 300S 2 5/8 8 2105 7.7
A 358 TP316L CL.1 5.97 704 75.93 300S 3 3/4 8 3561 15.4
B4K A 182 GR.F304H A453 GR.660CL.A Spiral wound SS A 312 TP304H 5.97 704 75.93 300S 6 3/4 12 4109 17.7
5.97 704 75.93 300S 8 7/8 12 6086 30.3
B5K A 182 GR.F316H A453 GR.660CL.A SP.WND A 312 TP316H 5.97 704 75.93 300S 12 1-1/8 16 9574 59.9
5.97 704 75.93 300S 14 1-1/8 20 8253 51.7
5.97 704 75.93 300S 16 1-1/4 20 10537 72.5
5.97 704 75.93 300S 18 1-1/4 24 11379 78.3
5.97 704 75.93 300S 20 1-1/4 24 12644 87.0
5.97 704 75.93 300S 24 1-1/2 24 15937 129.4
4.78 704 60.74 300B 26 1-1/4 32 10537 72.5
4.78 704 60.74 300B 28 1-1/4 36 11801 81.2
4.78 704 60.74 300B 30 1-3/8 36 12577 94.3
4.78 704 60.74 300B 32 1-1/2 32 15937 129.4
4.78 704 60.74 300B 34 1-1/2 36 15937 129.4
4.78 704 60.74 300B 36 1-5/8 32 19819 173.2
Page 662 of 1963

Ifgar Elf5i-jeg
lailiWeizasTera.ywrai,
INDIA LIMITED
(A Govt of Ind Undeftalung) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 25 of 33
PMS data _ Data

- - --- _____ -------- ------ ---
size Dia( of
4.78 - 704 60.74 300B 38 1-5/8 36 20581 179.9
4.78 704 60.74 300B 40 1-5/8 40 19819 173.2
4.78 704 60.74 300B 42 1-3/4 36 25142 235.5
LIST B-7
BIM A 182 GR.F316 A193 GR.B7 Spiral wound SS A 312 TP316 26.66 538 75.95 300S 3/4 5/8 4 1373 5.0
A 358 TP316 CL.1 26.66 538 75.95 300S 1 5/8 4 1373 5.0
B3M A 182 GR.F321 A453 GR.660CL.A Spiral wound SS A 312 TP321 26.66 538 75.95 300S 2 5/8 8 1556 5.7
A 358 TP321 CL.1 26.66 538 75.95 300S 3 3/4 8 2603 11.2
B5M A 182 GR.F316H A453 GR.660CL.A Spiral wound SS A 312 TP316H 26.66 538 75.95 300S 6 3/4 12 3972 17.2
26.66 538 75.95 300S 8 7/8 12 5706 28.4
26.66 538 75.95 300S 10 1 16 6999 39.5
26.66 538 75.95 300S 12 1-1/8 16 8253 51.7
26.66 538 75.95 300S 14 1-1/8 20 7593 47.5
26.66 538 75.95 300S 16 1-1/4 20 9694 66.7
26.66 538 75.95 300S 18 1-1/4 24 10537 72.5
26.66 538 75.95 300S 20 1-1/4 24 12222 84.1
26.66 538 75.95 300S 24 1-1/2 24 16256 132.0
20.53 538 60.82 300B 26 1-1/4 32 10537 72.5
20.53 538 60.82 300B 28 1-1/4 36 10537 72.5
20.53 538 60.82 300B 30 1-3/8 36 11791 88.4
20.53 538 60.82 300B 32 1-1/2 32 14981 121.6
20.53 538 60.82 300B 34 1-1/2 36 14343 116.5
20.53 538 60.82 300B 36 1-5/8 32 17913 156.6
20.53 538 60.82 300B 38 1-5/8 36 19056 166.6
20.53 538 60.82 300B 40 1-5/8 40 18294 159.9
20.53 538 60.82 300B 42 1-3/4 36 22897 214.4
LIST B-8
B1N A 182 GR.F316L A193 GR.B7 Spiral wound SS A 312 TP316L 23.90 454 63.27 300S 3/4 5/8 4 915 3.4
A 358 TP 316L CL.1 23.90 454 63.27 300S 1 5/8 4 1281 4.7
Format No. 8-00-0001-F7 Rev. 0 Copyrights EIL -All rights reserved
Page 663 of 1963

Th ENGINEERS
ro„:„ APPLICATION OF TORQUE AND HYDRAULIC
1=gz-ir fatgieg INDIA LIMITED 6-76-0002 Rev. 2
town eiroRe „num) IA Govt India Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 26 of 33
PMS data ___________________ - ____________ ____________ ____________ Calculation Data

