1.2 FS Pipeline PDF

ONSHORE Volume IIIA -1.
2
FUNCTIONAL SPECIFICATION
ENGINEERING Rev. 0
SERVICES South Banskandi GCS Discipline Pipeline
NEW DELHI and Pipeline Project Page : 1 of 1
PIPELINE
MATERIAL
SPECIFICATION
&
CONSTRUCTION
SPECIFICATION
OIL AND NATURAL GAS CORPORATION LIMITED

INDIA
ONSHORE Spec No Index
ENGINEERING Index Rev. No 2
SERVICES, Material Specifications Discipline Pipeline
DELHI SHEET 1 OF 1
TABLE OF CONTENTS
SL No Description Page No
01 Pipeline Ball Valves 4
02 Data Sheet Pipeline Ball Valves 17
03 Pig Launchers And Receivers 19
04 DS Pig Launcher and Receiver 30
05 Casing Insulators & End Seals 35
06 Line Pipe 39
07 Data Sheet For EW Line Pipe 51
08 Data Sheet Seamless Linepipe 52
09 Pipeline Flow Tees 53
10 Data Sheet Pipeline Flow Tee 62
11 Pipeline Specialities 64
12 Long Radius Bend 73
13 Monolithic Isolation Joint 83
14 DS Monolithic Isolation Joint 87
15 Pig Indicator 88
16 Data Sheet Pig Indicator 93
17 Hinged Closure 94
18 Data Sheet Hinged Closure 101
SERVICES, Construction Specifications Discipline Pipeline
DELHI SHEET 1 OF 1
TABLE OF CONTENTS
Page
SL No Description
No
01 SPECIFICATION FOR PIPELINE ROUTE SURVEY 103
SPECIFICATION FOR GEO-TECHNICAL &
02 116
HYDROGRAPHIC INVESTIGATION
SPECIFICATION FOR CONSTRUCTION OF
03 131
UNDERGROUND PIPELINE
04 WELDING SPECIFICATIONS 144
05 SPECIFICATION TRENCH-LESS OPERATIONS 154
06 SPECIFICATION FOR PAINTING 168
SPECIFICATION FOR 3 LAYER POLYETHYLENE
07 172
COATING
08 SPECIFICATION FOR FIELD JOINT COATING 206
SPECIFICATION FOR CONCRETE WEIGHT
09 222
COATING
SPECIFICATION FOR HYDROSTATIC TESTING OF
10 231
PIPELINE
ONSHORE Spec No OES/TD/INT/005/FS/PL02
ENGINEERING Functional Specifications
Rev. No 0
For
SERVICES, Discipline Pipeline
Pipeline Ball Valve
DELHI SHEET 1 OF 13
FOR
PIPELINE BALL VALVES
JC NG SUS 0 15.09.2012
Prepared by Reviewed By Approved By Rev No Date

Rev. No 0
For
Pipeline Ball Valve
DELHI SHEET 2 OF 13
INDEX
1.0 Scope
2.0 Reference Documents
3.0 Materials
4.0 Design and Construction
5.0 Inspection and Tests
6.0 Test Certificates
7.0 Painting ,Marking and Shipment
8.0 Spares and Accessories
9.0 Documentation
10.0 Warranty
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1.0 SCOPE
This specification covers the minimum requirements for design, manufacture and supply
of carbon steel ball valves of fire safe design, suitable for onshore pipeline handling oil,
gas (non sour) or LPG.
2.0 REFERENCE DOCUMENTS
2.1 All valves shall be manufactured and supplied in accordance with the Twenty-third edition
April 2008 of API 6D, Fire safe as per API 6FA with additions and modifications as
indicated in the following sections of this specification.
2.2 Latest edition of the following Codes, Standards and Specifications have been referred in
this specification.
ASME B 31.3 : Process Piping

ASME B31.4 : Pipeline Transportation System for Liquid Hydrocarbons
and Other Liquids.
ASME B 31.8 : Gas Transmission and Distribution Piping System.
ASME B16.5 : Pipe Flanges and Flanged Fittings.
ASME B16.47 : Large Diameter Steel Flanges

ASME B16.25 : Butt-welding Ends.
ASME B16.34 : Valves – Flanged, Threaded and Welding End.
API 6D : Petroleum & Natural Gas Industries Pipeline
Transportation System- Pipeline Valves.
API 5L : Specification for Line Pipe.
API 6 FA : Fire Test for Valves.
API 1104 : Welding Pipelines and Related Facilities
ASME Sec. : Boiler and Pressure Vessel Code.
VIII/IX
ASTM-370 : Standard Test Methods and definitions for Mechanical
Testing of Steel Products.
ASTM B733 : Autocatalytic 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.
ANSI 16.10 : Face to Face & End to End Dimensions of Valves.
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. In
addition, the material shall also meet the requirements specified herein. Other
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components shall be as per Manufacturer’s standard, which shall be subjected to approval

of the Company.
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 shall not exceed 0.45 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 High Vapour Pressure (HVP) liquid
services, Charpy V-notch test on each heat of base material shall be conducted as per
API 6D, clause 8.5 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 0o C. The Charpy V-notch test
specimen shall be taken in the direction of principal grain flow and notched perpendicular
to the original surface of plate or forging.
The minimum average absorbed energy per set of three specimens shall be 27 J with an
individual minimum per specimen of 22 J. Test procedure shall conform to ASTM A 370.
For valves specified to be used for other hydrocarbon services, Charpy V-notch
requirements as stated above are not applicable, unless required by the specified
material standard and data sheet as a mandatory requirement.
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.
3.4 For all such valves where Carbon Steel is used as ball material, the ball shall have 75
micrometers (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B733 with
following classification:
- SC2, Type II, Class 2.
The hardness of plating shall be minimum 50 RC.
3.5 When the valves are specified to be used for Gas service or High Vapour Pressure (HVP)
liquid service, hardness test shall be carried out on each heat of base material for all
pressure containing parts of the valve as per ASTM A-370. A full thickness cross section
shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10
based on minimum four (4) measurements representing the entire thickness.
4.0 DESIGN AND CONSTRUCTION
4.1 Valve design shall met the requirements of API Specification 6D, fire safe as per API 6FA
and shall be suitable for the service conditions indicated in the valve Data Sheet. The
ASME (Boiler & Pressure Vessels Code), Section VIII, Division 1 shall be used to design
the valve body. Allowable stress requirements shall comply the provisions of ASME B31.3.
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In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve
design. However, the minimum wall thickness shall not be less than the minimum
requirement of ASME B16.34.
The manufacturers shall have valid license to use API monogram on valves manufactured
as per API 6D. Valves shall be supplied with API monogram.
4.2 Valve body design shall be fully welded or bolted type. Valve body joints with threads are
not permitted.
4.3 Ball shall be 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 type of pipeline scraper and
inspection 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 valve shall be designed to minimize
accumulation of debris in the seat ring region to ensure that valve movement is not
impeded. In case of reduced bore valves, the nominal valve size indicate in the Valve
Data Sheet corresponds to the end connection.
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 Nominal Valve Nominal Valve Nominal Valve
Size, Size for reduced Size, DN(Inches) Size for reduced bore,
DN(Inches) bore, DN (Inches) DN(Inches)
2 2 24 20
3 2 26 22
4 3 28 24
6 4 30 24
8 6 32 26
10 8 34 28
12 10 36 30
14 10 38 32
16 12 40 34
18 14 42 36
20 16 48 42
22 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
4.6 Valve seats shall be with primary metal to metal contact. O-rings or other seals if used for
drip tight sealing shall be encased in a suitable groove in such a manner that it cannot be
removed from seat ring and there is no extrusion during opening or closing operation at
maximum differential pressure corresponding to valve class rating. The seat rings shall be
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so designed as to ensure sealing at low as well as high differential pressures. Seat

designs with PTFE inserts is not acceptable.
4.7 Valves shall have double block and bleed feature to facilitate complete flush, drain and
venting of the valve body cavity.
For valves to be used in liquid service, the body cavity over-pressure shall be prevented
by self-relieving seat rings/assemblies. A pressure relief hole in the ball is not permitted.
Self-relieving seat rings shall relieve at a body cavity differential pressure not exceeding
50% of the valve class rating pressure.
4.8 When specified in the Valve Data Sheet, Valves shall be designed to withstand a
sustained internal vacuum of at least 1 (one) milli-bar in both open and closed positions.
4.9 Full Bore valves of nominal valve size 200 mm (8”) & above and Reduced Bore valves of
nominal valve size 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 an 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 standard design.
4.10 Valves shall be provided with body vent and drain connections with valves (Ball or Plug
type).
4.11 Valve design shall ensure repair of stem seals/packing under full line pressure.
4.12 a) Valve ends shall be either flanged/ or butt welded as indicated in the Valve Data
Sheets. Valves suitable for buried installation shall have butt welded valve ends.
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
confirm 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 end shall have dimensions 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 as indicated in
Valve Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum
140 BHN.
c) 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. Valves shall be without transition pups. 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.
4.13 Design of weld end valves shall be such that during field welding operation, soft seals are
not liable to be damaged.
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4.14 Valve shall be provided with ball position indicator and stops of rugged construction at the
fully open and fully closed positions.
4.15 Full Bore valves of nominal valve size, DN ≥ 200 mm (8”) and Reduced Bore valves of
nominal valve size, DN ≥ 250 mm (10”), shall be equipped with support foot and lifting
lugs. Tapped hole and eyebolts shall not be used for lifting lugs. Height of support foot
shall be kept minimum.
4.16 If specified, 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 and
shall not interfere with operation of the valve.
4.17 Valves shall be fire resistant as per API 6FA, as indicated in the Valve Data Sheet.
4.18 Valves shall be provided with anti-static devices to ensure electrical continuity between
stem / ball and valve body. 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.
4.19 Valves shall be suitable for either buried or above ground installation as indicated in Valve
Data Sheet
4.20 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have
the following provisions.
a) Valves provided with stem extension shall have water proof outer casing. Length of
stem extension shall be as indicated in Valve Data Sheet. The length corresponds
to the distance between centerlines of the valve opening and the centerline of the
rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a
horizontal shaft.
b) 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. Pipe
used shall be API 5L Gr. B/ ASTM A 106 Gr. B, with Sch. 160. Fittings shall be
ASTM A 105/ ASTM 234 Gr. WPB, Socket Welded, ANSI class 6000.
c) 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.
d) Outer casing of stem extension shall have ᵌ/8” or ½” NPT plugs at the top and
bottom, for draining and filling with oil to prevent internal corrosion.
4.21 Operating Devices :
a) 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. 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 cab be replaces without the valve cover being removed.
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b) The power actuator shall be in accordance with the Valve and Actuator Data
Sheet.
c) 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.
d) 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 initial force required to operate the valve does not exceed 350 N. Manufacturer
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.
e) 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.
f) 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.
4.22 All welds shall be made by qualified welders as per the 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 3.5 and 3.6 of this
specification and shall meet the requirements as specified therein.
4.23 Repair by welding is not permitted for fabricated and forged body valves. However repair
by welding as per ASME B 16.34 is permitted for cast body valves. Repair shall be carried
out before any heat treatment of casting is done. Repair welding procedure qualification
shall also include impact test and hardness test when required as per Clause 3.5 and 3.6
of this specification and shall meet the requirements as specified therein.
4.24 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.
4.25 Valve steam 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.
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
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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 relevant
material standards and this specification, for each heat of steel used.
5.1.4 a) 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.
b) Body casting of all valves shall be radiographically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B16.34. The extent of the
radiography shall be as per under :
ANSI 150 # Class - All sizes - Nil
ANSI 300 # Class - DN 150 mm (6”) - Nil

DN 200 mm (8”) - 100%
ANSI 600 # Class - All sizes - 100%

and above.
All casting shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B16.34.
c) 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 B16.34. All forgings shall be wet magnetic particle
inspected 100% of the internal surfaces. Method and acceptance shall comply with
ASME B 16.34.
d) Bodies and bonnets made by welded assembly of segments of castings, forgings,

plates or combinations thereof shall be examined, as applicable, by methods of
5.1.4(b) for cast components or 5.1.4(C) 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 B 31.8 as applicable and
API 1104.
5.1.6 Welds, which 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.
b) Weld ends of all cast valves subject to welding in field shall be 100%
radiographically examined and acceptance criteria shall be as per ASME B 16.34.
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d) 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. No leakage is permissible
during hydrostatic testing. The body cavity self-relieving feature meeting the
requirements of clause 4.7 of this specification shall also be checked.
5.1.9 A supplementary air seat test as per API 6D shall be carried out for all valves. A bubble
tight seal is required without the use of any sealant. No leakage is allowed. Test
pressure shall be held for 15 min.
5.1.10 Valves shall be subjected to Operational Torque Test as per clause B 6 of API 6D under
hydraulic pressure equal to maximum differential pressure corresponding to the valve
rating. For manually operated valves, it shall be established that the force required to
operate the valve does not exceed the requirement stated in section 4.21 (d) 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 operating and closing time is within the
limits stated in Valve Data Sheet.
Hand operator provided on the actuator shall also be checked after the cyclic testing, for
satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves of
the same size, rating and the actuator model/type. In case, the tests do not meet the
requirements, retesting/rejection of the lot shall be decided by the Third Party Inspection
agency.
5.1.12 Subsequent to successful testing as specified in clause 5.1.8, 5.1.9, 5.1.10 and 5.1.11
above, one (1) valve out of the total ordered quantity shall be randomly selected by the
Company Representative/Third Party Inspection agency for cyclic testing as mentioned
below:
a) The valve shall be subjected to at least 100 Open-Close-Open c yc l e s with

maximum differential pressure corresponding to the valve rating.
b) Subsequent to t h e a b o v e , t h e v a l v e s h a l l b e s u b j e c t e d to
h y d r o s t a t i c test a n d supplementary air seat test in accordance with clause 5.1.8
and 5.1.9.
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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.
5.2 The 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 or inspection to the Company.
5.3 In no case shall any action of the 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 shall in no way relieve the
Manufacturer’s obligation to perform the required inspection and tests.
6.0 TEST CERTIFICATES
The Contractor shall submit the following certificates from the manufacturer:
a) Mill test certificates relevant to the chemical analysis and mechanical properties of
the materials used for the valve construction as per the relevant standards.
b) Test certificates of hydrostatic and pneumatic test compete with records of timing
and pressure of each test.
c) Test reports of radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 5.1 and 5.1.11 of this
specification.
e) Fire Safe Test Certificate as per API 6FA.
f) All other test reports and certificates as required by API 6D and this specification.
The certificates shall be valid only when signed by the Company’s representative/ Third
Party Inspection agency.
7.0 PAINTING, MARKING AND SHIPMENT
7.1 Valve surface shall be thoroughly cleaned, freed from rust, 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 valves to be installed underground, when indicated in Valve
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Data Sheet, the external surfaces of the buried portion of valves shall be painted with
three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300
microns. Manufacture shall indicate the type of corrosion resistant paint used in the
drawings submitted for approval.
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. Marking shall be done by die-stamping on
the bonnet or on the housing. However, for buried valves the marking shall be done on
the above ground portion of the stem housing only.
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 provided by a cost 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 Each valve shall be supplied with a stainless steel tag bearing the following :
a. Purchase Order Number
b. Manufacturer’s Name
c. Valve size and rating
d. Tag Number
e. Serial Number
8.0 SPARES AND ACCESSORIES
8.1 The Contractor/Manufacturer shall furnish list of recommended spares and accessories
for valve required during start up and commissioning and supply of such spares shall
be included in the scope of work of Contractor.
8.2 The Contractor shall furnish list of recommended spares from the manufacturer required
for two years of normal operation and maintenance of valves.
9.0 DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized below.

Number of Copies (Hard copies I soft copies etc.) shall be as indicated in CONTRACT
document. All document shall be in English language only.
9.1 The Contractor shall submit the following documents :
a) General arrangement/assembly drawings showing all features and relatives

positions and sizes of vents, drains, gear operator/ actuator, painting, coating and
other external parts together with overall dimension.
b) Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be
furnished complying the requirement of clause 4.6 of this specification
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c) Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque. In addition, sizing criteria and torque calculations
shall also be submitted for power actuated valves.
d) Installation, Operational and Maintenance Manual.
e) Details of support foot including dimensions and distance from valve centerline to
bottom of support foot.
f) Copy of valid API 6D certificate.
g) Compliance to technical specifications or clause wise list of Deviation from this

specification, if any.
h) Detailed sectional drawings showing all parts with reference numbers and material
specifications.
i) 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.
j) Welding, heat treatment and testing procedures.
k) Details of corrosion resistant paint to be applied on the valves.
l) Descriptive technical catalogues of the Manufacturer.
m) Quality Assurance Plan in line with technical specification duly signed, stamped
and accepted.
n) Duly filled in datasheets for all valves.
Valves manufacturing shall commence only after approval of the above documents. Once
the approval has been given by the Company, any changes in design, material and
method of manufacture shall be notified to the Company for approval.
9.3 With delivery of material ,Contractor shall submit to the Company one reproducible and
four copies of the following:
a) Test certificates as per clause 6.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions including a
list of recommended spares for the valves.
10.0 Warranty
The Contractor/Vendor shall have final and total responsibility for the design, fabrication
and performance of all items supplied under this specification. The Contractor/Vendor
shall warrant the items furnished by him and the performance of the said items in
accordance with this specification and with warranty requirements as specified in the bid
package.
ONSHORE Spec No OES/TD/INT/005/DS/PL02
ENGINEERING Data Sheet
Rev. No 0
For
SERVICES, Discipline Pipelines
Pipeline Ball Valves
DELHI SHEET 1 OF 2
DATA SHEET
FOR
PIPELINE BALL VALVES
JC NG SUS 0 15.09.2012

Rev. No 0
For
SERVICES, Discipline Pipelines
Pipeline Ball Valves
DELHI SHEET 2 OF 2
DATA SHEET FOR PIPELINE BALL VALVE

VALVE MANUFACTURER *
VALVE TAG NO
SPEC NO. _____________ ANSI RATING ____________
DESIGN STANDARD API 6D FIRE SAFE API 6FA,

SIZE, MM (INCH) NB _____________ VALVE BORE FULL BORE/
REDUCED BORE
ENDS BOTH ENDS BUTT FACE FINISH OF
WELDED AS PER FLANGES
ASME B16.25 OR
FLANGED
VALVE DESIGN CONDITIONS
CORROSION ALLOWANCE 1.5 mm TEMPERATURE ________ OC
SERVICE HYDROCARBON PRESSURE __________
DESIGN FACTOR 0.5 INSTALLATION ABOVE GROUND
OR UNDER
GEOUND
CONNECTING PIPE DETAILS
DIAMETER NB MM (INCH) ____, API 5L GR
WALL THICKNESS, MM __________MM
SCHEDULE
VALVE OPERATION
ACTUATION TYPE TYPE OF
ACTUATOR
ACTUATOR MANUFACTURER
ACTUATOR SPECIFICATION
VALVE MATERIAL SPECIFICATION
PART DESCRIPTION MATERIAL
BODY ASTM A 216 GR. WCB / ASTM A 234 GR. WPB
BALL (ASTM A 216 GR. WCB / ASTM A 234 GR. WPB) + 0.003” ENP
BODY SEAT RINGS (AISI 4140 + 0.003” ENP) / AISI 410
SECONDARY SEAT SEAL VITON
STEM (AISI 4140 + 0.003” ENP) / AISI 410
STEM SEAL PTFE/VITON
STUD BOLTS ASTM A 193 GR, B7/ GR. B7M
NUTS ASTM A 194 GR. 2H/ GR. 4
QUANTITY *****NOS.
Notes:
1. Bidder to note that the butt weld end thickness shall be calculated based on internal
pressure corresponding to pressure rating and allowable stress for valve body
material (considering specified design factor and corrosion allowance).
2. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at pipe end) shall be ≤0.5% of OD and tolerance on internal diameter at pipe
ends shall be same as diameter tolerance for the pipe ends indicated in Table10, API
Spec 5L, 44th edition (Effective October – 2008).
3. This valve data sheet shall be read in conjunction with Ball Valve specification.
4. Ball Mounting shall be trunnion type only.
5. Vendor shall submit valve drawings for approval.
6. For buried valves height of stem extension shall be such that centre of Actuator is 1.0
Meter above the finished ground level.
ENGINEERING Functional Specification
Rev. No 0
For
Pig Launchers and Receivers
DELHI SHEET 1 OF 11
FOR
PIG LAUNCHERS AND RECEIVERS
JC NG SUS 0 15.09.2012

Rev. No 0
For
DELHI SHEET 2 OF 11
CONTENTS
Sl. No. Description
1.0 SCOPE
3.0 MATERIALS
8.0 SPARES
9.0 DOCUMENTATION
10.0 GUARANTEE
Rev. No 0
For
DELHI SHEET 3 OF 11
1.0 SCOPE:
This specification covers the basic requirements for design, manufacture,

inspection, testing & supply of pig launchers & receiver to be installed in onshore pipeline
system transporting n o n - s o u r h y d r o c a r b o n i n l i q u i d o r g a s e o u s p h a s e .
2.0 REFERENCE DOCUMENTS:
2.1 Reference has also been made in this specification to the latest edition of the following
codes, standards and specifications:
ASME B 31.3 : Process Piping

ASME B 31.8 : Gas Transmission and Distribution Piping System
ASME B 31.4 : Pipeline Transportation System for Liquid Hydrocarbons &
other liquids
ASME B 16.5 : Steel Pipe Flanges and Flanges Fittings
ASME B16.9 : Factory made Wrought Steel Butt Welding Fittings
ASME B 16.11 : Forged Steel Fittings, Socket-Welding and threaded
ASME B 16.25 : Butt-Welding Ends
ASTM A 105 : Forging, Carbon Steel for Piping components
ASTM A 181 : Forging, Carbon Steel for general purpose piping
ASTM A 216 : Carbon Steel Castings suitable for Fusion Welding for High
temperature Service
ASTM A 234 : Piping Fitting of Wrought Carbon Steel and Alloy Steel for
moderated and Elevated Temperatures
ASTM A370 : Mechanical testing of steel products
ASTM A 20 : General requirements for steel plate for pressure vessels
ASTM A 516 : Carbon steel pressure vessel plates for moderate and low
temperature service
ASTM A 106 : Carbon steel seamless pipe for high temperature service
ASTM A 193/A193M : Alloy steel and stainless steel bolting materials for high
temperature
ASTM A 194/A194M : Carbon and alloy steel nuts for bolts for high pressure or
temperature
ASTM E92 : Test Method for Vicker’s Hardness of Metallic Materials
ASME Sec-V, VIII and IX: Boiler and Pressure Vessels Codes
API 1104 : Specification for Welding Pipeline and Related Facilities
API 5L : Specification for Line Pipe
API 6H : Specification for End Closure, Connector and Swivels.
MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges and
Connecting – End Flanges of Valves and Fittings
MSS-SP-44 : Specification for High Test Wrought Welding Fittings
MSS-SP-75 : Specification for High Test Wrought Welding Fittings
MSS-SP-97 : Integrally Reinforced Forged Branch Outlet Fittings Socket
Welding Threaded and Butt Welding Ends
SSPC-VIS-1 : Steel Structure Painting Council
ISO 10474 : Steel and Steel Structures Inspection documents
ISO 9000 : Quality Management and Quality Assurance Standards
ISO 9001 : Quality Systems – Model for quality assurance in design,
development, production, installation and servicing
Rev. No 0
For
DELHI SHEET 4 OF 11
ISO 9002 : Quality Systems – Model for quality assurance in

production, installation and servicing
2.2 In the event of any conflict of data or requirements in any of the above
documents, t h e r e q u i r e m e n t o f t h i s s p e c i f i c a t i o n s h a l l g o ve r n :
3.0 MATERIALS:
3.1 Materials and thicknesses of main components used in manufacture of

launcher/receivers shall be as per Manufacturer’s Standard and shall be suitable for
service conditions indicated in the data sheets / Technical specifications. These shall be
subject to approval by Company. The steel used for manufacture shall have a minimum
SMYS of 35,000 psi.
3.2 Fully killed carbon steel shall be used.
3.3 Material of the ends to be field welded shall have carbon equivalent less than or
equal to 0.45 based on check analysis for each heat of steel, calculated according to
the following formula:
Mn Cr + Mo + V Ni + Cu
CE = C + -------- + --------------------- + ---------------
6 5 15
0
3.4 For Materials of Barrel, Neck, Charpy V-notch test shall be conducted at 0 C
unless specified otherwise in accordance with the impact test provisions of ASTM A370.
The minimum transverse impact energy values of three full sized specimen shall be 27
joules with an individual minimum per specimen of 22 J.
All carbon steel forgings shall be heat-treated either in the normalized, normalized and
tempered or quenched and tempered condition.
3.5 For Pig Launcher/ Receiver, hardness test shall be carried out as per ASTM A370 for
each heat of steel used. A full thickness cross section shall be taken for this purpose and
the maximum hardness of the base material, weld metal and heat affected zone
(HAZ) of all the pressure containing parts shall not exceed 248 HV10.
3.6 Material Test Certificates s h a l l b e provided by the V e n d o r / Contactor.
Certified mill test report, showing the chemical and physical properties for each item
of material furnished by the Contractor, shall be witnessed / reviewed by third party
Inspection agency (TPIA).
A report of results obtained from magnetic particle and radiographic examinations of

welds indicating all defects identified and the disposition of all repairs shall be provided.
All original radiographs shall be available to the COMPANY / COMPANY’S
REPRESENTATIVE / TPIA f o r review upon request.
A certified copy of all hydrostatic test charts shall be provided.
4.0 DESIGN AND CONSTRUCTION R E Q U I R E M E N T S
4.1 T h e cylindrical portion of the launcher/receiver shall be designed as per design code and
Rev. No 0
For
DELHI SHEET 5 OF 11
design factor indicated in the data sheets. Quick opening end closure shall be
designed as per ASME Sec. VIII, Div. 1 for design conditions indicated in data sheets.
A corrosion allowance of 3mm shall be considered in design of the pig launcher /
receiver. Quality of welding shall be such that weld efficiency factor of 1.0 is achieved.
4.2 The launcher/receiver shall be capable of handling scrapper/cleaning/

gauging/batching/ instrumented pigs as specified in scraper Launcher/receiver data
sheet and technical specification.
4.3 Barrel for the launcher shall be at least 2 sizes higher than main pipe size and receiver
barrel shall be at least 3 sizes higher. Launcher/receiver length to suit the purpose and
thickness to meet the class rating shall be suggested by the Vendor/contractor and
approved by the Company. Circumferential weld on launcher / receiver body and neck
shall not be permitted.
4.4 Concentric or eccentric reducer used in the manufacture of traps shall be seamless type
for sizes up to and including NPS 14 and welded type for sizes NPS 16 and above.
Reducers for sizes up to and including NPS 14 shall conform to ASME B 16.9 and size
NPS 16 and above shall conform to MSS-SP-75. Thickness of the Reducer shall match
with that of the adjoining body / neck thickness.
4.5 V e n t s and drains shall be provided on each launcher/receiver. The launcher/receiver

shall be provided with a suitable slope and the drain location shall be such that complete
drainage of the launcher/receiver is possible. Sizes for vent and drain shall be as
indicated in data sheet. In case of R e c e i v e r , the minimum slope shall be 1:100
downwards the end closure where as in case of Launcher it shall be 1:100 downwards
the pipe line.
4.6 A thermal relief valve shall be provided at locations where the shut-in pressure of trapped
fluid could exceed the design pressure.
4.7 The reducer should be eccentric for launcher and concentric for receiver.
4.8 All branch connections shall be made by weldolets/nippolets/sockolet or by extrusions

as indicated in the data sheet. All weldolets shall confirm to MSS- SP-97 and nippolets
shall be as per manufacturer’s s t a n d a r d . The extruded opening shall be adequately
heat treated and stress relieved.
Stub-in or pipe to pipe connections shall not be used for making branch connections.
4.9 E n d connections of launcher/receivers shall be flanged or butt welded as indicated in

data sheet.
a) Flanged ends, if specified shall have dimension as per ASME B16.5 for sizes up
to 24" NB (excluding 22 NB) and as per ASME B16.47 / MSS- SP-44 for sizes
22 NB and 26 NB and above. Flanges shall be either raised face or ring joint
type (RTJ) as indicated in data sheets.
In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.
b) Butt weld ends if specified shall have ends prepared as per ASME B16.25.
However, end preparation for butt welding ends having unequal thicknesses with
respect to connecting pipe shall be as per ASME B31.4/ ASME B31.8 as
Rev. No 0
For
DELHI SHEET 6 OF 11
applicable.
c) The location & orientation of all nozzle connections shall be submitted for
Company's approval before manufacturing.
4.10 T h e quick opening end closure shall be of quick actuating band lock type, clamp ring or
equivalent design. The design of the quick opening end closure shall be in accordance
with design code adopted for the adjoining pig launcher/receivers stated in the data
sheet. The design of the end closure shall be robust and should consider fail safe design
of the opening mechanism and allow opening and closing by a single lever operation by
one man in a period of approximately one minute without the use of additional devices.
The closure shall also consist of a safety relief system allowing the opening only when
there is no pressure in the launcher/receiver. Safety bleeder device shall alert operator of
possible hazard unless pressure in the pig launcher/receiver is relieved completed.
Screwed type or plug-in types of end closures are not acceptable. End closures of
size 24" and above shall be fitted with worm gear operator for the opening of the
closure.
Hinge of the closure shall be so designed that the weight of the end closure is fully
supported without sagging. The end closure shall be designed in accordance with safety
requirement of ASME Sec. VIII Div. 1, Clause UG-35.
End closure hinge axis shall be horizontally aligned, notwithstanding any slope on the
barrel section.
The design of end closure shall be suitable for permanent location in open environment.
The end closure shall have the following safety devices:

 A pressure locking device to prevent opening the door when the pig
launcher/receiver is pressurized
 A safety bleeder that when released, will alert the operator to possible hazard
unless pressure in the pig launcher/receiver is relieved completely. Opening of the
door shall not be possible unless the bleeder is released. Engaging the bleeder
shall only be possible when the closure is closed. The bleeder shall be designed
such that there is no risk of blockage.
4.11 P i g L a u n c h e r / R e c e i v e r shall be provided with a pig indicator in the middle of

the neck and the indicator shall conform to the specification issued for the purpose. Pig
indicator shall be suitable for bi-directional operation and shall have visual flag and
manual reset. The same shall also have provision for remote indication. Refer Pig
Signaler Data Sheet. Two pig Indicators shall be supplied with each launcher/receiver.
One indicator is to be installed on Launcher/Receiver and other to be installed on pipeline.
Pig indicator to be installed on pipeline shall also be provided with electrical switches to
provide remote indication.
4.12 The Pig launcher/receiver for pipeline sizes above 6” ND shall be supplied with Pig
Handling system, Jib Crane and Winch for pulling the SS tray and Pig as mentioned
below:
 Pig handling trolley shall be designed from structural steel and shall be
suitable to move on rail through a gear train.
Rev. No 0
For
DELHI SHEET 7 OF 11
 Trolley shall be designed to contain pig tray which will contain pig. Trolley shall
have proper braking system. Pig tray shall have perforated holes and shall be
suitable to contain any type of pig, including intelligent pig. Tray shall have
proper strengthening system to avoid bending with load.
The tray shall be provided with suitable stops. Lock bracket shall be provided
such that the tray does not stop within the Launcher / Receiver. Rear end of
the tray shall be provided with suitable lug to enable retrieval of the tray by hooks.
 The handling system (for inserting and retracting the intelligent pigs from the
equipment) shall be complete with handling devices. In case any rails are
required for sliding of the handling system, the same shall be provided.
 Winch to push tray and pig inside the launcher / receiver shall be provided.
 Complete system shall be designed to operate by one person.
 Jib Crane shall be designed as per IS: 3177, IS: 3832, IS: 3938 of latest
edition and shall be mounted on a structural column.
 Jib Crane shall swivel 3600 with one person and shall have antifriction
bearing for swivel operation.
 Lifting of equipment and movement of Trolley shall be anti-spark type Hoist-
Trolley system, suitable to operate by one person.
 Crane shall be balanced with load at maximum span and shall have counter
weight if required. Suitable locking and braking system shall be provided. End
stoppers shall be provided for trolley movement.
 Crane shall be tested with 1.5 times of rated load at maximum radius.
Deflection test shall be as per IS: 807 of latest edition. Wire ropes used for
hoisting and traveling shall be checked as per IS: 6594 and IS: 3973 latest edition.
 Crane shall be complete with foundation bolts.
 Jib crane shall be designed to be operated by one man for all operations.
 Contractor shall furnish all technical parameters of Pig handling system, Winch
and Jib Crane along with offer.
4.13 Fabricated steel supports, minimum two numbers at suitable spacing shall be provided
with launcher/receivers for mounting on concrete blocks. These supports will not be
subjected to pipeline anchorage forces. The material of support shall be compatible with
launcher/receiver material for welding purposes. All welds shall be examined by magnetic
particle method.
4.14 Completed assembly shall be stress relieved as per the provisions of the design
codes.
4.15 Welds shall be made by welders and welding procedures qualified in accordance
with the provisions of ASME Sec. IX. The procedure qualification shall include impact
test and hardness test when required as per clause 3.4 & 3.5 of this specification and
shall meet the requirements as specified therein.
4.16 Repair by welding on parent metal is not allowed. Repair of welds shall be carried out
only after specific approval by Company’s representative for each repair. The repair
welding shall be carried out by the welders and welding procedures duly qualified
as per ASME Section IX and records for each repair shall be maintained. The repair
welding procedure qualification shall include impact test and hardness test when
required as per clause 3.4 & 3.5 of this specification and shall meet the requirements
as specified therein.
Rev. No 0
For
DELHI SHEET 8 OF 11
4.17 The launcher/receivers shall be equipped with a half internal removable filtering basket
consisting of a punched plate with a least five rows of drain holes.
4.18 The filtering basket shall slide on guides on wheels and in all cases the material of
the parts being in contact with each other shall be of the anti-spark type.
4.19 The tolerance on internal diameter and out of roundness at the ends for the welding end
of the neck (at the end where connecting pipeline will be welded) shall be as per
applicable connected pipe specification as indicated in the data sheet.
4.20 Opening for nozzles shall be from material conforming to the same requirements
as the pressure containing parts, and adequately reinforced as per ASME B31.4/ B31.8.
All nozzles shall be flushed with the inside contour of the barrel.
The minimum distance between the edges of any attachment weld of a pressure
part (e.g. a nozzle) to the edge of another pressure weld of the launcher/receiver
body shall be 50 mm or twice the thickness of the pressure part, whichever is the
greater.
The nozzles shall be terminated with weld neck type raised faced flanges conforming to
ASME B16.5/16.47.
4.21 All weld shall be made by welders and welding procedures qualified in accordance with
the provision of ASME standard. No welding shall be carried out after post weld heat
treatment. All repair works on pressure parts welding shall be in accordance with
approved weld repair procedure.
4.22 The inside diameter of the neck of the launcher/receiver and the main flange shall match
the inside diameter of the pipeline on which it is to be installed. Diameter and out of
roundness tolerances for the neck shall be in accordance with the requirements of
Project Specification for Line Pipe.
5.0 INSPECTION AND TESTS:
5.1 The m a n u f a c t u r e r shall perform all inspections and test as per the
requirements 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:-
5.1.1 All launcher/receivers shall be visually inspected. The internal and external surfaces
shall be free from undercuts, overlaps, craters and other unacceptable defects.
5.1.2 C h e m i c a l composition and mechanical properties including hardness shall be

checked as per relevant material specif ication and this specif ication for each
heat of steel used.
5.1.3 D i m e n s i o n a l check shall be carried out as per the approved drawings.
5.1.4 All butt weld shall be 100% radiographically inspected. Procedure and acceptance criteria
shall be as per API 1104. Ultrasonic or magnetic particle inspection shall be carried out on
Rev. No 0
For
DELHI SHEET 9 OF 11
all welds, which in company’s opinion cannot be radiographically inspected. Procedure

and acceptance criteria shall be as per ASME sec. VIII, appendix U and Appendix VI
respectively.
All finished wrought weld ends shall be 100% ultrasonically inspected for lamination type
defects for a distance of 50mm from the ends. Any lamination larger than (1/4”) 6.35 mm
shall not be acceptable.
All forgings shall be wet magnetic particle examined on 100% of forged surfaces. Method
and acceptance shall comply with MSS-SP-53.
5.1.5 H y d r o s t a t i c test shall be conducted for all scraper launcher/receivers complete in

all respects including mounting of pig indicators at a pressure equal to 1.25 times the
design pressure for liquid and 1.4 times the design pressure for gas. The test pressure
shall be held for a minimum period of four hours.
A continuous recording of the pressure test is to be made including a calibration
(witnessed and certified) and is to be included in the documentation to be provided by
CONTRATCTOR.
The pressure test shall be performed after completion of all welding, heat treatment,
installation of any specified instrument and building of all flanges, and before painting.
5.1.6 A minimum of two closing and opening cycles shall be performed and correct operation
of both quick opening closure and safety system shall be ascertained after the
pressure cycles. No excessive force should be required to operate the mechanism.
5.2 Company reserves t h e r i g h t t o p e r f o r m s t a g e w i s e inspection and witness

tests including hydrostatic test, as indicated in specification at Manufacturer’s works
prior to shipment. Manufacturer shall give reasonable notice of time & shall provide
without charge reasonable access and facilities required for inspection, to
the company's representative. Inspection and tests performed / witnessed by
Company’s Representative s h a l l in no way relieve the Manufacturer’s o b l i g a t i o n of
specific integrity of the pig launchers/receivers.
6.0 TEST CERTIFICATES:
Manufacturer shall furnish the following certificates:
a) Test certificates relevant to t h e c h e m i c a l a n d M e c h a n i c a l

properties including Hardness of the materials used for manufacture of
launcher/receiver as per relevant standards and this specification.
b) Hydrostatic test certificates.
c) Test reports on radiography, ultrasonic inspection and magnetic particle

examination.
d) Test reports on heat treatment carried out, if any.
e) Welding procedure and welder qualification reports.
The certificate shall be considered valid only when signed by Company’s