Temperature, pressure, size range and materials Fla nge Bolt No. -
Piping Des Des Test Flange I Tension Torque
size Dia( of 1
B6N A 182 GR.F316L A193 GR.B7 Spiral wound SS A 312 TP316L 23.90 454 63.27 300S 2 5/8 8 1464 5.4
A 358 TP 316L CL.1 23.90 454 63.27 300S 3 3/4 8 2466 10.6
23.90 454 63.27 300S 4 3/4 8 2740 11.8
23.90 454 63.27 300S 6 3/4 12 3150 13.6
23.90 454 63.27 300S 8 7/8 12 4945 24.6
23.90 454 63.27 300S 10 1 16 5249 29.6
23.90 454 63.27 300S 12 1-1/8 16 7263 45.5
23.90 454 63.27 300S 14 1-1/8 20 6933 43.4
23.90 454 63.27 300S 16 1-1/4 20 8851 60.9
23.90 454 63.27 300S 18 1-1/4 24 9694 66.7
23.90 454 63.27 300S 20 1-1/4 24 11379 78.3
23.90 454 63.27 300S 24 1-1/2 24 14662 119.1
LIST D-1
D1A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 58.00 427 156.08 600S 3/4 5/8 4 1373 5.0
A 672 GR.B60 CL.12 58.00 427 156.08 600S 1 5/8 4 2013 7.4
D2A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 58.00 427 156.08 600S 2 5/8 8 3112 11.4
A 672 GR.B60 CL.12 58.00 427 156.08 600S 3 3/4 8 5205 22.5
D5A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 58.00 427 156.08 600S 6 1 12 8998 50.7
A 672 GR.B60 CL.22 58.00 427 156.08 600S 8 1-1/8 12 12875 80.6
D9A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 58.00 427 156.08 600S 12 1-1/4 20 14751 101.5
A 672 GR.B60 CL.12 58.00 427 156.08 600S 14 1-3/8 20 17294 129.7
D16A A105 A193 GR.B7M Spiral wound SS A 106 GR.B 58.00 427 156.08 600S 18 1-5/8 20 27441 239.8
A 672 GR.B60 CL.22 58.00 427 156.08 600S 20 1-5/8 24 26679 233.2
D19A A105 A193 GR.B7 Spiral wound SS A 106 GR.B 46.40 427 124.90 600B 26 1-5/8 28 25917 226.5
A 672 GR.B60 CL.22 46.40 427 124.90 600B 28 1-3/4 28 28733 269.1
46.40 427 124.90 600B 30 1-7/8 28 35527 354.2
Page 664 of 1963

i=i)
\ ENGINEERS APPLICATION OF TORQUE AND HYDRAULIC
lig ea fdlaitg INDIA LIMITED 6-76-0002 Rev. 2
men ei2z62 0,1,3q217.11 IA Govt of Inds Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 27 of 33
___ PMS data ____ Calculation Data _

- -
Temperature, pressure, size range and materials
Temper Flange Bolt No.
size Dia( of
Class Flange Pr
Pr. Temp
Tem Pr.
Pr Std kg kg-m
Bolt Gasket Pipe In In Bolts
46.40 427 124.90 600B 32 2 28 39708 420.7
46.40 427 124.90 600B 34 2-1/4 24 55895 661.6
46.40 427 124.90 600B 36 2-1/4 28 49684 588.1
46.40 427 124.90 600B 38 2-1/4 28 54342 643.2
46.40 427 124.90 600B 40 2-1/4 32 51237 606.4
46.40 427 _ 124.90 600B 42 2-1/2 28 66195 865.9
LIST D-2
D4A A 350 GR.LF2 CL.1 A320 GR.L7 Spiral wound SS A 333 GR.6 86.47 204 147.05 600S 3/4 5/8 4 1373 5.0
A 671 GR.CC60 CL.32 86.47 204 147.05 600S 1 5/8 4 2013 7.4
86.47 204 147.05 600S 1-1/2 3/4 4 4520 19.5
86.47 204 147.05 600S 2 5/8 8 3112 11.4
86.47 204 147.05 600S 3 3/4 8 5205 22.5
86.47 204 147.05 600S 4 7/8 8 7228 35.9
86.47 204 147.05 600S 6 1 12 8998 50.7
86.47 204 147.05 600S 8 1-1/8 • 12 12875 80.6
86.47 204 147.05 600S 10 1-1/4 16 14751 101.5
86.47 204 147.05 600S 12 1-1/4 20 14751 101.5
86.47 204 147.05 600S 14 1-3/8 20 17294 129.7
86.47 204 147.05 600S 16 1-1/2 20 21037 170.8
86.47 204 147.05 600S 18 1-5/8 20 27441 239.8
86.47 204 147.05 600S 20 1-5/8 24 26679 233.2
86.47 204 147.05 600S 24 1-7/8 24 34482 343.7
LIST D-3
DID A 182 GR.F11 CL.2 A193 GR.B16 Spiral wound SS A 335 GR.P11 30.23 538 158.20 600S 3/4 5/8 4 1373 5.0
A 691 GR.1.25Cr CL.42 30.23 538 158.20 600S 1 5/8 4 2196 8.1
D2D A 182 GR.F11 CL.2 A193 GR.B16 Spiral wound SS A 335 GR.P11 30.23 538 158.20 600S 2 5/8 8 3295 12.1
A 691 GR.1.25Cr CL.42 30.23 538 158.20 600S 3 3/4 8 5342 23.1
D5D A 182 GR.F11 CL.2 A193 GR.B16 Spiral wound SS A 335 GR.P11 30.23 538 158.20 600S 6 1 12 9498 53.6
A 691 GR.1.25Cr CL.42 30.23 538 158.20 600S 8 1-1/8 12 13535 84.8
Page 665 of 1963

of 4 ENGINEERS
Ogell kit5teg INDIA LIMITED
APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
iNIEW2122612C11513) (A Gavt of Kau Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 28 of 33
PMS data ____ _ ___ Calculation Data

Temperature, pressure, size range and materials Flange I Bolt I No.
size Dia( of
30.23 538 158.20 600S 10 1-1/4 16 16016 110.2
30.23 538 158.20 600S 12 1-1/4 20 15594 107.3
30.23 538 158.20 600S 14 1-3/8 20 18342 137.6
30.23 538 158.20 600S 16 1-1/2 20 21674 176.0
30.23 538 158.20 600S 18 1-5/8 20 28966 253.2
30.23 538 158.20 600S 20 1-5/8 24 28203 246.5
30.23 538 158.20 600S 24 1-7/8 24 36572 364.6
24.19 538 126.56 600B 26 1-5/8 28 26679 233.2
24.19 538 126.56 6008 28 1-3/4 28 30529 285.9
24.19 538 126.56 600B 30 1-7/8 28 35527 354.2
24.19 538 126.56 600B 32 2 28 40911 433.4
24.19 538 126.56 600B 34 2-1/4 24 55895 661.6
24.19 538 126.56 600B 36 2-1/4 28 49684 588.1
LIST D-4
D5E A182 Gr. F22 CI. 3 A193 Gr. B16 Spiral wound SS A335 Gr. P22 37.61 538 158.20 600S 314 5/8 4 1556 5.7
A 691 GR2.25CR CL.42 37.61 538 158.20 600S 1 5/8 4 2471 9.1
37.61 538 158.20 600S 1-1/2 3/4 4 4657 20.1
37.61 538 158.20 600S 2 5/8 8 3478 12.8
37.61 538 158.20 600S 3 3/4 8 5479 23.7
37.61 538 158.20 600S 4 7/8 8 7798 38.8
37.61 538 158.20 600S 6 1 12 9748 55.0
37.61 538 158.20 600S 8 1-1/8 12 13535 84.8
37.61 538 158.20 600S 10 1-1/4 16 16437 113.1
37.61 538 158.20 600S 12 1-1/4 20 16437 113.1
37.61 538 158.20 600S 14 1-3/8 20 19914 149.3
37.61 538 158.20 600S 16 1-1/2 20 22949 186.3
37.61 538 158.20 600S 18 1-5/8 20 29728 259.8
37.61 538 158.20 600S 20 1-5/8 24 28966 253.2
37.61 538 158.20 600S 24 1-7/8 24 38662 385.4
30.09 538 126.60 600B 26 1-5/8 28 28203 246.5
30.09 538 126.60 600B 28 1-3/4 28 32325 302.7
30.09 538 126.60 600B 30 1-7/8 28 37617 375.0
Page 666 of 1963

ster i;taft.
iaaiTii eizasz 4713,18.11
INDIA LIMITED
(A Govt of India Undertaking) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 29 of 33
PMS data ___ __ ..._ Calculation Data ___

size Dia( of
30.09 538 126.60 600B 32 2 28 43318 458.9
30.09 538 126.60 600B 34 2-1/4 24 59000 698.3
30.09 538 126.60 600B 36 2-1/4 28 52789 624.8
LIST D-5
D1K A 182 GR.F304 A193 GR.B7 Spiral wound SS A 312 TP304 55.54 454 114.00 600S 3/4 5/8 4 915 3.4
A 358 TP304 CL.1 55.54 454 114.00 600S 1 5/8 4 1281 4.7
D2K A 182 GR.F304 A320 GR.B8CL.2 Spiral wound SS A 312 TP304 55.54 454 114.00 600S 2 5/8 8 1647 6.0
A 358 TP304 CL.1 55.54 454 114.00 600S 3 3/4 8 3150 13.6
55.54 454 114.00 600S 4 7/8 8 5135 25.5
55.54 454 114.00 600S 6 1 12 6249 35.2
55.54 454 114.00 600S 8 1-1/8 12 8913 55.8
55.54 454 114.00 600S 10 1-1/4 16 9272 63.8
55.54 454 114.00 600S 12 1-1/4 20 10115 69.6
55.54 454 114.00 600S 14 1-3/8 20 12053 90.4
55.54 454 114.00 600S 16 1-1/2 20 15299 124.2
55.54 454 114.00 600S 18 1-5/8 20 19056 166.6
55.54 454 114.00 600S 20 1-5/8 24 19056 166.6
55.54 454 114.00 600S 24 1-7/8 24 25078 250.0
44.44 454 91.20 600B 26 1-5/8 28 18294 159.9
44.44 454 91.20 600B 28 1-3/4 28 20652 193.4
44,44 454 91.20 600B 30 1-7/8 28 24033 239.6
LIST E-1
ElA A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 86.83 427 234.12 900S 3/4 314 4 3698 15.3
A 672 GR.B60 CL. 12 86.83 427 234.12 900S 1 7/8 4 4565 21.7
PMS rated Temperature / Pressure 427 / 86.83 Up to 24" 86.83 427 234.12 900S 1-1/2 1 4 6999 37.7
E2A A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 86.83 427 234.12 900S 2 7/8 8 5135 24.4
A 672 GR.B60 CL. 12 86.83 427 234.12 900S 3 7/8 8 6847 32.6
E5A A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 86.83 427 234.12 900S 6 1-1/8 12 10234 61.3
A 672 GR.B60 CL. 12 86.83 427 234.12 900S 8 1-3/8 12 15197 109.0
Page 667 of 1963