Rev. No 0
For
representative/TPI . Launcher/Receiver shall be dispatched from Manufacturer’s works

only after these have been inspected and certified by Company’s Inspector.
7.0 PAINTING, MARKING AND SHIPMENT:
7.1 After all inspection and tests required have been carried out; all external surfaces
shall be thoroughly cleaned to remove grease, dust and rust. Surface preparation
shall be carried out by shot blasting to SP-6 in accordance with "Steel Structures
Painting Council Visual Standard - SSPC- VIS-1". Machined parts shall be coated
with anti-rust removable paint and non- machined parts shall be applied with two
coats of protective paint. Manufactures shall indicate the type of paint used in the
drawings submitted for approval.
The inner surfaces must be free of loose particles, lamination flakes, welding spatter and
sharp edges or any protruding element that interferes with the pig / scraper.
7.2 Marking shall be done on a stainless steel plate and affixed to the body by means of
corrosion resistant fasteners. Marking shall include the following:-
a) Manufacturer's Name
b) Launcher/receiver/ Neck Diameter, Thickness
c) Material
d) ASME Class Rating
e) Tag Number
f) Design Pressure
g) Design Temperature
h) Test Pressure
i) Design Factor
j) Year of Manufacture
k) Empty weight of the launcher/receiver assembly.
7.3 Equipment shall be drained of test liquid, cleaned and thoroughly dried prior to
shipment. Surfaces subject to atmospheric corrosion or rusting shall be coated with rust
preventive. External non-painted surfaces including bolting and flange faces also shall
be coated with rust preventive designed for at least six months of storage.
Before shipment, Launchers/Receivers shall be properly packed against damage during
transportation.
7.4 All components shall securely anchor to the skid and package supports.
7.5 All opening, flange facings, etc., shall be sealed with waterproof coverings for
shipping. Threaded coupling shall be provided with steel plugs.
7.6 Two extra O-rings and the closure actuation tool shall be attached to the inside of
the barrel to prevent loss. The Launcher/Receiver shall be handled in such a manner
so as to prevent damage, including damage to the bevel or closure. Service bolting
and gaskets shall be suitably rated and properly marked.
7.7 Flanged openings shall be protected with one-piece plywood cover and rubber
gasket. Plywood covers shall be 3/8 inch thick, for flanges 6 inches and smaller, 1⁄2
inch thick for 8 inch through 12 inch flanges, and 3⁄4 inch thick for larger sizes.
Rev. No 0
For
8.0 SPARES:
8.1 Manufacturer shall furnish list of recommended spares and accessories for Scraper
Launcher/receivers required during start up and commissioning especially consumable
spares viz. gaskets/ O-rings/ seals etc. for each launcher/receiver. Supply of such
spares shall be included in the price quoted by Manufacturer
8.2 Contractor shall furnish separately a list of recommended spares and accessories
required for two years of normal operation and maintenance of Scraper
Launcher/receivers and price for such item shall be quoted separately.
9.0 DOCUMENTATION:
9.1 Manufacturer shall furnish the following documents, drawings and specifications for
Company’s approval:
(a) D e s i g n c a l c u l a t i o n a n d General Arrangement Drawings
(b) Completed data Sheets
(c) Confirmation of scope of supply, including detailed Material and painting
specifications
(d) Clause wise list of deviations to specification, if any along with reason for same.
( e ) Launcher/receiver assembly, Closure assembly and sectional drawings showing
all parts with materials and dimensions.
(f) Proposed manufacturing/delivery schedule.
(g) Support Assembly drawing
(h) Proposed Quality Assurance/Safety Plan
(i) Proposed Surface Treatment
(j) Typical Inspection and Test Plan
(k) Table of Compliance
(l) Catalogue of End Closure
9.2 Prior to shipment, the Manufacturer shall submit the following:

a) Test certificate as listed in clause 6.0 of this specification.
b) Manual for installation, erection instructions, maintenance and operations
instruction.
9.3 All documents shall be in English Language.
10.0 GUARANTEE
Contractor/Manufacturer shall guarantee that the launcher/receiver along with

accessories is in compliance with the requirements of this specification for
materials and workmanship. Contractor/Manufacturer shall replace or repair all parts
which should result defective due to inadequate design or the workmanship. In case
the defect cann ot be eliminated, Contractor/ Manufacturer shall replace the
launcher/receiver without any delay. Any defect occurring within the time period specified
elsewhere shall be repaired making all necessary modifications and repair of defective
parts free of charge to the Company.
Rev. No 0
For
DELHI SHEET 1 OF 5
DATA SHEET
FOR
PIG LAUNCHERS AND RECEIVERS
JC NG SUS 0 15.09.2012

Rev. No 0
For
DELHI SHEET 2 OF 5
STANDARD FIELD DESCRIPTION

OUTSIDE DIAMETER, MM ( INCH ) 1
PIPELINE
DETAILS
THICKNESS , MM 2
MATERIAL API 5L Gr. X-46, PSL -2 3
DESIGN CODE 31.4 / 31.8 4
TAG NO. 5
SCRAPER TRAP MANUFACTURER 6
SERVICE/ SERVICE CODE LIQUID AND GASEOUS HYDROCARBONS 7
TYPE HORIZONTAL SADDLE MOUNTED, SUITABLE FOR INTELLIGENT PIGS 8
ANSI RATING 9
DESIGN TEMPERATURE (OC)
DESIGN DATA
10
DESIGN PRESSURE (Kg/cm2) 11
OUTER DIAMETER MM (INCH) 12
THICKNESS MM 13
MATERIAL 14
CORROSION ALLOWANCE (mm) 3 MM 15
DESIGN FACTOR 0.5 16
LOCATION 17
DIMENS
MATERIAL
PART ENDS/TYPE/ ION/
DESCRIPTION ITEM (EQUIVALENT OR 18
NO. DESCRIPTION QUANTI
SUPERIOR)
TY
API 5L Gr. X-46,
1 BARREL PIPE BW, EW/LSAW 19
PSL-2
API 5L Gr. X-46,
FLANGED,WNRF, PSL-2 & ASTM A
2 NECK PIPE 20
EW 694, GR F-46
(Flange)
MSS SP 75, Gr.
3 REDUCER ECCENTRIC (FSD) BW,WELDED 21
WPHY-46, BW
ASTM A 694 Gr.
4 KICKER CONNECTION WELDOLET + FLANGE FLANGED WNRF 22
F46
5 DRAIN CONNECTION WELDOLET + FLANGE FLANGED WNRF ASTM A 105 23
CONSTRUCTION
6 UTILITY CONNECTION WELDOLET + FLANGE FLANGED ASTM A 105 24
7 VENT WELDOLET + FLANGE FLANGED ASTM A 105 25
8 PR.GAUGE CONNECTION NIPPOLET PE, FORGED ASTM A 105 26
9 PSV/ TSV CONNECTION NIPPOLET PE, FORGED ASTM A 105 27
PRESSURE BALANCING
10 28
CONNECTION
As
11 SUPPORTS PLATE WELDED ASTM A 36 Require 29
d
EMPTY 30
12 VESSEL WEIGHT
FULL OF WATER 31
ANSI RATING 32
BODY SA 694 GR F 60
QUICK OPENING HINGED
13 INSERTS/GASKETS VITON 33
CLOSURE
OTHER COMPONENT VS
END CONNECTION WELDED 34
14 SUPPORT SADDLE CS 35
SHOP PAINITING– DFT
15 SHOT BLASTING + PRIMER + FINISH COAT 36
COATING 200µ
16 PIG SIGNALLER 37
Rev. No 0
For
DELHI SHEET 3 OF 5
WELD JOINT EFFICIENCY 1 38

WELD RADIOGRAPHY 100 % 39
HEAT TREATMENT (PWHT) ASME SEC VIII DIV 1 40
TESTING DATA
HYDROTEST PRESSURE (SHELL) 1.5 X DESIGN PRESSURE FOR MIN. 4 HOURS 41

CHARPY IMPACT TEST FOR
YES 42
MATERIAL
HARDNESS TEST FOR MATERIALS YES 43
MATERIAL CERTIFICATE YES IN ACCORDANCE WITH EN10204 3.2 44
INSPECTION BY TPI 45
R.F. PAD 46
MARKING DIMENSION (MM)
A
B
DIMENSION DETAILS (NOTE-2)
C
D
E
F
G 47
H
I
J
K
L
M
O
DESIGN OF LAUNCHER ASME B 31.8 / ASME 31.4 48
STANDARDS
DESIGN OF END CLOSURE ASME SEC VIII DIV I , UG-35 49

DESIGN OF FLANGES ASME B 16.5 50
DESIGN OF FITTINGS ASME B 16.9 51
END PREPARATION ASME B 16.25 52
ADDITIONAL REQUIREMENTS / NOTES :
1 ALL REQUIREMENTS APPLICABLE TO CRUDE OIL/ GAS SERVICE SHALL BE COMPLIED WITH AS PER SPECIFICATION NO.
OES/TD/INT/005/FS/PL03
2 THE DIMENSIONS INDICATED ABOVE ARE SUGGESTED ONLY. THE VENDOR/CONTRACTOR SHALL CHECK AND PROVIDE DIMENSIONS SUITABLE
FOR ACCOMODATING LATEST ONLINE INSPECTION TOOL (LONGEST) INCLUDING INTELLIEGENT PIGS WHEREVER REQUIRED. FINAL
DIMENSIONS SHALL BE APPROVED BY COMPANY
3 ORIENTATION OF ALL THE NOZZLES IS INDICATIVE AND SHALL BE CONFIRMED BY COMPANY DURING DRAWING APPROVAL STAGE.
4 CONTRACTOR SHALL SELECT THE WALL THICKNESS BASED ON PIPELINE DESIGN CONDITIONS AND MANUFACTURING REQUIREMENTS, AND
SUBMIT NECESSARY CALCULATIONS TO COMPANY FOR APPROVAL.
5 FLANGES WELDED ON SCRAPER TRAP SHALL HAVE SMOOTH FACE FINISH TO 125 AARH
6 EACH SCRAPER LAUNCHER SHALL BE PROVIDED WITH SUITABLE HANDLING SYSTEM FOR INSERTION & LAUNCHING OF PIGS INCLUDING
INSTRUMENT PIGS AS PER SPECIFICATION.
7 ALL CARBON STEEL FITTINGS/FLANGES MADE FROM ASTM A105 MATERIAL SHALL BE HEAT TREATED BY NORMALISING IN ACCORDANCE
WITH ASTM A961. ALL CARBON STEEL FITTINGS/FLANGES FROM ASTM A105 MATERIAL SHALL BE FINISH FORGED TO REQUIRED SHAPE.
MACHINED FITTINGS AND FLANGES ARE NOT ACCEPTABLE. MACHINING IS PERMITTED FOR WELD END PREPARATION AND FLANGE FACE
FINISH PREPARATION
8 ALL WELDOLETS SHALL BE AS PER MSS-SP-97 & ALL NIPPOLETS SHAL BE AS PER MANUFACTURER’S STANDARD.
9 DIMENSIONS SHALL BE DECIDED MY CONTRACTOR AND APPROVED BY COMPANY.
10 SCRAPER TRAP SHAL BE SUPLIED INCLUSIVE OF MOUNTING AND TESTING OF PIG SIGNALLER.
Rev. No 0
For
DELHI SHEET 4 OF 5
STANDARD FIELD DESCRIPTION

OUTSIDE DIAMETER, MM ( INCH ) 1
PIPELINE
DETAILS
THICKNESS , MM 2
MATERIAL API 5L Gr. X-46, PSL -2 3
DESIGN CODE 31.4 / 31.8 4
TAG NO. 5
SCRAPER TRAP MANUFACTURER 6
SERVICE/ SERVICE CODE LIQUID AND GASEOUS HYDROCARBONS 7
TYPE HORIZONTAL SADDLE MOUNTED, SUITABLE FOR INTELLIGENT PIGS 8
ANSI RATING 9
DESIGN TEMPERATURE (OC)
DESIGN DATA
10
DESIGN PRESSURE (Kg/cm2) 11
OUTER DIAMETER MM (INCH) 12
THICKNESS MM 13
MATERIAL 14
CORROSION ALLOWANCE (mm) 3 MM 15
DESIGN FACTOR 0.5 16
LOCATION 17
DIMENS
MATERIAL
PART ENDS/TYPE/ ION/
DESCRIPTION ITEM (EQUIVALENT OR 18
NO. DESCRIPTION QUANTI
SUPERIOR)
TY
API 5L Gr. X-46,
1 BARREL PIPE BW, EW/LSAW 19
PSL-2
API 5L Gr. X-46,
FLANGED,WNRF, PSL-2 & ASTM A
2 NECK PIPE 20
EW 694, GR F-46
(Flange)
MSS SP 75, Gr.
3 REDUCER ECCENTRIC (FSD) BW,WELDED 21
WPHY-46, BW
ASTM A 694 Gr.
4 KICKER CONNECTION WELDOLET + FLANGE FLANGED WNRF 22
F46
5 DRAIN CONNECTION WELDOLET + FLANGE FLANGED WNRF ASTM A 105 23
CONSTRUCTION
6 UTILITY CONNECTION WELDOLET + FLANGE FLANGED ASTM A 105 24
7 VENT WELDOLET + FLANGE FLANGED ASTM A 105 25
8 PR.GAUGE CONNECTION NIPPOLET PE, FORGED ASTM A 105 26
9 PSV/ TSV CONNECTION NIPPOLET PE, FORGED ASTM A 105 27
PRESSURE BALANCING
10 28
CONNECTION
As
11 SUPPORTS PLATE WELDED ASTM A 36 Require 29
d
EMPTY 30
12 VESSEL WEIGHT
FULL OF WATER 31
ANSI RATING 32
BODY SA 694 GR F 60
QUICK OPENING HINGED
13 INSERTS/GASKETS VITON 33
CLOSURE
OTHER COMPONENT VS
END CONNECTION WELDED 34
14 SUPPORT SADDLE CS 35
SHOP PAINITING– DFT
15 SHOT BLASTING + PRIMER + FINISH COAT 36
COATING 200µ
16 PIG SIGNALLER 37
Rev. No 0
For
DELHI SHEET 5 OF 5
17 FILTERING BASKET PUNCHED PLATE ASTM A 36 38

WELD JOINT EFFICIENCY 1 39
WELD RADIOGRAPHY 100 % 40
HEAT TREATMENT (PWHT) ASME SEC VIII DIV 1 41
TESTING DATA
HYDROTEST PRESSURE (SHELL) 1.5 X DESIGN PRESSURE FOR MIN. 4 HOURS 42

CHARPY IMPACT TEST FOR
YES 43
MATERIAL
HARDNESS TEST FOR MATERIALS YES 44
MATERIAL CERTIFICATE YES IN ACCORDANCE WITH EN10204 3.2 45
INSPECTION BY TPI 46
R.F. PAD 47
MARKING DIMENSION (MM)
A
B
DIMENSION DETAILS (NOTE-2)
C
D
E
F
G 48
H
I
J
K
L
M
N
DESIGN OF RECIEVER ASME B 31.8 / ASME 31.4 49
STANDARDS
DESIGN OF END CLOSURE ASME SEC VIII DIV I , UG-35 50

DESIGN OF FLANGES ASME B 16.5 51
DESIGN OF FITTINGS ASME B 16.9 52
END PREPARATION ASME B 16.25 53
ADDITIONAL REQUIREMENTS / NOTES :
1 ALL REQUIREMENTS APPLICABLE TO CRUDE OIL/ GAS SERVICE SHALL BE COMPLIED WITH AS PER SPECIFICATION NO.
OES/TD/INT/005/FS/PL03
2 THE DIMENSIONS INDICATED ABOVE ARE SUGGESTED ONLY. THE VENDOR/CONTRACTOR SHALL CHECK AND PROVIDE DIMENSIONS SUITABLE
FOR ACCOMODATING LATEST ONLINE INSPECTION TOOL (LONGEST) INCLUDING INTELLIEGENT PIGS WHEREVER REQUIRED. FINAL
DIMENSIONS SHALL BE APPROVED BY COMPANY
3 ORIENTATION OF ALL THE NOZZLES IS INDICATIVE AND SHALL BE CONFIRMED BY COMPANY DURING DRAWING APPROVAL STAGE.
4 CONTRACTOR SHALL SELECT THE WALL THICKNESS BASED ON PIPELINE DESIGN CONDITIONS AND MANUFACTURING REQUIREMENTS, AND
SUBMIT NECESSARY CALCULATIONS TO COMPANY FOR APPROVAL.
5 FLANGES WELDED ON SCRAPER TRAP SHALL HAVE SMOOTH FACE FINISH TO 125 AARH
6 EACH SCRAPER RECIEVER SHALL BE PROVIDED WITH SUITABLE HANDLING SYSTEM FOR INSERTION & LAUNCHING OF PIGS INCLUDING
INSTRUMENT PIGS AS PER SPECIFICATION.
7 ALL CARBON STEEL FITTINGS/FLANGES MADE FROM ASTM A105 MATERIAL SHALL BE HEAT TREATED BY NORMALISING IN ACCORDANCE
WITH ASTM A961. ALL CARBON STEEL FITTINGS/FLANGES FROM ASTM A105 MATERIAL SHALL BE FINISH FORGED TO REQUIRED SHAPE.
MACHINED FITTINGS AND FLANGES ARE NOT ACCEPTABLE. MACHINING IS PERMITTED FOR WELD END PREPARATION AND FLANGE FACE
FINISH PREPARATION
8 ALL WELDOLETS SHALL BE AS PER MSS-SP-97 & ALL NIPPOLETS SHAL BE AS PER MANUFACTURER’S STANDARD.
9 DIMENSIONS SHALL BE DECIDED MY CONTRACTOR AND APPROVED BY COMPANY.
10 SCRAPER TRAP SHAL BE SUPLIED INCLUSIVE OF MOUNTING AND TESTING OF PIG SIGNALLER.
11 DIMENSIONS OF FLANGE SHALL BE AS PER ASME B16.5 SERIES A
ONSHORE FUNCTIONAL DOC NO: OES/TD/INT/005/FS/PL04
ENGINEERING SPECIFICATION FOR Rev. 0
SERVICES CASING INSULATORS AND Discipline PIPELINE
DELHI CASING END SEALS Page : 1 of 4
FOR
CASING INSULATORS & END SEALS
JC NG SUS 0 15.09.2012
PREPARED/ APPROVED
REVIEWED BY REV NO. DATE
REVISED BY BY
1.0 SCOPE
This specification covers the minimum requirements of design, material, manufacture and supply of
casing insulators end seals intended to be used for cased pipeline crossings.
2.0 FUNCTIONAL REQUIREMENTS
2.1 Casing Insulators
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 shall not soften at design temperature.
- Resist corrosion.
- 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 strength in order to ensure a permanent support to the carrier
pipe.
Manufacturer shall obtain prior approval from Company on drawing/design of casing insulators before
manufacturing.
2.2 Casing end-seals
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.
Manufacturer shall obtain approval from Company on design/drawing of end seals.
3.0 DESIGN REQUIREMENTS
3.1 Casing Insulators
Casing Insulator shall be made in segments duly held together with cadmium plated bolts and nuts, to
be supplied with casing insulators. The arrangement of insulator shall be generally in accordance with
Fig-1 given below .
Casing Insulators without metallic part having a flexible section with toothed male strap at one end and
an appropriate toothed female slot on the other end for locking and converting to ring with proper
mechanical and compressive strength , can also be used .. Manufacturer shall obtain prior approval
from Company on design/drawing of these Insulators.
The number of segments shall be two for pipe diameters up to 12" (generally). For larger diameters,
the number of segments may be more than two, but their number shall be kept minimum.
The skid height shall be obtained by the following formula & shall be ≥ 2 inch:-
MATERIAL:
Casing insulators shall be made of injection moulded high density polyethylene or other material
equivalent or superior as approved by Company and shall meet the requirements given in Table-1.
TABLE-1 : Material Properties for Casing Insulators

Sr Property Value ASTM Test Method
No.
1 Dielectric Strength 450 – 500 Volts/Mil D-149
2 Compressive Strength 3200 PSI D-695
3 Tensile Strength 3100 – 5000 PSI D-638 , D-651
4 Impact Strength 4.0 Ft.lb/Inch D-256
5 Water Absorption 0.01 % D-570
3.2 Casing end seals
The seals shall be suitable for the casing and carrier pipe diameter 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 seal 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
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, disbanding, organic and bio-deterioration. Manufacturer
shall confirm compatibility of end seals with carrier pipe coating. Material for casing end seals shall
meet the requirements given below in table 2.
TABLE-2 : Material Properties for Casing End Seals

Property Value Test Method
Backing
( Sleeve and closure patch)
Tensile Strength 2200 psi ASTM D-638
Ultimate Elongation 400% ASTM D-638
Hear Shock No visual cracks, flow or ASTM D-2671
drips (at 225 C, 4 hours)
Adhesive
Ring and Ball softening 90 C ASTM E-28

point 60 C – 25psi
Lap Shear 23 C - 250 psi ASTM D-1002
(2 inch/min.)
System (as applied)
Peel Strength 5 psi ASTM D-1000

(To casing and carrier pipe (10 inch/min.)
and closure patch)
4.0 Inspection and Testing
Manufacturer shall furnish material test certificates of the components used in the assembly of insulators
and casing end seals as per the requirements of this specification.
4.0 Documentation
Manufacturer shall submit documentation for casing insulators and end seals, which shall include
the following as minimum.
i. General Arrangement Drawings
ii. Test and material certificates of all components used in the assembly of casing insulators
and end seals
iii. 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.
iv. The manufacturer shall replace, at no extra cost, any material not conforming to the material and
performance requirements of this specification
Fig-1
OES/TD/INT/005/
SPEC. No.
Design Division FUNCTIONAL FS/PL05
Onshore SPECIFICATION Rev. No. 0
Engineering FOR
Services Discipline: Pipeline
ISO – 9001:2000
LINE PIPE PAGE : 1 of 12
FOR
LINE PIPE
PREPARED / TOTAL No.

REVIEWED BY APPROVED BY DATE REV. No.
REVISED BY OF PAGES
JC NG SUS 12 20.11.2012 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
INDEX
1.0 SCOPE
2.0 CODES, REGULATIONS AND STANDARDS
3.0 INFORMATION TO BE SUPPLIED BY THE PURCHASER
4.0 AMMENDMENTS / SUPPLEMENTS TO API 5L (FORTY FOURTH

EDITION)
5.0 DOCUMENTATION
6.0 WARRANTY
7.0 Annexure-1
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
1.0 SCOPE
This General Specification defines minimum requirements for the

manufacture of line pipes for use in oil / gas operations under non-sour
service applications.
This specification is based on API Specification 5L, 44th edition, October
2007 and shall be read in conjunction with that document. Clause 4.0 of
this General Specification gives amendments and supplements to clauses
of API Specification 5L, which are considered necessary to enhance
pipeline integrity in accordance with the Company’s requirements.
The manufacturer(s) shall have valid license from API authorities to
manufacture pipes as per API 5L. The Contractor shall submit to the
Company, a copy of valid API 5L license of the manufacturer, prior to
procurement. All pipes be procured for the project by the Contractor shall
be in accordance with this General Specification and shall comply with the
requirements of API Specification 5L, as amended and supplemented
herein.
2.0 CODES, REGULATIONS AND STANDARDS
2.1 The Contractor / Vendor shall meet or exceed the requirements of the
latest edition of the following codes, regulations and standards, except as
superseded herein. In cases of more than one code, regulation or
standard apply to the same condition most stringent shall be followed.
 American Petroleum Institute (API)
- API Spec 5L / Specification for Line pipe. (44th edition)

ISO 3183:2007
- API RP 5L1 Recommended Practice for Railroad

Transportation of Steel Line Pipe
- API RP 5LW Recommended Practice for Transportation
of Line Pipe on Barges and Marine Vessels.
- API Std. 1104 Welding of Pipelines and Related Facilities.
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
 American Society of Mechanical Engineers (ASME)
- ASME B 31.3 Chemical Plant And Petroleum Refinery

Piping
- ASME B 31.4 Pipeline Transportation System for liquid
Hydrocarbon and other liquids
- ASME B 31.8 Gas Transmission and Distributor Piping
Systems.
 American Society for Testing and Materials (ASTM)
- ASTM A 370 Standard Test Methods and Definitions for

Mechanical Testing of Steel Products
- ASTM E 112 Standard Test Methods for Determining

Average Grain Size
- ASTM E 165 Practice for Liquid Penetrant Examination
- ASTM E 309 Standard Practice for Eddy Current

Examination of Steel Tubular Products
using Magnetic Saturation
- ASTM E 570 Standard Practice for Flux Leakage

Examination of Ferromagnetic Steel Tubular
Products
- ASTM E 709 Practice for Magnetic Particle Examination.
 International Organization for Standardization (ISO)
- ISO 19232 - Non-destructive testing -- Image quality of

radiographs
- ISO 2566 -1 Steel, Conversion of Elongation Values

Part 1 Carbon and Low Alloy Steels.
- ISO 9712 Non-destructive Testing: Qualification and

Certification of Personnel
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
- ISO 10474 Steel and Steel Products Inspection

Documents
 Oil Industry Safety Directorate (OISD)
-OISD 141 Design and Construction Requirement for

Cross Country Hydrocarbon Pipelines.
-OISD 226 Natural Gas Transmission Pipelines and City
Gas Distribution Networks.
2.2 Any deviation from this specification must be approved by the Company
prior to the commencement of any work.
3.0 INFORMATION TO BE SUPPLIED BY THE PURCHASER
TABLE: 3.1
Sl. Information Reference
1. Specification API 5L 44th edition
2. Product Specification
PSL - 2
Level
3. Outside diameter (mm)
4. Quantity (mtrs.)
5. Grade
6. Manufacturing Process EW/Seamless/LSAW
7. Wall thickness (mm)
8. Nominal length (mtrs) Minimum Length: 11.0 m
Maximum Length: 12.5 m
Minimum Average Length: 12.00 m
However pipe with length between 10.0 m and
11.0 m can also be accepted for a max. of 5 %
of the ordered quantity. API 5L table 12 shall not
be applicable.
Jointers shall not be permitted.
9. End finish Plain-end pipe, with ends beveled to an angle of
30 degrees (+5 degree, -0 degree), measured
from a line drawn perpendicular to the axis of
the pipe and with a root face of 1/16 in. +/-1 / 32
in. (1.6 +/- 0.8 mm)
10 Delivery Date
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
4.0 AMMENDMENTS / SUPPLEMENTS TO API 5L (FORTY FOURTH EDITION)
TABLE: 4.1
API Spec 5L reference Amendment / Supplement

Section Clause
Quality System
1 Add new
Scope clause The line pipe manufacturer shall
establish and maintain a quality
assurance system in accordance with
ISO 9001: 2000 or an equivalent. The
Company shall have the right to
undertake such audits as it deems
necessary to assess the effectiveness
of the manufacturer’s quality system.
Add new Compliance
clause This specification adopts sampling as
a method to determine batch
compliance. Nevertheless the
manufacturer is responsible to ensure
and certify that all pipes meet the
requirements of this specification.
8 8.9 Cold Add to the existing clause:
Manufacturing sizing and EW pipes shall not be cold expanded.
cold
expansion
8.11 Add to the existing clause:
Jointers Jointers shall not be supplied.
8.12 Delete existing section & replace with
Heat the following:
Treatment Seamless pipe shall be furnished in
the hot formed, normalized and
tempered or quenched and tempered
condition. For hot formed pipe, the
finishing temperature shall be greater
than 7800C.
Pipe finished at a lower temperature

than 7800C shall be subjected to a
further normalizing heat treatment with
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
a minimum holding time of 30

minutes.
The heat treatment process shall be

performed in accordance with a
documented procedure. The
manufacturer shall establish and
follow procedures for maintaining heat
and / or lot identity.
9.2 Chemical Table 5 Delete existing carbon equivalent
composition column and the following shall be
applicable for all grades.
CEPCM ≤ 0.20 %
CEIIW ≤ 0.40 %
9.11 9.11.3.1 Delete existing clause and replace
Dimensions, with:
mass and The tolerance in diameter shall be as
tolerances follows:
For all pipe size tolerance shall
be ± 0.75 % or ± 3 mm
whichever is smaller.
The out of roundness tolerance shall

be as follows:
2mm ( pipe size ≤ 10 ¾ Inch)
3mm (pipe size ≥ 12 ¾ Inch)
9.11.3.2 Negative tolerance is not permitted
Wall The tolerance on specified wall
Thickness thickness shall be + 15% and - 0%.
9.11.3.3 Tolerance on length shall be as
Length indicated below:
Minimum Length: 11.0 m
Maximum Length: 12.5 m
Minimum Average Length:12.00 m
However pipe with length between
10.0 m and 11.0 m can also be
accepted for a max. of 5 % of the
ordered quantity. API 5L table 12 shall
not be applicable. Overall length
tolerance shall be (-) zero and (+) One
pipe length to complete the ordered
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
quantity.
Add new Each pipe shall be measure for
clause conformance to dimensions specified
and subject to applicable tolerance. All
dimensions and tolerance shall be
measured and recorded at least 3
times per operating shift (12 hours
maximum).
10 10.2.2 Samples Add to the existing clause:
Inspection and test Samples may be taken using any of
pieces for the methods indicated in API Spec 5L,
product provided they are taken from finished
analysis pipe, before trimming.
12 12.2 Delete existing section & replace with
Coatings and Thread the following:
thread Protectors END PROTECTORS
protectors Suitable end caps shall be provided to
protect the beveled ends.
Add New First Day General
Section Production Finished pipes of the first day’s
Tests production of each heat shall be
selected at random for testing to verify
that the manufacturing procedure
results in full compliance to the
specifications. Requirements
mentioned in clause B.4 of API 5L
shall be referred for first day
production test. However details of the
First Day Production test is at Annex
1.
The above first day production test
shall be repeated after any change in
the manufacturing procedure or
interruption to the programme.
Note:
1) This specification is not applicable for sour service.
2) For gas service, the pipe shall also comply with Annex G of API 5L
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
5.0 DOCUMENTATION
In addition to the documents specified at clause no.13 of API 5L (44th

edition) and elsewhere in the Bid Document, the Contractor shall obtain and
furnish from the manufacturer(s), the complete record of pipes, including
purchase order numbers, lists of pipe produced with identification numbers,
heat numbers, dimensions, individual pipe lengths, certificates for mill test &
third party inspection reports etc.
6.0 WARRANTY
The Contractor/Vendor shall have final and total responsibility for the design,
fabrication and performance of all items supplied under this specification.
The Contractor/ Vendor shall warrant the items furnished by him and the
performance of the said items in accordance with this specification and with
warranty requirements as specified in the bid package.
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
Annexure 1
FIRST DAY PRODUCTION TESTS
Two length of completely finished pipes( in case of only one heat on first day ) or
two length from the first two heats i.e. one pipe from each heat( in case of more
than one heat on first day) of first day’s production shall be selected at random for
testing 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 per lot as per relevant
clauses of this specification.
These first day’s production tests shall be repeated upon any change in the
manufacturing procedure or any change in the source of raw material as deemed
necessary by the Company’s Representative. The first day production test shall be
carried out on pipes for each wall thickness, each diameter and each grade of
steel.
The contractor shall submit to Company a report giving the results of all tests
mentioned below. The report shall be agreed and signed by Company’s
representative, prior to start of regular production.
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 first day production test shall not be carried out. Pipes in such
case shall be accepted based on regular production tests.
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 Annexure.
1. Visual Examination
All pipes shall be examined visually for dimensional tolerances
and apparent surface defects.
2. Ultrasonic Examination
The weld seam of all pipes shall be examined ultrasonically by
automatic ultrasonic equipment. If an automated ultrasonic or
electromagnetic inspection system is applied, the weld at any pipe
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
ends that are not covered by the automated inspection system

shall be inspected for defects by the manual or semi-automatic
ultrasonic angle beam method or by the radiographic method,
whichever is appropriate.
3. Mechanical Properties
The mechanical properties of all pipes shall be tested and shall
meet the requirements of this specification. The company’s
representative / TPI will select the places in pipe from where the
test specimen shall be removed. The following tests shall be
conducted:
i. Two flattening test specimen shall be removed; one
specimen shall be tested with weld at 0 o and other at 90 o.
ii. Two transverse base metal specimens and two transverse

weld specimens for tensile test shall be tested. In case
transverse base metal specimen is not applicable as per
API 5L, longitudinal specimen may be taken.
iii. Six weld cross-section specimens, three from each end of

the pipe joint, shall be taken for metallographic
examination. Two of these specimens shall be tested for
hardness at room temperature after etching.
iv. Fracture toughness testing specimen shall be extracted as

follows:
a. Four sets of three transverse specimens each from
base metal.
b. One set of 3 transverse specimens with weld in
middle.
c. One set of 3 transverse specimens with HAZ in
middle.
The base metal specimens shall be tested at -40, -10, 0,
+20 o C for shear area and absorbed energy to produce full
transition curve.
v. At points selected by Purchaser twelve (12) Drop Weight

Tear Test specimens shall be removed from base metal in
a transverse direction. The sets of 3 base metal specimen
shall be tested at -40,-10, 0, +20 oC for shear area to
produce full transition curve.
OES/TD/INT/005/
SPEC. No.
Engineering FOR
ISO – 9001:2000
vi. Four weld guided bend test specimen (only for LSAW)
transverse to longitudinal weld shall be removed. Of the
four specimens. Two specimens shall be used for face
bend test and two for root bend test.
4. In addition, all the tests and inspections required to be conducted

as per API 5L shall be conducted on all the pipes selected for
testing during first day production test.
DATA SHEET FOR EW LINE PIPE
SL. DETAILS DATA
1. SPECIFICATION API 5L 43RD EDITION

2. PRODUCT
PSL 1 / PSL 2
SPECIFICATION LEVEL
3. OUTSIDE DIAMETER ……..MM
3. PROCESS EW
4. GRADE
5. WALL THICKNESS ….. MM
6. MILL TEST PRESSURE …….BAR
7. QUANTITY …….MTRS.
7. NOMINAL LENGTH MINIMUM LENGTH: 11.0 M
MAXIMUM LENGTH: 12.5 M
MINIMUM AVERAGE LENGTH: 12.00 M
JOINTERS SHALL NOT BE PERMITTED.

8. END FINISH PLAIN-END PIPE, WITH ENDS BEVELED
TO AN ANGLE OF 30 DEGREES
(+5 DEGREE, -0 DEGREE), MEASURED
FROM A LINE DRAWN PERPENDICULAR
TO THE AXIS OF THE PIPE AND WITH A
ROOT FACE OF 1/16 IN. +/-1 / 32 IN. (1.6
+/- 0.8 MM)
CORPORATE DESIGN DOCUMENT NO. :

DATA SHEET FOR EW DS/CDG/PLM/01-EW
GROUP, MUMBAI
LINE PIPE
Page 1 of 1 Rev. 1
DATA SHEET FOR SEAMLESS LINE PIPE
SL. DETAILS DATA
1. SPECIFICATION API 5L 43RD EDITION

2. PRODUCT
PSL 1 / PSL 2
SPECIFICATION LEVEL
3. OUTSIDE DIAMETER ……..MM
3. PROCESS SEAMLESS
4. GRADE
5. WALL THICKNESS ….. MM
6. MILL TEST PRESSURE …….BAR
7. QUANTITY …….MTRS.
8. NOMINAL LENGTH MINIMUM LENGTH: 11.0 M
MAXIMUM LENGTH: 12.5 M
MINIMUM AVERAGE LENGTH: 12.00 M
JOINTERS SHALL NOT BE PERMITTED.