laf54-eg- INDIA LIMITED 6-76-0002 Rev. 2
landar didan-R dil,rarna,0 IA G0 CA India Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 30 of 33
Pi p'ing TemPerature r P ressure, size ran9a and materials Flange Bolt No.
Des Des Test Flange Tension Torque
size Dia( of
A 672 GR.B60 CL. 12 86.83 427 234.12 900S 14 1-1/2 20 21674 168.3
A 672 GR.B60 CL. 12 86.83 427 234.12 900S 20 2 20 40911 414.6
86.83 427 234.12 900S 24 2-1/2 20 62301 779.5
69.47 427 187.30 900B 26 2-1/2 20 60354 755.2
69.47 427 187.30 900B 28 2-3/4 20 66799 915.6
69.47 427 187.30 900B 30 3 20 77472 1152.8
LIST E-2
E5E A182 Gr. F22 CI. 3 A193 Gr. B16 RTJ - 5Cr-0.5Mo A335 Gr. P22 56.24 538 237.28 900S 3/4 3/4 4 3835 15.8
A 691 GR2.25CR CL.42 56.24 538 237.28 900S 1 7/8 4 5326 25.3
Up to 20" 56.24 538 237.28 900S 1-1/2 1 4 7749 41.8
A 335 GR.P11 56.24 538 237.28 900S 2 7/8 8 5896 28.0
A 691 GR.1.25Cr CL. 42 56.24 538 237.28 900S 3 7/8 8 6467 30.7
56.24 538 237.28 900S 4 1-1/8 8 9904 59.3
56.24 538 237.28 900S 6 1-1/8 12 10894 65.3
56.24 538 237.28 900S 8 1-3/8 12 16245 116.5
56.24 538 237.28 900S 10 1-3/8 16 16770 120.3
56.24 538 237.28 900S 12 1-3/8 20 17818 127.8
56.24 538 237.28 900S 14 1-1/2 20 22949 178.2
56.24 538 237.28 900S 16 1-5/8 20 28203 235.8
56.24 538 237.28 900S 18 1-7/8 20 36572 348.7
56.24 538 237.28 900S 20 2 20 44521 451.1
56.24 538 237.28 900S 24 2-1/2 20 68142 852.6
56.24 538 189.83 900B 26 2-1/2 20 64248 803.9
56.24 538 189.83 900B 28 2-3/4 20 73956 1013.8
56.24 538 189.83 900B 30 3 20 83211 1238.2
LIST F-1
A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 144.83 427 390.74 1500S 3/4 3/4 4 3972 16.4
Page 668 of 1963

„21 Er ENGINEERS
I
s~lr
(awn
kitOieg
riraale ils1.3R117,0
INDIA LIMITED
IA Gent of India Undertaking) BOLT TENSION FOR FLANGE JOINTS
6-76-0002 Rev. 2
Page 31 of 33
________ ____________ PMS data Calculation Data

--- ----- ----
Piping Temperature, pressure, size range and materials Des Des Test Flange
Flange Bolt NO.--
Tension Torque
size Dia( of
A 672 GR.B60 CL.12 144.83 427 390.74 1500S 1 7/8 4 4945 23.5
PMS rated Temperature / Pressure 427 / 144.83 Up to 24" 144.83 427 390.74 1500S 1-1/2 1 4 7499 40.4
F2A A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 144.83 427 390.74 1500S 2 7/8 8 6467 30.7
A 672 GR.B60 CL.12 144.83 427 390.74 1500S 3 1-1/8 8 12215 73.2
F5A A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 144.83 427 390.74 1500S 6 1-3/8 12 19914 142.8
A672 Gr. B60 Cl. 22 144.83 427 390.74 1500S 8 1-5/8 12 29728 248.5
F9A A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 144.83 427 390.74 1500S 12 2 16 43318 439.0
A 672 GR.B60 CL.12 144.83 427 390.74 1500S 14 2-1/4 16 55895 632.8
F19A A105 A193 GR.B7 RTJ - Soft Iron A 106 GR.B 144.83 427 390.74 1500S 18 2-3/4 16 85884 1177.3
A672 Gr. B60 Cl. 22 144.83 427 390.74 1500S 20 3 16 103296 1537.0
144.83 427 390.74 1500S 24 3-1/2 16 142889 2467.4
LIST F-2
PMS rated Temperature / Pressure • 538 / 75.93 Up to 24" 75.93 538 395.48 1500S 1/2 3/4 4 3972 16.4
F2D A 182 GR.F11 CL.2 A193 GR.B16 RTJ - 5Cr-0.5Mo A 335 GR.P11 75.93 538 395.48 1500S 3/4 3/4 4 4931 20.4
A 691 GR.1.25Cr CL.42 75.93 538 395.48 1500S 1 7/8 4 6277 29.8
75.93 538 395.48 1500S 1-1/2 1 4 9248 49.9
75.93 538 395.48 1500S 2 7/8 8 7037 33.5
75.93 538 395.48 1500S 3 1-1/8 8 13205 79.1
75.93 538 395.48 1500S 4 1-1/4 8 16858 110.9
75.93 538 395.48 1500S 6 1-3/8 12 20962 150.4
75.93 538 395.48 1500S 8 1-5/8 12 30490 254.9
75.93 538 395.48 1500S 10 1-7/8 12 41797 398.5
75.93 538 395.48 1500S 12 16 46927 475.5
75.93 538 395.48 1500S 14 2-1/4 16 55895 632.8
75.93 538 395.48 1500S 16 2-1/2 16 72036 901.3
75.93 538 395.48 1500S 18 2-3/4 16 88270 1210.0
75.93 538 395.48 1500S 20 3 16 106165 1579.7
75.93 538 395.48 1500S 24 3-1/2 16 146858 2535.9
Page 669 of 1963

ENGINEERS
LI n
Isar ktiegS INDIA LJMITED 6-76-0002 Rev. 2
to IEW eiRTUR CM.1.707.1) IA Govt d Intha Undertaking) BOLT TENSION FOR FLANGE JOINTS Page 32 of 33
HISTORY SHEET FOR FLANGE JOINTS ANNEXURE - I
Project : Test loop No. :

Unit : ISO Drawing No.:
System/Sub System Description : Connected P & ID No.:
Line No. :
Flange Flange Bolt

Flange Parallelity Torque Flange joint
Joint Dia Gasket Studs * Nuts Tension
OK/Not OK Value Acceptance
No. & Value
Rating
Accepted/
Down OK/ Total Nos Owner/
Upstream Spec. Size Spec Nos Spec. Contractor
Stream Not OK Nos. Accepted EIL
Accepted
Special Care to be taken for tapped hole and it is to be certified by Contractor that full engagement of stud is there to the tapped hole.
Contractor to carry out 100% verification
Acceptance by Licensor/Owner.
1. Pre-commissioning
(Signature with Name and Date)
2. Commissioning
(Signature with Name and Date)
Format No. 8-00-0001-F7 Rev. 0 Copyrights EIL-All rights reserved
Page 670 of 1963

41
- ENGINEERS
Zgar EtOleg INDIA LIMITED APPLICATION OF TORQUE AND HYDRAULIC 6-76-0002 Rev. 2
INITerrwartandvINPI (A Govt of IndLa undertaking]
Annexure - II
SEQUENCE OF ACTIVITIES INVOLVED FOR REOPENING / MAKING / BLINDING /

DEBLINDING / WEDGE OPENING OF FLANGE JOINTS
Si. Activity Checked by

No. Contractor
(Signature)
1 Compliance of all check points.
2 Availability and use of recommended tools i.e. Standard tools / Non-sparking
tools/Pneumatic of Hydraulic torque wrench with suitable sockets and other
accessories / Hydraulic bolt tensioner etc depending upon service pressure
temperature rating of the line on which job is to be carried out.
3 Skilled manpower with protective clothing, safety shoes etc.
4 Proper access to flange joints for all bolts, proper scaffolding etc if required.
5 Proper escape route
6 Readiness of proper type, size & rating of blinds/gaskets/wedges & fasteners
etc
7 Loosening of the flange joints, starting from 6 '0' clock position (vertical joints)
8 Check for leakage of any hot water / gas / steam / hydrocarbon etc and wait for
depressurization of line, if any product leakage is observed.
9 Complete opening of flange joint with recommended tools
10 Removal of gasket / blind / wedge etc. and checking of old gaskets for improper
loading from marking on gasket surface.
11 Checking of old fasteners for proper metallurgy, sizing, length etc and ensure
replacement of fasteners based on observations during final box up and also
ensure that all fasteners to be of same size for uniform loading.
12 Making gap in flange joints with proper tools (flange spreader etc.) For proper
observations of gasket sitting area. Ensure proper cleaning of gasket seating
surface with suitable non-sparking tools and inspection of gasket face.
13 Ensure use of recommended gaskets of proper type and size for blinding / final
box up
14 Placing of fasteners in bottom half of flange joint (vertical joints).
15 In case of blinding ensure that tail of the blind is vertically upward and blind is
of proper size and not interfering with studs movement.
16 Ensure proper placement of gasket on raised face/ring groove/serrated area.
17 Ensuring slight tightening of studs in random in bottom half vertical joint(s) for
holding of gasket in proper position
18 Fixing all fasteners in position and tightening of nuts by hand to ensure uniform
stud length on both sides.
19 Tightening of all studs as per tightening sequence by recommended tools.
ACCEPTANCE BY OWNER / EIL
Page 671 of 1963

SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
ENGINEERS MANAGEMENT SYSTEM 6-78-0001 Rev. 1
lakgINDIA LIMITED REQUIREMENTS FROM
mren ewaire mjvam) (A Gavt at India Undertaking)
BIDDERS Page 1 of 7
64)(11 Chrlf qui ciall -51-04ff

u tea aliikrrat t ?drift'
SPECIFICATION FOR QUALITY

MANAGEMENT SYSTEM
REQUIREMENTS FROM BIDDERS
QMS QMS
1 12.03.15 General Revision Standards Standards MPJ SC
Committee Committee