9. END FINISH PLAIN-END PIPE, WITH ENDS BEVELED
TO AN ANGLE OF 30 DEGREES
(+5 DEGREE, -0 DEGREE), MEASURED
FROM A LINE DRAWN PERPENDICULAR
TO THE AXIS OF THE PIPE AND WITH A
ROOT FACE OF 1/16 IN. +/-1 / 32 IN. (1.6
+/- 0.8 MM)

DATA SHEET -LINE DS/CDG/PLM/01-SL
GROUP, MUMBAI
PIPE SEAMLESS
Page 1 of 1 Rev. 1
ENGINEERING FUNCTIONAL SPECIFICATION FOR Rev. No 0
SERVICES, PIPELINE FLOW TEES Discipline Pipeline
DELHI SHEET 1 OF 9
FOR
PIPELINE FLOW TEES
JC & PSS NG VNM 0 15.05.2014

DELHI SHEET 2 OF 9
INDEX
SL TITLE PAGE NO
1.0 Scope 3
2.0 Reference Documents 3
3.0 Manufacturer’s Qualification 3
4.0 Materials 4
5.0 Design and Construction Requirements 4
6.0 Inspection & Tests 6
7.0 Test Certificates 7
8.0 Painting, Marking & Shipment 7
9.0 Documentation 8
10.0 Warranty 9
DELHI SHEET 3 OF 9
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture
and supply of carbon steel flow tees to be installed in onshore pipeline
systems handling non-sour hydrocarbons in liquid or gaseous phase.
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:
REFERENCE DOCUMENTS
ASMEB Pipeline Transportation Systems for Liquid
31.4 Hydrocarbons and Other Liquids
ASMEB Gas Transmission and Distribution Piping System

31.8
ASMEB Factory Made Wrought Steel Butt Welding Fittings
16.9
ASME Sec Boilers & Pressure Vessel Code - Rules for the
VIII Construction of Pressure Vessels
ASME Sec Boilers & Pressure Vessel Code - Welding and

IX Brazing Qualifications
API-1104 Specification for Welding Pipeline and Related Facilities

ASTMA370 Standard Test Methods and Definitions for
Mechanical Testing of Steel Products
MSS-SP-53 Quality Standard for Steel Castings and Forgings for
Valves, Flanges and Fittings and Other Piping
Components - Magnetic Particle Examination Method.
MSS-SP-75 Specification for High Test Wrought Welding Fittings
SSPC-VIS-1 Steel Structures Painting Council
In case of conflict between the requirements of this specification and the
codes, standards and specifications referred above, the requirements of this
3.0 MANUFACTURER'S QUALIFICATION
Manufacturers who intend supplying flow tees must possess the records of a
successful proof test for tees used in the fabrication of flow tees, in
accordance with the provisions of ASME B 16.9/ MSS-SP-75, as applicable.
DELHI SHEET 4 OF 9
4.0 MATERIALS
4.1 Materials for the pressure containing parts of the flow tees shall be as
indicated in the Flow Tees Data Sheet. Other parts shall be as per
Manufacturer's standard suitable for the service conditions and shall be
subject to approval by Company. In addition, the material shall also meet the
requirements specified hereinafter.
4.2 The Carbon Steel used in the manufacture of flow tees shall be fully killed.
4.3 Each heat of steel used for the manufacture of pressure containing parts of the
flow tees shall have Carbon Equivalent (CE) not greater than 0.45 based on
check analysis calculated as per the following formula:
Mn Cr+ Mo + V Ni + Cu
CE = C + ---------- + --------------- + -----------
6 5 15
4.4 For flow tees specified to be used for Gas service, Charpy V-notch test shall be
conducted at 0°C for each heat of steel used in the manufacture of pressure
containing parts of flow tee. The test procedure shall conform to MSS-SP-75 I
ASTM A370. The average absorbed impact energy values of three full-sized
specimens of base metal, weld metal and HAZ shall be 27 joules, unless
otherwise indicated in the Data Sheet. The minimum impact energy value of any
one specimen shall not be less than 22J.
When Low Temperature Carbon Steel (LTCS) materials are specified in Data
Sheet or offered by Manufacturer, the Charpy V-notch test requirements of
applicable material standard shall be complied with.
4.5 For flow tees specified to be used for Gas service, hardness test shall be carried
out as per ASTM A 370 for each heat of steel used in the manufacture of tees.
A full thickness cross section shall be taken for this purpose and the maximum
hardness of base metal, weld metal and HAZ of all the pressure containing parts
shall not exceed 248 HV 10.
5.0 DESIGN AND CONSTRUCTION REQUIREMENTS
5.1 Flow tees shall be designed and manufactured in accordance with the
provisions of Codes, Standards and Specifications referred in Section 2.0 of
this specification. In addition, design factor and corrosion allowance, as
indicated in the Data Sheet, shall also be taken into account for design of Flow
tees.
5.2 Flow tees shall generally conform to the figure shown in the Data Sheet and
shall meet the following requirements:
a) An internal pipe having the same internal diameter as the connecting

pipeline allowing the passage of scraper/instrumented pigs, shall be
provided with holes/slots located in the centre line of the branch. The
DELHI SHEET 5 OF 9
holes/slots shall be oriented at 45° angle. The number(s) and size of

holes/slots shall be such as to prevent the pig getting stuck or damaged
without affecting the flow through the branch line. The area of the
holes/slots shall be at least equal to the internal area of branch size.
Calculations for the area shall be furnished.
b. A seamless / submerged arc welded "tee" as per ASME B 16.9 / MSS-

SP-75, enclosing the internal pipe and fixed to it by suitably shaped
forged steel rings. Machined steel rings shall not be used. The center to
end dimension of the outlet shall meet the minimum recommended
dimension of the referred standard. Circumferential welding on the
branch outlet is not acceptable. Pups shall not be provided either at the
run or at the branch.
c) Tees used for fabrication of flow tees shall be seamless type for run
sizes DN ≤ 350 mm (14") and shall be either welded or seamless type
for run sizes DN ≥ 400 mm (16"). Tees shall conform to ASME B 16.9
for run size up to DN 350 (14"). For run size DN ≥ 400 mm (16"), the
tees shall conform to MSS-SP-75/ASME B 16.9.
d) The flow tees run/branch diameter and wall thickness shall be as indicated
in the data Sheet, matching with the connecting pipeline.
5.3 Butt weld ends of flow tees shall be beveled as per MSS-SP-75.
5.4 All flow tees shall be completely stress relieved as per the provisions of MSS-SP-
75.
5.5 Stub-in or pipe-to-pipe connection shall not be used in the manufacture of flow
tees. Tees used for manufacturing of flow tees shall be manufactured by forging
or extrusion methods. In case flow tees are manufactured using welded tees,
the longitudinal weld seam shall be oriented at least 90° to the branch
connection.
5.6 All welds shall be made by welders and welding procedures qualified in
accordance with ASME Section IX. The procedure qualification shall include
impact test and hardness test and shall meet the requirements of clause 4.4 and
4.5 of this specification respectively.
5.7 Repair by welding on parent metal of the flow tee is not permitted. Repair of
weld seam by welding shall be carried out only after specific approval by
Company's Inspector for each repair. The repair welding shall be carried out
by the welders and welding procedures duly qualified as per ASME Section IX
and records for each repair shall be maintained. Repair welding procedure
qualification shall include all tests, which are applicable for regular production
welding procedure qualification.
5.8 The tolerance on internal diameter and out of roundness at the ends for welded
flow tees shall be as per applicable connected pipe specification as indicated in
the Data Sheet.
DELHI SHEET 6 OF 9
6.0 INSPECTION & TESTS
6.1 The Manufacturer shall perform all inspections and tests as per the
requirements of this specification and the relevant codes, standards and
specifications, prior to shipment at his works. Such inspections and tests shall
be, but not limited to, the following:
6.1.1 All flow tees shall be visually inspected. The internal and external surfaces of
the flow tees shall be free from any strikes, gauges and other detrimental
defects.
6.1.2 Dimensional checks shall be carried out as per the approved drawings.
6.1.3 Chemical composition and mechanical properties shall be checked as per MSS-
SP-75/relevant material standards, and this specification for each heat of steel
used.
6.1.4 Nondestructive examination of individual flow tees shall be performed as given

below:
a) 100% inspection by radiography shall be carried out on all butt welds of

pressure containing parts. Acceptance limits shall be as per API-1104.
b) All finished wrought weld ends shall be 100% ultrasonically tested for
lamination type defects for a distance of 25 mm from the end. Any
lamination larger than 6.35 mm shall not be acceptable.
c) Magnetic particle or liquid penetrant examination shall be performed on

cold formed butt welding tees with extruded outlets that are
subjected to an extreme fiber elongation of greater than 5%. The
examination shall be carried out as per the Supplementary Requirement
SR 3 ofMSS-SP-75.
d) Welds, which, in Company's Inspector's opinion, cannot be inspected by

radiographic methods, shall be checked by ultrasonic or magnetic
particle methods. Acceptance criteria shall be as per ASME Section VIII
Appendix 12 and Appendix 6 respectively.
e) All forgings shall be wet magnetic particle examined on 100 % of the

forged surfaces. Method and acceptance shall comply with MSS-SP-53.
6.2 Company'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 Company's Inspector.
Inspection and tests performed/witnessed by Company's Inspector shall in no

way relieve the Manufacturer's obligation to perform the required inspection and
DELHI SHEET 7 OF 9
tests.
Manufacturer shall submit the following certificates to Company's inspector:
a) Test certificates relevant to the chemical analysis and mechanical properties

including hardness of the materials used for construction as per this
specification and relevant standards.
b) Test reports on radiographic, ultrasonic inspection and wet magnetic particle

examination.
c) Test certificates for each flow tee stating that it is capable of withstanding
without leakage a test pressure which results in a hoop stress
equivalent to 95% of the specified minimum yield strength for the pipe with
which the flow tee is to be attached without impairing its serviceability.
d) Test reports on heat treatment carried out.
e) Welding procedures and welders qualification reports.
8.0 PAINTING, MARKING & SHIPMENT
8.1 After all inspection and tests required have been carried out/witnessed
by Company's Inspector, entire surface of flow tees shall be thoroughly
cleaned, freed from rust and grease and shall be applied with sufficient coats of
standard mill coating/corrosion resistant paint, for protection against corrosion
during transit and storage. The surface preparation shall be carried out by shot
blasting to SP6 in accordance with "Steel Structures Painting Council - Visual
Standard- SSPC-VIS-I".
8.2 Manufacturer shall indicate the type of mill coating I corrosion resistant paint
used in the drawings submitted for approval.
8.3 Flow tees shall be suitably protected to avoid any damage during transit.
Metallic or high impact plastic bevel protectors shall be provided for weld ends.
8.4 Flow tees shall be marked with indelible paint with the following data:
a. Manufacturer's name
b. Nominal diameter in mm (inches) D1
x D2. End thickness in mm T1 x T2
d. Material
e. Tag numbers
8.5 Coating and Painting
Coating to be same as that of main line pipe i.e. 3LPE Coating for pipe to be laid
DELHI SHEET 8 OF 9
underground and anti-rust paint coating for pipes laid above ground.
9.0 DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized

below. Number of Copies (Hard copies I soft copies etc.) shall be as indicated in
CONTRACT document.
9.1 Bidder shall submit the following documents:
a. General arrangement drawings of flow tees with overall dimensions

and cross sectional drawings.
b. Reference list of similar supplies including all relevant details viz.

Project, Year of supply, Client, Size, Rating and Service for the last five
years.
c. Records of successful proof test for tees used for fabrication of flow
tees, qualifying the range of sizes quoted.
d. Brief description of the manufacturing, heat treatment and quality control

facilities of the Manufacturer's Works.
e. Clause wise list of deviations from this specification,

if any.
9.2 The Manufacturer shall submit the following drawings, documents and
specifications for approval:
a. Fabrication drawings and relevant calculations for pressure

containing parts.
b. Calculations for the no. and size of holes/slots and flow area.
c. Method of manufacture, welding procedure and heat

treatment details.
d. Quality Control Manual and Quality Control Plan.
e) Type of mill coating/anti-corrosion/anti-fouling
paint
Once the approval has been given by Company, any change in design, material
and method of manufacture shall be notified to the Company whose approval
in writing of all changes shall be obtained before the flow tees are
manufactured.
9.3 Manufacturer shall submit all the approved drawings, documents and
specifications as listed in clause 9.2 of this specification.
9.4 Prior to shipment, the Manufacturer shall submit the test certificates as listed in
clause 7.0 of this specification.
DELHI SHEET 9 OF 9
10.0 Warranty
fabrication and performance of all items supplied under this specification. The
Contractor/Vendor shall warrant the items furnished by him and the
ONSHORE Data Sheet Spec No OES/TD/INT/005/DS/PL06
ENGINEERING For Rev. No 0
SERVICES, Pipeline Flow Tee Discipline Pipeline
DELHI SHEET 1 OF 2
DATA SHEET
FOR
PIPELINE FLOW TEE
JC & PSS NG VNM 0 15.05.2014

ONSHORE Data Sheet Spec No OES/TD/INT/005/DS/PL06
SERVICES, Pipeline Flow Tee Discipline Pipeline
DELHI SHEET 2 OF 2
DATA SHEET FOR PIPELINE FLOW TEE
DESIGN DATA
1. Flow tee MFR. : _______________________
2. Purchaser's specification no : _______________________
3. Rating : # _____________________
4. Design pressure : _________________ kg/cm2
5. Design temperature : (-) 29°C to _______°C
6. Service : Natural gas / Crude Oil
7. Corrosion allowance : _______mm (Same as that of main line)
8. Size NB mm (inches) : __________ (D1 X D1 X D2)
9. End connection : butt-weld at both ends
10. Design code : ASME B31.8 / ASME 31.4
11. Design factor : 0.5
12. Hydrostatic test pressure : _________________ kg/cm2
13. Charpy test : Required AT (-) 200C, CV (Avg.) - 35
J/cm2 / CV (Min.) - 28 J/cm2
14. Hardness test : required as per spec.
15 Suitability of flow tee : for pigs and spheres
16 Flow directions : bi - directional
17 Materials Specification (equivalent or superior)
1) Tee : MSS - SP - 75 Gr. WPHY 70
2) End pieces : ASTM A - 694 F - 70
3) Internal sleeve : API 5L Gr. B
18 Connecting pipe specification:
Sl Tag Run Pipe Details Branch Pipe Details Qty.

. No. D1 T1 Min Material D2 T2 Min Material Nos.
Thickness Thickness
NB(Inch) mm NB(Inch) mm
1 API 5L API 5L X___(ref-
X___(ref- Main line)
Main line)
Note:
1- Manufacture to indicate dimensions marked a & b in the sketch above.
2- Manufacturer to furnish details of the holes in internal sleeve. The area of the holes shall be
minimum equal to the internal area of the branch pipe.
3- Relevant calculations to this extent shall be furnished.
4- The thickness of end pieces & tee of flow tee shall match with the thickness of the run pipe &
branch pipe as indicated above.
SPECIFICATION
FOR
PIPING SPECIALITIES
2 17.10.2005 KRK SN PKM
1 23.03.2005 KRK SN PKM
REV.NO. DATE PREPARED REVIEWED BY APPROVED BY

BY

SPECIFICATION FOR CDG/MUM/PLM/07
GROUP, MUMBAI
PIPELINE SPECIALITIES
Page 1 of 9 Rev. 2
SPECIFICATIONS FOR PIPING SPECIALITIES
1.0 INTRODUCTION
1.1 General
The minimum and mandatory requirements of designs & materials

for piping specialties & components are as hereunder. All piping
assemblies, specialties & materials supplied or installed under
these specifications shall be in accordance with sound engineering
principles.
1.2 Contractor’s Responsibilities
The Contractor shall be responsible for the selection and design of

piping specialties, including full compliance with all applicable project
specifications and design Codes / Standards, including those listed in
Section 2.0 of this Specification. Approval shall be obtained from the
Company before any work is sub-contracted.
2.0 SCOPE OF SUPPLY
2.1 The Contractor shall be responsible for the design, engineering, supply
of materials, fabrication, coating, installation and testing of the pipe work,
supply of drawings and data, all sub-contractor co-ordination and
guarantees as required, not withstanding any omissions from this
Specification.
1. Hydro-test Condition (The empty weight plus weight of water to fill the
piping).
2. Operating and Design Conditions (The empty weight plus the weight
of operating fluid).
3. Wind loading condition
4. Dynamic Loading Condition
5 Periodic Site Test Condition
2.2 Drawings and Calculations
GAD/ Vendor drawing, Isometric drawings shall contain all pertinent

information relating to the Standards, Codes & standards and
Specifications used in the design, fabrication, inspection and testing of
all the specialties, the pipe work, including the materials used.

GROUP, MUMBAI
Page 2 of 9 Rev. 2
The Contractor shall submit detailed calculations establishing the
compliance of their design with the requirements of ASME B31.3.
Contractor to prepare the data sheets for each specialty & shall provide
the information such as item description, pipe size, thickness, valve
selection & tag Nos, designed pressure- temperature ratings, hydrostatic
pressure, list of spares and applicable codes/standards. Contractor to
submit the data sheets of each specialty for company’s review &
approval.
Contractor to prepare the specifications, data sheets based on the

functional parameters, relevant piping class as per approved P&ID &
material of construction and submit to company for review & approval.
Methods of calculations which are not in accordance with the relevant

Code or established procedures shall be subject to approval by the
Company for its applicability to the design.
All calculations shall be complete, giving all references and showing all
working methods. The Contractor shall be able to provide proof of
software verification for any software used. Computer printouts will not
be accepted without the program flow chart, input data and complete
printout, and then only by prior written agreement with the Company at
the quotation stage.
Where relevant, additional calculations shall be undertaken regarding

the effects of slug forces.
The pipe work shall be analyzed in its corroded state for each load
combination.
Approval of drawings, calculations and other documents by the

Company does not relieve the Contractor of their responsibility for the
correctness of the design to suit the stated conditions.
Notes
• The Contractor shall furnish sizing calculations, material of

construction etc. along with the PR during detailed engineering.
• A pre-commissioning functional test will be demonstrated by the

Contractor before commencement of pigging operations during
cleaning prior to pipeline hydro-test.
• Pressure drop and noise level to be within specified / acceptable

limits so as to ensure cavitations / vibration free operation.

GROUP, MUMBAI
Page 3 of 9 Rev. 2
• In case there is a fault/malfunctioning Contractor / vendor shall
carryout necessary rectification / replace the parts / complete
assembly at his cost.
3.0 MATERIALS
3.1 Materials shall be new and unused, clean and free from rust, pits and
obvious defects. Material older than one year from date of manufacturing
shall not be permitted.
Cast, ductile or malleable iron, aluminum, copper, or copper-bearing

alloys shall not be used in hydrocarbon service.
Materials of construction for pressure parts shall be in accordance with

the design code and the data sheets. Alternative materials may be used
if they offer technical advantage, subject to the prior approval by the
Company. Proposed substitutions must be clearly defined.
All pipe fittings specified as galvanized shall be hot dip galvanized with a
minimum of 763 grams of galvanizing material per square meter of
surface area, in accordance with ASTM A123M/ASTM A153.
When two dissimilar piping materials are in contact, an insulating gasket

or sacrificial spool piece of 600 mm shall be provided.
3.2 Material Identification
All piping specialties except those with threaded connections shall be

supplied with mill certified test reports and certificates to identify the type
of steel, composition, heat number and any special testing.
The Contractor shall furnish to the Company one (1) copy of all mill
certificates for all the materials purchased by him duly endorsed by
Company approved third party inspection agency.
3.3 Supports and Miscellaneous
Any material welded directly to pressure retaining pipe work shall be of

similar quality as the pipe work, including impact requirements, if any, for
a length measured from the vessel wall of at least 150 mm. The material
of such items beyond this point may be structural quality A283 Gr. C. or
equal/superior (contractor to substantiate with sufficient information &
documentary evidence).

GROUP, MUMBAI
Page 4 of 9 Rev. 2
3.4 Bolting
For carbon steel and stainless steel flanged piping systems, stud bolts
shall comply with ASTM A193-B7 and ASME B1.1. Nuts shall be heavy
hexagon semi-finished per ASTM A194-2H and ASME B18.2.2.Carbon
steel studs and nuts shall be hot dip galvanized in accordance with
ASTM A153.
Stainless steel and duplex stainless steel flange studs and nuts shall be
Zeron 100 and do not need coating.
Flange bolting of nominal size M40 (1-½”) and above shall be subject to
bolt tensioning. The Contractor shall supply flange stud bolts over length
by one thread each end and complete with 2 nuts to facilitate bolt
tensioning.
For carbon steel (NACE) flanged piping systems, stud bolts shall comply
with ASTM A193-B7M and ASME B1.1. Nuts shall be heavy hexagon
semi-finished per ASTM A194-2HM and ASME B18.2.2. Carbon steel
(NACE) studs and nuts shall be hot dip galvanized in accordance with
ASTM A153.
3.5. Flanges
Flange materials shall be compatible with pipe material.
3.6 Gaskets
Gasket materials must be such that the internal fluids shall have no
harmful or corrosive effects on them.
Gaskets for raised face flanges shall be spiral wound, non-asbestos

filled, with 316 stainless steel inner rings, windings and outer rings, in
accordance with ASME B16.20, with the exception that compressed fibre
gaskets complying with ANSI B16.21 are acceptable for cooling water
service.
Full-face gaskets for flat face flanges shall be made from 3-mm (1/8”)
thick compressed, oil-resisting non-asbestos sheets, or neoprene for
non-metallic flanges. Materials are to be specified in the pipe class Data
Sheets.
Ring gaskets for ring-type joint flanges with pressure ratings of ASME
Class 900 shall be octagonal, stainless steel SS316, Type R, in
accordance to ASME B16.20.

GROUP, MUMBAI
Page 5 of 9 Rev. 2
3.7 Certification Documents
All pressure parts material certification shall be traceable to heat

numbers. Certificates, including all material certificates, mechanical test
certificates, welding qualification certificates, heat treatment certificates
and hydrostatic test certificates shall be available at final inspection and
for counter signature by the certification authority and stored by the
Contractor for a minimum of 5 years after acceptance of the piping by
the Company. Pressure retaining parts shall be clearly marked to allow
verification of tractability.
4.0 SPECIALTY ITEMS
Specialty items shall be supplied with a stainless steel tag attached to

the gland bolting, or hand wheel, with stainless steel wire bearing the
applicable Valve Identification, Tag Number or Specialty Item Number
and Purchase Order Number. Specialty Items shall be supplied,
designed, tested & installed as specified in the Project Specification for
specialty items. This refers to items like Strainers, Scrapper Tees,
Hinged Closures, Pig Detector, Corrosion Probes, 5D Bends etc. The
materials of construction, piping class, governing codes and standards,
quality assurance shall be followed as per relevant clauses of this
specification. All specialty items shall be hydro tested as per respective
piping clause and 1.5 times the design pressure. All pressure welds
shall be 100% radio graphed. All piping specialties shall be painted in
accordance with General Spec. for painting.
4.1 Strainers
All basket type strainers shall be designed as per ASME Section – VIII.
Div. 1 and others as per ASME B 31.3. Body material shall be as per
relevant piping class. Screen material shall be as follows:
Body Material - Screen Material

CS - S 316
C.S. (NACE) - SS 316 (NACE)
Mesh size for all strainers shall be 40, unless otherwise specified. Drains
with block valve and blind shall be provided
4.2 Scrapper Tees
Scrapper tee (or spare tee or flow tee as it is called) essentially consists
of concentric barrel tees. The purpose of the scrapper tee is not to allow
passage of pig sphere/scrapper on to the branch side.

GROUP, MUMBAI
Page 6 of 9 Rev. 2
The scrapper tee shall be suitable for pigging operation with process
hydrocarbon. The scrapper tee inside diameter shall be same as that of
inside diameter of main pipeline to permit smooth pigging operations.
No bars shall be used. Maximum possible opening shall be provided

through slots to limit the pressure drop i.e. total opening shall be 1.0 to
1.5 times the branch pipe area.
Thickness of run / branch is to be calculated by the Contractor / Vendor

to the required design pressure and temperature and it shall match with
the corresponding matching pipeline for free passage of pig.
Test shall be witnessed by Company.
4.3 5D Radius Bends
Bends shall be manufactured by hot bending of pipe applying heating

only. Company’s approval for bending procedures shall be obtained prior
to start of work. The adopted procedure shall be such that the finished
product shall not require any additional heat treatment after bending. If
such a heat treatment is required, the same shall be permitted only after
written approval of the Company.
• Bends shall not have any circumferential joint.

• No repair by welding is allowed on any part of the bends.
• Bulges, dents and flats shall not appear within 100 mm from the
ends and for remaining part they shall be as per MSS-SP-75.
4.3.1 Wrinkles : Measurement of the outside diameter shall be taken in the

plane of bend at the locations where wrinkles are present
(O.D. max) and at locations where wrinkles are not present
(O.D. min.). The acceptance limit shall be as given below:
O.D. Max – O.D. Min. < 2% Nominal dia
CTOD TEST shall be performed on each size, service & piping class as
per BS 7448 PART I.
4.4 Corrosion Probes & Retrieval Tools Kit
4.4.1 The corrosion probe unit shall consist of the following assemblies
A) The access fitting assembly consisting of three parts:

a) Access Fitting Body (Non Tee): Access fitting body shall be of a
nominal 2” system. Body shall have a weldolet (Flare Weld) base

GROUP, MUMBAI
Page 7 of 9 Rev. 2
and 3” ACME Threads on the outlet. Weldolet Base shall be 2”
Flare weld size.
b) Plug assembly: Solid plug assembly for holding scale/corrosion/
biological probe coupon.
c) Protective Cover: A steel protective cover for the ACME Threads.
B) Corrosion Coupons and Coupon Holder:
Multiple disc coupons and holders shall be supplied for a nominal 2”

system. Holder shall be supplied with mounting and insulating
hardware. Each holder shall position three discs. one each at top of
line, middle of line, and bottom of the line. Coupons shall be multiple
disc type.
4.4.2 Retrieval Tool Kit :
A retrieval tool kit shall consist of complete kit for inspection and
removal of corrosion coupons. The retrieval tool kit shall be for nominal
size of 2" system.
The retrieval tool kit shall be sized for the largest line size and pressure
rating and shall be suitable for retrieving all corrosion probes during
operation.
Tool shall be complete with full-bore ball valve kit as per the respective
piping class. All probes to be installed in 6 O’clock position. All probes
shall be accessible for maintenance / retrieval while in operation. Probe
retrieval shall be demonstrated to Company.
4.5 Pig indicator
Refer standard spec no.BDA/ODG/PLM/09 (Rev. 1)
4.6 Hinged Closure
Refer standard spec no.BDA/ODG/PLM/010 (Rev. 1)
5.0 SPARES
The Contractor shall furnish list of recommended spares and accessories

from the manufacturer required during start up and commissioning for all
specialties.
The Contractor shall furnish separately a list of recommended spares and

accessories from the manufacturer required for two years of normal
operation and maintenance for all specialties.

GROUP, MUMBAI
Page 8 of 9 Rev. 2
6.0 WARRANTY
The Contractor/Vendor shall have final and total responsibility for the
design, fabrication and performance of all items supplied under this
specification. The Contractor/Vendor shall warrant the items furnished by
him and the performance of the said items in accordance with this
specification and with warranty requirements as specified in the bid
package.
*******

GROUP, MUMBAI
Page 9 of 9 Rev. 2
ONSHORE Functional Specifications Spec No OES/TD/INT/005/FS/PL07
SERVICES, Long Radius Bend Discipline Pipeline
DELHI SHEET 1 OF 10
FOR
LONG RADIUS BEND
JC & PSS NG VNM 0 15.05.2014

DELHI SHEET 2 OF 10
INDEX
SL TITLE PAGE NO
1.0 Scope 3
2.0 Reference Documents 3
3.0 Material 3
4.0 Manufacture 4
5.0 Inspection and Tests 6
6.0 Test Certificates 7
7.0 Marking, Packing and Shipment 7
8.0 Bend Manufacturing Procedure Qualification 8
9.0 Documentation 9
10.0 Warranty 10
DELHI SHEET 3 OF 10
1.0 SCOPE
This specification covers the minimum requirements for manufacturing supply of

long radius bends made from carbon steel line pipes for use in onshore pipeline
systems handling hydrocarbons in liquid or gaseous phase.
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) ISO15590-1 Petroleum and Natural Gas Industries – Induction

bends, fittings and flanges for pipeline transportation
systems – Part 1: Induction bends
b) ASME B 31.4 Pipeline Transportation Systems for Liquid Hydrocarbons
and Other Liquids.
c) ASME B 31.8 Gas Transmissions and Distribution Piping Systems
d) MSS-SP-75 Specification for High Test Wrought Welding Fittings
e) Company Specifications for Line Pipe
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.
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 p a r a m e t e r s deviate from those established i n the Company approved
bend manufacturing procedure.
DELHI SHEET 4 OF 10
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.
DELHI SHEET 5 OF 10
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 ± 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 at least
equal to:
0.95 (t actual - tlt)

where: t actual is the wall thickness of pipe used for bending
tlt = 0.35 mm for a wall thickness < 10 mm
= 0.5 mm for a wall thickness ≥ 10 mm
Note: Selection of Mother pipe: The mother pipe shall be selected such that final wall
thickness after wall thinning due to induction bending shall not be less than the
wall thickness of main line or else next higher wall thickness pipe be selected.
4.11.3 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 (OD max) and at locations where wrinkles are not
present (OD min) Out of roundness shall be considered acceptable, if the value of ((OD
max - OD min)/OD nom) does not exceed:
2.5% for rb ≥ 5D
3.0% for 3D ≤ rb <5D
And by agreement for smaller radius bends.
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.
DELHI SHEET 6 OF 10
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.
4.11.4 Off-Plane
Off-Plane of bends shall not exceed (6/90) x 10 mm, where 6 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.
4.11.5 Squareness
Bevel and squareness of bend ends shall comply with the requirements of relevant
company specification referred in Clause 2.0.
4.12 Coating and Painting
Coating to be same as that of main line pipe i.e. 3LPE/ FBE/ PP etc. coating for pipe to
be laid underground and anti-rust paint coating for pipes laid above ground.
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:
a) 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 beveling 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.
DELHI SHEET 7 OF 10
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.
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.
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 hydro test 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).
DELHI SHEET 8 OF 10
8.0 BEND MANUFACTURING PROCEDURE QUALIFICATION
8.1 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.
8.2 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°.
8.3 Inspection and Testing of Bends
8.3.1 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.
8.3.2 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 line pipe specifications referred in Clause 2.0 of this specification.
Test procedure and acceptance criteria shall be in accordance with the line pipe
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 m applicable
pipe specification referred under clause 2.0 of this specification.
DELHI SHEET 9 OF 10
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.
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) CTOD Test shall be performed on each size, service & piping class as per BS 7448
Part I
g) 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.
9.0 DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized below.

Number of Copies (Hard copies I soft copies etc.) shall be as indicated in CONTRACT
document.
9.1 All documents shall be in English language.
9.2 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.
9.3 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 bends 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.
9.4 Within 30 days from the approval date, Manufacturer shall submit to Company the
approved drawings, documents and specifications as listed in clause 8.3 above.
9.5 Prior to shipment, the Manufacturer shall submit test certificates as listed in Section 6.0
of this specification.
10.0 Warranty
fabrication and performance of all items supplied under this specification. The
Contractor/Vendor shall warrant the items furnished by him and the performance of the
said items in accordance with this specification and with warranty requirements as
specified in the bid package.
SPECIFICATION FOR
MONOLITHIC ISOLATION JOINT
2 17.10.2005 KRK SN PKM
1 23.03.2005 KRK SN PKM
REV.NO. DATE PREPARED BY REVIEWED BY APPROVED BY
CORPORATE DESIGN SPECIFICATION FOR DOCUMENT NO. :

CDG/MUM/PLM/08
GROUP, MUMBAI MONOLITHIC ISOLATION
JOINT
Page 1 of 4 Rev. 2
MONOLITHIC ISOLATION JOINT
1.0 GENERAL
Electrically isolation joints, single unit (Monoblock) to be used on

pipeline system, handling petroleum product, governed by relevant
American standards. The isolation joints shall allow free passage of
scrapper / instrumented pig and shall be suitable for underground /
overground pipeline. The repair / welding on parent metal shall not be
allowed. Bolted or threaded joint should not be used.
2.0 TECHNICAL REQUIREMENTS
2.1 The Manufacturer / Contractor shall specify the materials used for
isolation joints including pup piece in the data sheets.
2.2 The pup material of the isolation joints should have compatibility with
the pipe line material.
2.3 The Manufacturer / Contractor shall specify the standard used for the
isolation joints, suitable for oil/gas service in the data sheets.
2.4 The Chemical composition of the isolation joints end connection

should match with that of pipe to which it is subjected to welding.
However, carbon equivalent of the material should not exceed 0.45 for
each heat of steel used.
2.5 Charpy ‘V’ notch test shall be conducted on each heat of base
material, weld metal and heat affected zone of each pressure
containing parts, in accordance with ASTM-A-370 at a Temperature of
0 degree Celsius. Average absorbed energy value of three specimen,
shall be 20 ft. lbs. Value of more than one specimens shall not be
below the average value of 20 ft. lbs., but in no case the energy value
shall be less than 16 ft. lbs.
2.6 The hardness of the base metal weld and heat affected zone of
pressure containing parts shall not exceed 221 R.C.
2.7 The make and type of the isolation material should be suitable for its
intended use.
2.8 Butt weld end preparation shall be as per ANSI-B-16.25
2.9 The average dielectric strength of the isolation joint shall be minimum
15 Kilo Volts, at 50 Hz.

CDG/MUM/PLM/08
JOINT
Page 2 of 4 Rev. 2
3.0 INSPECTION AND TEST
The Manufacturer shall perform all inspection and tests as per the
requirements of this specification and the relevant codes prior to
shipment at his work. Such inspection and tests shall be but not limited
to the following :-
i) All Isolation joints shall be visually inspected.

ii) Chemical composition and mechanical properties shall be
checked as per relevant material standards for each heat of steel
used.
iii) 100 % inspection by radiography shall be carried out on all butt
welds of pressure containing parts. Acceptance limits shall be as
per API-1104.
iv) Welds, which can not be inspected by radiographic methods,
shall be checked by Ultrasonic or magnetic particle methods.
Acceptance criteria shall be as per ASME section VIII, Appendix
–V and Appendix –VI respectively.
v) All finished welds ends shall be 100 % ultrasonically tested for
lamination type detects for a distance of 50 mm from the ends.
vi) Isolation joints shall be hydrostatically tested to a pressure which
will cause a calculated hoop stress equivalent to 90 % of
specified minimum yield strength of the pipe to which it is
attached. The test duration shall be of 15 minutes.
vii) After the hydrostatic test, Isolation joints shall be tested with air at
5 Kg. / Cm2 for 10 minutes.
viii) Isolation joints before and after the hydrostatic test shall be
tested electrically for one minute with 5000V-AC-50 Hz.
ix) The Insulating resistance shall be at least 25 Mega Ohms,
before & after the hydrostatic test when tested with 1000 Volts
DC megger.
x) Inspection and tests performed shall in no way relieved the
Contractor’s obligation of defect found on later date.
4.0 DOCUMENTATION
The Contractor shall submit the following certificates :
a) Test certificate relevant to the chemical analysis and mechanical
properties of the materials used for construction as per specification
and relevant standards.

CDG/MUM/PLM/08
JOINT
Page 3 of 4 Rev. 2
b) Test report for radiographic and ultrasonic inspection.
c) Test certificate for hydrostatic and air tests.
d) Test certificate for electrical tests.
5.0 WARRANTY
package.
*******

CDG/MUM/PLM/08
JOINT
Page 4 of 4 Rev. 2
DATA SHEET FOR MONOLITHIC ISOLATION
JOINT
SL. DETAILS DATA
1. SPECIFICATION NO. BDA/ODG/PLM/08 (REV.2)

2. NAME OF THE MANUFACTURER *
3. MODEL NO. *
4. INSTALLATION (ABOVE GROUND) SUITABLE FOR ….INCH ND
PIPE
5. CONNECTING PIPE
SPECIFICATION
a) DIAMETER (NB,MM) X THK. (MM)
b) MATERIAL API 5L GR. ……….
6. DESIGN CONDITION
7. DESIGN CODE ASME SECTION -VIII DIV - I
a) PRESSURE …………. KG/CM2(G)
b) TEMPERATURE …………. 0C
8. CORROSION ALLOWANCE 3.0 MM
9. DESIGN FACTOR 0.5
10. ANSI RATING
11. SERVICE HYDROCARBON
12. END CONNECTION BUTT-WELDED AT BOTH ENDS
13. MATERIAL SPECIFICATION
(EQUIVALENT OR SUPERIOR)
a) BODY
b) INTERNALS
14. QUANTITY …………NOS.
NOTE : * CONTRACTOR TO INDICATE
CORPORATE DESIGN DATA SHEET FOR DOCUMENT NO. :

DS/CDG/PLM/08
JOINT
Page 1 of 1 Rev. 2
SPECIFICATION
FOR
PIG INDICATOR
1 07.10..2005 KRK SN PKM

GROUP, MUMBAI
PIG INDICATOR
Page 1 of 5 Rev. 2
SPECIFICATION FOR PIG INDICATOR
1.0 SCOPE
This specification covers the basic requirements for the design and
manufacture testing & supply of pig indicator, used for the detection of
passage of scraper and gauging pigs, to be installed in pipeline systems
handling hydrocarbons in liquid or gaseous phase. This specification does
not cover pig indicators for sour hydrocarbons (liquid / gas) service as
defined in NACE Standard MR 0175-98.
2.0 MATERIALS
2.1 All materials used in the manufacture of the main components of the pig
indicator shall be as indicated in the data sheets. Other components shall
be as per manufacturer’s standard suitable for the service conditions
indicated in Data sheet which will be subject to approval by Purchaser.
2.2 Welding base shall have Carbon Equivalent (CE) not greater than 0.45 on
check analysis, calculated as per the following formula :
Mn Cr + Mo + V Ni + Cu
CE = C + -------- + ------------------ + -----------------
6 5 15
2.3 Fully killed carbon steel shall be used in the manufacture of pig indicators.
2.4 The maximum hardness of the base material, weld metal heat affected
zone of the pressure containing parts shall be 248 HV10 . Hardness test
shall be carried out as per ASTM A370 for each heat of steel used.
3.0 DESIGN AND CONSTRUCTION REQUIREMENTS
3.1 Pig indicator shall be bi-directional type having pivot-less tumbler

mechanism and laminated trigger blades.
3.2 Pig indicator shall be designed to meet the requirements of pipeline

material, diameter, wall thickness & service conditions indicated in the data
sheet.
3.3 Design of pig indicator shall also be such that repair and installation of
internals/ accessories are possible under pressure, without removing the
unit from the line.

GROUP, MUMBAI
PIG INDICATOR
Page 2 of 5 Rev. 2
3.4 Pig indicator shall indicate the passage of pigs, by means of spring
loaded metal shaft. The arm shall lock in down position when manually
reset.
accordance with the provision of ASME Section IX.
The procedure qualification shall include hardness test and shall meet
the requirements of clause 2.4 of this specification.
4.1 All inspection and tests shall be performed to supply the indicator as per
the requirements of this specification.
4.2 All pig indicator shall be visually inspected.
4.3 Chemical composition & mechanical properties including hardness shall

be checked for each heat of steel used.
4.4 All welds shall be non destructively examined.
4.5 The welding end shall be inspected ultrasonically over the entire
circumference for lamination type defects. Any lamination larger than
6.35 mm shall not be acceptable.
4.6 Hydrostatic test shall be conducted at a pressure equal to 1.5 times the
design pressure. Hydro-test duration shall be 15 Minutes.
4.7 All functional tests shall be performed to establish satisfactory

performance.
5.1 The Contractor shall supply the test certificates from the manufacturer for
material compliance as per the relevant Material Standards.
5.2 Certificate for hydrostatic test and functional test
5.3 Test reports on heat treatment carried out, if any.
The certificates shall be considered valid only when duly endorsed by


GROUP, MUMBAI
PIG INDICATOR
Page 3 of 5 Rev. 2
6.1 Exterior surface of the pig indicator shall be thoroughly cleaned, freed
from rust and grease and applied with sufficient coats of corrosion
resistant paint. The type and corrosion resistant paint used in the
drawings submitted for approval shall be indicated.
6.2 A stainless steel metal tag shall be permanently attached with each unit,
with the following marking :-
i) Manufacturer’s name
ii) Suitable for installation on the pipeline size indicated in the data
sheet.
iii) ANSI Rating
6.3 Each unit shall be suitably protected to avoid any damage during transit.
Care shall be exercised during packing to prevent any damage to the
welding ends. All machined surfaces subject to corrosion shall be well
protected by a coat of grease or other suitable materials.
7.0 SPARES AND ACCESSORIES
7.1 The Contractor shall furnish list of recommended spares and accessories
from the manufacturer of pig indicator required during start up and
commissioning.
7.2 The Contractor shall furnish separately a list of recommended spares and
accessories from the manufacturer required for two years of normal
operation and maintenance of Pig indicator.
8.0 DOCUMENTATION
8.1 The Contractor shall submit the following drawings, documents and
specifications for review and approval of the Company :
i) General Arrangement drawing with overall dimensions.

ii) Fabrication drawings/sectional arrangement drawings showing all
parts with reference numbers and material specification.
iii) Assembly drawing with overall dimension.
iv) Welding and testing procedure.