QMS QMS
0 04.06.09 Issued as Standard Specification Standards Standards SCT ND
Committee Committee
Standards Standards
Committee Bureau
Rev. Checked
Date Purpose Prepared by Convener Chairman
No by
Approved by

Page 672 of 1963

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
INDIA LIMITED SYSTEM 6-78-0001 Rev. 1

lft2 (AG'"ind'Undelt6ung) REQUIREMENTS FROM BIDDERS Page 2 of 7
Abbreviations:
CV Curriculum Vitae
PO Purchase Order
PR Purchase Requisition
QA Quality Assurance
QMS Quality Management System
QMS Standards Committee
Convener: Mr. M.P. Jain
Members: Mr. A.K. Chaudhary (Insp.)

Mr. S.K. Kaul (C&P)
Mr. R.K. Trivedi (Engg.)
Mr. Ravindra Kumar (Const.)
Mr. Tilak Raj (Projects)
Mr. Vinod Kumar (CQA)

Page 673 of 1963

Igar llks INDIA LIMITED SYSTEM 6-78-0001 Rev.
Oiren
'A
Govt
At ' nth' Und"k"V) REQUIREMENTS FROM BIDDERS Page 3 of 7
CONTENTS
Clause Title Page

No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
4.0 QUALITY MANAGEMENT SYSTEM — GENERAL 4
5.0 QUALITY SYSTEM REQUIREMENTS 4
6.0 AUDITS 7
7.0 DOCUMENTATION REQUIREMENTS 7
Page 674 of 1963

el ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

$1g-zg faReg INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1
own 120.2 .I J40.9) IA GOVt of India Undertaking) REQUIREMENTS FROM BIDDERS Page 4 of 7
1.0 SCOPE
This specification establishes the Quality Management System requirements to be

met by BIDDER for following purpose:
• QMS requirements to be met by suppliers/contractors after award of work/

during contract execution.
2.0 DEFINITIONS
2.1 Bidder
For the purpose of this specification, the word "BIDDER" means the person(s), firm,
company or organization who is under the process of being contracted by EIL /
Owner for delivery of some products (including service). The word is considered
synonymous to supplier, contractor or vendor.
2.2 Project Quality Plan
Document tailored from Standard Quality Management System Manual of BIDDER,

specifying how the quality requirements of the project will be met.
2.3 Owner
Owner means the owner of the project for which services / products are being
purchased and includes their representatives, successors and assignees.

6-78-0002 Specification for Documentation Requirements from
Contractors
6-78-0003 Specification for Documentation Requirements from Suppliers
4.0 QUALITY MANAGEMENT SYSTEM — GENERAL
Unless otherwise agreed with EIL / Owner, the BIDDER proposed quality system
shall fully satisfy all relevant requirements of ISO 9001 "Quality Management
Systems — Requirements." Evidence of compliance shall be current certificate of
quality system registration to ISO 9001 or a recent compliance audit recommending
registration from a certification agency. The quality system shall provide the
planned and systematic control of all quality related activities for execution of
contract. Implementation of the system shall be in accordance with BIDDER'S
Quality Manual and PROJECT specific Quality Plan.
5.0 QUALITY SYSTEM REQUIREMENTS

5.1 BIDDER shall prepare and submit for review / record, Project Quality Plan / Quality
Assurance Plan for contracted scope / job. The BIDDER'S Quality Plan shall
address all of the applicable elements of ISO 9001, identify responsible parties
within BIDDER'S organization, for the implementation / control of each area,
reference the applicable procedures used to control / assure each area, and verify
the documents produced for each area. The Project Quality Plan shall necessarily
define control or make reference to the relevant procedures, for design and
engineering, purchase, documentation, record control, bid evaluation, inspection,
production/manufacturing, preservation, packaging and storage, quality control at

Page 675 of 1963

INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

(A Gavt of India undertaking' REQUIREMENTS FROM BIDDERS Page 5 of 7
construction site, pre-commissioning, commissioning and handing over (as

applicable) in line with contract requirement and scope of work.
5.2 BIDDER shall identify all specified or implied statutory and regulatory requirements
and communicate the same to all concerned in his organization and his sub
contractor's organization for compliance.
5.3 BIDDER shall deploy competent and trained personnel for various activities for
fulfillment of PO / contract. BIDDER shall arrange adequate infrastructure and work
environment to ensure that the specification and quality of the deliverable are
maintained.
5.4 BIDDER shall do the quality planning for all activities involved in delivery of order.
The quality planning shall cover as minimum the following:
Resources
Product / deliverable characteristics to be controlled.
Process characteristics to ensure the identified product characteristics are
realized
Identification of any measurement requirements, acceptance criteria
Records to be generated
Need for any documented procedure
The quality planning shall result into the quality assurance plan, inspection and test
plans (ITPs) and job procedures for the project activities in the scope of bidder.
These documents shall be submitted to EIL/Owner for review/approval, before
commencement of work.
5.5 Requirements for sub-contracting / purchasing of services specified in contract /