GROUP, MUMBAI
PIG INDICATOR
Page 4 of 5 Rev. 2
Once the approval has been given by the Company, any change in
design, material, etc. shall be notified to the Company, whose approval in
writing for all changes shall be obtained before Pig indicator are
manufactured.
8.2 The Contractor shall submit one reproducible and four copies of the
approved drawings and specifications as listed in 8.1 of this specification.
8.3 Prior to shipment, the Contractor shall submit one reproducible and
four copies of following :
a) Test certificates as per clause 5.0 of this specification.

b) Manual for installation, erection instructions, maintenance and
operation instructions.
9.0 WARRANTY
package.
********

GROUP, MUMBAI
PIG INDICATOR
Page 5 of 5 Rev. 2
DATA SHEET FOR PIG INDICATOR
SL. DETAILS DATA
1. SPECIFICATION NO. BDA/ODG/PLM/09 (REV. 1)

2. NAME OF THE *
MANUFACTURER
3. MODEL NO. *
4. INSTALLATION (ABOVE SUITABLE FOR ……INCH ND PIPE
GROUND)
5. CONNECTING PIPE
SPECIFICATION
a) DIAMETER (NB,MM) X THK.
(MM)
6. DESIGN CONDITIONS
7. DESIGN CODE ASME B 31.4 / 31.8 AS APPLICABLE
8. CORROSION ALLOWANCE 3.0 MM
10. ANSI RATING
11. SERVICE
12. END CONNECTION
a) BODY ASTM A106, GR.B
b) INTERNALS SS-316
14. QUANTITY …………NOS.
NOTE :
1) * CONTRACTOR TO INDICATE
2) PIG INDICATOR SHALL BE PROVIDED WITH ISOLATION VALVE FOR ON-
LINE REPAIR.

DATA SHEET FOR DS/CDG/PLM/09
GROUP, MUMBAI
PIG INDICATOR
Page 1 of 1 Rev. 1
SPECIFICATION
FOR
HINGED CLOSURE
1 07.10.2005 KRK SN PKM

GROUP, MUMBAI
HINGED CLOSURE
Page 1 of 7 Rev. 1
SPECIFICATION FOR HINGED CLOSURE
1.0 SCOPE
This specification covers the minimum requirements for design and

manufacture of hinged closures to be installed on pipelines handling
hydrocarbon. This specification does not cover hinged closures for sour
hydrocarbons service as defined in NACE standard MR0175-98.
2.0 REFERENCE DOCUMEMTS
Reference has been made in this specification to the latest edition of the
following codes, standards and specification :
a) ANSI B 31.4 : Pipeline Transportation system for liquid

hydrocarbons and other liquids.
b) ANSI B 31.8 : Gas Transmission and Distribution Piping
Systems
c) ASME Sec. VIII : Boiler and Pressure Vessels Code Rules for
the Construction of Pressure vessels
d) ASME Sec. IX : Qualification standard for Welding and
Brazing procedures, welders, brazers and
welding and brazing operators.
e) API 6H : Specification on End closures, Connectors and
Swivels.
f) API 5L : Specification for line pipe.
g) API 1104 : Specification for Welding Pipeline and Related
Facilities
h) SSPC-VIS-1 : Steel Structures Painting Council
In case of conflict between the requirement of this specification and the

requirements of above referred documents, the requirements of this

GROUP, MUMBAI
HINGED CLOSURE
Page 2 of 7 Rev. 1
3.0 MATERIALS
3.1 Material used in the manufacture of pressure containing parts of hinged

closure shall be fully killed carbon steel, forged construction. In addition, the
material shall also meet the requirements specified herein.
Other Components shall be as per Manufacturer’s Standard. However, all

the materials used shall be suitable for the service conditions indicated in the
data sheets which will be subject to approval by the Company.
3.2 Material of the ends to be field welded shall have carbon equivalent not
more than 0.45 based on check analysis, for each heat of steel used,
calculated as per the following formula :
MN Cr+Mo+V Ni + Cu
CE = C+ ------------- + --------------------+----------------
6 5 15
3.3 Unless specified otherwise, Charpy V-notch test shall be conducted for each
heat of steel, in accordance with the impact test provisions of ASTM 370.
The average absorbed impact energy valves of three full-sized specimens
shall be 27 joules.
3.4 Hardness test shall be carried out as per ASTM A 370 for each heat of steel
used. A full thickness cross section shall be taken for this purpose and the
maximum hardness of base metal, weld metal and HAZ of all pressure
containing parts shall not exceed 248 HV10.
4.1 Hinged closure shall be designed in accordance with the provisions of

relevant ANSI Standard and ASME Sec. VIII Division 1. Corrosion allowance
and design factor as indicated in the data sheets shall be considered in the
design of hinged closure.
4.2 Diameter, thickness, material, ANSI Rating of the pipeline with which the
hinged closure to be welded is indicated in the Data Sheets. Hinged closure
supplied shall be suitable for the same.
4.3 Hinged closure shall be of clamp ring, band lock or equivalent type and
operable by a single lever operation. The threaded closures are not
acceptable.
4.4 Hinged closure shall be of hinged and quick opening type and operable by a
single lever operation. The threaded closures are not acceptable.

GROUP, MUMBAI
HINGED CLOSURE
Page 3 of 7 Rev. 1
4.5 When closed, the closure shall provide a positive seal without any leakage.
Gaskets or seals when provided for this purpose shall be self sealing and
suitable for the service condition indicated in Data Sheets.
4.6 The handling device shall be attached to the welding end hub, which
shall be suitable for such attachment.
4.7 Hinged closure shall be provided with a butt-welding end for direct welding
with the pipeline. The weld end shall be prepared in accordance with
relevant ANSI standard.
accordance with the provisions of ASME Standard. The procedure
qualification shall also include impact test and hardness test when required
as per clause 3.3 and 3.4 of this specification and shall meet the
requirements as specified herein.
4.9 Completed assembly shall be stress relieved as per the provisions of the
design codes.
4.10 The tolerance on internal diameter end out of roundness shall be as per
connected pipe specifications indicated in the Data Sheet.
5.1 All inspection and tests shall be performed as per the requirements of this
specification and the relevant codes, prior to shipment at his works. Such
inspection shall be, but not limited to the following :
5.1.1 All closures shall be visually inspected.
5.1.2 Chemical composition and mechanical properties shall be checked.
5.1.3 Dimensional check shall be carried out as per the approved drawings.
5.1.4 Hydrostatic test shall be conducted for all end closures complete in all
respects, at a pressure equal to 1.5 times the design pressure. Test
duration shall be as 15 minutes. No leakage is allowed.
5.1.5 All butt welds shall be 100% radio graphically inspected. Procedure and
acceptance criteria shall be as API 1104.
5.1.6 Welds, which cannot be radio graphically inspected, shall be inspected by

ultrasonic or magnetic particle methods. Procedure and acceptance criteria
shall be as per ASME Sec. VIII, Appendix ‘U’ and Appendix-VI respectively.

GROUP, MUMBAI
HINGED CLOSURE
Page 4 of 7 Rev. 1
5.1.7 All finished wrought weld ends shall be ultrasonically inspected for
lamination type defects for a distance of 50mm from the end. Any lamination
larger than 6.35 mm shall not be accepted.
5.1.8 A minimum of two closing and opening cycles shall be performed and correct
operation of both quick opening and safety system shall be established.
5.2 The Company reserves the right to perform inspection and witness tests
including hydrostatic test, as indicated in para 5.1 at manufacturer’s works
prior to shipment. The Contractor shall give reasonable notice of time and
shall provide without charge reasonable access and facilities required for
inspection, to the Company.
Inspection and tests performed/witnessed by the Company shall in no way

relieve the Contractor’s obligation to perform the required inspection and
tests.
The Contractor shall furnish the following certificates :
a) Test certificates relevant to chemical and mechanical properties of the

material used as per the relevant standards.
b) Hydrostatic test certificates.
c) Report on Non-Destructive examination.
d) Certificate of satisfactory performance of end closure as per clause 5.1.8.
e) Certificates of stress relieving.
The certificates shall be considered valid only when duly endorsed by

7.1 After all inspection and tests required have been carried out, all external
surfaces shall be thoroughly cleaned to remove grease, dust and rust.
Surface preparation shall be carried out by shot blasting to SP-6 in
accordance with “Steel Structures Painting Council – Visual Standard –
SSPC-VIS-1”. Machined parts shall be coated with anti-rust removable paint
and non-machined parts shall be applied with two coats of protective paint.
The type of paints used in the drawings submitted for approval shall be
indicated.
7.2 Marking shall be done on a stainless steel plate and affixed to the body
permanently. Marking shall include the following :-
a) Manufacturer’s Name
b) Suitable for the pipeline as indicated in the data sheet.
c) ANSI Rating
d) Year of Manufacturer

GROUP, MUMBAI
HINGED CLOSURE
Page 5 of 7 Rev. 1
7.3 Before shipment, closures shall be properly packed against damage during
transportation. Bevel ends shall be protected with metallic & high impact
plastic bevel protectors.
7.4 Only those closures, which have been inspected and certified by Company
shall be shipped.
8.0 SPARES
from the manufacturer for Hinged Closures required during start up and
commissioning.
from the manufacturer for Hinged Closures required for two years of normal
operation and maintenance of Hinged Closures.
9.0 DOCUMENTATION
9.1 The Contractor shall submit the General Arrangement drawing of hinged
closure with overall dimensions and showing the operational arrangement.
9.2 The Contractor shall submit four copies of, but not limited to, the following
drawings, documents and specifications for review and approval of the
Company :
a) Closure assembly and sectional drawing showing all parts with
materials and dimensions.
b) Welding procedure and method of manufacture.
Once the above said documents have been approved by the Company, any
change in design, material and method of manufacture shall be notified to
the Company, whose approval in writing of all changes shall be obtained
before the closures are manufactured.
9.3 The Contractor shall submit one reproducible and four copies of Approved
drawings, documents and specifications listed in clause 9.2 of this
specification.
9.4 Prior to shipment, the Contractor shall submit one reproducible and four
copies of the following :-
a) Test certificated as listed in clause 6.0 of this specification.

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

GROUP, MUMBAI
HINGED CLOSURE
Page 6 of 7 Rev. 1
9.5 All documents shall be in English Language only.
10.0 WARRANTY
package.
*******

GROUP, MUMBAI
HINGED CLOSURE
Page 7 of 7 Rev. 1
DATA SHEET FOR HINGED CLOSURE
SL. DETAILS DATA
1. SPECIFICATION NO. BDA/ODG/PLM/10 (REV. 1)

2. NAME OF THE MANUFACTURER *
3. MODEL NUMBER *
4. INSTALLATION (ABOVE GROUND) SUITABLE FOR ….INCH ND
PIPE
5. CONNECTING PIPE SPECIFICATION
a) DIAMETER (NB,MM) X THK. (MM)
6. DESIGN CONDITION
7 DESIGN CODE RELEVANT ANSI STANDARD
AND ASME SECTION -VIII DIV
– I AS APPLICABLE.
8. CORROSIONA ALLOWANCE 3.0 mm
10. ANSI RATING
11. SERVICE HYDROCARBON
12. END CONNECTION
a) BODY ASTM A – 105
b) INSERTS/GASKETS VITON
c) OTHER COMPONENT AS PER MANUFACTURE’S
STANDARD BUT MATERIALS
USED SHALL BE SUITABLE
FOR SERVICE MENTIONED
ABOVE.
14. QUANTITY …NOS.
NOTE : * CONTRACTOR TO INDICATE.

DATA SHEET FOR DS/CDG/PLM/10
GROUP, MUMBAI
HINGED CLOSURE
Page 1 of 1 Rev. 1
SERVICES, Functional Specifications Discipline Pipeline
DELHI SHEET 1 OF 1
TABLE OF CONTENTS
SL No TITLE
01 Specification for Pipeline Route Survey

02 Specification for Geo-Technical & Hydrographic Investigation
03 Specification for Construction of Underground Pipeline
04 Welding Specifications
05 Specification Trench-Less Operations
06 Specification for Painting
07 Specification for 3 Layer Polyethylene Coating
08 Specification for Field Joint Coating
09 Specification for Concrete Weight Coating
10 Specification for Hydrostatic Testing Of Pipeline
SPECIFICATIONS
FOR
PIPELINE ROUTE SURVEY
1 23.03.2005 KRK SN PKM
CORPORATE DESIGN SPECIFICATION DOCUMENT NO. :

CDG/MUM/PLM/001
GROUP, MUMBAI FOR PIPELINE
ROUTE SURVET
Page 1 of 13 Rev. 1
PART-A
SPECIFICATIONS FOR PIPELINE ROUTE SURVEY
1.0 Scope
This specification covers the minimum requirements of topographical

survey along the pipeline route including locating the centre-line of pipeline
alignment on the ground, constructing survey monuments, field
measurement for planimetry and profiles and preparation of drawings and
documents.
All survey works shall be performed by or under the supervision of a

qualified land surveyor.
2.0 Alignment and Location Survey:
The Contractor is expected to make himself aware of the general

conditions of the terrain before starting survey. A preliminary survey for
locating the center line of pipeline alignment of the ground shall be carried
out as follows;
2.1 Preliminary survey shall be carried out along the route of the proposed
pipeline to establish and flag control points.
2.2 The existing features or obstructions along the route that are not shown in
available maps or drawings shall be located and identified. Mining and built
up areas shall be avoided.
2.3 Turning points (TPs) shall be located considering the following:

Construction viability so as to avoid objects like power, telephone &
telegraph poles, walls, tube wells or such other structures falling on the
trench alignment, also structures like boundary walls, houses, etc.
should be at a sufficient distance.
Ensuring proper angle of crossing by keeping as nearly right angle to
road/rail/streams, etc. as possible.
3.0 Staking of Pipeline Route
The Contractor shall install marker stones /pre-cast concrete block at a

regular interval of two hundred meters minimum duly marked for easy
identification with name of the Company, name of pipeline, progressive
pipeline chainage, bearing and number of the stone with yellow paint on
base colour of the stone i.e. post office red.

CDG/MUM/PLM/001
ROUTE SURVET
Page 2 of 13 Rev. 1
The stones are also to be installed at every turning point, and on both sides
of all road, river, rail and canal crossing etc.
4.0 Bench Marks
A temporary bench mark shall be established at every 5 Kms. preferably on

some permanent structure. The bench mark should be painted and marked
for easy identification as in the case of marker stone.
5.0 Crossings
As far as possible, crossings shall be made at right angles. The Contractor

shall record the angles of crossing for all fences, property lines, utilities,
roads, railways, rivers, canals, streams, etc. that are crossed. In addition,
the magnetic bearings of the centre line of the road, railways, canal etc.
along with that of the pipe center-line shall be recorded
5.1 Railway Crossings
The angles for all railway crossing shall be as close to 90 degrees, but in no
case less than 35 degree to the center line of the railways.
5.2 Primary Road Crossing
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 degree as possible, but in no case
less than30 degrees to the center line of the road.
5.3 Secondary Road Crossing
The angles of crossing for secondary roads shall be close to 90 degrees as

possible, but In no case less than 45 degree to the center-line of the roads.
All seasonal roads, unpaved village roads, cart-tracks etc. fall under this
category.
5.4 River / Canal Crossings
These crossings shall be located in a comparatively straight reach of the

River / Stream/ Nala/ drainage ditch where the banks are stable and there is
sufficient area for construction. Angle of crossings shall be as close to 90
degree as possible.
5.5 Utility Crossings
Utilities crossed shall be located at their center lines with stakes containing
station numbers in the survey. The angle of crossings shall be measured

CDG/MUM/PLM/001
ROUTE SURVET
Page 3 of 13 Rev. 1
and locations established relative to their aboveground facilities. The
details pertaining to names, lines etc. shall be included in the survey notes.
In case overhead high tension pole / tower are running parallel to the
pipeline route survey, the minimum distance of 50 meters should be
maintained. The details pertaining to numbers of poles / towers, line voltage
shall be recorded.
In case overhead high tension lines are to be crossed, the angle of crossing
should be as close to 90 degree as possible but in no case less than 30
degree. The crossing point should be minimum 20 meters from the existing
pole/tower.
Underground utilities shall also be located as far as possible and staked for
a minimum distance of 20 meters on each side of the survey line.
6.0 Accuracies in Measurement
6.1 The Contractor shall incorporate corrections to the line and ground
measurement due standard errors, variations from standard temperature and
pull.
6.2 The error for angular closure for the work shall not exceed one minute per
station and for linear measurement it shall be read to the nearest 0.005 m.
6.3 The error on closure for measurements on vertical distance to establish

bench marks shall not be more than 24 √ K. millimetres (where “K” is the
linear distance in Kms.). The observations for measurement of vertical
distance on benchmarks and intersection points shall be read to an accuracy
to the nearest 5 mm and for others to the nearest 10 mm. The error of
misclosure in vertical distance shall be distributed linearly.
7.0 MEASUREMENT OF HORIZONTAL ANGLES
Horizontal angles shall be measured to indicate the change in direction of

alignment and specify the horizontal bend at the tuning points.
7.1 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 angles.

CDG/MUM/PLM/001
ROUTE SURVET
Page 4 of 13 Rev. 1
7.2 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 every 15-20 Kms, shall
be observed to keep a check on errors in angular measurement.
8.0 PROFILE
The continuous profile of the proposed pipeline route shall be established

from the reduced levels taken:
i) At the starting point.

ii) At all the Turning points (TPs).
iii) At all the intermediate points staked on the ground.
iv) At all points on the pipeline route where there is a change in slope.
8.1 When the terrain is flat, reduced level shall be additionally recorded along the
pipeline route at 100 m interval.
8.2 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.
8.3 For road, railway, canal and water-course crossings, the reduced levels shall
be recorded at all points along the pipeline alignment wherever there is a
change in slop within the entire width of Right-Of-Use of the road/railway.
8.4 In the right of ways having slope, across the pipeline Azimuth checks shall
be made by observations of sun or polaries at intervals of 15-20 Kms.
These observations of bearings together with deflection angles shall be
recorded in survey note.
8.5 Azimuth misclosure based on bearings with observed angles at

Intersection 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.
8.5 Method of RISE and FALL shall be used to compute reduce levels of various
points. Check on computation shall be made by using the following formula :
Back Site – Fore Site = ∑ Rise - ∑ Fall = First R.L. – Last R.L.
9.0 CHAINAGE
Cumulative chainage from the starting point shall be observed and recorded
at all turning points and intermediate points staked along the pipe line route,
center line of all crossings, utilities, over and underground facilities and other
features relevant to Engineering, Design, and Construction of pipeline. If
more than one party is deployed for the survey cumulative chainage for each
party shall be shown on the stones but not on the survey data sheets.

CDG/MUM/PLM/001
ROUTE SURVET
Page 5 of 13 Rev. 1
9.1 The magnetic bearing of all straights shall be observed and recorded.
9.2 Slack distance measurement will be made using 50 m steel tape or 30 m

chain. However, in case of abrupt slope change the tape / chain is
straightened to the probable grading.
9.3 Chaining will be continuous in the direction of survey.
9.4 Data on nature of terrain viz. sandy, stony, vegetation, etc. and type of
ground will also be recorded along with chain age of change points. Check
on distance measurements will be by stadia method at the time of leveling.
9.5 Standard chain survey format will be used for record keeping.
- Between existing / planned electrical power cables / lines and the

proposed line 50.0 mtrs.
- Between existing / planned communication cables / lines and the

proposed line 7.0 mtrs.
10.0 PARALLEL ENCROACHMENT
Unless stated otherwise, then the pipeline alignment runs generally parallel
to a road or railways, it shall be kept clear of the Right of way limits of the
facility.
11.0 AZIMUTH OBSERVATIONS
Azimuth control shall be maintained by either observation of azimuth at

every fifteen to twenty kms. by closing the traverse on existing control
points. Azimuth may be obtained by making observations to sun or star
depending upon the location of the area and direction control. In case of
azimuth from sun the computed values must be within one minute.
Incase of stars the computed values should agree within 10 to 15 sec,
Horizontal misclosure between two Azimuth stations shall be equally
distributed among TPs in-between.
12.0 SURVEY NOTES, OBSERVATIONS & COMPUTATIONS.
The procedures following both for field and office calculations shall be such
that the results obtained shall be readily understood and retraceable.
12.1 All up to date notes and observations related to the basis for
determination boundary lines and corners shall be maintained by surveyor.

CDG/MUM/PLM/001
ROUTE SURVET
Page 6 of 13 Rev. 1
12.2 Survey records must contain schematic diagrams of all horizontal
controls pertinent to the project showing all existing and established control
points, bench marks, and any triangulation station and boundary lines.
13.0 MAPS & DRAWINGS
The Contractor shall perform mapping and drawings work so as to contain

all relevant alignment as encountered in hilly areas, Ghat regions, ravines,
and other similar areas as directed by the Company, cross-section at 50m
interval and for a length of 25 m on either side of the pipeline alignment
shall be observed and recorded. For major water crossing sites, cross
section as above shall be observed at both banks.
14.0 BUILT UP AREAS
Monuments & Properties:
The pipeline alignment shall run clear of the existing monuments,

properties and structures etc. as follows:
• Habitable dwellings - 100 Meters.
• Structures - 50 Meters.
• Property corners, Monuments - 20 Meters.
For congested area, a lesser distance may be adopted, however / location

shall be approved by the Company.
15.0 PARALLEL ALIGNMENT
15.1 The pipeline alignment wherever it runs along an existing or planned

under/over ground facility will be fixed parallel to the same. The existing
underground facilities shall be identified and located with suitable equipment
and any special ground features marked. The following clearances shall be
observed in case of parallel alignment defined above.
15.2 The drawings shall also contain details of roads, streets, highways,
structures, all types of crossings, terrain, surface vegetation and all other
details which will be required for the purpose of engineering design.
Following types of detailed survey drawings will be made :
Right of way planimetry 1:5000 along the line

1:1000 across the line

CDG/MUM/PLM/001
ROUTE SURVET
Page 7 of 13 Rev. 1
Ground Profile 1:5000 Horizontal
1:500 or 1:100 Vertial
Crossing Details 1:100 Horizontal
1:100 Vertical
Detailed Route Map 1:50,000 or 1:25,000
Additional Route Map for Hilly, Ghat and 1:15,000
ravines regions.
Cross section for sloping Right – of – way 1:500 Horizontal
1:100 Vertical
16.0 Presentation of Field Survey Data
Survey drawings shall contain the following data as a minimum requirement:-
16.1 Pipe line route map:
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 Kms. from the pipeline center-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 to flooding, rocky area and forests shall also be shown on the
route maps.
16.2 Additionally for area which are undulating such as hilly area, Ghat, Regions,
ravines and other areas as directed by the Company. Pipeline route map to
a scale 1:15,000 shall be drawn over a distance of 1:0 Km. from the
pipeline center-line on either side of it. For such area, contours shall be
placed at 10 m contour interval.
16.3 Right-of-way planimetry drawings shall show all objects within 30 meters on
either side of the pipeline in plan.
16.4 All rail, road and canal crossing details shall be furnished on survey data
sheets.
16.5 All stream and river crossing details shall be recorded and the profile drawn
on suitable scale so as to define the crossing completely.
16.6 In case of all rail, road, river, stream and canal and utility crossing, the angle
of crossing shall be mentioned.
16.7 In case of rail, road, river steam and canal crossings wider than 10 m the
distance at the start and at the end of the crossing from the nearest TP shall
also be mentioned. For crossings less than 10 m, the distance of the centre
line of crossing from the nearest TP shall be given.

CDG/MUM/PLM/001
ROUTE SURVET
Page 8 of 13 Rev. 1
17.0 Specifications for Cadastral / Soil Surveys
The specification also covers the cadastral survey and soil investigation
along the pipeline route. The soil investigation includes classification of soil,
resistivity of soil, PH value, bacteria content and chemical analysis etc.
The scope of work includes, but is not limited to the following.
17.1 Transferring the centre line of the final alignment on the village / revenue
maps.
17.2 Cadastral survey along the route of the pipeline by plane table survey (strip
of land for ROU purpose will be about up to 20 mtrs wide) to the scale of
1:400 or the scale of available revenue maps to determine the right of way of
the pipeline on the village map.
17.3 Computing the area of the right of way, for each plot subplot and completion
of the data in prescribed proforma, giving the name of the village, talukas,
district, plot owners(s) survey no./block no. and the name of the seasonal
crops(S) cultivated in the area.
17.4 Collection of village maps and 7/12 extracts from the office of Land Records,
village level revenue officials etc. for above purpose at no extra cost to the
Company.
17.5 Encroachment details, if any, shall also be supplied by the

Contractor which shall include – to the scale drawing of the encroached
area, particulars of the party encroached and 7/12 extract of the property.
Notes:
1. The above specifications (both route survey and cadastral survey)

will be applicable in those cases / locations where the route
alignment etc has either not been finalized by the Company or a
change is necessitated during the course of pre-engineering
surveys / detailed engineering etc, and fresh ROU is required to be
obtained.
2. The Contractor shall get the revised route / alignment approved

from the Company.
3. In all other cases the Contractor shall first obtain approval for the
preliminary alignment from the Company, before proceeding for
Cadastral survey as per the approved preliminary survey.
4. Detailed survey to be carried out as per the final cadastral survey.

CDG/MUM/PLM/001
ROUTE SURVET
Page 9 of 13 Rev. 1
PART-B
GENERAL SPECIFICATIONS FOR SOIL INVESTIGATION
1.0 Scope
The purpose of soil investigation is to obtain visual engineering classification

of soil resistivity of soil PH value, bacterial content and chemical analysis of
soil, with particular reference to sulphate, chloride, sulfides etc
The scope of soil investigation includes boring, collection of disturbed

samples from bore holes and carrying out classification of soil, resistivity of
soil, PH value, bacteria content and chemical analysis of soil along the
pipeline route and submission of detailed report. Visual classification of soil
shall be in accordance with IS – 1498, “IS Classification and Identification of
Soils for General Engineering Purposes”
2.0 Boring
2.1 Collection of soil samples at every 500 mtrs. intervals and also at location
having abnormal values of resistivity and analyzing the soil for PH value,
bacteria content and chemical analysis as well as determine the nature /
type of soil.
2.2 Carrying out of soil resistivity survey, over the final pipe line alignment at
every 200 mtrs. interval and at 0.5, 1.0, 1.5, 2.0 & 2.5 mtrs. depth and
plotting the result in graphical form.
2.3 Minimum diameter of borehole shall be 250 mm, Auger boring shall be
restored-to above the water table and boreholes shall be advanced by shell
and auger.
2.4 The boring shall be either terminated at a depth of 3 m below NGL or top of
bed rock if rock encountered at a depth of less than 3 m.
2.5 Disturbed representative sample shall be collected from boreholes to classify

the sub-soil visually at site.
3.0 Detailed Report
3.1 The report shall include proper visual Engineering classification of soil
encountered along the pipeline route in bore log form. Depth of ground
water table (GWT) below NGL shall also be mentioned if encountered.

CDG/MUM/PLM/001
ROUTE SURVET
Page 10 of 13 Rev. 1
3.2 Soil profile along the pipeline route shall also be prepared and attached with
the report.
3.3 Region along the pipeline route where special excavation techniques like
blasting etc. need to be adopted for excavation of pipeline trench shall be
clearly indicated in the reports.
3.4 Soil resistivity survey along the pipeline route should be submitted in
graphical form also.
4.0 Soil Exploration for Designing of River Crossing for Laying of Pipeline
at Rivers
4.1 The Contractor shall submit the details of soil data of half a meter depth
interval for the particle size. Data should be taken up to 6 meters depth from
the lowest river bed of water stream, drawing. Generally four bores are to be
done in the water stream and two bores on the banks of the river. The work
comprises of conducting standard Penetration test in the field and collecting
samples for testing in the laboratory. The report should present the details
of work analysis of the test results, etc.
4.2 Technique to be Used
Suitable drilling technique should be adopted for boring in the area. Casing
pipes and bentonite slurry should be used to protect the sides of the bore
hole, if required Standard Penetration Test should be conducted at change of
layers and at specified half meter interval.
4.3 Soil Profile
Profile of the area in the bore hole should be provided Cross sectional profile
of the soil layers, cohesion less and cohesive, consisting of silky sand and
silky clay shall be classified.
4.4 Analysis of Test Results
The following various tests should be conducted
1. Standard Penetration test

2. Determination of liquid and plastic limit.
3. Grain size Analysis.
4. Determination of specific gravity.
If the cohesive layers are not of hard consistency, undisturbed samples

should be collected and test pertaining to undisturbed samples should be
conducted.

CDG/MUM/PLM/001
ROUTE SURVET
4.5 Standard Penetration Test
Test should be conducted at change of layers and at specified intervals,

commencing the test at one meter below the existing ground level. The
relative density of the cohesion less layers and the consistency of the
cohesive layers should be in the form N-values in the bore log.
4.5.1 Determination Of Liquid And Plastic Limits
The limit values of the cohesive layers should be determined from the
disturbed samples.
4.5.2 Grains size analysis
Combined river and hydrometer analysis should be conducted on the various

samples. The results should be given in the tabular form.
4.5.3 Determination of specific gravity
The specific gravity of the soil grains should be determined from the
various samples collected. The results should be given in a tabular form. If
any abnormality is observed same should be classified.
5.0 Specification for Preparation of As-built drawings of Existing

Installations:
The scope of the contractor includes but not limited to the following:
5.1 Making as built drawings of existing installations, conducting topographical

ground survey in the specified area handed over by Company to the
Contractor as per enclosed specifications and directions of Company:
- Triangulation,
- Closed traverse survey,
Covering details of physical features like nallah, ponds, etc. and cultural
information like roads, culverts, transmission lines, telegraph/ telephone/
electric poles, underground services and cross drainage works etc.
5.2 Recording spot levels as specified, plotting and developing topographical

contour maps showing true north including establishing survey reference
stations as per specifications.
5.3 Super imposition of revenue survey maps showing survey nos. and other
relevant details establishing the HFL of the area.
5.4 The to-the-scale drawings should show existing underground and over
ground facilities & equipments.

CDG/MUM/PLM/001
ROUTE SURVET
6.0 Determination of Population Density Index & Class Location
Population density index along the pipeline route shall be determined (in
accordance with the relevant ASME code.
6.1 A zone 400 m (one quarter mile) wide, shall be considered along the pipeline
route with the pipe line in the centre line of this zone. Then the entire route
of the pipeline shall be divided into lengths of 1600 m (one mile) such that
the individual lengths will include the maximum number of dwellings intended
for human occupancy within each 1600 m. (one mile) zone shall be counted
and reported along with other survey data.
6.2 In addition to the criteria contained in the paras above, while classifying
areas, additional consideration must be given 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 of more of these
facilities are present, the areas shall be classified as a class 3 location.
6.3 Notwithstanding the provisions of clause 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.
*****

CDG/MUM/PLM/001
ROUTE SURVET
FUNCTIONAL SPEC. No. 2101
Design Division SPECIFICATION FOR
Engineering Services GEO-TECHNICAL Rev. No. 1
ISO – 9001:2000 INVESTIGATION &
HYDROGRAPHIC Discipline: Pipeline
INVESTIGATION PAGE : 1 OF 1
FUNCTIONAL SPECIFICATIONS
FOR
GEO-TECHNICAL INVESTIGATION
&
FOR
WATER CROSSINGS
PREPARED / TOTAL No.

REVIEWED BY APPROVED BY DATE REV. No.
REVISED BY OF PAGES
KRK SN PKM 15 06.10.2005 1
ODS/SOF/004B ODS/SOP/008 TO 015 02 01 01/08/2006
PART-A
TECHNICAL SPECIFICATION
FOR
GEO-TECHNICAL INVESTIGATION &
HYDROGRAPHIC INVESTIGATION FOR WATER CROSSINGS
1.0 INTRODUCTION
This specification deals with detailed hydrographic survey and collection of

Geotechnical parameters including soil investigation proposed to be carried
out for river crossings.
The number of bore hole to be survey type shall be decided on the basis of
Category of river/water bodies.
2.0 OBJECTIVE
The objective of Hydrographic investigation is to obtain riverbed profile,

nature of bed material, hydrographic data. The purpose of obtaining this data
is to establish accurate bed profiles, to map surface features in the river
crossing and to obtain scour profiles at crossing location.
Similarly, the requirement of soil investigation is to develop various soil

parameters for calculation of scour depth and installation of pipeline.
3.0 SCOPE OF WORK
Depending upon the bank to bank width of river/water body the scope of work
shall be decided in consultation with the Company :
3.1 Soil Investigation
The work comprises, but not limited to the following :
a) Bore Holes up to 10m below GL (At least one for rivers having bank to
bank width less than 30 m and 1 nos each at the bank on one side and
center of river having bank to bank width 30-50 m).
b) Standard Penetration tests and collections of disturbed and undisturbed

soil sample from bore holes at every 2.0m interval and change of strata.
c) Laboratory tests on soil samples collected.
d) Submission of reports in four number of copies.
3.1.1 Requirement
The work shall be carried out in line with the relevant clauses of the attached
technical specification for soil investigation (Part-I). For boring in water,
suitable arrangement shall be made by the Contractor. Borehole shall be
measured from riverbed level/GL.
3.2 Hydrographic Investigations
The scope of work for hydrological investigations shall be as follows or as

directed by the Company.
i) To carry out hydrographic surveys in river crossings along the proposed

pipeline routes.
ii) To collect, store, transport and analyze river bed samples of rivers as
specified.
iii) To process all the survey data in order to establish accurate bed profiles,
surfacial features both dry bed as well as under water areas.
iv) To assess geological and geotechnical nature of the material in the close
vicinity of the proposed pipeline crossing.
v) To obtain scour profile at pipeline crossing location for the river.
3.2.1 Scope of work for hydrographic investigation work comprises of the

following:-
Technical Specification for hydrographic investigation (Part-II).
a) River Bank Grid Survey As per Technical Specifications attached

b) Historical data collection on As available from authentic sources /
HFL/LWL Regime, silt local enquiry
factor, river course etc.
c) Determination of scour From the grain size distribution on the

depth basis of results of exploratory boreholes
d) Submission of Report A draft report in 2 sets and final report in

4 sets shall be submitted by contractor.
The reports shall include a write-up on
proposed methodology for river crossing
Technical Specification for hydrographic investigation (Part-II).
4.0 INSPECTION OF WORK :
4.1 The work is subject to inspection/ supervision at all times by the Company.
The Contractor shall carry out all instructions given during inspection and
shall ensure that the work is being carried out according to technical
specifications, the technical documents and the relevant codes of practice.
4.2 All the survey details collected by the Contractor shall be furnished to the
Company in the form of a survey report.
5.0 SITE CLEANING AND RESTORATION :
5.1 The contractor shall take care for cleaning the area from time to time for easy
access to work site and also from safety point of view.
5.2 Working site should be kept cleaned and ground restoration shall be up to the
entire satisfaction of the Company.
PART – I
TECHNICAL SPECIFICATIONS FOR SOIL INVESTIGATION
1.0 SPECIAL INSTRUCTION
1.1 Each boring and field test shall be conducted under the direct supervision of
a qualified and experienced engineer. The bore hole locations shall first be
fixed at site with reference to a permanent reference point. A report
incorporating all field observation test findings and recommendations for
foundations at different depth with allowable settlements shall be submitted.
1.2 All data/ information’s including any unusual data/ information obtained
during the execution of the work shall be immediately brought to the notice
of the Company.
1.3 Survey and leveling work for establishing location and levels of bore holes
and the contractor shall carry out other exploratory work. However,
reference point/ lines will be provided by the Company to successful bidder
for carrying out such work. Depending on site condition, the locations and
nos of test can be altered at site, if found necessary by the Company.
1.4 All field investigations, laboratory tests and reports etc., shall be done in
accordance with the latest relevant Indian Standard Codes.
2.0 TECHNICAL SPECIFICATION OF WORK
2.1 Field Investigation and Test
2.1.1 Exploratory bore holes and core drilling
a) BY SHELL & AUGER :
All bore holes shall be of minimum 150 mm in diameter. The exploratory

work at site shall be carried out using shell and auger equipment. The
boreholes shall be terminated at a depth whenever with chiseling and
subsequent cleaning with bailer, the bore hole cannot be advanced more
than 300 mm in one hour. The casing shall be extended up to a maximum
depth which could be possible as per site conditions. No bentonite mud

shall be used to advance boring. Chiseling shall be carried out with
minimum 0.5 mm tonne cross type chisel falling from a height of 2.0 m.
Chiseling and cleaning with bailer shall be done alternately, each
operating from 5 to 10 minutes. Refusal to chiseling shall be considered
after one hour of chiseling or when progress is less than 30 cms. for each
200 drops, whichever is later. One bore hole thereafter shall be extended
by core drilling method using Nx size drilling bits untill 50% core recovery
is achieved. Cores shall be properly preserved in core boxes and shall be
handed over to the Company,if required. Whenever clay or other soft
material is interspersed in rocky strata, the drilling shall continue deeper
into rock to ascertain such formation. Disturbed samples from boring shall
be collected every 2.0 m or change in stratum and representative samples
placed systematically for proper logging of the strata. The existing ground
level shall be marked. Proper logging shall be done with description of
different strata encountered with their reduced levels. (Profile of the
different strata shall be plotted joining all adjacent boreholes apart from
individual boreholes. All bore holes after completion of work shall
immediately be filled in with a mixture of bentonite slurry and clay sand
mixture).
b) BY MUD CIRCULATION DRILLING :
In case the site conditions require the bore drilling shall be employed using
Mud circulation method. It should be adopted in all type of soils. Minimum
dia of bore holes shall be 150 mm if the rate of progress of boring in hard
strata is observed to be slow (Not more than 20 cm in two hours)
contractor may be permitted to adopt core drilling with Nx size bit.
However, the bit for core drilling shall be with double tube core barrel and
this core drilling operation shall be at no extra cost to the Company, so
long as to core recovery is less than 25%. Commencement of rock coring
shall be considered at a depth below which the core recovery is min 25%.
For rock strata encountered having RDQ 50% diamond head of Nx size
shall be used. Termination of bore holes shall be as indicated below. Max
length cored in rock shall be limited to 10 x Nx if rock available within 2.0
m from the Bed/GL level. Length of rock coring will decrease linearly.
2.1.2 Depth of Bore holes :
2.1.2.1 Depths indicated for bore holes or trial pits or any other depth correspond
to the depth from general ground level unless otherwise specified.
2.1.2.2 Boring shall be done to a minimum depth of 10 meter from the ground level
/River Bed level of each location marked in the drawing. However, boring
shall be terminated in case hard rock is met at depth lesser than
mentioned above with minimum 500 mm core recovery beyond 3 m depth
from ground level provided provisions of Clause 2.1.1(a) are met with.
Alternatively, in case the mud circulation method is employed the criteria
contained in 2.1.1 shall be met with.
2.1.3 Sampling :
In cohesive and semi cohesive soils, undisturbed samples conforming to

IS:2132 shall be taken using open tube samples with an area ratio of less
than 15% so as to obtain a core of sample of 100 mm diameters and 450
mm long at every change in stratum or at intervals of 2.0 meter which ever
is less. The tube shall be properly marked and the ends of the sample
tube shall be sealed properly with wax of thickness not less than 25 mm
and capped properly immediately after the sample is recovered from the
bore holes to ensure no loss of moisture with time while retained in the
tube. Sample tubes shall be immediately shifted to the laboratory for
testing.
2.1.3 Disturbed samples
Representative disturbed samples obtained from boring at every staggered

2.0 m interval in depth and change in stratum shall be placed in suitable jars
labeled properly for onward transmission to the laboratory. These samples
shall be sent to the laboratory immediately after the boring is completed. All
SPT samples shall also be similarly preserved.
2.1.4 Standing Ground Water Level :
Records shall be maintained of the level at which water is struck and the
level of any rapid inflow shall also be recorded. On reaching such level the
borehole shall be left open for a period of two hours to observe the rise of
water in the casing. Bore hole can be continued, thereafter, up to the end of
the day. The level of water in the casing at the end of the day and at the
beginning of the next day shall be recorded properly. For studying the
ground water table no drilling mud will be permitted for stabilizing the hole.
2.2 Laboratory Tests :
2.2.1 Introduction :
Laboratory tests shall be conducted on selected samples collected from site

to establish the physical and chemical properties of soil. Following tests
shall be done as appropriate in accordance with latest relevant Indian code
of practice.
i) Natural moisture content

ii) Void ratio
iii) Liquid, Plastic and Shrinkage limits
iv) Specific gravity
v) Dry density and Bulk density
vi) Cohesion and Angle of internal friction
vii) Particle size analysis
viii) Identification of core
ix) Chemical properties of the soil and subsoil water
2.2.2 Atterberg limits :
Liquid and plastic limit test shall be conducted on all cohesive soils for
classification purposes and for predicting engineering properties. The
results of limits tests shall be plotted on the plasticity chart of A.
Casagrande. Shrinkage limit shall also be determined for half of the soil
samples.
2.2.3 Particle Size Analysis
Particle size analysis shall be done on all clayey and sandy samples. Both
sieve and hydrometric Analysis shall be conducted and gradation curves
shall be plotted to show the Particle size distribution.
2.2.4 Shear Tests
Shear tests shall be conducted on the un-disturbed samples. The cohesion

value and angle of internal friction are to be determined by Mohr’s circle
method.
2.2.5 Specific gravity and Bulk density
These shall be determined as per standard procedure.

2.2.6 Standard Penetration Tests
Standard Penetration Tests shall be conducted as per IS Specification in

bore hole nos. as specified. These shall be conducted at interval of 1.0 m
starting first test of 1.0 m depth below existing ground level. The disturbed
representative samples shall be visually classified, labeled for identification
and properly preserved for laboratory testing.
3.0 REPORT
Brief report as per standard specification shall be prepared and submitted

to the Company as soon as the field and laboratory works are completed in
a draft form for review and comments. All the information as mentioned
below shall be furnished in the draft copy of final report. After reviewing,
contractor shall be informed about comments/ remarks, if any, the same
shall be incorporated. The report shall also include but not limited to
following:-
1. A plot plan showing all the test locations with respect to reference
change.
2. General geological information of the site.
3. Procedure of investigation and method of various testing adopted.
4. Detailed bore-logs indicating co-ordinates, reduced level, ground
water table etc., subsoil section along various profiles indicating
boreholes nos. depth wise in situ tests like SPT.
5. All field and laboratory test results shall be plotted against depth and
also in tabular form.
6. Summary of results obtained from various tests and their
interpretation to evaluate various soil parameters.
7. Silt factor for scour able soil strata, borehole and depth wise shall be
furnished in a tabular form.
8. Stable slope near bank both in natural as well as excavated states.
9. Longitudinal lateral friction co-efficient between pipeline and soil.
10. Stable trench slope along the width of the river through.
11. Proposal on the type of foundation for pipeline and methodology for
river crossing.
12. Anti-buoyancy measures at specified locations.
13. Presence of high levels of chlorides, sulphates and other chemically
aggressive elements in soils shall be reported and protective
measures suggested.
14. All data be digitised and supported with photographs wherever
necessary.
PART – II
TECHNICAL SPECIFICATION FOR

1.0 SCOPE
These specifications cover the Technical requirement and procedure for

Hydrographic and Topographic Survey of River.
2.0 EQUIPMENT
The Contractor shall provide boats and all equipments required for carrying
out the survey works. Details of the boats and survey equipment including
specifications along with relevant certificates of the equipment to be
mobilized for carrying out the survey works shall be submitted by the
Contractor. Before setting out for survey mobilization status shall be
indicated as per Annexure-I.
2.1 Small Survey Boat
The Contractor shall mobilize a suitable survey boat/ floating Platform

equipped with dual-frequency echo-sounder for conducting sounding
surveys in the river.
2.2 Survey Equipment
A dual-frequency precision echo-sounder/sounding poles, distomats, the

odolites, sextants, masts, levels etc., as needed for the land and river
survey shall be mobilized.
2.3 Grab/ bed Materials Samples
The Contractor shall provide a suitable equipment such as grab or push

sampler to sample the bed material.
3.0 PERSONNEL
The Contractor shall provide necessary experienced personnel for

operation of the survey equipment and for conducting field surveys.
The Contractor shall provide qualified personnel with relevant experience to

collect and assess hydraulic and sedimentalogical parameters.
4.0 REQUIREMENTS & METHODOLOGY
4.1 River Surveys
Bank grid survey of the river bed shall be carried out upto 20 mtrs. on either
side of the proposed pipe alignment in a grid with the centerline along the
proposed alignment. The wing lines shall be located at 10 m intervals on
either side of the proposed pipe line alignment. Cross lines (along the river)
shall be run at every 5 m intervals. The dry bed shall be surveyed upto HFL
on either side and spot levels shall be taken at 5 m intervals. Closer spot
levels may be taken whenever a change occurs. However, the exact
location and number of wing lines shall be decided by the Company at site
depending on the site conditions at the time of survey.
Contractor shall assess change in river bed slope upto 200 m on either side
of the pipeline crossing.
All levels shall be referred to M.S.L.
Fixing the transit marks and using sextant angles shall carry out positioning
of the survey boat.
4.2 Historical Data Collection
Contractor shall collect/obtain the HFL and other hydrological data for river
crossing site from the local/ regional agencies such as CWC, Department of
Irrigation Drainage Works; Flood Control Authority, PWD etc. The data shall
be collected for the nearest available gauge station irrigation and/ or
drainage head works for past ten years.
- Contractor shall provide all the necessary back-up calculations/

details for the estimated hydrological data at the point of interest.
- Contractor shall provide detailed methodology and procedures for

field works, data collection and computations of hydrological
parameters with/ without availability of historic data.
4.3 Equipment Calibration
Contractor shall carry out calibration/ checks/ trails of all the survey
equipment in the field and obtain necessary approvals for the start of
operations from the Company.
5.0 OBLIGATIONS OF THE CONTRACTOR
5.1 The Company shall monitor survey procedures, data quality, preparation of
charts and drawings. Contractor shall repeat the work that has not been
certified and accepted by the Company to obtain acceptable quality.
5.2 Contractor shall obtain completion certificate from the Company after
completion of all the field works required as per the scope of work.
Completion Certificate shall be issued to the Contractor only after
collections/ obtaining data of acceptable quality.
5.3 The Company shall be informed of the progress of survey at specified

locations. Contractor shall provide necessary facilities to access the data
collected at site/base. The Company shall have access to all the data
collected during surveys. All the details regarding positioning, methodology
of surveys, equipment deployment shall be provided to the Company.
5.4 In case of any follow-up field work is required to incorporate comment/

suggestions made by the Company on the survey documents submitted by
the Contractor in order to meet technical requirements, the same shall be
carried out by the contractor.
5.5 Contractor shall provide the following documentation:
Details including specification of all equipments, survey boats, personnel

etc., as per Annexure-I.
5.6 The Company shall not accept any liability towards loss/ damage of any
equipment/boat etc. during course of investigations.
5.7 The Company will not collect the data for the Contractor from the regulatory
agencies nor provide any information regarding place of availability or the
procedure to go about the data collection. However, the Company shall
provide to the Contractor any letters of clarifications/ projects details
addressed to the agency. Entire data collection is the responsibility of the
Contractor.
6.0 REPORT
Preliminary Report
The Contractor shall submit within a week of completion of surveys a
preliminary report. This report should include:
a) A summary of all work carried out by the Contractor including location of

areas covered.
b) Track charts of the boat and the grid points of the surveys carried out.
c) Co-ordinates of the shore control station need for positioning the boat.
6.1 Final Report
Detailed report shall be prepared as per specification in addition to the

following specific requirement.
The report should consist of :
a) Details of the field surveys

b) Final track charts
c) Geological and morphological features
d) Cross-sectional details each riverbed along with the profiles across
and along the riverbed.
e) The grain size distribution curves of the soil samples collected from
the riverbed including data of sampling, locations etc.
f) Hydrological data such as HFL for each river-crossing site, based on
the past data. The details of the basis of the data presented shall
also be furnished i.e. details of the data from agencies and methods
of computation.
g) The historical local data available for any bank erosion, scour
observed at nearby bridges etc. change in the river course including
the source of the data.
h) Scour profile of the riverbed along the pipeline crossing.
i) Analysis of pipeline depth and buoyancy calculations for the
specified pipeline.
j) All the working drawings shall be in 1:500 scale or as specified by
the Company.
k) Proposal and analysis for the pipeline crossing.
l) Proposal for anti-buoyancy measures.
PART-II
(Ref. Clause 5.5 - Documentation to be provide by the Contractor )
ANNEXURE–I
Details of Boat, Equipment and Personnel to be mobilised.
1. SURVEY BOAT
Size and other details of small boat and the proposed methodology of
mobilisation at sites.
2. SURVEY EQUIPMENT
a) Echo-sounder
b) Positioning system
c) Survey equipment
3. PERSONNEL
Details of qualification and experience of survey personnel required for

smooth
operation:
a) Boat positioning during survey and track plotting

b) operation of survey equipment like echo-sounder
c) data processing and report preparation
4. Set of all equipment, plant machinery etc. for successful completion of soil
investigation
PART-II
ANNEXURE – II
LIST OF INDIAN STANDARDS REFERRED
1 IS: 1498 Classification and Identification of Soils for General

Engineering Purposes.
2 IS: 1888 Method of Load Tests on Soils.
3 IS: 1892 Code of practice for Site Investigations for Foundations.
4 IS: 2131 Method for Standard Penetration Test for Soils.
5 IS: 2132 Code of Practice for Thin Walled Tube Sampling of Soils.
6 IS: 2720 Method of Test of Soils (Relevant Parts)
7 IS: 4434 Code of practice for In Situ Vane Shear Test for Soils.
8 IS: 4968- Part-I Method for subsurface sounding for soils – Dynamic
Method Using Cone without Bentonite Slurry.
9 IS: 4968- Part-II Method for subsurface sounding for soils – Dynamic
Method
Using Cone and Bentonite Slurry.
10 IS: 4968- Part-III Method for subsurface sounding for soils static cone
penetration test.
11 IS: 5249 Method of Tests for Determination of In situ Dynamic
Properties of Soils.
SPECIFICATION FOR
CONSTRUCTION OF UNDERGROUND
PIPELINE
1 23.03.2005 KRK SN PKM
CORPORATE DESIGN SPECIFICATION FOR DOCUMENT NO :

CDG/MUM/PLM/002
GROUP, MUMBAI CONSTRUCTION OF
UNDERGROUND
Page 1 of 13 Rev. 1
PIPELINE
CONSTRUCTION SPECIFICATIONS
The pipeline will be laid as per Code ASME B-31.4 (Latest Edition) for oil pipe
line and as per code ASME-B-31.8 latest edition for Gas pipeline.
1.0 RIGHT-OF WAY, CLEARING AND GRADING
1.1 The Right - of - way shall be cleared and prepared for the
convenient passage of all construction equipment required for various
pipe laying operations by removing there from all bushes, trees,
undergrowth, stamps, rocks and other obstacles liable to impede the
convenient passage of the equipment and the laying of the pipe to the
specified width and as shown in map or plan exhibit or to the limited width
specified in the grant of the right-of-way, to the satisfaction of the
Engineer –In -Charge . Where ever necessary the minimum amount of
trees, bushes, and shrubs shall be removed to clear through cultivated
areas. All consideration shall be given to the preservation of trees within
the right-of-way as directed by the Site Engineer/Engineer-In-Charge.
1.2 After clearing the right of way, grading shall be so performed so as to

allow passage of loaded trucks and equipment without undue wear and
tear thereon. The right off way shall be graded preceding the trenching
operation in order to permit the trench to be properly graded for
placement of the pipe with no sharp over bends or sags ..
1.3. Clearing and grading shall also include all necessary right-of way, such
as excavation, filling etc., at points where the pipeline route crosses
roads, railways, streams, ditches, landfalls, etc., for easy passage of
trucks and equipment, Necessary grading of the right-of way at all such
special crossings and other locations where needed to provide a suitable
ditch for the laying of the line and to protect the line from injury and
damages to the entire satisfaction of the Site Engineer/Engineer-In-
Charge.
1.4 Necessary arrangements shall be made such as ramps, temporary

bridges, etc., near canals, ditches and streams, etc., to the extent
necessary for crossing them with men and machinery. This should,
however, be done in such a way as to permit the natural flow therein and
to preserve the banks thereof.
1.5 Any materials or structures removed from the right-of-way shall be

treated as property of the ONGC and shall either be carefully dismantled

CDG/MUM/PLM/002
UNDERGROUND
Page 2 of 13 Rev. 1
PIPELINE
kept for re-use during restoration or destroyed or otherwise dealt with as
per the direction of the Site Engineer/Engineer-In-Charge.
1.6 Care must be exercised in clearing all debris from the right-of way to
prevent the soil from the ditching operation intended to be used for
backfilling the ditch becoming mixed with such debris.
2.0 HANDLING, HAULING, STRINGING AND STORING
2.1 Necessary arrangements and exercise due care to prevent damage in

loading and unloading, hauling, handling and stringing. In these
operations suitable lifting and handling equipment shall be used to the
satisfaction of the Site Engineer so as not to cause any damage to the
Pipes and materials. Care should be exercised in handling Pipes to avoid
distortion, flattening, denting, scoring scratching or any other damage.
2.2 Special care shall be exercised in handling of Pipes and material by

using appropriate padding so as to avoid damage to the pipes and
materials. Pipes shall be loaded on trucks with each succeeding length
rested evenly with other lengths on the truck and the load shall all be
packed and securely tied to each bolster by suitable chains in such a
manner that flexing and shifting of the Pipes during hauling is avoided.
When lifting Pipes 8"/in diameter and larger, lifting hooks should be
equipped with a brass or copper lined plate curved to fit inside of the
Pipe.
2.3 Pipes should not be allowed to drop or strike objects and should be
lifted or lowered by approved hoisting equipment as desired by Site
Engineer/Engineer-In-Charge, care being exercised that pipes are not
lowered in such a manner as to distort the ends thereof.
2.4 Dragging and skidding of pipes shall not be permitted and unchecked
rolling of pipes from stringing trucks should not occur. Special care
should be exercised in lowering the pipes to ground in rocky terrain to
avoid dropping or being allowed to rest on protruding rocks or sharp or
jagged surfaces. An overlap of about 25 mm shall be kept between
adjacent pipes. The pipes shall be strung parallel to the ditch and at a
distance of about 1.5 Mtr. from the center line of the ditch.
2.5 Care should be taken during stringing of Pipe to see that the pipe is
strung in accordance with its proper placement along the route by grade
size thickness of pipe.

CDG/MUM/PLM/002
UNDERGROUND
Page 3 of 13 Rev. 1
PIPELINE
3.0 TRENCHING
3.1
a) Pipeline trench shall be dug by any method that may be necessary
or directed on the cleared and graded right-of-way according to the
routes as stated and approved by Engineer-In-Charge.
b) Trenching operations shall as far as possible be kept ahead of the

lining up and welding operations.
c) Due care shall be exercised so that the soil from trenching

operations intended to be used for back-filling is not mixed with
loose debris or foreign matter.
3.2
a) Without regard to soil conditions and/or the topography of the
ground, the trench shall be excavated and finished to the
minimum dimensions shown for earth and rock in map or plan
exhibit. the depth of the trench shall be measured from the
average level of the original ground or grade on the two sides
of the trench whichever is lower.
b) The specified width shall be measured at the bottom of the

trench.
c) The trench shall be shut with square bottom so that the full width
is available for providing slack in the line at the time of laying.
3.3 If necessary, the trench shall be dug to such additional depth and
width as will ensure that the finished trench shall meet the minimum
dimensions given in the exhibits and shall grade the trench so that the
pipe has a firm continuous support on bottom of the trench and field
made pipe bends conform in all respects to the field bending
specifications given herein and as shown on map or plan Exhibit.
3.4
a) The bottom and side of the finished trench shall be uniformly,
graded and must be free of loose rock, hard clods, large gravel,
protruding roots or rock projects, bush, skids, sticks, welding
rods or others hard objects and debris which could damage the
coating when the pipe is lowered in.
b) In locations where the soil on trench bottom is clayey and gets

hard on becoming dry thereby endangering the pipe coating on
lowering into the trench, the Site Engineer/Engineer-In-Charge at

CDG/MUM/PLM/002
UNDERGROUND
Page 4 of 13 Rev. 1
PIPELINE
his discretion may demand the running of water wagon to render
the trench bottom wet/soft.
3.5 Where the trench is across or adjacent to roads, highways, railways,

canals ravines and other water courses or land falls and at locations
where the contour of the land may require additional depth to
eliminate unnecessary bending of pipe, such additional depth shall be
dug as shown in the construction Drawings or as directed by the
Engineer-In-Charge to reduce to a minimum, the required number of
bends to lay the pipes to conform with the contour of the ground and
shall maintain a normal covering by cutting the trench slightly deeper
at the crest of ridges and by gradually depending the ditch in
approaches to crossings.
3.6 The trench shall be made wide enough where slack loops are lowered
into the trench so that no coating is rubbed off or abraded at the
sides.
3.7 In special locations shown where in the opinion of the Engineer-In-

Charge, the use of trenching machinery may result in unnecessary
damage to property or sub-surface structures likely to be encountered
in excavation, the trench shall be excavated by hand.
3.8 Locating and protecting the existing and operating underground

pipeline in the same right-of-way shall be done. Sufficient care shall
be exercised to avoid any damage to the pipeline arising out of the
activity on the existing right-of way.
3.9 If damage occurs to any structures, line or property as specified

above, the owner of the damaged structure(s),line(s) or property shall
be contacted and the repairs shall forthwith be made/carried out
under the direction and to the satisfaction of the Site
Engineer/Engineer-In-Charge. Reports shall be made to Site Engineer
/ Engineer-In-Charge of any damage or any other incidents relating to
interfering adjacent structures.
3.10 Unless expressly permitted by the Engineer-In-Charge and the owner

of the interfering structure(s) etc., the trench shall be dug to such a
depth as is required to install the pipeline with a minimum free
clearance of O.S.M. (or such greater minimum free clearance as may
be required in special cases) above or below any existing
underground metallic or non-metallic line or structure or utility
crossing the trench, it being understood, however, that the specified
minimum cover shall in all cases be maintained.

CDG/MUM/PLM/002
UNDERGROUND
Page 5 of 13 Rev. 1
PIPELINE
3.11 Clearance on one side or the other of any interfering structures shall
be determined in the field in accordance with the circumstances of
each case with the provision that the line should be at a minimum
distance of 10 meters from any building or other structure or sewage
system component wherever the cover of the Pipe can be considered
of gas tight nature and of 5 meters if the line cover can be considered
of non-gass tight nature. Temporary underpinning supports and other
protective devices necessary to keep any interfering structure intact
shall be provided and same shall be of such design as to ensure
against their possible failure.
3.12 Sufficient width of the trench shall be provided as directed by the Site
Engineer at all such places where it is likely to cave in due to soil
condition.
3.13 All necessary arrangements shall be made to remove, bail or pump

water from the trench if required by the Site Engineer/Engineer-In-
Charge.
3.14 The expression "rock trench" shall in the specification mean trench
excavation(s) of the right-of-Way to the specification requirements
that cannot be performed by mechanical means.
3.15 Where the line is to be laid in sand or earth dunes, the trench which
shall be cut until firmly packed soil does not move with the wind and
water is reached. Such excavated material is to be removed away
from the trench line and disposed off but shall not be disposed off into
depressions along the ditch line.
4.0 BENDING OF PIPE
4.1 a) The pipes shall be laid to conform to the bottom of trench & trench
shall be so graded as to reduce bends in the pipe to a minimum and
to maintain the pipe within the specifications given.
b) All necessary bends required in the construction of the system up to

the minimum radius allowed for field cold bonds shall be made.
c) Bends shall be necessary in the pipe at points that will coincide with
changes in the grade of alignment of the trench when the pipe has to
be deflected beyond such curvatures as allowed by these
specifications to leave as few residual stresses in the line as possible.

CDG/MUM/PLM/002
UNDERGROUND
Page 6 of 13 Rev. 1
PIPELINE
d) Any irregular tendency in the gradient of the trench bottom may be
corrected by filling with loose earth about 0.10 meters in depth,
provided the minimum cover of the virgin soil is available.
e) The middle over bends shall clear with proper vertical clearance the
bottom of the trench at its high point and sags shall fit the bottom off
the trench neatly and lateral bends shall have proper lateral
clearance.
f) No bends shall be closer to any circumferential weld than 6(six) pipe

diameters, except where it is other wise mentioned in the relevant
drawings for locations like scrapper platforms and standard valve
platforms etc.
g) The longitudinal weld of welded pipe shall preferably be near the

natural axis of the bend.
4.2 a) No hot or mitered bends shall be allowed and all bends shall be made
by cold smooth stretch method with bending machine of proper size in
such a manner as to preserve cross sectional shape of the pipe with a
difference between the maximum and minimum diameter not in
excess of 2.1/2% of the nominal diameter and without undue
stretching of pipe or thinning of the wall thickness. To minimize
distortion of pipe and to avoid impairing its strength, bends shall be
made to as long a radius as possible and the minimum radius for field
cold bends on pipe sizes 12" and larger should not be less than 40
times the outside diameter of the pipe.
b) For size smaller than 12" the minimum permissible radius for field
bends shall be 20 times the outside diameter of the pipe except where
other size authorized by the Site Engineer.
c) Any pipe that is buckled, wrinkled, cracked or shows other evidence

of mechanical damage by bending operation shall be cut out and
replaced.
5.0 SWABBING AND NIGHT CAPPING
a) Preparatory to aligning pipe or welding, the inside of each length of

pipe shall be thoroughly cleaned and swabbed with a leather or
canvas belt disc of the proper diameter and sufficient length to
remove all sand, dirt, loose mill scale or other debris that might clog
the line or disturb or damage during operation of the equipment
installed on the system such as valves, metering equipment etc.

CDG/MUM/PLM/002
UNDERGROUND
Page 7 of 13 Rev. 1
PIPELINE
b) Any obstruction remaining in the line after its completion shall be
removed.
5.1 At the end of each day's work, the open ends on the pipe sections
shall be night capped with a securely closed metal cap so as to
prevent the entrance of dirt, water and foreign matter into the pipeline
until the work is resumed.
6.0 PREPARATION OF THE JOINTS :-
6.1 The beveled ends of each joint of the pipe shall be thoroughly cleaned
of paint, grease, rust, mill scale, slag, dirt or other foreign matter so as
to avoid defects in the completed welds.
6.2 In order to maintain correct alignment and spacing of the pipe for
welds, wherever necessary pipe ends shall be re-formed or re-cut
and rebevel to specifications by an approved bevelling machine. Any
dents in the pipe beyond the permissible limit shall be cut out if
jacking is not possible and pipe ends rebevelled as directed by the
Site Engineer. The permissible limits would be specified in the field.
7.0 LINE-UP :-
7.1 The details of pipe joint design and end preparation shall be as given
in map or plan exhibit.
7.2 a) Pipes shall be lined up in such a manner as to prevent damage

thereto.
b) The ends of pipe to pipe or pipe to fitting joints shall be aligned as

accurately as practicable giving consideration to existing commercial
tolerances on pipe diameter, pipe wall thickness and out of
roundness. Alignment shall provide the most favourable condition for
the deposition of the root bead and shall be preserved during welding
of the root bead.
c) When laying electric resistance welded pipe having a longitudinal

seam, the pipe shall be so assembled that the seam will be on the
upper surface of the line and within 45 of the top center during coating
and wrapping and after lowering into the trench. Successive joints
shall be rotated to right and left so that pipe seams are staggered by

CDG/MUM/PLM/002
UNDERGROUND
Page 8 of 13 Rev. 1
PIPELINE
not less than 20 (twenty degrees) to avoid alignment of seams in
adjacent joints.
d) When aligning the pipe for position welding no tack welds shall be
permitted. Each joint shall be held in alignment by means of a line-up
clamp while parts of the stringer bead are applied amount to less than
50% (fifty percent) of the pipe circumference before tension of the
line-up clamp is released provided that the pipe is fully supported and
the completed part of the stringer bead is in segments approximately
equal lengths spaced about the circumference of the pipe.
e) External line-up clamps are subjected to the same limitations of

paragraph 4.3 of API Std.1104. The space between abutting pipe
ends shall be uniform around the pipe circumference and shall be
such as to ensure complete penetration without burn through and
shall be as specified in the welding procedure and submitted to the
Engineer-In-Charge prior to the start of welding. For pipe having the
same dimensions the off-set shall not exceed 1.5 mm (1/16"). After
removal of the line-up clamp the stringer bead is to be completed
before the welder proceeds to the next joint.
8.0 WELDING : Refer specification no. BDA/ODG/PL/003
9.0 LOWERING PIPE IN TO TRENCH
9.1 a) After inspection of coating and wrapping the entire welded-up lines
(without exception of slack loops) in the amount and at locations as
necessary shall be normally lowered into the finished trench next
day after completion of joint coating and wrapping.
b) The pipe shall fit the trench without being forced to remain in place
until the backfilling operation is completed. Any extra excavation that
may be required for this purpose shall be done.
c) In lowering the line vertical slack loops shall be placed at regular

intervals. Slack loops shall move horizontally from side to side of the
trench after lowering. Untill enough of the lowered line is
securely anchored by backfill, slack loops shall be suspended above
the trench on padded support of sufficient strength to prevent
collapsing of the trench and in sufficient number as that the pressure
at the points of support will not damage the coating and wrapping,
slack loops shall be lowered into the trench without being forced into
it only early in the morning when the pipe temperature is normally at
its lowest value, and immediately back-filled. Excessive slack shall
be removed by widening the trench as may be necessary.

CDG/MUM/PLM/002
UNDERGROUND
Page 9 of 13 Rev. 1
PIPELINE
d) Vertical and lateral bends of the lowered line must be fitted into the
trench with proper clearance. Necessary works required for
ensuring proper clearance shall be performed. The coating and
wrapping shall be inspected by running holiday detector at the
required voltage just before lowering in the pipe in the trench.
9.2 a) The trench into which the coated and wrapped line is to be lowered
must present on even and smooth bottom and care shall be exercised
to remove there from all hard projecting objects so that the protective
coating and wrapping of pipe is not damaged.
b) The bottom of the trench shall be padded with a minimum of 0.10 M

of loose earth in accordance with the specifications given herein for
rock trenching which might damage the protective coating and
wrapping of pipe.
c) Water present in the trench at the time of lowering in shall be pumped

out before lowering in the pipe to enable checking of the conformity of
the trench to specifications, if required. If the trench has collapsed,
necessary repairs shall be done, as directed by the site
Engineer/Engineer-In-Charge.
d) Across water logged areas, if required concrete weights as per exhibit

and heavy coating and wrapping consisting of an extra coat of enamel
and an extra wrap of fibre glass in addition to the normal coating and
wrapping shall be installed/applied as directed by the Engineer-In-
Charge.
9.3 BACK FILLING AND DRESSING THE TRENCH
9.3.1 a) Provided that the pipe has been properly fitted into the trench and
lowered to the specifications, the backfilling operation shall follow as
closely as practicable the lowering in of the pipe so as to anchor the
pipe in the ground and to prevent unnecessary exposure of the
coating and wrapping to temperature or weather.
b) The backfilling operation shall be performed in such a manner as to

provide firm support under the pipe and to avoid injury to the coating
and wrapping.
c) All over bends, size bends and the section of slack loops shall be
backfilled as soon as the pipe is placed in the trench. The excavated
materials shall be neatly centered over the trench and neatly rounded

CDG/MUM/PLM/002
UNDERGROUND
PIPELINE
thereon to a minimum of 0.30 M above the adjacent ground, except
through road crossing and irrigated farm lands where all the
excavated material must be returned to the trench as directed by the
Engineer- In-Charge. Where in any locations the backfill is unevenly
centered over the trench due to carelessness or any other cause it
shall be redressed. No debris shall be allowed in backfill at any time.
The compaction of the backfill should be accomplished tamping by or
by running on the top of the fill one thankful of crawler tractor or by
flooding, or otherwise as directed by Engineer -In-Charge.
d) The finished backfill must be sufficiently levelled to permit normal

irrigation even if how rowing, discoing or hand racking is required to
accomplish this in cultivated areas. The hard core and other surface
material excavated in trenching shall be replaced and tamped in the
trench to its original condition after the ditch trench has been
practically and sufficiently filled up and tamped with the sub-soil
material.
e) At locations where the backfill material contains hard clods, rock

fragments and other hard material that would damage the coating and
wrapping and where rock has been excavated from the trench and it
is intended to refill the trench in whole or in part with such excavated
rock or material, the trench shall be initially filled, in order to prevent
damage to the protective coating and wrapping and pipe from hard
fragments, with not less than 0.10 M of de-rocked loosed earth above
the tops of pipe to be screened through a suitable mesh if so required,
and backfilling shall only thereafter be completed and finished with the
excavated materials.
f) At locations where rock gravel is encountered at the bottom of the

trench and sufficient loose earth for protection of pipe is not available
at site, necessary loose sand shall be hauled to pad the bottom of the
trench and to fill in to a point 0.10 M above the top of pipe.
g) Loose rock shall neatly pile up on the crown of the backfill or placed at
the edges of the right-of-way.
9.3.2 The backfill shall be maintained against wash out settlement below
original levels and rotting until final completion of the work and until
reinstate to the original surface conditions as acceptable to the
authorities having jurisdiction and to the satisfaction of the Site
Engineer.

CDG/MUM/PLM/002
UNDERGROUND
PIPELINE
9.3.3 a) Where the trench has been dug through public and private streets,
drive ways and roads the backfill shall be thoroughly tamped as it is
replaced the trench to prevent setting and the surface shall be
reinstated after proper consolidation of the backfill, to its original
condition to the full satisfaction of the person(s) or authorities
concerned. Backfilling of public, private roads and railways crossing
shall be performed immediately after the lowering in operation and
made safe to traffic.
b) In repairing highways, drains and waterways concerned authorities

(having jurisdiction over the same) may require revetment using logs,
stones, bags of earth or other such reverting materials as may be
specified and said requirements shall be complied with.
c) When backfilling trenches on hill sides or slopping areas and on the

banks of water course where backfill may be washed out of the
trench, furrows or terraces or effective water breakers across the
trench shall be provided against such so as to divert the flow of water
away from the trench into natural drainage, followed before the laying
of the line. In no case is surface drainage to be diverted into channels
other than those followed before the line was laid. Manual backfilling
shall be used where mechanical equipment would damage building or
other structures. drain tile and underground drainage building system
interrupted by the trench shall be carefully restored and protected
and damaged parts replaced.
d) All stream and water course banks shall be properly redropped and
restored to former conditions to prevent washouts.
9.4 HYDROSTATIC TESTING :

Refer specification no. BDA/ODG /PL/007
9.5 CLEAN-UP AND RESTORATION
a) The cleaning-up operation performed on the Right-of-way by the

clean-up crew shall follow as closely as practicable the installation
and the backfilling of the line so that the Right-of-Way shall suffer
disturbance from construction for the shortest practical period of time.
All surplus soil, waste material, debris, rock, broken stumps, wasted
and rejected coating and wrapping materials shall be cleared &
removed to the designated places.

CDG/MUM/PLM/002
UNDERGROUND
PIPELINE
b) On completion of clean-up the ground shall be restored to such stable
and usable condition as may be reasonably required consistent with
the condition of the ground prior to the building of the pipeline and in
particular cultivated farm lands and pastures shall be restored to
useable condition and irrigation ditches and water courses repaired
and restored to near original condition and all damages repaired to
the satisfaction of the Engineer-In-Charge as also to the land owners.
c) All temporary access to the Right-of-Way installed shall be removed

excepting any which may be left at request of the Engineer-In-Charge
for latter's use in the maintenance of the system.
d) All fencing and other structures shall be restored to their near original
condition.
Damaged structures shall have to be restored to their original

condition.
e) All exposed steel works, pipes, valves, fittings, etc., shall be painted
as directed by the Engineer-In-Charge.
Note : Following condition has not been considered as a part of technical

specification. However, same should be included in the General
Conditions of Contract
The ONGC shall be completely indemnified from and against all claims,
demands, cost (inclusive between attorney and client) charges,
expenses and losses and damages that may arise in behalf or that the
ONGC may any way suffer or sustain relative to arising out of or in
connection with the same. The ONGC may demand from the
CONTRACTOR, if necessary a certificate from land owners regarding
satisfactory restoration of their lands.

CDG/MUM/PLM/002
UNDERGROUND
PIPELINE
SPECIFICATIONS
FOR
PIPELINE WELDING
1 23.03.2005 KRK SN PKM

SPECIFICATION CDG/MUM/PLM/003
GROUP, MUMBAI
FOR PIPELINE
WELDING Page 1 of 10 Rev. 1
GENERAL SPECIFICATIONS FOR PIPELINE WELDING
1.0 SCOPE
This specification defines the minimum technical requirements for

welding and inspection of pipeline field weld joints.
2.0 APPLICABLE CODES AND STANDARDS
The Contractor shall meet or exceed the requirements of the latest

edition (unless otherwise mentioned) of the following codes. In cases
where more than one code, regulation or standard apply to the same
condition, the more stringent shall be followed.
API 1104 : Standard for Welding Pipelines Related Facilities

ASME B 31.3 : Chemical Plant And Petroleum Refinery Piping
ASME B 31.4 : Pipeline Transportation System for Liquid Hydro-
carbon and other liquids.
ASME B 31.8 : Gas Transmission and Distribution Piping Systems.
ASME Code : Sections IC, V & IX
OISD 141 : Design and Construction Requirement for Cross
Country Hydrocarbon Pipelines
The Contractor shall also comply with the requirements of any other
applicable regulations required by law, which is not indicated above.
The intent of present specification is to provide general guidelines in
addition to the code requirements by way of addition and not by way of
limiting.
3.0 PREPARATION FOR WELDING
3.1 All welding for pipe sizes 100 mm and larger shall be done in accordance
with the latest edition of API Standard 1104. Welds shall be made by the
manual shield metal arc method. The same and following are not to be
construed, however, as the complete specifications for welding.
3.2 Before welding, all foreign matters shall be removed from the beveled
ends. If any of the ends of the pipe joints are damaged to the extent that
satisfactory welding contact cannot be obtained, the damaged pipe ends

GROUP, MUMBAI
FOR PIPELINE
shall be cut and field beveled with beveling machine. Should laminations,
split ends of other defects in the pipe be discovered, the length of pipe
containing such defect shall be cropped, repaired or removed from the
line. This contingency of detection shall hold good during various stages
of pipeline operations like welding, bending, coating and wrapping etc.
Should any other defects like scratches, weld sparks, indentation be
detected, the same shall be removed / replaced.
3.3 End Preparation
The preparation of edges to be welded shall be made by machining or by

oxyacetylene cutting. In the latter case, all grooves and irregularities and
all oxidation shall be ground or filed off. The end preparation for butt
joints shall be as indicated below:
• For piping with thickness up to 26 mm, the preparation shall be “V”

type, with 30 0 +5 0 beveling and root face of 1.6 ± 0.8 mm.
• For piping with thickness over 26mm, the preparation shall conform to
ASME B 31.3, or shall be of another type approved by Company.
3.4 Cleaning of Edges
The edges to be welded shall be properly cleaned. In particular, any oil,

bitumen, grease and paint shall be removed by flame or solvents. Earth,
oxide, rust, sand and any other material, which could be detrimental to
the weld, shall be removed by means of grinding and / or a wire brush.
The cleaning shall be extended for about 10 mm from the edge on the
internal pipe surface by grinding.
3.5 Branch Connections:
The preparation of branch connection shall be in accordance with

ASME B 31.3 and shall ensure full penetration. Reinforcing pads, when
required, shall be of the same material and thickness as the pipe that is
to be reinforced.
3.6 Alignment, Fit-up, and Spacing
3.6.1 Components to be welded shall be aligned, spaced and fitted up so as to

hold the edges, during welding, at a proper distance to obtain full root

GROUP, MUMBAI
FOR PIPELINE
penetration. The root opening shall range from 1.6 to 4 mm depending
upon the thickness of pipeline and welding procedure.
3.6.2 All welding equipment, line-up clamps, beveling machines and other
welding tools, materials and equipment are to be used in welding
operations and must be maintained in a satisfactory condition.
3.6.3 Welding machines shall be operated within the amperage and voltage
ranges recommended for each size and type of electrode to ensure
proper fusion and maximum penetration.
3.6.4 All welding electrodes and their storage & handling shall conform to the
requirements of API Std.1104 latest edition. Electrodes that show signs
of deterioration or damage shall be rejected. Stubs of welding rods and
pieces that are rejected shall be disposed of at suitable places at the end
of each day's work.
4.0 WELDING PROCEDURE
4.1 Prior to start of production welding, a pipe welding procedure shall be

established, qualified and recorded for submission to the Company for
approval and adhered to in accordance with relevant API Std.
4.2 All position welds shall be made with the pipe resting on suitable and
sufficient number of skids with the work clearance as specified in the
relevant API Std.
4.3 Special care shall be taken to ensure that the pipe is properly aligned
and not subjected to any strain.
4.4 The number of beads required shall be governed by the wall thickness
of the pipe, provided that the completed weld shall have a substantially
uniform cross section around the circumference of the pipe. The root
bead shall be applied completely around the pipe and immediately run by
a grinder and the grove shall be thoroughly cleaned for visual inspection
of all free scale, slag or flux and other foreign material prior to the
application of successive beads.
4.5 The stringer bead must approach full and complete penetration through
out the periphery of the weld and build up with reinforcement at the root.
4.6 The hot pass shall fully penetrate the pipe level at each side of the
stringer making a deposit heavy enough to avoid pin holing. The
completed weld is to be cleaned free of all scale, the standards of
acceptability are as given in relevant API Std. The minimum and
maximum limits of reinforcement and the width of completed welds shall
be in accordance with relevant API Std and with the procedure to be
recorded as shown in API Std.1104.

GROUP, MUMBAI
FOR PIPELINE
4.7 Any section in which only stringer and hot pass beads have been
completed, should be completed at the end of the day in all respects. In
no circumstances shall a weld be left with only the stringer bead applied.
4.8 Defective welds should be repaired according to the requirements of

relevant API Std and re-test of repaired welds shall be carried out in
accordance with relevant API Std.
4.9 Welding shall not be carried out when weather conditions are unsuitable
as per the provisions of relevant API Std.
5.0 WELDER QUALIFICATION TEST
5.1 Each welder shall have been qualified with the procedure specified in
para 3.0 of API Std.1104 and recorded in accordance with the relevant
API Std. on a pipe nipple of the same diameter and specifications as the
pipe to be used in the system. The manner of performing the test and the
test result and records required shall be in accordance with relevant API
Std. Each test weld shall be carried out and tested using the testing
methods described therein. The welder may be recognized as qualified
and employed on the line if the test weld is acceptable in accordance with
relevant API Std.
5.2 All welds shall be marked with approved stamping by the welders on the
pipe adjacent to the weld according to identifying numbers assigned to
them.
6.0 TIEING-IN
6.1 The length of section to be tied in shall be such as to permit in the

Company’s judgment a good line up and weld. The Company may also
suggest some other locations for tie-in for any other reason in addition to
the above if needed.
6.2 The tie-in of two sections shall be carried out only after the section has
been welded and lowered and preferably back filled except for the ends
which are to be joined which shall be kept on skids or kept in the ditch
and shaded.
6.3 The tie-in operation includes necessary cutting, beveling, line-up,

cleaning, welding, priming, coating and wrapping, lowering in, backfilling
for the tie-portion as per standard practice. Necessary widening of the
trench should be carried out as per requirement.
6.4 As far as possible the tie-in welding shall be executed early morning or
when the ambient temperature is a minimum.

GROUP, MUMBAI
FOR PIPELINE
6.5 The tie-in should be done in such a way as to leave no strain in the pipe.
If necessary, redressing of the trench shall be done to eliminate force or
strain in the pipe.
6.6 When a welded section so overlaps as to prevent a proper tie-in, welding
the line-up shall be made by moving ahead the section or by carefully
cutting of the overlapping end.
6.7 In case additional pipe is needed for tie-in, the minimum length shall be
1.00 metre.
7.0 INSPECTIONS AND TESTING
7.1 General
7.1.1 The Company shall have free access to all concerned areas, where the
actual work is being performed. All facilities necessary to carry out
inspection by the Company shall be arranged by the Contractor.
7.1.2 The Company is entitled to depute its own Inspector to the shop or field
where prefabrication and erection of pipe lines are being done with,
but not limited to, the following objectives.
• To check the conformance to relevant standards and codes and

suitability of various welding equipments and the welding
performance.
• To witness the welding procedure qualification.
• To witness the welder performance qualification.
• To check whether shop / field welding being executed is in conformity

with the relevant specifications and codes of practice followed in
piping construction.
7.1.3 The Contractor shall intimate sufficiently in advance the

commencement of qualification tests, welding works and acceptance
tests, to enable the Company’s Inspector to be present to witness the
tests.
7.1.4 The standard acceptability of welds shall be examined as set forth in API
Std.1104 by non-destructive means of inspection, decision of the
Company for acceptability of welds shall be final. The non-destructive

GROUP, MUMBAI
FOR PIPELINE
test of welds shall consist of examination of a proportion of the welds on
the line according to the procedure set forth in API Std.1104.
7.1.5 In case test weld have been cut from the main line, replacement weld
shall be made by adding a pipe length of not less than 1 Metre.
7.2 Visual Inspection
Inspection of all welds shall be carried out as per the latest editions of the
applicable standards & codes.
The following minimum requirements shall be applicable.
A Internal misalignment 1.5 mm or less

B Cracks or lack of fusion None permitted
C Incomplete penetration Depth shall not exceed the lesser
(for other than 100% of 0.8 mm or 0.2 of thickness of
radiography butt-weld) 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
(4.7 mm nominal wall
thickness and less ).
E Concave root surface For single sided welded joints,
(suck up ). concavity of the root surface shall
not reduce the total thickness of
joint, including reinforcement, to
less than the thickness of the
thinner of the components being
joined.
F Weld ripples irregularities 2.5 mm or less.
G Lack of uniformity in bead 2.5 mm or less.
width
H Lack of uniformity of leg 2.5 mm or less.
length.
I Unevenness of bead 2.0 mm or less
J Weld undercutting 0.8 mm or ¼ thickness of thinner
components joined by butt weld
whichever is less. Shall be
smooth finished.
K Overlap 1.5 mm or less
L Bead deflection 2.5 mm or less
M Wall thickness of thinner Maximum weld reinforcement or
component joined by butt internal weld protrusion
weld ( mm )

GROUP, MUMBAI
FOR PIPELINE
6.4 and under 1.6 mm
6.4 – 12.7 3.2 mm
12.7 – 25.4 4.0 mm
Over 25.4 4.8 mm
N Throat thickness of fillet Nominal thickness of the thinner
welds. component x 0.7 or more
O 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.
Welds having any of imperfections which exceed the limitations

specified above shall be repaired by welding, grinding, overlaying or
welding etc. Number of times of repair welding for the same weld shall
not exceed two times.
7.3 Radiographic Examination
7.3.1 The radiographic examination procedure to be adopted shall be

submitted by the Contractor and shall be got approved by the Company.
The radiographic procedure and technique adopted shall conform to the
requirements mentioned in Article 2, as well as Article 22 of ASME Sec.
V. Source side pentameter shall be used in establishing radiographic
procedure / technique.
7.3.2 The number of welds to be examined shall be as follows:
• Minimum 10% (ten) of total welds in case of oil pipelines.
• Minimum 20% (twenty) of total welds in case of gas pipelines
• 100% (one hundred) for all critical locations such as highways,

railways, rivers, nallahs, major water bodies, tie-ins, scrappers, valve
platforms and related fabricated works including in-plant piping etc.
7.3.3 The acceptable limits of defects and removal of defects shall be as per the
relevant codes of fabrication. Contractor shall be responsible for carrying
out radiography, rectification of defects and re-radiography of welds
rectified / repaired.
7.3.4 Radiographic examination shall be carried out using X-ray. Gamma ray
sources may be used in place of X-ray with the approval of the Company.
7.3.5 The Contractor shall fulfill all the statutory safety requirements
while handling Gamma ray and X-ray equipments.

GROUP, MUMBAI
FOR PIPELINE
7.3.6 The joints for radiography shall be selected by the Company. The
Contractor shall furnish all the radiographs to the Company immediately
after processing. The details of the radiographs along with the joint
identification number shall be duly recorded and signed by the Contractor
and shall be submitted to the Company for approval.
7.3.7 The Contractor shall provide the Company all the necessary facilities at
site such as a dark room with controlled temperature, film viewer etc. to
enable him to examine the radiographs.
7.3.8 “Random 10% Radiography” shall mean examining not less than one from
each 10 welds or less made by the same welding procedure or welder or
both. Irrespective of percentage, no. of welds to be radio-graphed shall
be minimum one. However first two welds made by each welder shall
also be radio graphed in case of “Random Radiography”.
7.3.9 Number of radiograph per one circumferential weld shall be as per ASME
Sec. V.
7.4 Liquid Penetrant (LP) and Magnetic Particle (MP) Examination
7.4.1 Whenever such tests are specified, the tests shall be carried out on
joints chosen by the Inspector as per ASME Section V article 6 and 7
respectively.
7.4.2 For austenitic stainless steels and other non-magnetic materials, liquid
(dye) penetrant test shall be carried out. For carrying out this test, the
materials shall be brought within a temperature limit of 15o C to 50o C.
7.4.3 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 Company.
7.4.4 Wherever LP / MP tests are specified, either LP or MP test may be used.
But wherever only MP test is specified, LP method of examination may
be used only if MP examination is impracticable.
7.4.5 “Random 10%” of LP/MP test shall mean testing one weld for each ten
welds or less made by the same welding procedure or operator or both.
7.4.6 For fabricated elements, LP / MP test shall be done on root pass in
addition to radiography as applicable.
7.4.7 For branch connections, LP / MP test shall be done on root pass and final
pass.
7.5 Hardness Test
7.5.1 Hardness test shall be in accordance with ASTM specification E10

and ANSI B 31.3.

GROUP, MUMBAI
FOR PIPELINE
7.5.2 A minimum of 10% of welds and of hot formed and hot bent materials in
each heat treatment batch which are furnace heat treated and 100% of
those which are locally heat treated shall be hardness tested. The
hardness limit applies to the weld and heat affected zone. 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.
8.0 DEFECTS OR REPAIRS / ACCEPTANCE CRITERIA

8.1 In case of 100% examination, any unacceptable weld shall be repaired
and re-inspected.
8.2 If required random examination reveals a defect requiring repair, then two
additional examinations of same type shall be made of the same kind of
item ( if welded joint, then by the same welding operator or procedure or
both ).
8.3 If the group of items examined as required by para 8.2 above is
acceptable, the items requiring repair shall be repaired or replaced and
re-examined as required and all items represented by this additional
examination shall be accepted.
8.4 If any of the items examined as required by para 8.2 above reveals a
defect requiring repair, two further comparable items shall be examined
for each defective item found by examination.
8.5 If all items requiring repair as required by para 8.4 are acceptable, the
items requiring repair shall be repaired or replaced and re-examined as
required, and all items represented by this further examination shall be
accepted.
8.6 No. 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
AUSTENTIC S.S. 2 OR LESS
8.7 Welds not found acceptable for allowed no. of times of repair as per para
8.6 above shall be replaced and re-examined.
8.8 If any of the items examined as per para 8.5 above reveals a defect
requiring repair, all items represented by these examinations shall be
repaired or replaced and re-examined as required.
**** *

GROUP, MUMBAI
FOR PIPELINE
SPECIFICATIONS
FOR
TRENCH-LESS OPERATIONS
1 23.03.2005 KRK SN PKM

GROUP, MUMBAI
FOR TRENCH-LESS
OPERATIONS Page 1 of 14 Rev. 1
SPECIFICATIONS FOR TRENCH-LESS OPERATIONS
1.0 GENERAL
This specification defines the minimum technical requirements for design,

engineering, fabrication, installation of pipeline(s) across rivers / canals,
railways, highways or at major obstacle locations as directed by the
Company, using trench-less methods including HDD.
2.0 DESIGN & OPERATING CONDITIONS
The design and operating conditions for the trench-less operation under
this project are provided in the Basic Design Report of the Bid Document.
In case any increase / addition in number and / or length of crossings

is warranted during pre- engineering survey, detailed engineering,
construction etc, the Contractor shall be required to provide for and
install such additional numbers / increased lengths at no extra cost
and time to the Company except as may be provided elsewhere in the
Contract.
3.0 SCOPE OF WORK
3.1 The scope of work includes, but is not limited to taking up the minimum
requirements (as indicated hereunder) for various activities to be carried
out by the Contractor for the design engineering and construction of
pipeline crossing(s) using trench-less methods. The Contractor shall
execute the work in compliance with laws, by-laws, ordinance and
regulations and shall take full responsibility for the stability and safety of all
operation and methods involved in the work.
However, all such works, which are not indicated here below but are
otherwise required to complete the work in all respects shall form part of
Contractor’s Scope of Work.
All labour, materials, tools, equipment, machinery, consumables, water,

electricity, utilities, transportation, installation of other facilities and services
necessary for the proper execution and completion of the Works shall be
supplied by the Contractor. The Contractor shall be fully responsible for the
dismantling & repatriation of the equipment(s) / machineries etc.
• Carrying out all required surveys such as topographical, bathymetric,

profile, hydrological, geo-technical or any other surveys as may be
necessary for the execution of the work at the crossing locations.

GROUP, MUMBAI
FOR TRENCH-LESS
• Carrying out all engineering, design calculations and preparation of all
construction drawings for trench-less operation of pipeline(s)
crossings.
• Supply including procurement, inspection, expediting, port clearance,
transportation to site of all equipment / machines, materials and
consumables to be supplied by Contractor and supply of all
construction, testing, survey and communication equipment etc.
required for the installation of the crossings.
• Preparation of procedures / work instructions, quality records.
Obtaining approval from the Company.
• Staking, clearing, grading and fencing the right-of-way (if required).
• Stringing, aligning, bending, field welding, NDT including radiography,
joint coating, protective coating and installation of insulating joints with
extension pipe pieces on both sides of the crossing.
• Backfilling, clean-up and restoration of the right-of-way and obtaining
certification from concerned parties as per specifications and
instructions of the Company.
• Pre- testing of the crossing section.
3.2 Obligations of the Contractor
• The Contractor shall perform all engineering activities that are needed
to complete the basic documentation provided by the Company.
• The Contractor shall be deemed to have taken into account all the
considerations including feasibility of the method of construction for
trench-less crossing at the time of formulating his bid and no extra
compensation either by way of time or cost shall be admissible to the
Contractor on this account.
• The Contractor shall pay any duty tax, load and unload port duties,
temporary import taxes etc. for all the equipments, if applicable.
• The Contractor shall be fully responsible for all means, methods,

techniques, sequences & procedures and for the co-ordination of all
operations of the work under the Contract.
• Any problems encountered at the time of construction due to any

reason whatsoever shall be to Contractor’s account, and Contractor
shall not be entitled for any compensation or extension of time for this
reason.

GROUP, MUMBAI
FOR TRENCH-LESS
4.0 DESIGN AND ENGINEERING
The limits of each crossing shall be determined by the Contractor on the

basis of crossing profile based on survey drawings, design, equipment,
installation technique and site conditions. Prior to execution of the work,
the Contractor shall furnish all engineering design calculations and
crossing drawings etc. to the Company for review and approval.
While carrying out design and engineering, the Contractor shall inter-alia
give due considerations to the following:
4.1 Crossing Profile & Other Parameters
Basic profile drawings of rivers and other obstacles are provided in the
Bidding Document. Contractor shall specify and submit to the Company for
approval the final profile and other parameters and their limited value that
define the location & configuration of the bore path. These include, but not
limited, to the following:
• Locations of entry and exit point.

• Equipment and pipe layout areas.
• Proposed drill path alignment (both plan & profile view).
• Location, elevations and proposed clearances of all utility crossings
and structures.
• Proposed depth of cover.
• Soil analysis.
• Product material, length, diameter-wall thickness, reamer diameter.
• Detailed pipe calculations, confirming ability of product pipe to
withstand installation loads and long term operational loads.
• Proposed composition of drilling fluid (based on soil analysis)
viscosity and density.
• Drilling fluid pumping capacity, pressures and flow rates proposed.
• State right-of-way lines, property, and other utility right-of-way or
easement lines.
• Elevations.
• Type of tracking method / system.
• Survey grid establishment for monitoring ground surface movement
settlement or heave) due to the drilling operation.
4.2 Entry and Exit points
The entry and exit points of the pipeline at ground level shall not come
within the limits of crossing as specified in the crossing drawing.

GROUP, MUMBAI
FOR TRENCH-LESS
4.3 Maximum Permissible Load on Pipeline
The Contractor shall carry out engineering calculations for determining the
maximum permissible load on pipe, to check that the empty pipeline is safe
from collapse at any point along the bored / drilled cross section.
4.4 Pipeline Axis
The plane containing the pipeline route axis shall be perpendicular to the
horizontal plane. There shall be no bending of the pipeline route axis at
depths lower than 2 meters below the ground level.
4.5 Maximum Shear Stress in Pipeline Coating
The Contractor, based on the operational parameters selected by him,

shall work out the maximum shear stress that will develop in the pipeline
coating at any phase of installation. The maximum shear stress thus
calculated shall be within the permissible value as specified in the relevant
codes / standards.
4.6 Maximum Longitudinal Stress during Installation
Total maximum longitudinal stress in the pipeline due to tension and

bending at location shall not exceed 90% of the SMYS of the pipe material.
In order to check this requirement, the Contractor shall evaluate the
maximum tensile forces to which the pipe is subjected to at any phase of
its installation.
4.7 Maximum Equivalent Stress during Final Hydrostatic Test
During the hydrostatic testing, the combined equivalent stress in the

pipeline due to bending and test pressure shall not exceed 90% of the
SMYS of pipe material.
4.8 Maximum Equivalent Stress during Service
Permissible values of maximum equivalent stress during services shall be

governed by the requirements of the relevant ASME standard as
applicable. The details of pipeline operating parameters are provided in the
Bid Document (Clause No. 3.0 - Basic Design Report )
4.9 Minimum Allowable Elastic Bend Radius

GROUP, MUMBAI
FOR TRENCH-LESS
The Contractor shall carry out engineering computations for determining
the minimum allowable radius of curvature for the pipeline.
4.10 Pipeline Configuration along the Support String before Entry Point
The Contractor shall determine the required pipeline configuration in order

to allow smooth pull in the crossing entry point and admissible stress in the
supported pipeline string. Pipeline combined stress shall not exceed 95%
of the SMYS of the pipe material.
5.0 EXECUTION METHODOLOGY
The Contractor shall prepare and submit a detailed execution methodology

package, including design, engineering drawings and installation
procedures etc. for Company’s review and approval for trench-less
installation of pipeline.
5.1 The execution methodology package shall include, but not limited to, the
following :
• Construction plan
• Site layout plan
• Operation schedule
• Communication plan
• Emergency procedures
• Contingencies plan and drilling fluid management plan.
5.1.1 Construction Plan:
5.1.1.1 The Contractor shall as a minimum include the following in the construction plan
:
• Location of entry and exit pits.

• Working areas and their approximate size.
• Proposed pipe fabrication and layout areas.
• State right-of-way lines, property lines.
• Other utility right-of way and easement lines.
• Pipe material and wall thickness.
• Location of test pits or boreholes undertaken during the soil
investigation.
• Proposed bore / drilling alignment (both plan & profile view) from
entry to exit.
• All grades and curvature radii.
• All utilities (both horizontal and vertical).
• Method of installation, covering all the stages of construction.
• Structures with their clearances from the proposed drill alignment.

GROUP, MUMBAI
FOR TRENCH-LESS
• Confirm minimum clearance requirements of affected utilities &
structures
• Required minimum clearances from existing utilities and structures.
• Diameter of pilot hole, number and size of pre-reams / back- reams.
• Access requirements to site
• Crew experience.
• Equipments to be deployed for preparation of pipe string & installation
of crossing.
• Tracking, monitoring & control equipment(s).
• Pipeline string preparation details (hauling, stringing & welding etc.)
• Hydrostatic test procedure.(Pre & post installation)
• Time schedule for construction.
5.1.1.2 Construction Drawings:
The Contractor shall, based on the result of design and engineering carried
out by him, prepare construction drawings for the crossing. The
construction drawings shall indicate the pipeline profile with levels
furnished at sufficient intervals for proper control during construction. Other
relevant details viz. entry and exit angles, radius of bends etc. shall also be
indicated.
5.1.2 Equipment Setup and Site Layout:
• Required clear span shall be made available on the rig side to safely
set up and operate the equipment.
• Sufficient space shall be allocated to fabricate the pipeline into one

string, thus enabling the pull back to be conducted in a single
continuous operation.
The Contractor shall make arrangement for the work area(s) required for
fabrication, construction, material storage & camp office / workshop etc.
5.1.3 Communication Plan:
The communication plan shall include the following:
• The phone numbers for communication with the Company’s

representative on the site.
• Identification of all key personnel which will be responsible for ensuring

that the communications plan is followed.
• Means of communication between units / teams involved in the

crossing work.

GROUP, MUMBAI
FOR TRENCH-LESS
5.1.4 Contingency Plans:
In addition to the guidelines prescribed in “General Requirements for

Safety, Health & Environment” of this Bid Document, the Contractor shall
also prepare contingency plans to handle any emergent situation during
the operation. The Contingency plan shall besides other aspects also
address the following:
• Inadvertent boring into a natural gas line, live power cable, water
main, sewer lines, or a fiber-optic cable etc.
• Containment and removal, of an inadvertent return or spill (e.g.,

drilling fluids, and hydraulic fluids).
5.1.4 Drilling Fluids Management Plan
The Contractor shall provide the following information as part of the drilling
fluid management plan:
• Identify source of fresh water for mixing the drilling mud

• Method of slurry containment
• Method of recycling drilling fluid and spoils (if applicable)
• Method of transporting drilling fluids and spoils off site
5.2 While formulating the installation procedures, the Contractor shall inter-
alia give due consideration to salient guidelines indicated hereunder:
• The Contractor shall be deemed to have taken cognizance of width of

crossing, minimum requirements of cover, limitations of Contractor’s
equipment and additional drilling lengths as may be necessary while
formulating his bid.
• The Contractor shall make all arrangements for access to his work
site at his own cost and responsibility.
• The Contractor shall ensure that his construction activities shall not
cause inconvenience to public nor shall there be any undue
interference with the normal use of the land and watercourses.
• Complete pipe string shall be prepared as a single string for pulling.

Welding, radiographic inspection of joints and joint coating of the
string shall be performed in accordance with the respective
specifications approved by the Company for the main pipeline.
• The entire trench-less crossing shall be accomplished in a single

operation.

GROUP, MUMBAI
FOR TRENCH-LESS
• The Contractor shall carry out megger test for the integrity check of
the external corrosion coating on the bored string before it is tied-in to
the mainline pipe.
• The Contractor shall formulate a methodology for locating and

tracking system to be used during the operation and shall also provide
all the required associated hard wares & software.
• In the case of rail, road and waterway crossings, the minimum

pipeline cover below the lowest level shall be 1.5 meters.
• Cover to top of pipe shall be minimum 2.5 mtrs below the scour profile
at any point within the limits of the river crossings. Bidder to note that
to achieve this minimum requirement of cover, he may have to
actually install the pipe by drilling at greater depths at some locations
below the riverbed and banks. Contractor shall be deemed to have
taken cognizance of such deeper drilling as may be necessary while
formulating his bid, and no extra compensation shall be admissible on
this account.
• The bore path alignment should be as straight as possible to minimize

the fractional resistance during pullback and maximize the length of
the pipe that can be installed during a single pull.
• The radius of curvature is determined by the bending characteristics

of the pipe line, and it is increasing with diameter.
• If any bore hole has to be abandoned beneath a road, it must be

backfilled with grout or bentonite to prevent future subsidence.
• The time schedule for construction of crossing(s) shall be in

accordance with the overall time schedule for the project.
6.0 PRE-CONSTRUCTION SURVEY & SITE EVALUATION
Prior to commencement of the execution, the Contractor shall take

following actions in order to ensure safe and efficient construction with
minimum interruption of normal, everyday activities at the site.
• Inspect the site for evidence of substructures such as manhole

covers, valve box covers, meter boxes, electrical transformers,
conduits or drop lines from utility poles, and pavement patches etc.

GROUP, MUMBAI
FOR TRENCH-LESS
• Notify owners of subsurface utilities along and on either side of the
proposed path of the impending work. All utilities along and on either
side of the proposed path shall be located.
• Obtain all necessary permits or authorizations to carry construction

activities near or across all such buried obstructions.
• Construction schedule should be arranged so as to minimize
disruption (e.g. drilling under railroad beds, major highways, and /or
river crossings).
• The proposed path should be determined and documented, including

its horizontal and vertical alignments and the location of buried utilities
and substructures along the path.
• The Contractor shall ensure availability of sufficient clear span at the

site for :
- Entrance and exit pits
- Stationing of equipment and its safe unimpeded operation
- Support vehicles
- Fusion machines
- Stringing out the pipe to be pulled back in a single continuous
operation.
• The Contractor shall establish the suitability of soil conditions.
7.0 STATUTORY PERMISSIONS
Contractor shall obtain all the necessary permits for all works from the
authorities having jurisdiction before the actual execution of the various
phases of the works and all stipulations / conditions / recommendations of
the said authorities shall be strictly complied with at no extra cost to the
Company.
The Company, however, may assist Contractor for obtaining such

permissions, wherever required, by issuing recommendation letters, etc.
8.0 PRIORITIES
The Company may, at its sole option, assign priority of construction to any
section of total pipeline length or to any part / segment of the Work.
Contractor shall comply with such priority of execution without any time
and cost implication to the Company.
9.0 CONSTRUCTION / INSTALLATION
The Contractor shall comply with all the conditions and requirements
issued by the authority(ies) having jurisdiction in the area where work is to

GROUP, MUMBAI
FOR TRENCH-LESS
be performed. During construction, the Contractor shall give due
considerations to the following indicative guidelines:
• The Contractor shall undertake continuous monitoring and plotting

of progress and bore path to ensure compliance with the proposed
installation alignment and allow for appropriate course corrections in
the event when the bore start to deviate from the intended bore path.
• Monitoring shall be accomplished by manual plotting based on

location and depth readings provided by the locating / tracking system
or by computer generated bore logs which map the bore path based
on information provided by the locating / tracking system. Readings or
plot points shall be undertaken on every drill rod.
• Excess drilling fluids shall be contained at entry and exit points until
recycled or removed from the site. Entry and exit pits should be of
sufficient size to contain the expected return of drilling fluids and soil
cuttings.
• Restoration of damage to any highway or non-highway facility caused

by escaping drilling fluid, or the trench-less operation, shall be the
responsibility of the Contractor.
• To minimize heaving during pullback, the pull back rate shall be

determined which maximizes the removal of soil cuttings and
minimizes compaction of the ground surrounding the borehole. The
pullback rate shall also minimize over cutting of the borehole during
the back reaming operation to ensure excessive voids are not created
resulting in post installation settlement.
• The Contractor shall, prior to and upon completion of the operation,

establish a Survey Grid Line and provide monitoring as outlined in
their submitted detailed monitoring plan. Subsurface monitoring points
shall be utilized to provide early indications of settlement as large
voids may not materialize during the operation due to pavement
bridging.
• Should pavement heaving or settlement occur, necessary restoration

of the same / replacement of the asphalt including saw-cutting etc
shall be the responsibility of the Contractor.
• To prevent future settlement should the trench-less operation be

unsuccessful the Contractor shall ensure the backfill of any void(s)
with grout or backfilled by other means.
• After pulling the pipeline across the crossing, Contractor shall cut the
extended portion of the pipeline at the entry and exit points.
Thereafter, the installed portion of the pipeline shall be cut at suitable

GROUP, MUMBAI
FOR TRENCH-LESS
location/depth and extended on either side by installing a cold field
bend with minimum bend radius of 40 times the pipe OD and a
straight pipe of sufficient length, such that at the ends the top of the
pipeline is minimum 1.0 m below the natural ground level.
10.0 PROTECTION OF UNDERGOUND UTILITIES
• The Contractor shall obtain plans and full details of all existing and
planned underground services from the relevant local authorities and
be responsible for location and protection of the same. The Contractor
shall deploy pipe / cable locations for the purpose during survey / prior
to excavation / construction.
• The Contractor shall fully co-ordinate with all local and related
statutory bodies for clearances and permissions.
• The Contractor shall first manually excavate to a depth and in such a
manner that the utilities / structures are not damaged in the locations
where the pipeline crosses.
• The installation procedure proposed / adopted by the Contractor for
the installation of the pipeline at such locations shall take into
consideration the safety and security of all such features. To this end
the Contractor shall design and provide at his own cost any temporary
supports such as under pinning or any other type and other protective
devices as necessary to keep the interfering structure intact.
• Should any damage to any structure / utility etc. occur despite all
precautions, the Company / 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(ies). If Contractor
fails to carry out necessary remedial action / repair in a reasonable
time, the Company reserves the right to have the repairs executed at
the cost of the Contractor.
• In case the pipeline crosses other utilities, viz., other pipelines,
sewers, drain pipes, water mains, telephone conduits and other
underground structures, the pipeline shall be installed with at least 50
cm free clearance from the obstacle or such greater minimum
distances as may be required by authorities having jurisdiction.
• Whenever any utility / facility, etc. is encountered within the length of

the pipeline to be installed by drilling, such utility/facility crossing shall
be executed as part of the river crossing works at no extra cost / time
to the Company.
11.0 INTEGRITY TEST FOR EXTERNAL CORROSION COATING

GROUP, MUMBAI
FOR TRENCH-LESS
In order to ensure the integrity of pipeline external coating, the Contractor
shall carry out megger test for the bored string before and after the pull-
back operation, in accordance with the procedure approved by the
Company. The megger test shall be carried out before the bored string is
tied-in to the mainline pipe.
12.0 DISPOSAL OF SURPLUS SOIL , DRILLING FLUIDS & CHEMICALS
The Contractor shall ensure that all surplus soil, chemicals & drilling fluids
etc. are disposed of in a manner acceptable to the appropriate local, state,
or central regulatory agencies and / or as instructed by the Company and
prices quoted by Contractor shall be inclusive of all such works.
• Drilling fluids, additives and their Material Safety Data Sheets (MSDS)
shall be identified within the Contractors submittal permit package.
• Excess drilling fluids shall be contained within a lined pit or

containment pound, until removed from the site.
• When an area of contaminated ground is encountered, the slurry shall

be tested for contamination and disposed of in a manner, which
meets Local, State and / or Central regulations / requirements.
• Precautions shall be taken to keep drilling fluids out of the streets,

manholes, sanitary and storm sewers, and other drainage systems,
including streams and rivers.
• The contractor shall make all diligent efforts to minimize the amount of
drilling fluids and cuttings spilled during the drilling operation, and
shall provide complete clean-up of all drilling mud overflows or spills.
13.0 REINSTATEMENT / RESTORATION
• The ground occupied during the work shall be reinstated / restored to

its original condition as quickly as possible after completion of the
works.
• Accesses to property, fences, ditches, retaining walls, irrigation

systems and other structures shall be reinstated in compliance with
the agreements drawn up at the time of initial survey.
• Land marks re-located / removed for the work shall be replaced with
the assistance of a surveyor.

GROUP, MUMBAI
FOR TRENCH-LESS
• Wherever necessary or directed by the Company or other appropriate
authorities, additional measures to prevent erosion of the backfill
materials shall be taken when reinstating embankments and slopes.
• Reinstatement / restoration of footpaths, road surfaces, banks,

shoulders etc. shall be performed with the agreement of authorities
concerned.
• All surfaces affected by the work shall be restored to their pre-

existing conditions.
14.0 DOCUMENTATION
In addition to the documentation specified elsewhere in this specification,

the Contractor shall submit to the Company the following documents /
records:
• Copies of permits obtained from Authorities having jurisdiction.
• Records of pre and post installation hydrostatic testing.
• Record of non-destructive testing of welds.
• Clearance certificate form the land owners and Authorities having

jurisdiction regarding satisfactory clean-up and restoration of the
pipeline ROW and work sites.
• After the completion of construction, the Contractor shall prepare and

furnish four sets of copies and two sets of reproducible “As Built” for
the crossings along with two soft copies on CD-ROM prepared using
‘MICROSOFT OFFICE’ latest version. As built drawings shall as a
minimum include the following information :
- True alignment & profile of the crossing(s) along the pipeline.
- True profile of the pipeline as installed and the depth of cover to

top of pipe at regular intervals.
- Location of entry and exit point and angles of entry and exit
along with lateral offset of exit point from the original pipeline
alignment.
- Location and angle of field bends.
- Location of pipeline markers, boundary stones & CP

measurement points etc.
******

GROUP, MUMBAI
FOR TRENCH-LESS
SPECIFICATION
FOR
PAINTING OF OVERGROUND
PIPELINE
2 17.10.2005 KRK SN PKM
1 23.03.2005 KRK SN PKM
DOCUMENT NO. :
CORPORATE DESIGN CDG/MUM/PL/CIVIL/DES.03
SPECIFICATION FOR
GROUP, MUMBAI
PAINTING OF
OVERGROUND PIPELINE Page 1 of 4 Rev. 1
GENERAL SPECIFICATIONS FOR PAINTING OF OVER GROUND PIPELINE
1.0 SCOPE
Painting of all over ground pipes, fittings, valves & allied structures etc.
Supply of all primers, paints, epoxy and all other material required for
surface preparation, painting / epoxy coating and identification marks.
2.0 APPLICABLE CODES
The following codes and standards shall be followed for the work covered
under this specification.
SIS-05-5900 / Swedish Standards for surface preparation (ST.2,

ISO- 8501-1 ST.3, SA1/2/3, SA2½.
BS-4232 Surfaces finish or blast cleaning for painting.
SSPC-SP- American standards equivalent to Swiss standards

2/3/5/6/7/10 for surface preparation.
IS: 5 Color coding
IS: 101 Methods of test for ready mixed paints and enamels.
IS: 161 Heat resisting paints
Specifications for ready mixed red oxide zinc chrome

IS: 2074
primer
Aluminum paint for general purposes in dual

IS: 2339
container.
IS: 2379 Color code for identification of pipelines
Specification for manual, synthetic, exterior (a)

IS: 2932
undercoating (b) finishing
ASA A 13.1 Scheme for identification of piping systems.
3.0 EXECUTION METHODOLOGY
The Contractor shall prepare & submit painting procedures for review and
approval of the Company. The procedures shall be in compliance to
statutory requirements, industry regulations, codes, standards, specifications
etc. and also based on the recommendations of reputed paint
manufacturers.
DOCUMENT NO. :
SPECIFICATION FOR
GROUP, MUMBAI
PAINTING OF
In case of conflict between referred regulation, codes and standards or
project specifications the more stringent shall apply. A list of applicable
codes is indicated at Cause 2.0 above.
3.1 General Requirements
While preparing the methodology, the Contractor shall inter-alia give due
consideration to salient guidelines indicated hereunder:
• The Contractor shall provide paint formulation for various painting

systems and shall guarantee that the workmanship and chemical &
physical properties of paint materials used shall meet their specified life.
• Un-insulated austentic stainless steel, plastic and/or plastic coated

material, non-ferrous materials like aluminium, galvanized piping,
gratings shall not be painted unless otherwise specified and shall be
suitably protected.
• All tools, equipments, brushes, rollers, spray guns, abrasive material,

sand, quartz, tools/equipments required for cleaning and blasting,
scaffolding materials, inspection tools, test blocks shall be suitable, in
good order, in sufficient quantity and shall be arranged by the Contractor
at site.
• Surface preparation shall be carried out as per manufacturer’s
instructions either by mechanical / power tool cleaning or blast cleaning
(as per SA 2½ of Swedish standard), as the case may be , depending on
condition of steel surface and as instructed by the Company.
• Irrespective of the method of surface preparation, the first coat of primer
must be applied on dry surface immediately after cleaning of surface.
However, during unfavorable weather conditions, blasting and painting
shall be avoided as far as practicable.
• Colour code scheme intended for identification of the individual group of
pipeline, equipments, tanks etc shall be decided with the approval of the
Company. The system of color-coding shall consist of a ground color and
color bands superimposed on it.
• All primers and finish coats should be cold cured and air-dried unless
otherwise specified.
• Selected chlorinated rubber paint should have resistance to corrosive
atmosphere and suitable for marine / saline environment.
• No coat shall be applied until the preceding coat has dried. No coat shall
be forced dried under conditions, which will cause checking, wrinkling,
blistering, formation of pores, or detrimentally affect the condition of the
paint.
• Painted surface shall be protected from rain, condensation,
contamination, snow and freezing until dry to the fullest extent
practicable.
DOCUMENT NO. :
SPECIFICATION FOR
GROUP, MUMBAI
PAINTING OF
• Where ever damage to painted surface occurs in handling or during
transportation, same shall be repaired after erection / fabrication.
• An arrow shall be painted to indicate flow direction as directed by the
Company. Colors of arrows shall be black or white and in contrast to the
color on which they are superimposed.
4.0 INSPECTION AND TESTING
• Technical data sheets for all paints and painting schemes shall be
supplied prior to commencement of painting.
• All painting materials including primers and thinners brought to site by

contractor shall be accompanied by manufacturer’s test certificates.
• The painting work shall be subject to inspection by the Company.
Company at its discretion may also call for fresh tests for paint
formulations. Contractor shall arrange to have such tests performed at
his cost.
• Final inspection shall include measurement of paint dry film thickness,
check of finish and workmanship. The thickness should be measured at
as many paints / locations as decided by the Company.
• Contractor shall be responsible for making good any defects found during
final inspection/guarantee period/defect liability period as defined in the
contract.
5.0 WARRANTY
The Contractor shall have final and total responsibility for the performance
of all items supplied under this specification. The Contractor shall warrant
the items furnished by him and the performance of the said items in
accordance with this specification and with warranty requirements as
specified in the bid package.
*******
DOCUMENT NO. :
SPECIFICATION FOR
GROUP, MUMBAI
PAINTING OF
SPECIFICATION FOR
3 LAYER POLYETHYLENE
COATING
1 06.10.2005 KRK SN PKM
DOCUMENT NO. :
CORPORATE DESIGN SPECIFICATION CDG/MUM/PLM/016
GROUP, MUMBAI FOR 3 PLAYER PE
COATING Page 1 of 34 Rev. 1
SPECIFICATION FOR 3 LAYER POLYETHYLENE COATING
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 DIN-30670, 1991,
`Polyethylene Coating of Steel Pipes and Fittings' and the requirements of
this specification.
Reference has also been made to the latest edition of the following
standards, codes and specifications. The edition enforce at the time of
floating the enquiry shall be termed as latest edition.
Sl. Code Description
1. ASTM D-149 : Standard Test Methods of Dielectric

Breakdown voltage and Dielectric strength
of solid electrical insulating materials at
commercial frequencies.
2. ASTM D-257 : Standard Test Methods for D-C

Resistance or conductance of insulating
materials.
3. ASTM D-543 : Standard Method of Test for Ressistance
of lastics to Chemical Reagents.
4. ASTM D-570 : Standard Method of Test for Water
Absorption of Plastics.
5. ASTM D-638 : Standard Test Method for Tensile
Properties of Plastics.
6. ASTM D-792 : Standard Test Method of Specific Gravity
and Density of Plastics by Displacement.
7. ASTM D-1238 : Test Method for Low Rate of
Thermoplastics by Extrusion.
8. ASTM D-1525 : Test Method for Vicat Softening
Temperature of Plastics
9. ASTM D-1603 : Test Method for Carbon Black in Olefin
Plastics
DOCUMENT NO. :
10. ASTM D-1693 : Test Method for Environmental Stress
Cracking of Ethylene Plastics
11. ASTM D-2240 : Test Method for Rubber Property –
Durometer Hardness
12. ASTM D-3895 : Test Method for Oxidative – Induction
Time of Polyolefins by Differential Scanning
calorimetry
13. ASTM G-42 : Tentative Methods for Cathodic disbonding
of Pipeline Coatings Subjected to Elevated
or Cyclic Temperatures.
14. API RP 5L1 : Recommended Practice for Railroad
Transportation of Line pipe.
15. API RP 5LW : Transportation of Line Pipe on barges and
marine vessels
16. DIN EN 10204 : Metallic Products – Types of Inspection
Documents
17. DN 53735 : Testing of Plastics : Determination of Melt
Index of Thermoplastics.
18. ISO 8502-3 : Preparation of Steel Stubstrates before
Applic application of Paints and
Related Products – Part-3 – Assessment of
Dust on Steel Surfaces Prepared for
Painting (Pressure Sensitive Tape Method)
19. ISO 9002 : Quality Systems : Specification of
Production and Installation
20. ISO 11124 : Preparation of Steel Substrates Before
Application of Paints and Related Products
21. SIS 055900 : Preparation of Steel Substrates before
Application of Paints and Related Products
– Visual Assessment of Surface
Cleanliness.
22. APL 5L : Specification for Line Pipe
23. ASME B 31.8 : Gas Transmission and Distribution
Piping Systems
24. ASME B 31.4 : Liquid Transportation systems for
Hydrocarbons, Liquid petroleum Gas
Anhydrous ammonia, and Alcohols
25. CSA Z245.20-98 : External Fusion Bond Epoxy Coating for
Steel Pipe
DOCUMENT NO. :
The Contractor shall be familiar with the requirements of these documents and
shall make them readily available at the coating plant to persons concerned
while carrying out the works specified in this specification.
3.0 PLANT SCALE AND INSTALLATION
3.1 The Contractor shall size coating plant(s) after evaluating the scale of
work and the time schedule required for the works. Coating plant(s), 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 when required the Contractor shall 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.
3.3 The Contractor shall at his own responsibility 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, the Contractor shall provide to stipulate servitude agreements as
required with the relevant Authorities, and, on work completion, to clean,
restore and pay servitude and claims for damages, as applicable.
3.4 The Contractor shall at its own responsibility provide for water and
power supply and other utilities and consumables and obtain authorisation
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 provide a fully equipped laboratory and test facilities
with adequate inventory to carry out tests required for the procedure
qualification and during regular production. Outside testing for qualification
and regular production is not acceptable to the 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,
polyethylene adhesive and a polyethylene top coat. Coating materials shall
be suitable for the service conditions and the pipe sizes involved. The
DOCUMENT NO. :
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 the Company. The Contractor shall obtain
prior approval from the Company for the coating system and coating of all
materials.
4.2 All the tests for all properties specified in para 5.3.1 and 5.3.2 for each batch
of epoxy, adhesive and polyethylene compound including Infra-red Scan for
each batch of epoxy powder shall be carried out. The Contractor shall
furnish test certificates as per DIN EN 10204, 3.1B issued by the
manufacturer for Company’s approval prior to their use.
4.3 Samples from each batch of epoxy, adhesive and polyethylene shall be
drawn in the presence of the 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 certificates.
a) Epoxy Powder
i. Gel Time
ii. Cure Time
iii. Moisture Content
iv. Thermal Characteristics (Tgl, Tg2, .H)
b) Adhesive
i. Specific Gravity
ii. Melt Flow Rate
iii. Vicat Softening Point
c) Polyethylene
i. Melt Flow Rate
ii. Specific Gravity
iii. Vicat Softening Point
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 and identifiable with the following
minimum information:
a. Name of the manufacturer
b. Type of material
c. Batch Number
d. Place and Date of Manufacture
DOCUMENT NO. :
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 the Company. Such materials shall not be
used for coating and shall be removed from site and replaced by the
Contractor.
4.5 The Contractor shall ensure that all coating materials properly stored in
accordance with the Manufacturer’s recommendation at all times, to prevent
damage and deterioration in quality prior to use.
4.6 The 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 must be able to withstand a maximum in service

operating temperature of +65°C and shall conform to `S’ Type of coating as
per DIN 30670. In addition, in open storage the coating must be able to
withstand a temperature of at least +80°C, without impairing its serviceability
and properties specified.
5.2 The top coat polyethylene used shall be black readymade compound,
fully stabilized against influence of ultraviolet radiation (.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 paragraph. 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
The Contractor shall choose such a brand of epoxy powder and adhesive
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.
Epoxy powder properties shall be as per CSA Z245.20.98.
Copolymer grafted adhesive shall have the following properties.
Sl Properties Unit Requirement Test
DOCUMENT NO. :
Method
a Melt Flow Rate g/10 minutes 1.0 ASTM
(190°C / 2.16 kg) D1238
b Vicat Softening Point °C 90 min. ASTM
D1525
c Specific Gravity - 0.926 min. ASTM D792
5.3.2 Properties of Polyethylene Compound
Sl Properties Unit Requirement Test Method

a Tensile Strength N/mm2 17 min. ASTM D 638
@+25°C
b Melt Flow Rate (190°C / g/10 0.25 min. ASTM D 1238

2.16 kg) minute or DIN 53735
c Specific Gravity @+25 - 0.941 min. ASTM D 792

°C (HDPE)
d Hardness@+25°C Shore D 50 min. ASTM D 2240
e Water Absorption, 24 % 0.05 max ASTM D 570

hours, @+25°C
f Volume Resistivity Ohm-cm 1015 min ASTM D 257

@+25°C
g Dielectric Volts/mm 30,000 min ASTM D 149

withstand,1000 Volt/sec
rise @+25°C
h Vicat Softening Point °C 110 min. ASTM D 1525
i Elongation % 600 min. ASTM D 638
j Oxidative Induction Time Min 10 ASTM D3895

in Oxygen at
220°C, Aluminium pan,
no screen
k Environmental Stress Hours ASTM D1693

Crack Resistance
(ESCR) (for F50)
Medium Density, 300
Condition “C”
High Density, Condition 300
DOCUMENT NO. :
“B”
l Carbon Black Content % 2 min. ASTM D1603
5.3.3 Properties of Coating System

Sl Properties Unit Requireme Test
nt Method
a Bond Strength (using Type 2 Kg/cm DIN
Test 30670
Assembly i.e. Dynamometer)
@ 20±5°C 8.0 min
@ 60±5°C 5.0 min.
b Impact Strength (min. of 30 Joules 7 min DIN
impacts on body along the per mm 30670
length. No breakdown of
allowed when tested at 25 kV) coating
thickness
c Indentation Hardness mm DIN

@ 23±2°C 0.2 max 30670
@ 70±2°C 0.3 max
d Elongation at Failure % 300 min. DIN
30670
e Coating Resistivity (*) Ohm-m2 108 min. DIN
30670
f Heat Ageing (*) - Melt flow DIN
rate shall 30670
not deviate
by more
than 35% of
original
value
g Light Ageing (*) - Melt flow DIN
rate shall 30670
not deviate
by more
than 35% of
original
value
h Cathodic Disbondment mm ASTM
@+65°C after 30 days radius of 15 max. G42
@+65°C after 48 hrs dis- 7 max.
bondmen
t
(**)
i Degree of Cure of Epoxy CSA
DOCUMENT NO. :
Percentage Cure, ∆H ∆Tg % 95 Z245.20-
°C +3/ -2 98(*)
(*) Test carried out in an independent laboratory of national/ international

recognition on PE top coat is also acceptable.
(**) Disbondment shall be equivalent circle radius of total unsealed area as
per ASTM G42.
(***) Temperature to which the test specimens are to be heated during cyclic
heating shall however be as per the recommendations of epoxy powder
manufacturer.
6.0 MEASUREMENT AND LOGGING
The Contractor shall maintain records of all the relevant data of individual
pipe and pipe coating including heat number, diameter, length, wall
thickness, defects, pipe number, batches of materials, materials balance,
sampling, testing, damages, repairs, rejects and any other information that
the Company considers to be relevant and required for all incoming bare
pipes and the Company approved outgoing coated pipes as applicable. The
Contractor shall submit this information in the form of a report at the agreed
intervals. The above data shall also be provided in MS EXCEL format in
Compact Disc (CD). The Contractor shall also submit the material balance
details to the Company for information at the end of shift.
7.0 COATING PROCEDURE AND QUALIFICATION
7.1 The Contractor shall submit a detailed report for the Company’s approval
indicating but not limited to the following:
a. Details of plant(s), locations, 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.
d. Details of chemicals pre-treatment facilities including process control and

inspection equipment for phosphoric acid wash, de-ionised - ionised
water wash and chromate wash.
DOCUMENT NO. :
e. 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.
f Plant Organo-gram Chart and availability of manpower including coating

specialist.
g Details of utilities /facilities such as water, power, fuel, access roads &
communication etc. After approval has been given by the Company, no
change in plant set-up shall be made. However, unavoidable changes
shall be executed only after obtaining written approval from the
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 the Company 's
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. Complete details of chemical pre-treatment viz phosphoric acid wash,

deionised water wash, and chromate wash including product data sheets,
health and safety sheets and manufacturer’s recommended application
procedure.
d. Pipe heating, temperatures and control prior to epoxy application.
e. Complete details of raw materials including current data sheets

showing values for all the properties specified together with quality
control and application procedure recommendation from manufacturer(s).
f. Application of FBE powder, adhesive and polyethylene, including

characteristics, temperature, line speed, application window, curing time,
etc.
g. Quenching and cooling, including time and temperature.
h. Quality assurance system, Inspection and testing methods and reporting

formats, including instrument and equipment types, makes and uses etc.
DOCUMENT NO. :
i. Detailed method of repair of coating defects duly classified depending
upon nature and magnitude of defects and repairs thereof including
coating stripping technique.
j. Details of instrument and equipment calibration methods including

relevant standards and examples of calibration certificates.
k. Complete details and inventory of laboratory and equipment for procedure

qualification and regular production.
l. Pipe handling and stock piling procedures.
m. Sample of recording and reporting formats, including laboratory reports,

certificates and requirement as per clause 6.0 of this specification.
n. Complete details of test certificates for raw materials including test

methods standards used.
o. 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.
p. Health, safety and environment plans.
q. Storage details of coating materials and chemicals.
r. 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 the Company. No change in
the procedure shall be made after approval has been given by the
Company.
However, unavoidable changes shall be executed only after obtaining written

approval from the Company.
7.3 Prior to start of production, the Contractor shall carry out a coating procedure
qualification trial for each pipe diameter, 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. The
Contractor shall give seven(7) working days notice to witness procedures
and tests.
A batch representing a normal production run, typically 15 pipes, shall be

coated in accordance with the approval coating procedure and the coating
operations witnessed by the 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 east 5 (five) test pipes shall be selected by
DOCUMENT NO. :
Company Representative for coating procedure approval tests and shall be
subjected to procedure qualification testing as described hereinafter. All tests
shall be witnessed by the Company‘s representative. Out of 5(five) test pipes
1(one) pipe shall be coated partly with epoxy and partly with both epoxy and
adhesive layers. Remaining 4(four) test pipes shall be coated with 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 vs coating thickness, etc. shall
be established. Dew point of air used to supply the fluidised 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 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, the
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.
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 to shots to
grits 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 in the abrasive blast cleaned pipe
surface.
7.4.4 Chemical Pre-Treatment
7.4.4.1 Phosphoric Acid Wash followed by De-ionised Water Wash
DOCUMENT NO. :
The procedure to apply the chemical pre-treatment viz. phosphoric acid
wash followed by de-ionised water wash shall be in accordance with the
recommendation 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-ionised water shall be established during PQT.
7.4.4.2 Chromate Treatment
The procedure to apply the chromate treatment shall be in accordance with

the recommendation 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 preheat 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.
7.4.5 Coating Application
The Company will check the correctness of each coating application

operation, values of the main parameters of each operation, preheating
pipe surface temperature prior to epoxy powder application temperature,
line speed, fusion bonded epoxy curing time, temperature and flow rate of
copolymer 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 (min 4 Nos.) shall be scrapped from the coated
pipe using hammer and cold chisel and the samples shall be taken for
cure test using Differential Scanning Calorimatry (DSC) procedure.
Care shall be taken to remove the samples of full film thickness
avoiding inclusion of steel debris. Glass transition temperature
differential (.Tg) and % cure (.H) shall comply the specified
requirements.
b. Epoxy Layer Thickness
DOCUMENT NO. :
Epoxy layer thickness shall be checked at every one meter spacing at
3, 6, 9 and 12 o’clock positions. The thickness shall comply the
specified thickness requirements.
c. Adhesive Layer Thickness

Adhesive layer thickness shall be checked at every one meter spacing
at 3, 6, 9 and 12 o’clock positions. The thickness shall comply 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. Adhesion Test
i) Adhesion Test (24 hrs or 48 hrs) shall be carried out on the

epoxy coated pipe. Test method, no. of test specimen and
acceptance criteria shall comply CSA Z.245,20-98, Table 4.
ii) Adhesion of FBE shall also be separately determined at ambient

temperature at two locations by the “St Andrews Cross” method
and the test shall comply with the specified requirements.
f. 2.5° Flexibility Test
2.5° Flexibility test shall be carried out on the epoxy coated pipe at test
temperature of 0°C. Test method, no. of test specimen and acceptance
criteria shall comply CSA Z.245,20-98.
g. Cross-section & Interface Porosity Test
Cross section porosity and interface porosity tests shall be carried out on
the epoxy coated pipe. Test method, no. of test specimen and
acceptance criteria shall comply CSA Z.245,20-98, Table-4.
7.5.2 Tests on pipes coated only with all three layers
a. Bond Strength
Three test pipes shall be selected for bond strength tests. On each of the
selected pipes, three bond strength test 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
65mm. None of these samples shall fail.
DOCUMENT NO. :
b. Impact Strength
Three test pipes shall be selected for impact strength test and the test
shall meet the requirement.
c. Indentation Hardness
Two samples for both the temperatures from all pipes shall be taken. If
any one of these samples fail to satisfy the requirements, then the test
shall be repeated on four more samples. In this case, none of the samples
must fail.
d. Elongation at Failure
Six samples each from two 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
Two CD test shall be carried out for the total lot of test pipes having all
three layers. One test shall be carried out for 30 days duration and
another test for 45 hours duration The tests shall comply the specified
requirement. Whenever Procedure Qualification is necessitated for
different pipe size with same coating material combination, 48 hours test
only be conducted. 30 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 measurement.

Acceptance criteria shall be as per para 10.3
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. Care shall be taken
to remove the samples of full film thickness avoiding inclusion of steel
DOCUMENT NO. :
debris. Glass transition temperature differential (.Tg) and % cure (.H)
shall comply with the specified requirements.
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
immediately after De-ionised water wash.
b. PH of pipe surface before and after phosphoric acid wash.
c. Visual inspection of chromate coating.
d. 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 the 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 the Company, the 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 approval coating procedure
specification. Remaining pipes will be accepted by the 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 the
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.
• 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 the Company’s opinion the properties are deemed to be
suspect during regular production tests.
7.9 The Company reserves the right to conduct any or all the test required for
qualification through an independent laboratory or agency at the cost of the
Contractor when in the Company’s opinion, the results are deemed suspect.
the Company’s decision shall be final.
DOCUMENT NO. :
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, the 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 of 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. Solvents cleaning shall be
in accordance with SSPC-SP1. Steel surface shall be allowed to dry before
abrasive cleaning.
8.4 All pipes shall be preheated to a temperature 65°C to 85°C prior to

abrasive blast cleaning. The external surface of the pipe shall be cleaned
using 2 no. dry abrasive blasting cleaning units to achieve the specified
surface cleanliness and profile. After first abrasive blast cleaning, chemical
pre-treatment with phosphoric acid solution as per para 8.6 shall be carried
out prior to second abrasive blast cleaning. However at the option of the
Contractor, chemical pretreatment with phosphoric acid solution as per para
8.6 may be carried out after the second abrasive blaster.
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. The equipment used for abrasive blast cleaning shall meet
the specified requirements and shall be free from oil, water soluble salts and
other forms of contamination to ensure that the cleaning process is not
impaired. Traps, separators and filters shall be checked for condensed water
and oil at the start of each shift and emptied and cleaned regularly. During
abrasive blast cleaning the metallic abrasive shall be continuously sieved to
remove “fines” and “contaminates” and the quality checked at every four
hours. Abrasive 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 pipe during blast cleaning operations. These plugs shall be
removed after blast cleaning. Alternatively the Contractor may link pipes
suitably together to prevent the entry of any short/grit into the pipe.
8.6 Chemical Pre-treatment with Phosphoric Acid Solution
8.6.1 All pipes shall 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 contaminations.
DOCUMENT NO. :
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 prior to the application of
the specific fusion bonded epoxy powder being applied.
8.6.2 The pipe temperature immediately prior to the phosphoric acid treatment
shall be in the range of 45 to 75 °C. Phosphoric acid treatment shall be
followed immediately by washing with de-ionised water. Deionised water
used shall conform to the following requirements :
Sl Properties Unit Requirement

a Turbidity NTU 1 max.
b Conductivity µmho/cm 5 max.
c Hardness - Nil
d Total Alkalinity as CaCO3 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
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 deionised water shall be monitored at the start of each shift
and at every four hours interval. Non-compliance of deionised water wrt 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
deionised 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 the
Company. The measured pH shall be as follows :
Before de-ionised water wash : 1 to 2

After de-ionised water wash : 6 to 7
8.6.4 After the de-ionised 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-ionised water rinse. One test shall
be carried out at one end of each pipe. The acceptance criteria shall be
2µg/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 recommendation.
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
DOCUMENT NO. :
Sa 2½ of Swedish Standard SIS 055900 latest edition. Surface of pipe after
abrasive blast cleaning shall have an anchor pattern of 50 to 70 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 2½), 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.
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 be 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 and on permission from the
Company, 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. Ay pipes having thickness
less than 95% of specified thickness shall be kept aside and disposed off as
per the instructions of the Company. The method employed to remove
surface defects shall not burnish or destroy then anchor pattern or
contaminate the surface. Pneumatic tools shall not be used unless they are
fitted with effective air/ oil and water traps. Where burnishing results in
destruction of anchor pattern, the anchor patter shall be restored by suitable
means. Pipes which have damages repaired by grinding and have ground
areas more than 50 mm in diameter shall be recycling-blasted.
Any dust or loose residues that have been accumulated during blasting and/
or during filing/ grinding operations shall be removed by vacuum cleaning.
DOCUMENT NO. :
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 the
Company for final decision on rejection or re-blasting/ removal of defects.
Re-blasting/ removal of defects or returning pipe to the yard shall be the
Contractor’s responsibility.
The Company, 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.
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 Chemical Pre-treatment with Chromate Solution
8.13.1 Following completion of abrasive blast cleaning, all pipe surface shall be
chemically Pre-treated with a 10% strength chromate solution.
8.13.2 The Contractor shall provide data sheets and supporting documentation for
the chemical to be used. The documentation shall verify that the chemical
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.
8.13.3 The chemical pre-treatment shall be applied fully in accordance with the
chemical suppliers’ instructions and in a manner that ensures 100%
uniform coverage of the pipe surface without introducing surface
contamination.
8.13.4 The Contractor shall check that the concentration for the chemical
pretreatment solution remains within the range recommended by the
chemical manufacturer for the pipe coating process. The concentration
shall be checked at the make up of each fresh solution and once per hour,
using a method approved by the chemical manufacturer. The Contractor
shall also ensure that the chemical pre-treatment solution remains free
from contamination at all times. Recycling of chemical pre-treatment
solution is not permitted.
8.13.5 The Contractor shall ensure that the temperature of the substrate is
maintained between 40°C and 80°C and the chromate solution
temperature does not exceed 60° or as recommended by the
manufacturer.
DOCUMENT NO. :
8.13.6 The chromate coating shall be smooth, even, free from runs, drips or
excessive application and lightly adherent with no flaking of the coating.
The chromate coated steel must be thoroughly dried immediately after
application and shall be achieved by boiling off any residual solution on the
surface.
8.14 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 on 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.
8.15 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/ 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 the
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
both inside and outside 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 furnace 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
DOCUMENT NO. :
bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces
prior to coating (in the form of bluing 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 line pipe. The monitoring instrument shall be able to raise
an 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 and recoated.
9.1.5 Temperature measuring & monitoring equipment shall be calibrated

twice every shift and/ or as per the Company ‘s instruction.
9.1.6 The Contractor shall ensure that pipe surface emissivity variations
are minimized 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 0.150 mm, unless otherwise specified. The maximum
thickness shall not exceed the epoxy thickness specified by epoxy
powder manufacturer.
ii. Grafted co-polymer adhesive applied by extrusion, minimum thickness

0.200 mm.
iii. Polyethylene coating by extrusion.
The coated pipe shall be subsequently quenched and cooled in water for a
period which shall sufficiently lower the temperature of pipe coating to permit
handling and inspection.
DOCUMENT NO. :
9.2.2Minimum total thickness of finished coating shall be as under :
Pipe Size Min. Coating Thickness (mm)(*)

Specified outside diameter (mm) Normal Type (n)
Up to 10¾” (273.1) 1.8

Over 10¾” (273.1) to below 20” (508.0) 2.0
From 20” (508.0) to below 32” (813.0) 2.25
(*) HDPE material is to be used as top coat.
Required coating thickness shall be normal type (n), unless otherwise
specified.
9.2.3Coating 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 air as per the
directions of the Company.
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 subjected to:
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 for this purpose filters, dehumidifier/ heater as required
along with control & monitoring system shall be provided for this purpose. Dew
point of air used to supply the fluidized bed, epoxy spray system and epoxy
recycling system shall be at least (-) 40°C and this shall be shall 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
DOCUMENT NO. :
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. The application of the adhesive layer shall not be
permitted after epoxy is fully cured. The Contractor shall establish, to the
satisfaction of the Company, 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.
9.2.9The 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, the Contractor shall supplement by other method to avoid air
entrapment. The methods used shall be witnessed and approved by the
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. The 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°.
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 the Company.
10.1 General
DOCUMENT NO. :
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 coated, 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 inclusion. The coating shall not slow and defects
such as blisters, pinholes, scratches, wrinkles, engravings, cuts swelling,
disbanded zones, air inclusions, tears, voids or any other irregularities. Special
attentions shall be paid to the areas adjacent to he longitudinal weld (if
applicable), adjacent to the cut back at each 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 line end while inspection is
carried out visually form other end.
10.3 Coating Thickness
a. The coating thickness shall be determined by taking at least 10

measurement at locations uniformly distributed over the length and
periphery of each pipe. In case of weld 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 the readings must meet the minimum
requirements. However, localised 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 5cm2 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, which shall be further reduced depending upon consistency of
results, at the sole discretion of the Company. Results of all measurement
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 pipe shall be the
Contractor’s responsibility.
DOCUMENT NO. :
c. Coated pipes not meeting the above requirements shall be rejected. The
Contractor shall remove the entire coating and the pipe shall be recycled to
the cleaning and coating operations as per the approved procedure.
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 the Company for
detecting holidays in the finished coating.
b. The holiday detector shall be a low pulse DC full circle electronic detector
with audible alarm and precise voltage control with DIN VDE 0433 Part 2.
The set voltage for inspection shall be 25 kV. Travel speed shall not
exceed 300 mm/s.
c. The Contractor shall calibrate the holiday detector at least once every
4 hours of production. The 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 cm2 in size are detected in its length attributable to
coating process.
e. Holidays which are lesser in number and size than those mentioned in (d)
above, shall be repaired in accordance with a approved procedure.
10.5 Bond Strength Test
a. The Contractor shall conduct bond strength test for composite coating
as per clause 5.3.3 (a) of this specification. A minimum of 65mm length
shall be peeled. First 20mm and last 20mm shall not be counted for
assessment of bond strength.
b. The frequency of test for cut back portions shall be one pipe in every
fifteen (15) pipes coated and for middle of pipe shall be one pipe in every
sixty(60) pipes coated or one pipe per shift whichever is higher. 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. Dis-bondment / 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 above tests do not comply with the above requirement, the
Contractor shall test all the preceding and succeeding coated pipes. 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 the shift shall be tested until the
DOCUMENT NO. :
coating is provided acceptable. Rejected coated pipes shall be stripped
and re-coated in accordance with approved procedure.
d. The frequency of bond strength test as per para 10.5(b) for cut back
portion may be reduced depending upon the consistently of result to one
pipe in every twenty five(25) instead of every fifteen pipes, at the sole
discretion of the COMPANY Representative.
10.6 Impact Strength
a. Impact resistance test shall be conducted as per clause 5.3.3 (b) of this
specification. Initially the frequency of test shall be 2(two) coated pipes
per shift, which may be further reduced and/ or waived depending upon
consistently acceptable results at the sole discretion of the Company.
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. In case of test failure, retesting and disposal of coated pipe shall be as

per 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 results.
Two samples for each temperature shall be taken from the cut back
portion of coated pipe and one in middle of the pipe for this test.
b. In case of test failure, retesting and disposal of coated pipe shall be as

per 10.5(c) above.
10.8 Air Entrapment Test
a. Strips from bond strength tests 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.
DOCUMENT NO. :
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 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. Care shall be taken to remove the
samples of full film thickness avoiding inclusion of steel debris. Glass
transition temperature differential (.Tg) and % cure (.H) shall comply the
specified requirements.
b. Frequency of this test shall be once per shift. Pipe shall be selected
randomly by the Company during the middle of a shift. Suitable
provisions/ arrangements as per the instructions of the Company 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 Adhesive Test
a. Adhesion of epoxy layer shall be determined at ambient temperature by

the “St Andrews Cross” method i.e. by cutting two straight lines through
the epoxy layer with a sharp knife. The incisions shall intersect at an
angle of 30°/ 150°. The epoxy coating shall resist disbondment from the
steel when attempts are made to flick/ lift the coating from the 30° angle
with a sharp knife.
b. Frequency of this test shall be once per shift. The test shall be carried out
at the cut back portion of 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 10.9(c) above.
DOCUMENT NO. :
10.11 Cathodic Disbondment Test
a. 48 hours CD test shall be conducted as per clause 5.3.3. (h) of this

specification.
b. The frequency of this test shall be once in every two weeks or one test
representing each batch of epoxy powder used, whichever is more
frequent.
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 or the shall be repeated using two additional samples
taken from the same end of the affected pipe.
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. The 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 Damages occurring to pipe coating during above tests shall be repaired in
accordance with approved coating repair procedure.
10.13 Repairs occurring on account of the production test are however excluded
from above mentioned limitations at para 10.4 (d) above.
10.14 The 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 dispatch 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. Inspection and tests performed or witnessed by the Company
shall in no way relieve the Contractors obligation to perform the required
inspection and tests.
10.15 In case rate of defective or rejected pipes and/ or samples tests are 10% or
more for a single shift (typically 8 hours), the Contractor shall be required to
stop production and carry out a full and detailed investigation and shall
submit findings to the Company for approval. The Contractor shall
recommence the production only after getting the written permission from
The Company. Under no circumstances any action or omission of the
Company shall relieve the Contractor of his responsibility for material and
quality of coating produced. No pipes shall be transported from the coating
plants unless authorised by the Company in writing.
DOCUMENT NO. :
11.0 HANDLING, TRANSPORTATION AND STORAGE
11.1 The Contractor shall be fully responsible for the pipe identification marking
in line with the requirement indicated at clause 6 above.
All pipes shall be checked for bevel damages, weld seam height, dents,
gouges, corrosion and other damages. the Company shall decide whether
pipe defects/ damages are suitable for repair.
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 the Company a
procedure/ calculation generally in compliance with API RP-5L1 for pipe
stacking, which shall be approved by the 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 procedure shall be approved by
the Company prior to commencement of work.
11.4 Coated pipes may be handled by means of slings and belts of proper width
(minimum 60mm) 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 are prohibited. Fork lifts may be used provided that
the arms of the fork lift are covered with suitable pads preferably rubber.
11.5 Bare/ coated pipes at all times shall be stacked completely clear from the
ground so that the bottom row of pipes remain 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 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.
Stacks shall consist of limited number of layers such that the pressure
exercised by the pipe’s own weight does not cause damages to the coating.
The Contractor shall submit calculations for the Company’s 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
DOCUMENT NO. :
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 as 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. 3 Nos. 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 suitable 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. 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 bot 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. The Contractor shall strictly follow Manufacturer’s
instructions regarding storage temperature and methods for volatile
materials which 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. The Contractor
shall furnish all details pertaining to marine transportation including
necessary 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, the Contractor shall also
DOCUMENT NO. :
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
The Contractor shall submit to the Company, its methods and materials
proposed to be used for executing a coating repair and shall receive
approval from the 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 serviceability and properties. The 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 pipe leaving coating plant, shall have sound external coating with no
holiday 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 welding 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 2.0mm and an area not
exceeding 20 cm2 shall be rebuild by heat shrink patch only and without
exposing to bare metal.
• Defects or size exceeding above mentioned area or holidays of width less

than 300 mm shall be repaired with heat shrinks 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 500mm shall be repaired using heat
shrinkable sleeves.
• Pipes with bigger damage shall be stripped and recoated.
• In case of coating defect close to coating cut back, the 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 shrinkable sleeves thereby
making up the coating cut back length of 120 mm.
DOCUMENT NO. :
Not withstanding the above, under no circumstances, if the defects 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.
Defects to be repaired by heat shrink patch/ sleeve shall be maximum 2

(two) per pipe.
Cosmetic damages occurring only in the Polyethylene layer only need not be
repaired by exposing up to steel surface, as deemed fit by the Company. In
any case the Contractor shall establish his material, methods and procedure
of repair that results in acceptable quality of product by testing and shall
receive approval from the Company prior to use.
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.
The Contractor shall test repairs to coating as and when required by the
Company.
13.0 MARKING
The 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
The Contractor shall obtain prior approval on making procedure to be

adopted from the COMPANY.
14.0 QUALITY ASSURANCE
14.1 The Contractor shall have established within the 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.
DOCUMENT NO. :
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 to satisfy the requirements of
this specification. The plan shall include any sub-contracted work, for which
the sub-contractor’s 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 who will witness and
accept the inspection testing and associated work required by this
specification.
15.0 WARRANTY
The Contractor/Vendor shall have final and total responsibility for the design
and performance of all items supplied under this specification. The
******
DOCUMENT NO. :
SPECIFICATION
FOR
FIELD JOINT COATING

SYSTEM
1 06.10.2005 KRK SN PKM

GROUP, MUMBAI
FIELD JOINT
COATING SYSTEM Page 1 of 16 Rev. 1
SPECIFICATION FOR FIELD JOINT COATING SYSTEM
1.0 INTRODUCTION
This specification describes the minimum technical requirements for

materials, equipment, application, inspection and testing of the field applied
shrink sleeves used for external coating of welded joints on a yard applied 3-
layer polyethylene coated pipeline.
The field joint corrosion materials shall be suitable for a maximum service
temperature of 60oC. The coating should be able to withstand pipe
temperatures of at least 80oC during construction and laying.
1.1 Shrink Sleeve System
1.1.1 The shrink sleeve system used for external coating of welded joints on a
buried 3-layer PE coated pipeline shall consist of the following as a
minimum :
a) Epoxy Primer : An epoxy coating layer, which may be applied directly

onto the blast cleaned and pre-heated steel surface to improve the
adhesion of the shrink sleeve to the pipe surface.
b) Adhesive : An intermediate coating layer to improve the adhesion

between the (primed) steel and the shrink sleeve.
c) Shrink Sleeve : A type of field joint coating, applied to a pipeline in the

form of a sleeve, which shrinks in the circumferential direction under the
influence of heat or by other means, forming an adherent field joint
coating.
1.1.2 The minimum width of shrink sleeve shall be ensured, considering the
external coating cut back of the pipeline & an overlap of 50 mm (minimum)
on external coating.
1.1.3 The Shrink Sleeve system shall be compatible with and shall have good
bonding properties with the 3 layer external PE coating of line pipe in
accordance with CAN/CSA –Z245.21-M98. The design life of the shrink
sleeve system shall be compatible with the design life of pipeline system.

GROUP, MUMBAI
FIELD JOINT
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS
The latest revision of the following codes, standards and specifications shall
be used unless indicated else where in the bid.
DIN 30670-91 : Polyethylene Coating of steel tubes, fitting and

matching pieces
DIN 30672-91 : Coating of corrosion protection tapes and heat
shrinkable material for pipelines for operational
temperatures up to 500C.
ISO 8501-1 : Preparation of Steel Substrate Before Application of
Paint and Related Products – Visual assessment of
Surface Cleanliness. Part-I.
ASTM D2249 : Standard Test Method for rubber / plastic property –
Durometer Hardness
ASTM D3359 : Standard Test Methods for Measuring Adhesion by
Tape Test. X cut Method.
ASTM D4541 : Standard Test Method for Pull-Off Strength of
Coatings Using Portable Adhesion Testers
DIN EN 12068 : Tapes and shrinkable materials
NACE RP0274 : High Voltage Electrical Inspection of Pipeline
Coatings
CAN/CSA- : External Polyethylene Coating for pipe
Z245.21-M98
SIS 05 59 00-M98 : Pictorial surface Preparation Standard for Painting
Steel Surfaces.
3.0 PRE-PRODUCTION DOCUMENTATION
3.1 General
3.1.1 Prior to commencing the coating pre-qualification trails (PQT), the Contractor
shall submit a detailed written description of the coating equipment,
procedure and materials for the Company’s review. The description shall be
accompanied by full details and results of tests on similar coating, or trials
performed by the Contractor. Such test results and / or trials shall
demonstrate, to the satisfaction of the Company, that the Contractor’s
equipment, procedures and materials can supply a finished coating meeting
the requirements of this specification. The Contractor shall provide pre-
qualification test records of the past jobs for Company’s review.

GROUP, MUMBAI
FIELD JOINT
3.1.2 The description of the coating procedure shall include :
a) Complete details of the joint coating materials including quality control

data, certification and safety sheets.
b) Details of materials and technique for repair of damaged materials.
c) Inspection and testing including typical reports, instrument and
equipment types, together with methods of calibration and operation.
d) Sample of recording and reporting formats including laboratory
reports and certificates.
3.1.3 Qualification testing of the field joint corrosion coating prior to field
production shall include the following :
a) Visual inspection of joint.

b) Thickness of installed sleeve.
c) Adhesion to steel and adjacent line coating.
d) Holiday detection.
e) Lap shear strength of adhesive at 550C. This test shall be done in a
test lab on three specially prepared plate samples.
f) Indentation resistance
g) Impact resistance
h) Cathodic disbanding resistance
i) Destructive Testing
j) Ultraviolet radiation
3.1.4 The coating equipment description shall cover all equipment to be used for
cleaning, coating, testing and inspection of the field joints. Details of all
materials to be used for coating of field joints shall also be provided.
3.1.5 The Contractor shall demonstrate by his qualification of this special process
and applicable test data to the satisfaction of the Company that specified
thickness of the coating system will meet the requirements of this
specification.
4.0 COATING MATERIALS
4.1 General Requirements
4.1.1 The Contractor shall submit methodology for application of shrink sleeves
for Company’s review & approval, covering the following as a minimum:
• Pipe cleaning
• Chemical cleaning / pre-treatment if required
• Pipe heating and coating application pre-heating, if required
• Field joint coating system application method, testing and inspection
• Quality control
• Repair procedures

GROUP, MUMBAI
FIELD JOINT
4.1.2 Material shall be selected such that the coating system shall be suitable for
maximum ambient temp of 550C and shall withstand the black bulb temp of
800C.
4.1.3 All coating materials shall be supplied in sealed damage free, clearly marked
containers giving the following information:
• Manufacturer’s name
• Date and place of manufacture
• Material identification
• Type of product contained
• Storage requirements
• Batch number
• Safety instructions
• Expiry date for use
4.2 Properties of Coating System
4.2.1 The field joint coating shall have broadly equivalent properties to the main
3 layer PE pipeline coating and shall have minimum thickness of
2.5 + 0.25 mm. Prior to commencement of work, the Contractor shall provide
necessary back-up details and qualification test records to justify the
suitability of thickness proposed for Company’s approval. The coating
system shall satisfy the properties as given in Table 4.2.1 as a minimum.
Table 4.2.1 : Properties of Shrink Sleeve Elements
Performance Parameter Test Required Result for

Method Shrink Sleeve
Tensile strength (sleeve ASTM D-638 3000 psi.
backing only)
Elongation to break (sleeve ASTM D-638 600% min.
backing only)
Penetration resistance ASTM G-17 No holiday at 10kV
(installed sleeve) @550C for 24
hours
Dielectric Break-down of ASTM-D149 20kV/mm, min.
installed sleeve at 230C
Softening Point of adhesive ASTM E-28 1000C min.
Cathodic Dis-bondment of EN 12068 10 mm Max. @ 230C
installed sleeve
Lap Shear Strength of EN 12068 0.05 N/mm2
0
adhesive at 23 C
Peel Strength of layer to layer DIN 30672 >15N / 10 mm @ 230C
> 2N / 10 mm @ 550C

GROUP, MUMBAI
FIELD JOINT
Performance Parameter Test Required Result for
Method Shrink Sleeve
Impact Resistance of installed EN 12068 >15J
sleeve at 230C
Soil Stress Creep Resistance TP-206 0.1 inch max. after 24
of installed sleeve at 550C hrs.
Holiday Detection of installed 5kV + 5 kV per mm of
sleeve coating thk.
Indentation Hardness EN12068 10 N / mm2 @ 550C
(Residual thk. 0.6 mm)
Specific electrical insulation EN12068 108 ohm-m2
resistance
Moisture Vapor Transmission ASTM E-398 0.08 gm/24hr/100 sq. in
of sleeve at 380C, 90% RH max.
Hot water Immersion resistance ASTM D-870 After 120 days, no
of installed sleeve at 550C blisters or delamination.
No water under sleeves.
Thermal Ageing EN12068 In accordance with
Table-2, point no. 2 of
EN 12068
Ultraviolet irradiation EN12068 In accordance with
Table-2, point no. 3 of
EN 12068
Destructive Testing - See clause 7.2.5
4.2.2 The Contractor shall ensure that all material proposed for field joint coating
have been tested and have met the requirements as agreed with the
Company for physical, chemical and electrical properties.
4.2.3 The Contractor shall ensure that test certificates are provided for all
accepted materials, detailing the information as required in this Specification.
4.2.4 The self-adhesive layer of the coating adopted shall be homogeneous, free
from flaws, defects, pinholes, bubbles, cracks and inclusions.
4.2.5 The corrosion coat shall be resistant to bacterial attack and shall not
deteriorate during the design life of the pipeline. A certificate shall be
produced by the Contractor to the Company conforming to the requirement
of resistance to bacterial attack as per EN 12068.
4.3 Liquid Epoxy Primer
4.3.1 The liquid applied epoxy primer shall be a two pack product suitable for
hand application and be completely suitable for use at continuous maximum
operating temperature of 550C and shall be suitable to withstand Black Bulb

GROUP, MUMBAI
FIELD JOINT
temperature of 800C which will be experienced during installation in the field
prior to burial of pipeline.
4.3.2 Each batch of liquid applied epoxy primer shall be accompanied by a

certificate (ISO 1047/3.1.A or equivalent) stating the tests carried out on
every batch and results are in accordance with the manufacturer’s product
specifications. The density or specific gravity of primer shall also be
specified.
4.3.3 The Contractor shall provide this information for the Company’s approval
prior to the start of coating operations.
5.0 CLEANING AND SURFACE PREPARATION
5.1 General
The Contractor shall prepare detailed shrink sleeve field application coating
procedures which comply with the requirements below for the relevant field
joint coating system. These procedures shall be qualified and documented.
5.2 Inspection Before Cleaning
Prior to surface preparation, all joints shall be visually examined for dents,
laps and other obvious defects. Defective joints shall be repaired by light
grinding. Weld spatter shall be removed by wire brushing and / or light
grinding.
5.3 Cleaning Prior to Blast Cleaning
The exposed steel area and adjacent pipe coating shall be cleaned of all
dust, dirt, moisture, grease or other contaminants, If necessary using a
non-contaminant solvent XYLENE (N) or equivalent.
5.4 Surface Preparation
5.4.1 After cleaning and prior to abrasive blasting the pipeline shall be uniformly
heated to 600C to remove all moisture and preclude any condensation of
moisture on the pipe after blast cleaning.
5.4.2 No blast cleaning shall take place when the prevailing relative humidity is
greater than 85% unless the pipe is preheated to at least 30C above the
dew point or 250C whichever is greater.
5.4.3 The exterior surface of the pipe joints shall be abrasively cleaned by using
suitable abrasives to remove all mill scale, and other impurities from the
surface. Blast cleaning shall be to ISO 8501-1, Grade Sa 2½ quality defined
as “near white metal blast’. The surface profile (anchor pattern) shall be

GROUP, MUMBAI
FIELD JOINT
between 50 and 80 microns, tested twice daily in accordance with NACE
standard RP0287, using approved replica tape. The exposed FBE cutback
shall be lightly abraded.
5.4.4 Blasting abrasive shall be kept dry, clean and free from contamination.
Blasting and other dust producing operations shall be kept separate from
coating application operations.
5.4.5 The equipment used for blast cleaning shall be free from oil, water and
other forms of contamination to ensure that the cleaning process is not
impaired. Traps, separators and filters shall be checked for condensed
water and oil at the start of each shift and emptied and cleaned regularly.
5.5 Final Cleaning and inspection
5.5.1 After completion of abrasive cleaning operations, the steel surface must be
thoroughly checked. Any slivers, swabs, burrs, laminations and gouges
shall be removed by grinding. After grinding, the remaining wall thickness
shall comply with the specified minimum wall thickness. Ground areas shall
blend smoothly with the surrounding pipe surface, and those larger than 50
mm in diameter shall be re-blasted in accordance with the requirements of
Section 5.4
5.5.2 The chamfer and approximately 50 mm on the outer surface of the

polyethylene mill / yard applied coating shall be scraped or abraded using
suitable equipment to expose fresh material.
5.5.3 Any dust or loose residue that has accumulated during blasting and / or
grinding operations shall be removed by the use of clean compressed air or
by any other suitable alternative.
6.0 COATING APPLICATION
6.1 General
6.1.1 The pipe metal temperature shall not exceed 2750C. Pipe temperature shall
be checked periodically using tempil sticks.
6.1.2 Any joint not coated within 2 hours of cleaning shall be re-blasted prior to
coating.
6.1.3 Oxidation of the steel prior to coating in the form of ‘bluing’ or other apparent
oxide formation is not acceptable. If such oxidation occurs, the joint shall be
re-blasted.
6.1.4 The coating shall be cooled to below 600C before handling.

GROUP, MUMBAI
FIELD JOINT
6.2 Liquid Epoxy Primer
6.2.1 The field joint shall be uniformly heated using a propane torch or clean
Propane / LPG torch to the temperature recommended by the manufacturer.
After blasting and as soon as possible to avoid flash rusting (within ½ hour of
blasting), joint area shall be pre-heated to at least 500C or as recommended
by the manufacturer to ensure that coating area is free from moisture. A
pyrometer shall be used to ensure that correct temperature is reached on
steel and the line coating. As a minimum, Pre-heating of the steel surface
30C above dew point is required. The temperature of the joint shall be
checked and recorded at a minimum of four locations around the joint using
a pyrometer. The pyrometer shall be checked for error on a daily basis
against a temperature-measuring instrument. Tempil sticks shall not be
used. Contractor shall include in methodology, the control of temperature
especially for large diameter pipes.
6.2.2 The two components of the liquid epoxy primer shall be thoroughly mixed
and applied to the heated field joint surface using a small brush or suitable
applicator, to give a wet film thickness suitable to achieve a dry film
thickness of a minimum 100 microns. The wet film thickness required shall
be determined during PQT and shall be checked during application using a
comb gauge. The epoxy shall be visually checked for integrity prior to the
application of the wrap around sleeve.
6.3 Heat Shrink Sleeve
6.3.1 Application of the polyethylene backed heat shrink sleeve and any epoxy
primer, if required shall be performed in strict accordance with the
Manufacturer’s recommendations and qualified production procedures. The
steel temperature locally on welds shall not exceed 2000C at time of
application.
6.3.2 The sleeve will be considered to be fully applied when all the following have
occurred :
a) There are no cold spots or dimples on the sleeve surface;

b) Weld bead profile can be seen through the sleeve;
c) After the sleeve is cool, flow of adhesive is evident onto the mainline
coating at both edges;
d) The sleeve has fully conformed to the pipe and adjacent coating and
there is no trapped air.
6.3.3 The surface preparation, cleanliness and roughness, shall ensure adhesion
to the steel is superior than the cohesive strength of the adhesive.
6.3.4 Holidays will not be accepted. Repairs shall be performed by applying sleeve
on top of the defective sleeve.

GROUP, MUMBAI
FIELD JOINT
7.1 General
In addition to the test required on the material batches the Contractor shall
perform the tests detailed below on finished coatings to demonstrate
compliance with this Specifications. Details of all inspections and testing
shall be fully documented.
7.2 Coating Procedure Qualification Testing
7.2.1 Samples taken from field joint coating trials on test joints shall be subject to
the inspection and testing requirements detailed in Appendix-A. All pre-
qualified tests shall be scheduled such that test results are obtained prior to
production field-joint coating.
7.2.2 Three field joints which shall then be coated in accordance with the
requirements of this specification and shall be witnessed by the Company.
7.2.3 The sample coated filed joints shall be subjected to a complete set of tests
as specified in Appendix-A. The sample shall pas all the criteria contained in
Appendix-A before production commences.
7.2.4 The test methods for all tests required for PQT on the complete coating
system shall be performed in the same manner as the production tests.
7.2.5 The regular distribution of the adhesive and the adhesion of the adhesive to
the steel surface shall be demonstrated by complete removal of a sleeve by
cutting the sleeve into smaller sections and pulling it from pipe. A number of
sleeves as specified in Appendix-A shall be selected at random for
qualification testing.
After removal of the sleeve the pipe surface shall be visually examined. The
sleeve fails the test if :
- more than 5% of the steel surface shows bare steel or

- more than 5% of the circumference on the weld and 20 mm at
either side of the weld shows bare steel or
- more than 10% of the pipe coating is bare or
- more than 10% of the surface area shows voids (signs of air
inclusions)
(If one sleeve fails the test, 2 more sleeves shall be tested, neither of which
shall fail.)
7.2.6 Additionally during the coating PQT the Contractor shall demonstrate and
qualify his proposed repair procedures for both line pipe and the mill / yard
applied coating.

GROUP, MUMBAI
FIELD JOINT
7.2.7 The Contractor shall provide a written procedure that complies with all tests
carried out during PQT. These procedure shall be used during production
testing.
7.2.8 A PQT report shall be issued, before production coating commences,

describing the filed joint application procedure and including results of all
tests carried out on raw materials and the finished coating and all
measurements recorded during joint preparation and coating application.
7.2.9 Repair procedure shall be qualified in accordance with this document.

Repairs shall be carried out on actual defects. Artificial defects shall be
introduced in to the coating if necessary to qualify the repair procedures.
7.3 Production Testing
7.3.1 Production testing shall be performed at the frequency shown in

Appendix-B.
7.3.2 The frequency of tests shown in Appendix-B will be for normal production
operations. Every test shall be required on the first field joint coated after a
material change or quality acceptance failure.
7.3.3 As part of the standard batch testing of shrink sleeves supplied, the following
Batch tests shall be carried out and results submitted to the Company :
a) Dimensional check
b) Peel test
c) Tensile Strength
d) Ultimate Elongation
e) Heat Shock
f) Pre-heat temperature
7.4.1 Coated field joints and adjacent areas shall be visually inspected for surface
defects. The coating shall be smooth, free of detrimental defects and contain
no dust, grit, or other inclusions.
7.4.2 The inspection of the joint shall only be done after the cool down of the
sleeve and the substrate to ambient temperature. The sleeve shall be
visually inspected for the following points:
a) The weld bead profile contour shall be visible through the sleeve.
b) The ends of the sleeve shall be firmly bonded to the mainline coating.
c) There will be no upstanding edges.
d) Adhesive flow will be smooth; there will not be any dimples, cold
spots, bubbles, punctures, burn holes or any signs of holidays.

GROUP, MUMBAI
FIELD JOINT
e) The sleeve will be smooth; there will not be nay dimples, cold spots,
bubbles, punctures, burn holes or any signs of holidays.
f) There will be no signs of entrapment of foreign materials in the
underlying adhesive.
7.5 Coating Thickness
7.5.1 The thickness of the cooled field joint coating shall be checked using a
Company approved magnetic or electro-magnetic type thickness gauge.
Measurements shall be made at ten locations on the flat portion of a pipe
joint. The joint to be selected at random.
7.5.2 The installed sleeve thickness shall be considered as the average of the
readings and shall meet the coating thickness requirements.
7.6 Holiday Detection
7.6.1 Each field joint shall be 100 per cent tested for “holidays” in accordance with
NACE RPO274, using a high-voltage DC holiday detector.
7.6.2 The detector shall maintain intimate contact with the coating, detector can
be either a constant or pulsed voltage type. For a constant voltage type
Holiday detection shall be performed on a dry coating. The operating voltage
between electrode and pipe shall be checked at least twice per shift.
7.6.3 The correct travel speed shall be determined by consistent detection of an

artificial pinhole made in a good coating sample but shall not exceed 300
mm/s.
7.6.4 All holidays and other defects shall be marked for subsequent repair and
re-testing. On retesting, no holidays shall be permitted in the final coating.
7.7 Adhesion Test
The coating adhesion shall be determined in accordance with DIN 30672

and Manufacturer’s recommendations. Tests shall be carried out on samples
adjacent to and over the weld on each of the selected test joints and the
failure mode shall be recorded. The minimum properties as specified in
Table 4.2.1 shall be achieved.

GROUP, MUMBAI
FIELD JOINT
7.8 Repair of Shrink Sleeve
Repair of shrink sleeve system shall be carried out as described below :
a) Small Damages measuring not more than 10 mm in length or width,

or diameter extending up to 1.0 cm2 in area. Small damages to 3LPE
or sleeve should be repaired using PE melt sticks; with epoxy primer
if bare metal is visible.
b) Damages measuring greater than 10 mm and not more than 100 mm

in length, or width, or diameter. Polyethylene repair patches pre-
coated with hot melt adhesive, should be used in conjunction with a
hot melt filler adhesive and epoxy primer (if bare steel visible) as per
manufacturer’s recommendations. Repair patches when installed
should overlap the damaged area by minimum 50 mm all round.
c) Damages having length, or width, or diameter exceeding 100 mm,

extending up to 300 mm or 100 cm2 in area. Polyethylene repair
sleeves pre-coated with hot melt adhesive, should be used in
conjunction with a hot melt filler adhesive and epoxy primer (if bare
steel visible) as per manufacturer’s recommendations. Repair sleeves
when installed should overlap the damaged area by minimum 50 mm
all around.
8.0 HANDING AND STORAGE OF MATERIALS
8.1 Materials
All materials for coating activities shall be stored in accordance with the
Manufacturer’s recommendations considering the climate conditions of the
coating location.
8.2 Pipe Handling
All coated and uncoated field joints shall be carefully handled to prevent
damage to both the pipe and coating. The pipe shall not be dropped or
dragged, and bare cables, chains, metal hooks. Etc. shall not be permitted to
come into contact with coated pipes. Pipes shall be handled and stockpiled
by means of wide non-abrasive belts of a flexible materials.
8.3 Material Control Records

GROUP, MUMBAI
FIELD JOINT
The Contractor shall record the receipt, issue return or disposal of all
materials. In particular, the records shall reference the pipe number of each
pipe. The records shall be such that each joint is traceable.
9.0 DOCUMENTATION
Prior to the start of production, the Contractor shall submit the following
documentation to the Company for their approval :
a) Coating and testing procedures

b) Detailed descriptions of coatings equipment and materials
c) Material control recording procedure
d) Inspection quality plan
e) Repair procedure
f) Procedure for all PQT and production tests.
g) Manufacturer’s certificates for each batch of coating materials
h) Pre-production qualification test results, including qualification repair
test.
i) All relevant coating application variables
j) Inspection and test records, results, and other documentation of all
materials and coating tests
k) Coating installation report
l) Records of all repairs.
10.0 WARRANTY
The Contractor/Vendor shall have final and total responsibility for the design
and performance of all items supplied under this specification. The
*******

GROUP, MUMBAI
FIELD JOINT
Appendix –A
INSPECTION SUMMARY FOR PROCEDURE QUALIFICATION TEST FIELD

JOINT COATING SYSTEM FOR ONE PIPE DIAMETER
Property Relevant Acceptable Values Frequency of Tests

Clause
After Abrasive Blasting
• Cleanliness
Sa 2 ½ Each joint
• Profile 7.2 50-80 um Each joint
Holidays 7.6 No holidays Each joint
Visual inspection 7.4 No wrinkles, Each joint
creases, air
entrapment, etc.
Thickness Check 7.5 2.5 + 0.25 mm on Average of test of 10
flat part of pipe locations per joint
Adhesion (Peel) 7.7 Table 4.2.1 2 Sleeves with base
metal, circ. Welds
and with each type
of mill coating.
Lap Shear Strength of - 0.05 N / mm2 3 special plate
adhesive at 230C samples as per
EN 12068
Indentation - Table 4.2.1 4 Sleeves
Impact Resistance - Table 4.2.1 2 Sleeve on base
metal
Cathodic disbanding - Table 4.2.1 2 sleeves on base
metal
Destructive Testing - Clause 7.2.5 4 Sleeves
UV irradiation testing - Table 4.2.1 2 Sleeves

GROUP, MUMBAI
FIELD JOINT
Appendix-B
INSPECTION SUMMARY FOR PRODUCTION TESTING ON FULL FIELD JOINT

COATING SYSTEM FOR ONE PIPE DIAMETER
Property Relevant Acceptable Values Minimum

Clause Frequency
Check Raw Materials - Check certificates Every Batch
and labeling
Cutback preparation 1.1.2 - Every Joint
Cleanliness 5.2 and No contamination Every joint
5.3
After Abrasive Blasting
• Cleanliness
ISO Sa 2 ½ Each joint
• Profile 5.4 50-80 um Each joint
Holidays 7.6 No holidays 100% Every Joint
Visual Inspection
• Coating
• Wrinkles, Creases, 7.4 Air void free Every Joint
air entrapment (see Notes)
Thickness Check 7.5 2.5 + 0.25 mm on 10 points on each
flat part of pipe joint (Joint to be
selected at Random)
Adhesion (Peel) 7.7 Table 4.2.1 1 out of 100
(Minimum 1 per day)
Destructive Testing 7.2.5 As per Clause 7.2.5 1 out of 500
(minimum 1 per
days) for first 10
days
Notes :
Check points for Air Voids:
a. The maximum dimension of voids extending to bare does not exceed 50
mm.
b. At least 99% of the metal surface is free of voids extending to bare
metal.
c. The maximum dimension of voids extending to bare epoxy does not
exceed 10 cm2.
d. At least 97% of the adhesive layer is free of voids and / or lack of
adhesive wetting.
e. If Destructive Testing results are found satisfactory during first 10 days,
then no further destructive testing shall be carried out.

GROUP, MUMBAI
FIELD JOINT
SPECIFICATION
FOR
CONCRETE WEIGHT
COATING
1 06.10.2005 KRK SN PKM

CDG/MUM/PL/018
GROUP, MUMBAI SPECIFICATION FOR
CONCRETE WEIGHT COATING
Page 1 of 9 Rev. 1
SPECIFICATION FOR CONCRETE WEIGHT COATING
1.0 GENERAL
The Contractor shall prepare and submit a detailed application procedure

for concrete weight coating of corrosion coated steel pipes for the
Company’s review and approval. While preparing the procedure, the
Contractor shall inter-alia give due consideration to salient guidelines
indicated hereunder :
Reference has been made in this specification to the latest editions of the
following Codes and Standards :
Sl. Code / Standard Description
1. BIS 2266 Steel Wire Ropes for General Engineering

purposes.
2. BIS 4948 Welded Steel Wire Fabric for Concrete
Reinforcement.
3. BIS 2629 Recommended Practice for Hot Applied
Galvanizing on Iron & Steel.
4. BIS 6745 Zinc Coated (Galvanized) Carbon Steel
Wire.
5. BIS 383 Concrete Aggregates.
6. BIS 2386 Concrete Testing.
7. BIS 456 Compressive Strength of Cylindrical
Concrete Specimens.
8. BIS 2386 Organic Impurities in Sands for Concrete
9. BIS 1199 Unit Weight Yield and Air Content
(Gravimetric) of Concrete.
10 BIS 269, 8112, Portland Cement.
12269
11. BIS 4031 Testing of Portland Cement.
12. BIS 516 Methods of Testing Concrete for Strength.
In case of conflict between the requirements of this specification and the

documents referred above, the requirements of this specification shall
govern.

CDG/MUM/PL/018
Page 2 of 9 Rev. 1
3.0 MATERIALS AND WORKMANSHIP
3.1 All material furnished by the Contractor shall be as per the specifications
approved by the Company.
3.2 All work shall be done in a thorough workmanlike manner. The

entire operation of pipe receiving, stockpiling, coating application, storage
and load out shall be performed under the supervision of and by
experienced personnel skilled in the application of concrete weight
coating.
4.0 FACILITIES
The facilities required to carry-out concrete weight coating shall be

sufficient, adequate and in good working condition so as to obtain desired
results.
The mechanical 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 ensure consistently proportioned materials by weight
and thorough mixing of all materials. Equipment shall have either the
batching of materials by weight or continuous mixing, where all feeds are
accurately controlled and percentages of mixer calibrated by weight.
Batching scales/weighing devices shall be maintained in good conditions.
Proportioning equipment shall be calibrated in the presence of Company
representative. Any equipment that tends to separate the ingredients shall
not be used.
5.0 COATING MATERIALS
5.1 Cement
All cement shall conform to BIS-456 and12269 latest revision. The

Tricalcium Aluminate content shall be within the range of 5% to 8%.
Cement that has hardened partially set, or which has become lumpy shall
not be used.
5.2 Fine Aggregate
Fine aggregate comprising of natural or manufactured sand used shall

conform to the requirements of BIS- 383 and shall be clean, free from
injurious amounts of salt, alkali, deleterious substances or organic
impurities. Maximum particle size shall be 4.75 mm and minimum particle

CDG/MUM/PL/018
Page 3 of 9 Rev. 1
size shall be 0.15 mm. Each source of sand shall be tested for organic
impurities as per BIS-2386 and approved by Company prior to its use.
5.3 Coarse Aggregate
Coarse aggregate consisting of gravel, broken stone, etc., in compliance

with BIS-516 & BIS-2386 shall be used. It shall be free of clay and
injurious amounts of alkali, deleterious substances and organic impurities
that may affect the strength of the concrete. Maximum particle size shall
be 9.5 mm and the minimum particle size shall be 0.15 mm. Iron or barium
ore aggregates of a type may be mixed with coarse aggregate to obtain
the required concrete density.
5.4 Water
Water used shall be clear, fresh and clean and shall not contain chloride &
sulphates or other deleterious substances etc. Water from each source
shall be tested prior to its acceptance as a concrete ingredient, according
to the latest revision of BIS 456 / 10500.
5.5 Reinforcement
Reinforcement steel shall consist of welded steel wire fabric manufactured

in rolls (ribbon mesh) conforming to BIS-432, 2266,4948,1566,1786 etc.
Steel wires shall be galvanized and finished as per BIS-2629.
Reinforcement mesh shall be 25 mm x 67.5 mm size and steel wire shall
be of φ1.8 mm. A sample of reinforcement shall be furnished to the
Company for approval.
6.0 Coating Requirement
Pipes shall be coated with concrete to a thickness and dry density as

specified in the Contract document. The compressive strength of concrete
shall not be less than 33 N/mm² in 28 days and 25 kg/cm² in 7 days.
Acceptable tolerance on concrete density shall be (+) 5% and (–) 2%.
The concrete coating shall not absorb water more than 4% of its weight in
water.
7.0 Procedure Qualification
7.1 The Contractor shall prepare and submit a procedure, for design mix and
concrete application for the approval of the company.
7.2 Samples shall be tested in accordance with BIS 516 and 2386 to
determine the strength of concrete, dry specific gravity of the concrete and
the saturated weight after immersion.

CDG/MUM/PL/018
Page 4 of 9 Rev. 1
Test according to BIS codes as above shall also be performed to
determine the expected correlation between the fresh concrete density and
dry density.
7.3 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. The mix so determined shall be then used for sampling of
concrete for compressive strength test in accordance with BS- 1881.
7.4 Subsequent to selection of the design mix, trials shall be performed by

concrete coating application on length(s), to test the placing procedures of
the concrete for the determination of the following:-
- Workability of the concrete and pouring / cement gun rates.
- Number of passes required to meet the concrete coating thickness as

specified.
7.5 The Contractor shall furnish the above procedure qualification details in
the form of a report to the Company for approval prior to application of
regular concrete coating.
8.0 Non-Slip Adhesive (Optional)
In case of PE (poly ethylene) / Fusion bonded epoxy corrosion coated

pipe, non-slip adhesive is required immediately prior to the application of
concrete coating. The Contractor shall apply non-slip adhesive to ensure
appropriate bonding between corrosion coated pipe and concrete.
This adhesive is not required in case of hot applied corrosion coated

pipe.
9.0 APPLICATION OF CONCRETE COATING AND REINFORCEMENT
9.1 Application Method
Concrete coating shall be applied by impingement method. This method

shall ensure the basic characteristics of concrete in compliance with the
minimum requirements of these specifications.
9.2 Concrete Mixing
The components of the concrete mix shall be weigh batched before mixing
by a proper weight-batcher or a continuous mixer with weigh devices.
Weighing devices for each component shall have an accuracy of + 1.0%.
The calibration of the weighing devices and the water meter shall be

CDG/MUM/PL/018
Page 5 of 9 Rev. 1
checked at the beginning of each shift. 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.
Mixing shall be as per the approved design mix proportions.
9.3 Pipe length preparation
Prior to placement 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 issued for this purpose 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 manner to cover
the whole pipe length or sections to be concrete coated. The
reinforcement shall not protrude beyond the concrete coating at ends.
9.4.2 Splicing shall be done either by binding with soft steel wire having a
diameter of 1.5 mm and an overlap of three meshes or pre-bend the end of
the wires on the new roll into hooks and then engage it in the end of the
preceding roll and pressed short. Wire fabric in rolls (ribbon mesh) shall
be provided with a spiral lap of one mesh.
9.4.3 One layer of reinforcement steel for a minimum concrete thickness of 30

mm and wire mesh shall be placed in the center of the concrete. If concrete
thickness exceeds 30 mm or part thereof, additional reinforcement shall be
placed accordingly.
Contractor shall demonstrate that the procedure used ensured no physical

contact between steel reinforcement and the pipe and the reinforcement is
placed in position.
For the first pipe of every shift a water jet shall be used to clear away the
freshly placed concrete in the center of pipe, down to the corrosion coating
for an area of approximately 75 mm wide and 200 mm long in the
longitudinal direction. The concrete shall be inspected to confirm that the
reinforcement mesh is positioned as specified. If the reinforcement is not
positioned correctly; the pipe shall be rejected and re-coated.
9.5 Concrete Placing
9.5.1 Concrete shall be placed within 30 minutes from the time of mixing (i.e.
after adding water to mix) and shall be handled in such a way to prevent
aggregate segregation and excessive moisture loss. Concrete containers

CDG/MUM/PL/018
Page 6 of 9 Rev. 1
shall always be kept clean and free from hardened or partially hardened
concrete.
9.5.2 Concrete shall be projected at high velocity against the external surface of
pipe to produce a hard, tight-adhering coating of the specified thickness. In
case of any interruption beyond 30 minutes, coating shall be removed and
entire joint shall be re-coated at no extra cost to Company.
9.5.3 Coating at each end of the pipe shall be bevelled to a slope of

approximately two-to-one (2:1). Coating shall terminate about 75 mm
short of the surface and the fresh concrete shall be washed of at the ends
accordingly.
9.5.4 Inside and outside surfaces of the uncoated sections of all pipes shall
be kept clean and free from cement concrete and grout.
9.5.5 Bevel protectors shall be installed in order to prevent any damages to pipe
beveled end.
10.0 CURING
Curing shall be performed by suitable method. The freshly coated pipes

surface shall be kept wet for seven days after application of the concrete
coating. Pipes shall not be handled, stacked or loaded out from the yard
until so cured. Transportation and handling of concrete coated pipe shall
be done only after 28 days of coating.
11.0 REPAIRS
The continuous concrete coated pipe shall be handled and stored in a

manner as to minimize cracking or other damage to the concrete coating.
Repairs of defects in the hardened concrete coating shall be made in

accordance with the following:
• Spalling due to compression or shearing caused by impact against

other objects. Spalling is defined as the damage that causes a loss in
concrete of more than 25% of the total thickness of the coating at the
point of damage.
• Damage due to spalling of an area of less than 0.1 m2 where the

remaining concrete is sound and reinforcement steel not exposed will
be accepted with out repairs.
• 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 removed as necessary to expose the

CDG/MUM/PL/018
Page 7 of 9 Rev. 1
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 aggregates shall be
troweled into and through the reinforcement and built up until the
surface is level with the coating around the repaired area at the top and
shall be moist cured for a minimum of 36 hours before further handling.
• Should the damaged area be more than 0.3 m2 coating shall be

removed around the entire damaged area. A repair shall be made by
satisfactorily restoring the reinforcement similar to that from which the
coating was made. 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 period of 36
hours before further handling.
• The entire procedure of applying the concrete weight coating material

shall be rigidly inspected from the time the bare pipe is received until
the coated pipe is loaded on the carrier for shipment.
• The Company shall be provided free access to the plant at any time
during any operation involving the pipe, with the right to inspect and to
accept or reject work performed.
• The Contractor shall be responsible for stopping operations, when

conditions develop which could adversely affect the quality of the
completed work.
• Inspection shall also include examination for previously undetected

defects on the pipe surface or the pipe ends. Pipe having such defects
shall be set aside for subsequent repair or replacement and for any
necessary coating repair. The Contractor shall carry out necessary re-
coating or coating repair as required.
• Coating thickness measurements (diameter readings) shall be made on

every pipe at 3 equally spaced locations and recorded. All thicknesses
must lie within (+/- ¼”) of the specified thickness.
• The Contractor shall provide at the worksite, weigh scales of sufficient

capacity to accommodate the weighing of the finished concrete coated
pipe joint. The weigh scales shall have an accuracy of +/- 0.5%. The
weight of each concrete coated pipe shall be within –5% +7 ½% of the
theoretical coated pipe weight in air. Coated pipe weight shall be
marked on the inside of one end of the pipe.

CDG/MUM/PL/018
Page 8 of 9 Rev. 1
• The Contractor shall provide daily Proctor samples (4” cylinders) of
concrete used in the application of the concrete coating to determine
the compressive strength of this material and to compare it to the
specification for compressive strength. The concrete compressive
strength samples will be taken 2 times per shift in accordance with
relevant BIS code tests which shall be conducted at 7 days and 28
days with a minimum compressive strength of 21N/Sq mm at 7 days.
13.0 UNLOADING, LOADING, TRANSPORT, STORING AND HAULING
• Contractor shall unload, load, stockpile and transport the corrosion

coated pipes and concrete coated pipes using suitable means and in a
manner to avoid damage to coating, pipe wall and bevelled ends, from
the site of receipt to the coating yard and after concrete coating
completion.
• Rolling, skidding of dragging shall not be permitted. Adequate strapping

and padding shall be provided during handling. Proper handling/ lifting
equipments shall be deployed to prevent any damage to the coated
pipes.
• The coated pipe shall be protected from standing water and sharp or
hard objects that might damage the coating.
• The concrete coated pipe shall be stockpiled either by laying out one
high or by nesting on sand windrows. Pipes shall not be stockpiled until
such time as all end cleaning and patching, if required, have been
completed. Pipe may be stacked directly off the coating machine.
14.0 WARRANTY
The Contractor shall have final and total responsibility for the design and
performance of all items supplied under this specification. The Contractor
shall warrant the items furnished by him and the performance of the said
items in accordance with this specification and with warranty requirements
as specified in the bid package.
*******

CDG/MUM/PL/018
Page 9 of 9 Rev. 1
SPECIFICATION FOR
HYDROSTATIC TESTING OF PIPELINE
1 23.03.2005 KRK SN PKM
SPECIIFICAION NO. :
SPECIFICATION FOR HYDROSTATIC TESTING OF BDA/ODG/PL/007
Onshore Design Group
PIPELINE
Vadodara Page 1 of 3 Rev. 1
SPECIFICATION FOR HYDROSTATIC TESTING OF PIPELINE
1.0 The final high pressure test on the completed sections of line shall be
performed after the backfilling operations have been completed. The testing
shall be carried out in strict compliance with the testing procedure as per
relevant ASME code.
1.1 The final hydrostatic pressure test on the pipeline shall be performed with water
as test fluid. All arrangements required for testing including manifolds etc. shall
be made and after testing they shall be removed to the satisfaction of
Company.
1.2 In order to clear the air out of the line, a pig of correct pattern and size shall be
propelled through the line ahead of the water from portable pumps.
1.3 Water to be used for testing shall be clean and filtered.
1.4 While the line is full, hydrostatic pressure shall be applied at the specified test
pressure as per relevant ASME code / as directed by Company and maintained
on the line without significant loss. The testing would be for at least 24 hours
after the pressure has been stabilized. Should any doubt arise at the end of 24
hours test as to the possibility of any leak on account of any loss of pressure,
Company may direct to repeat or retest the line.
1.5 Approved test pressure and temperature recorders shall be furnished to obtain
permanent record of testing results and necessary connections for pumping
and testing the line shall be made. Pressure recording instruments used for
testing the pipeline shall be checked by means of a dead weight tester.
1.6 The time and length of sections to be tested and other details of the test shall
depend on the individual requirements as directed by Company. Complete
safety during tests shall be insured.
1.7 In case of pressure drop, it shall be calculated according to relevant formula,

before acceptance of hydrostatic test.
1.8 Failure in the line disclosed by loss of pressure shall be located and repaired.
1.9 After any leaks and failures on the line disclosed by the test have been
repaired, the test shall be repeated until the specified test pressure has been
satisfactorily maintained.
1.10 After satisfactory completion of the test and prior to tie-in the line section shall
be cleared of water by running of an air swab. This process of air swabbing by
propelling pig of correct pattern and size shall continue till the complete section
of pipeline tested is deemed to be dry.
SPECIIFICAION NO. :
PIPELINE
1.11 If required, "Corrosion inhibitor" shall be added to the testing water during
hydrostatic testing of the pipeline.
SPECIIFICAION NO. :
PIPELINE

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What are the main components discussed in the document?

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What specifications are provided for pipeline ball valves?

What specifications are provided for pipeline ball valves?

ONSHORE Volume IIIA -1.

OIL AND NATURAL GAS CORPORATION LIMITED

PIPELINE BALL VALVES

Prepared by Reviewed By Approved By Rev No Date

2.0 Reference Documents

4.0 Design and Construction

5.0 Inspection and Tests

6.0 Test Certificates

7.0 Painting ,Marking and Shipment

8.0 Spares and Accessories

2.0 REFERENCE DOCUMENTS

ASME B 31.3 : Process Piping

ASME B16.47 : Large Diameter Steel Flanges

components shall be as per Manufacturer’s standard, which shall be subjected to approval

- SC2, Type II, Class 2.

The hardness of plating shall be minimum 50 RC.

4.0 DESIGN AND CONSTRUCTION

4.3 Ball shall be single piece, solid type construction.

so designed as to ensure sealing at low as well as high differential pressures. Seat

4.21 Operating Devices :

e) Direction of operation of hand wheel or wrench shall be in clock-wise direction

5.0 INSPECTION AND TESTS

5.1.4 a) Non-destructive examination of individual valve material and component consisting

ANSI 150 # Class - All sizes - Nil

ANSI 300 # Class - DN 150 mm (6”) - Nil

ANSI 600 # Class - All sizes - 100%

d) Bodies and bonnets made by welded assembly of segments of castings, forgings,

5.1.6 Welds, which cannot be inspected by radiographic methods, shall be checked by

a) The valve shall be subjected to at least 100 Open-Close-Open c yc l e s with

6.0 TEST CERTIFICATES

c) Test reports of radiograph and ultrasonic inspection.

e) Fire Safe Test Certificate as per API 6FA.

7.0 PAINTING, MARKING AND SHIPMENT

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

8.0 SPARES AND ACCESSORIES

Documentation to be submitted by Manufacturer to Company is summarized below.

9.1 The Contractor shall submit the following documents :

a) General arrangement/assembly drawings showing all features and relatives

d) Installation, Operational and Maintenance Manual.

f) Copy of valid API 6D certificate.

g) Compliance to technical specifications or clause wise list of Deviation from this

j) Welding, heat treatment and testing procedures.

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

l) Descriptive technical catalogues of the Manufacturer.

n) Duly filled in datasheets for all valves.

Prepared by Reviewed By Approved By Rev No Date

DATA SHEET FOR PIPELINE BALL VALVE

DESIGN STANDARD API 6D FIRE SAFE API 6FA,

Prepared by Reviewed By Approved By Rev No Date

Sl. No. Description

2.0 REFERENCE DOCUMENTS

4.0 DESIGN AND CONSTRUCTION

5.0 INSPECTION AND TESTS

6.0 TEST CERTIFICATES

7.0 PAINTING, MARKING AND SHIPMENT