tender shall be adhered to. In general all outsourced items will be from approved
vendors of EIL. Wherever requirements are not specified, or approved sub vendors
do not exist, the sub-contractor shall establish and maintain a system for purchasing
/ sub-contracting to ensure that purchased product / service conforms to specified
requirements. Criteria for selection of sub-contractor, evaluation, re-evaluation,
maintenance of purchasing data and verification of purchased product (sub-
contractor services), constitute important components of this requirement.
5.6 BIDDER shall plan and carry production and service provision under controlled
conditions. Controlled conditions shall include, as applicable
the availability of information that describes the characteristics of the product

the availability of work instructions
the use of suitable equipment
the availability and use of monitoring and measuring devices
the implementation of monitoring and measurement
the implementation of release, delivery and post-delivery activities
5.7 BIDDER shall validate any processes for production and service provision where
resulting output cannot be verified by subsequent monitoring and measurement.
This includes any process where deficiencies become apparent only after the
product is in use or service has been delivered.
5.8 BIDDER shall establish a system for identification and traceability of product /
deliverable throughout product realization. Product status with respect to inspection
and testing requirements shall be identified.

Page 676 of 1963

ei ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
lge.ji id5fez INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

Oren erRRIZ .71.1.113,70 IA Govt of India undettaking) REQUIREMENTS FROM BIDDERS Page 6 of 7
5.9 BIDDER shall identify, verify, protect and safeguard EIL / Owner property (material /
document) provided for use or incorporation into the product. If any Owner / EIL
property is lost, damaged or otherwise found to be unsuitable for use, this shall be
reported to the EIL / Owner.
5.10 BIDDER shall ensure the conformity of product / deliverable during internal
processing and delivery to the intended destination. Requirements mentioned in the
tender shall be adhered to.
5.11 BIDDER shall establish system to ensure that inspection and testing activities are
carried out in line with requirements. Where necessary, measuring equipments
shall be calibrated at specified frequency, against national or international
measurement standards; where no such standard exists, the basis used for
calibration shall be recorded. The measuring equipments shall be protected from
damage during handling, maintenance and storage.
5.12 BIDDER shall ensure effective monitoring, using suitable methods, of the processes
involved in production and other related processes for delivery of the scope of
contract.
5.13 BIDDER shall monitor and measure the characteristics of the product/deliverable to
verify that product requirement has been met. The inspection (stage as well as
final) by BIDDER and EIL / Owner personnel shall be carried out strictly as per the
ITPs forming part of the contract. Product release or service delivery shall not
proceed until the planned arrangements have been satisfactorily completed, unless
otherwise approved by relevant authority and where applicable by Owner / EIL.
5.14 BIDDER shall establish and maintain a documented procedure to ensure that the
product which does not conform to requirements is identified and controlled to
prevent its unintended use or delivery
5.15 All non-conformities (NCs) / deficiencies found by the BIDDER'S inspection /

surveillance staff shall be duly recorded, including their disposal action shall be
recorded and resolved suitably. Effective corrective and preventive action shall be
implemented by the BIDDER so that similar NCs including deficiencies do not recur.
5.16 All deficiencies noticed and reported by EIL / Owner shall be analyzed by the
BIDDER and appropriate corrective and preventive actions shall be implemented.
BIDDER shall intimate EIL / Owner of all such corrective and preventive action
implemented by him.
5.17 BIDDER should follow the standards, specifications and approved drawings.
Concessions/Deviations shall be allowed only in case of unavoidable circumstances.
In such situations Concession/deviation request must be made by the BIDDER
through online system of EIL eDMS. URL of EIL eDMS is
http://edocx.eil . co . in/vportal.
5.18 BIDDER shall have documented procedure for control of documents.
5.19 All project records shall be carefully kept, maintained and protected for any damage
or loss until the project completion, then handed over to EIL / Owner as per contract
requirement (Refer Specification Nos. 6-78-0002 - Specification for Documentation
Requirements from Contractors and 6-78-0003 - Specification for Documentation
Requirements from Suppliers), or disposed as per relevant project procedure.
Page 677 of 1963


ei MANAGEMENT SYSTEM
IftJr
kif51ft. INDIA LIMITED 6-78-0001 Rev. 1
wirer riraxem3Tmil (A Goof of India UndertakIngi
REQUIREMENTS FROM BIDDERS Page 7 of 7
6.0 AUDITS
BIDDER shall plan and carry out the QMS audit for the job. Quality audit programme
shall cover design, procurement, construction management and commissioning as
applicable including activities carried out by sub-vendors and sub-contractors. This
shall be additional to the certification body surveillance audits carried out under
BIDDER'S own ISO 9001 certification scheme.
The audit programmes and audit reports shall be available with bidder for scrutiny
by EIL / Owner. EIL or Owner's representative reserves the right to attend, as a
witness, any audit conducted during the execution of the WORKS.
In addition to above EIL, Owner and third party appointed by EIL/Owner may also
perform Quality and Technical compliance audits. BIDDER shall provide assistance
and access to their systems and sub-contractor / vendor systems as required for this
purpose. Any deficiencies noted shall be immediately rectified by BIDDER.
7.0 DOCUMENTATION REQUIREMENTS
BIDDER shall submit following QMS documents immediately after award of work
(Within one week) for record / review by EIL / Owner.
Organization chart (for complete organization structure and for the project)
Project Quality Plan/Quality Assurance Plan
Job specific Inspection Test Plans, if not attached with PR
Job Procedures
Inspection/Test Formats
In addition to above QMS documents, following documentation shall be maintained

by the BIDDER for submission to EIL / Owner on demand at any point of time during
execution of the project.
Quality Manual
Certificate of approval for compliance to ISO: 9001 standard
Procedure for Control of Non-conforming Product
Procedure for Control of Documents
Sample audit report of the QMS internal and external audits conducted during
last one year
Customer satisfaction reports from at least 2 customers, during the last one
year
Project QMS audit report
Technical audit reports for the project
Corrective action report on the audits
Documents as specified above are minimum requirements. BIDDER shall submit

any other document/data required for completion of the job as per EIL/Owner
instructions.
Page 678 of 1963

SPECIFICATION FOR STANDARD SPECIFICATION No.

101 ENGINEERS DOCUMENTATION
g
** el!2RAfi'aA
IAIRON
g
Meavow INDIA LIMITED
IA GoN. Of India Undeftakingi
REQUIREMENTS FROM
6-78-0002 Rev. 1
CONTRACTORS Page 1 of 8
-4-4-<R1 51(t)01
tr-g 1-4-4vr
SPECIFICATION FOR
DOCUMENTATION REQUIREMENTS
FROM CONTRACTORS
QMS QMS
1 12.03.15 General Revision Standards Standards MPJ SC
Committee Committee
QMS QMS
0 04.06.09 Issued as Standard Specification Standards Standards SCT ND
Committee Committee
Standards Standards
Rev.
Date Purpose by by Convener Chairman
No
Approved by
Page 679 of 1963

SPECIFICATION FOR STANDARD SPECIFICATION
k311 ei ENGINEERS DOCUMENTATION No.
51g-a 015teg INDIA LIMITED 6-78-0002 Rev. 1
1.1FA 2IETIN

IA Govt of India undertaking) REQUIREMENTS FROM
Abbreviations:
DCI - Document Control Index

eDMS - Electronic Document Management System
FOA - Fax of Acceptance
HOD - Head of Division / Department
IC - Inspection Certificate
IRN - Inspection Release Note
ITP - Inspection and Test Plan
LOA - Letter of Acceptance
MOU - Memorandum of Understanding
QMS - Quality Management System
URL - Universal Resource Locator
QMS Standards Committee
Convener: Mr. M.P. Jain
Members: Mr. A.K. Chaudhary (Insp.)

Mr. S.K. Kaul (C&P)
Mr. R.K. Trivedi (Engg.)
Mr. Ravindra Kumar (Const.)
Mr. Tilak Raj (Projects)
Mr. Vinod Kumar (CQA)

Page 680 of 1963

SPECIFICATION FOR STANDARD SPECIFICATION

adaelei m,4 ENGINEERS DOCUMENTATION No.
$1fgar 051ft INDIA UMITED
Merl evensmaR3sTWIl (A Govt of India UndertakIng) REQUIREMENTS FROM 6-78-0002 Rev. 1
CONTENTS
Clause Title Page

No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
4.0 DOCUMENTATION REQUIREMENTS 4
Attachments
Format for completeness of Final Documentation Format No. 3-78-0004
Page 681 of 1963

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PMC Services for capacity augmnetation of Jamnagar-Loni LPG

PIPELINE LAYING TENDER, COMPOSITE CIVIL TENDER

GAIL (INDIA) LIMITED

TENDER FOR PIPELINE LAYING WORKS FOR JLPL

CLIENT PIPELINE CODE NO : 22101500

0 06.01.17 Issued For Bids

GAIL (INDIA) LIMITED

PIPELINE CODE NO : 22101500

PIPELINE SECTION CODE : 22101501

A 16.12.16 DRAFT RB AR/NR MSG

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

2.0 WORK TENDERED ................................................................................................................. 3

3.0 SCOPE OF WORK .................................................................................................................. 4

4.0 SCOPE OF SUPPLY ............................................................................................................. 15

6.0 OTHER CONDITIONS OF BID ............................................................................................ 24

7.0 AS-BUILT DOCUMENT/ DRAWINGS ................................................................................ 34

8.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING ................................. 35

9.0 GENERAL ............................................................................................................................... 35

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

transportation including unloading, handling, stacking, hauling and stringing of line

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

3.20.17 Carrying out radiographic inspection and interpretation of radiograph of welds.

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Pipe Size, inch (mm) CCWC Thickness, mm

Contractor shall also provide anti-buoyancy measures based on site specific

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Certificates/ Inspection Reports as per specifications and as per the instructions of

Pipe OD, Wall

For size 8.625 inch pipeline of approx. 17 km long

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Pipe OD, Wall

Storage Yard at LR Bends &

For size 14 inch pipeline section of approx. 200 m long

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Pipe OD, Wall

Casing pipe for 8.625 inch pipeline crossing

API 5L Gr. Railway

API 5L Gr. Bare/ Railway

API 5L Gr. Bare/ Railway

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

per the requirements of the authorities, whichever is deeper. All National

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

The above stated requirements are minimum requirements for river

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

and CS conduit shall be 4 m based on as installed dimension. In no case OFC

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved