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Hindustan Urvarak and Rasayan Limited Barauni & Sindri: Job Specification For Supply Pipe and Piping Components

This document is a job specification for supplying pipe and piping components to Hindustan Urvarak and Rasayan Limited for their Barauni & Sindri project. It specifies requirements for materials, inspections, documentation, marking, and preparation for shipment. Materials must meet general requirements and specific standards for pipes, fittings, flanges, gaskets, and bolting. Inspections include material, visual, dimensional, hydrostatic, and for welded items. Documentation, marking, and preparation for shipment are also outlined.

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0% found this document useful (0 votes)
254 views38 pages

Hindustan Urvarak and Rasayan Limited Barauni & Sindri: Job Specification For Supply Pipe and Piping Components

This document is a job specification for supplying pipe and piping components to Hindustan Urvarak and Rasayan Limited for their Barauni & Sindri project. It specifies requirements for materials, inspections, documentation, marking, and preparation for shipment. Materials must meet general requirements and specific standards for pipes, fittings, flanges, gaskets, and bolting. Inspections include material, visual, dimensional, hydrostatic, and for welded items. Documentation, marking, and preparation for shipment are also outlined.

Uploaded by

Amit Sharma
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© © All Rights Reserved
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Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 1 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

JOB SPECIFICATION FOR SUPPLY

PIPE AND PIPING COMPONENTS

DOCUMENT CATEGORY
‫܆‬ INFORMATION – Class 1
‫܈‬ REVIEW – Class 2

ISSUED FOR
‫܈‬ OWNER
‫܆‬ INTERNAL- CONSORTIUM
‫܆‬ INTERNAL-TECHNIP-FMC
‫܆‬ INTERNAL - LTHE

Arunkumar Jayapal
2018.08.27 19:40:56
Bruno Martin Venkataraman
Krishnamoorthy
+02'00' 2018.08.27 2018.08.28 08:40:30 +02'00'

19:43:34 +02'00'
A 28/08/18 IFQ – ISSUED FOR QUOTATION J ARUNKUMAR B. MARTIN K VENKATARAMAN
Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MM/YY (name & visa) (name & visa) (name & visa)

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the margin

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 2 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

HOLDs

HOLD n° REF. § DESCRIPTION


1
2

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expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
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TP 077625 C00 JSS 1300 0001 A Page 3 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

CONTENTS

1. INTRODUCTION 5

2. DEFINITIONS AND ACRONYMS 5

3. REFERENCE DOCUMENTS 6

3.1 Project Reference 6

3.2 Owner Documents References 6

3.3 Licensor Documents 6

3.4 Codes and standards 6

4. PURPOSE 7

5. ORDER OF PRECEDENCE 8

6. MATERIALS 8

6.1 General requirements 8

6.2 Pipes 11

6.3 Fittings 12

6.4 Flanges 14

6.5 Gaskets 16

6.6 Bolting 16

7. INSPECTION AND TESTS 17

7.1 General requirements 17

7.2 Material Inspection 18

7.3 Visual Inspection 18

7.4 Dimensional Inspection 18

7.5 Hydrostatic Test 19

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 4 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

7.6 Welded Items 19

8. DOCUMENTATION 21

9. MARKING 22

9.1 General 22

9.2 Other requirements 22

10. PREPARATION FOR SHIPMENT 22

10.1 Pipe 23

10.2 Fittings 23

10.3 Flanges 23

10.4 Gasket 23

10.5 Bolting 23

11. ATTACHMENTS 24

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
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TP 077625 C00 JSS 1300 0001 A Page 5 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

1. INTRODUCTION
Government of India has formed a joint venture company of M/s NTPC Ltd., M/s Coal India Limited
(CIL), M/s Indian Oil Corporation (IOCL) & FCIL/HFCL by name M/s Hindustan Urvarak &
Rasayan Ltd. (“HURL”) hereinafter also referred to as “OWNER”, for setting up Ammonia Urea
Fertilizer Complex along with its associated offsite & utility facilities at the 2 following locations:
• Barauni, Bihar, India.
• Sindri, Jharkhand, India.
The 2 Ammonia & Urea Plants will each be having a capacity of 2200 MTPD & 3850 MTPD
respectively (“PROJECT”).
The consortium of TECHNIP France and TECHNIP India limited, India (Collectively “TECHNIP),
and LARSEN & TOUBRO Hydrocarbon Engineering Limited, has been awarded contracts for the
PROJECT covering the following activities:
• Process Licenses;
• Basic Design and Detailed Engineering;
• Procurement, Catalyst Supply;
• Construction;
• Pre-Commissioning, Commissioning, Start up;
• Sustained load test, Performance Guarantees test.

2. DEFINITIONS AND ACRONYMS


• OWNER means “HURL” a Joint Venture of NTPC, CIL, IOCL, FCIL and HFCL
• PMC means Projects & Development India Limited (PDIL), who has been awarded by
OWNER for PMC services
• PROJECT means Ammonia Urea Fertilizer Complex for BARAUNI and SINDRI or
BARAUNI only or SINDRI only.
• CONTRACTOR means the CONSORTIUM made of TECHNIP France, L&T Hydrocarbon
Engineering Limited and TECHNIP India, who has been awarded contracts to execute for
the PROJECT
• LICENSOR means each of the Companies who have granted to OWNER a Process License
and are providing the corresponding Licensor Basic Engineering Package, namely:
o HALDOR TOPSOE for Ammonia
o SAIPEM for Urea

• VENDOR means a Company/Agency with whom CONTRACTOR has entered any Purchase
Orders to supply equipment or material for the Project

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 6 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

• SUBCONTRACTOR means any party with whom CONTRACTOR has entered any
subcontract.

3. REFERENCE DOCUMENTS

3.1 Project Reference


[1]. 077625-C00-JSD-2310-0001 – Job Specification for Design-External Painting
[2]. 077625-C00-JSS-6300-0003 - Job Specification for Supply-Positive Material Identification

3.2 Owner Documents References


[3]. 5003/E-01/P-II/5.2.3 – Design Philosophy & General Specification for Piping of Ammonia Urea
Fertilizer Plant, Barauni
This procedure refers to 5003/E-1/P-II/5.2 PART II: TECHNICAL SECTION - 5.2.3
DESIGN PHILOSOPHY & GENERAL SPECIFICATION - PIPING BARAUNI only since owner
specification for BARAUNI and SINDRI are identical.

3.3 Licensor Documents


[4]. SPC.CR.UR.510_REV4 - General specification – Austenitic Stainless steel for Urea Plant High
Pressure Section
[5]. SPC-SPA-ENG-MAEU-536-E-R01 - Inspection and Testing of High Pressure Equipment for Urea
Plant during Fabrication
[6]. TS-COR-ENG-PIPMT-002-E-R03draft - Piping Material for Urea Service H.P

3.4 Codes and standards


Edition and/or issue dates of Codes, Standards and Specification shall be latest, unless otherwise
specified.
Authority Title
ASME B1.1 – Unified inch screw threads
B1.20.1 – Pipe threads - general purpose
B16.1 – Gray iron pipe flanges and flanged fittings
B16.5 – Pipe flanges and flanged fittings
B.16.9 – Factory made wrought butt welding fittings
B16.11 – Forged steel fittings, socket welding and threaded
B16.20 – Metallic gaskets for pipe flanges – Ring-joint,
spiral-wound, and jacketed

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 7 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

B16.21 – Non-metallic flat gaskets for pipe flanges


B16.25 – Butt welding ends
B16.36 – Orifice flanges
B16.42 – Ductile iron pipe flanges and flanged fittings
B16.47 – Large diameter steel flanges
B16.48 – Steel line blanks
B18.2.1 – Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy
Hex, Hex flange, Lobed Head, and Lag Screws
B18.2.2 – Square and Hex Nuts (Inch series)
B31.1 – Power piping
B31.3 – Process piping
B36.10 – Welded and seamless wrought steel pipe
B36.19 – Stainless steel pipe
B46.1 – Surface Texture
MSS SP 25 – Standard Marking System for valves, fittings, flanges and unions
SP 43 – Wrought Stainless Steel Butt Welding Fittings
SP 44 – Steel Pipeline Flanges
SP 95 – Swage Nipples & Bull Plug
SP 97 – Integrally reinforced forged branch outlet fittings – Socket welding,
Threaded and Buttwelding ends
NACE MR 0103 – Materials Resistant to Sulphide Stress Cracking in Corrosive
Petroleum Refining Environments
MR 0175 – Petroleum and Nature Gas Industries – Material for Use in H2s
Containing Environments in Oil and Gas Production
IBR Indian Boiler Regulation
EN 10204 – Metallic products – Type of inspection documents
API 601 – Specifications for Metallic Resistant Gasket for Refinery piping
605 – Large diameter carbon steel flanges.
AWWA C207 – Steel Pipe Flanges for Waterworks Service – Sizes 4” through 144”

4. PURPOSE
The specification covers minimum technical requirements for procurement of pipe and piping
components be used for 077625C - HURL project BARAUNI and SINDRI.

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 8 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

This specification covers:


ƒ Seamless or welded pipes,
ƒ Fittings,
ƒ Flanges,
ƒ Gaskets,
ƒ Bolting.
This specification does not cover valves, Y-strainer, steam traps, sight glasses.
This specification shall be read in conjunction with the material requisition, commodity code
description (if any) and the relevant codes and standards referenced within.

5. ORDER OF PRECEDENCE
In case of conflict between requirements specified herein and the requirements of any other
referenced document, the order of precedence shall be:
ƒ Material requisition,
ƒ Ident/Commodity code description (if any),
ƒ This specification,
ƒ Referenced codes and standards

6. MATERIALS

6.1 General requirements

Materials shall be according to the requirements indicated in the ITEM DESCRIPTION shown in the
Material Requisition, in the relevant "DETAILED SUPPLY SPECIFICATIONS’’ and in any
reference document. In any case, the SUPPLIER shall notify PURCHASER of all conflicts among the
aforesaid documents.
Post weld heat treatment (PWHT)
Unless otherwise heat treatment is specified all welds shall, as a minimum, be PWHT in accordance
with the material groupings and thickness ranges defined in ASME B31.3. Any required NDE
examinations shall be executed after the final PWHT.
Indian Boiler Regulation (IBR)
For all materials specified as IBR (Indian Boiler Regulation) in the ITEM Description, the
requirements of Indian Boiler Regulation shall be followed.
Piping systems for Steam and Boiler Feed Water are subject to the requirements of the Indian Boiler
Regulation (IBR).

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 9 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

IBR piping components, irrespective whether fabricated inside or outside India, shall be fully in
compliance with the requirements of the IBR code (latest edition) in design, inspection, erection and
certification. It is SUPPLIER’s responsibility to comply in full with the requirements of the IBR and
to obtain all the required approvals and certification.
For carbon steel Pipes, Fittings and Flanges under IBR the chemical composition shall conform to
the following:
Carbon (Max) 0.25 %
Others (S, P, Mn) As prescribed in IBR regulation
The chemical composition as indicated in this clause is not applicable for pipes other than IBR
services.
• Pipes under purview of IBR shall be accompanied with IBR certificates in form IIIA, duly
approved and countersigned by IBR authority/local authority empowered by central boiler
board of India.
• Flanges and Fittings under purview of IBR shall be accompanied with IBR certificates in
form III-C, duly approved and countersigned by IBR authority/local authority empowered
by central boiler board of India

6.1.1 Carbon Steels and Low Temperature Carbon Steel


Materials shall confirm to the applicable Standard specification.

Impact test requirements on carbon steel


According to ASME B31.3, carbon steel pipes, fitting and plates shall be impact tested depending of
design minimum metal temperature-thickness combination.
Minimum design temperature for the Project being 2.3° C impact tests are required
ƒ For pipes and fittings wall thickness 27.2 mm and over
ƒ Plates wall thickness 27.2 and over
ƒ Plates used for blanks: The wall thickness to be considered equal 4 times the plate wall thickness
here above.
Impact testing includes all welds (re. ASME B31.3 para. 323.3).

Impact test requirements on Low temperature carbon steel


Materials shall conform to the applicable Standard specification and any supplementary requirement
specified in Item description.

6.1.2 Alloy steels


Alloy Steel piping components shall be always normalized and tempered as per ASTM code.

Alloy piping components with weld ends (i.e. socket ends and bevel ends) shall have the following
final minimum mill tempering temperature:

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 10 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

1,25 Cr - 0,5 Mo Alloy Steels: not less than 730 °C;


2,25 Cr - 1 Mo, 5 Cr and 9 Cr Alloy Steels: not less than 750°C.

For all alloy steel welded piping components, the required carbon content of the weld filler metal
shall be equal or greater than 0,05 C wt.

6.1.3 Austenitic stainless steels


All items/parts shall be supplied in solution annealed condition. Austenitic stainless steels shall be
furnished in the solution heat treated condition and free of sub sequent cold work.

Dual Grade or Dual Marked Stainless Steel (e.g. 316/316L) shall be supplied provided that the chemical
and mechanical properties comply with the requirements of both grades.

For austenitic stainless steel 300 series “H Grade” (with min carbon content 0,04%), high carbon
electrodes /wires with 0.04 to 0.08% Carbon shall be used. Filler metal shall be selected to produce weld
deposit that fall within the ferrite number (FN) range of 4-8 as determined by the WRC (Welding
Research Council) diagram which is included in AWS A-5.4

For all items of stabilized SS grades, resolution annealing shall be done. lt shall be carried out subsequent
to normal resolution annealing. Soaking temperature and holding time for stabilizing heat treatment
shall be 900 deg. Celsius and four hours

Inter Granular Corrosion


For all austenitic stainless steel pipes, inter-granular corrosion test shall have to be conducted as per
following:
-ASTM A262 PRACTICE “B” with acceptance criteria of 60 mils/year (max.) or ASTM A262
PRACTICE “E” with acceptance criteria of no cracks as observed from 250x micrograph
When specifically asked for in MR for high temperature. Application of some grades of austenitic
stainless (eg. SS309, 310,316,316H etc.) ASTM A262 practice "C" with acceptance criteria of 15
miles/Year (Max.) shall have to be conducted.

All stainless-steel fittings shall undergo Inter-Granular Corrosion (IGC) test to ASTM A262 practice
“B” & acceptance criteria shall be that the corrosion rate shall not exceed 48 mils/year. Two sets of
samples shall be drawn from each heat treatment lot, one set corresponding to highest carbon content
and other set corresponding to highest wall thickness of the fittings.

Austenitic stainless steel flanges shall undergo Inter Granular Corrosion (IGC) test to ASTM A 262
practice 'B' and acceptance criteria shall be that the, corrosion rate shall not exceed 48 mils per year.
Two sets of samples shall be drawn from each heat treatment lot, one set corresponding to highest carbon
content and other set corresponding to highest rating / thk.
Urea grade stainless steel.
For all stainless-steel material specified as “Modified Urea Grade Material” in the item description
requirements shall be as per the Technical notes – Urea Grade Piping Material (Refer Attachment
1).

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 11 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

6.1.4 Plastic materials


HDPE shall be provided with long term UV protection (2% to 3% carbon black).
All fittings moulded or fabricated shall meet the full pressure ratings.

6.1.5 Galvanized materials


Unless otherwise specified, galvanizing of piping components shall be coated with zinc inside and
outside by hot dip galvanized as following:
pipe according to ASTM A53;
fittings according to ASTM A153.
flanges according to ASTM A123.
All threads and end connection preparation on galvanized pipe, fittings and flanges shall be done
after galvanizing.

6.2 Pipes

6.2.1 General
The material type, specification and grade shall be strictly in accordance with the standards referred
to this specification. All materials shall be new materials with all surfaces clean and free from defects,
weld spatter, arc strike, rust, dirt, sand, scale, paint or any other foreign substance.
• For carbon and alloy steels, diameters and wall thicknesses shall conform to ASME
B36.10M where applicable.
• For austenitic stainless steels, duplex stainless steels and nickel alloys diameters and wall
thicknesses shall conform to ASME B36.19M where applicable, otherwise ASME B36.10M
is applicable.
Dimensional tolerances shall be within the limit specified in the applicable material
standards(ASTM/API).

6.2.2 Length of pipes


Pipes shall be supplied in double random length as defined in the applicable standard. If standard
does not define length, reference shall be made to ASTM A106.
Shorter lengths of pipe shall not be butt welded together to make up a single or double random length.

6.2.3 Welded pipe


Unless specifically exempted, welded pipes shall be acceptable only with longitudinal weld made
employing automatic welding. 100% radiography for all welds.

Double seam 180 deg apart is allowed for sizes up to 36


Two (or more) longitudinal weld seams and circumferential weld may be allowed for large diameter
but shall be subject to Purchaser’s approval.
Furnace butt-welded, furnace lap-welded, and spiral welded pipes are not permitted. And also
circumferential welds shall not be permitted unless otherwise permitted.

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
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Project N° Unit Number Doc. Type Material Code Serial Number Revision Page

TP 077625 C00 JSS 1300 0001 A Page 12 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

Stainless Steel Welded Pipes which refer to ASTM A358 shall be Class 1, as indicated in the relative
ITEM DESCRIPTION.
However, Class 3 (single welded) is acceptable instead of Class 1 (double welded) only for thickness
thinner than 10 mm. In this case, Supplier will precise at bid stage, if the pipe is Class 3 instead of
the required Class 1.
Film of examination is mandatory. Radioscopy is not accepted in lieu of Radiographic examination.
Welded Pipe not referenced in ASME B31.3 or ASME Div. II part D (e.g. ASTM A358 Grade
317/317L) shall have the same mechanical properties (yield strength and tensile strength) of
applicable plate specification (e.g. ASTM A240 Grade 317/317L) at room temperature and at the
maximum design temperature. If SUPPLIER has not data relevant to the required mechanical
properties, a hot tensile test at the maximum design temperature is required. The hot tensile test shall
be performed with a procedure that shall be agreed with Purchaser.

6.2.4 Pipe ends


When pipes are ordered bevelled ends, bevel shall conform ASME B16.25 fig 2a for wall thickness
22mm and smaller and 3a for greater that 22mm unless standard to which refers the pipe asks for
specific bevel.
Threaded ends shall be NPT in accordance with ASME B1.20.1. Threaded/Coupled: Each length of
threaded pipe shall be supplied with a coupling at one end and the coupling shall be forged 3,000 Lbs
class to ASME B16.11 with thread form as specified on the Purchase order documents
The plain ends pipe shall be cut square.

6.3 Fittings

6.3.1 Butt welding fittings


Type of fittings shall be equivalent to pipe type and all welded fittings shall have maximum negative
tolerance equivalent to pipe selected. Thickness/Schedule lower or higher than specified shall not be
accepted.
Thickness of fittings at ends to match pipe thickness for BW fittings. For reducing BW fittings having
different wall thicknesses at each end, the greater one shall be employed and the ends shall be
matched to suit respective thickness
The gasket contact surfaces of stub ends shall be flat with face finish between 125 AARH to 200
AARH according to ASME B46.1.
Butt welding fittings up to 48” shall conform to ASME B16.9 and fittings from 52” to 60” shall
conform to MSS SP75. All welded fittings shall be double welded. Inside weld projection shall not
exceed 1.6 mm. However, 25 mm from the ends shall be flush smooth.
For fittings made out of welded pipe the welded pipe shall be double welded type & are manufactured
with the addition of filler metal.
Elbows and tees shall not be machined direct from bar stock.
Nozzle welded type tees (fabricated type tees) are not permitted except for NPS 60 and larger.

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

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TP 077625 C00 JSS 1300 0001 A Page 13 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

All welded fittings shall be normalised for CS, normalised & tempered for AS; and 100%
radiographed by X-ray for all welds made by fitting manufacturer as well as for welds on the parent
material. Bevel ends of all BW fittings shall undergo 100% MP/DP test
At the exception of miter bends, fabricated tees, elbows and other fittings employing circumferential
or intersection welds are considered pipe fabrications, and are not acceptable.
All pipes employed for manufacturing of fittings shall be required to have undergone Hydro test to
ASTM A530 to the extent so as to produce wall stress of 75% of SMYS of the material.
Fittings with diameter over 60":
Large diameter fittings that the material standards(ASME) do not cover in size or shape shall be
designed in accordance with ASME B31.3 and be manufactured to have the same quality as the
requirements of the applicable material standards. Design of fittings should be established according
to ASME B16.9 paragraph 2.2 (mathematical analysis or proof test).
Tolerances shall be the same as those specified for fittings of 48” diameter. Cross sectional drawing
or catalogue drawings shall be supplied for all these items.
For intermediate diameters not covered by MSS-SP-75, SUPPLIER shall guarantee the end-to-end
dimension of the next larger fittings.
Concentric and eccentric reducers produced as a conical shape are permitted only for sizes larger
than 48”.
Welded fittings
Welded stainless steel and nickel alloy fittings shall be Electric Fusion Welded according to ASME
B31.3 unless otherwise specified.
Welded tees
Welded tees made by joining sections of pipe are not acceptable. When tees are fabricated from plate
the weld seams shall be parallel to the axes of both the run and the branch.
Wall thickness of elbows:
Wall thickness of elbows shall not be in excess of more than 15 % of the specified wall thickness.

6.3.2 Wall thickness of tee on special request


If specified to meet the ASME B31.3 Appendix D flexibility characteristic 4.4 T/r2, design of equal
and unequal tees will meet the following requirements:
ƒ The crotch thickness of the branch outlet of butt welding tees shall be no less than 150 % of the
nominal wall thickness of the tee.
ƒ The crotch radius of the branch outlet of the butt welding tees shall be no less than 12.5 % of the
branch outlet outside diameter.

6.3.3 Forged Fittings (socket welding or screwed)


Unless and otherwise specified all socket weld and screwed fittings shall be in accordance with
ASME B16.11 to the extent covered in the specification except for unions which shall be in
accordance with MSS-SP-83. Threaded ends shall have NPT taper threads in accordance with ASME
B1.20.1 up to 1.5” NB & IS: 554 from 2” to 6” NB.

CONFIDENTIAL INFORMATION – The information contained in this document belongs to TECHNIP. All IP rights relevant to this document are
expressly reserved.
Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
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TP 077625 C00 JSS 1300 0001 A Page 14 of 24


JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

The threaded portion of the galvanized fitting shall be protected from the galvanizing process.
No welding as weld repair is acceptable.

6.3.4 Integrally reinforced forged branch outlet fittings


Design, dimensions and tolerances shall conform to MSS SP 97.
Integrally reinforced branch connection fittings (weldolets, sweepolets, etc) shall provide 100%
header pipe strength as required by ASME B.31.3 or ASME B31.1 whichever is applicable.
ƒ SUPPLIER must be able to produce calculation sheets if requested by Purchaser.
ƒ SUPPLIER will precise at bid stage range of run diameters on which the same fitting can be
welded.

6.3.5 End preparation of Fittings


Unless otherwise specified on the Purchase order documents, end connections shall be as follows:
Threaded: Threaded to American National Standards Taper Pipe Threads (ASME Bl.20.1)
Socket-Welding: Socket weld to ASME B16.11
Beveled: End preparation shown on Figure 2a for pipe wall thickness 22 mm and smaller, And Figure
3a for pipe wall thickness greater than 22 mm in ASME.
Dimensional tolerances on fittings shall be within the limit specified in the applicable ASME or MSS
standards, except that circumferential tolerance at the bevelled end in sizes NFS 26 and larger shall
be within the range of -0.2 to +0.3 percent of the nominal circumferential length.

6.3.6 Spectacle Blinds


Unless otherwise specified, spectacle blinds, blanks and spacers shall conform ASME B16.48.
Depending of material, design minimum temperature and thickness combination, an impact test may
be required. Hardness number for blind and spacer shall be as per mentioned in the para 6.4.2.

6.4 Flanges
All flanges shall be of forged one piece material (seamless), and plate may not be substituted without
written approval from the Purchaser.

6.4.1 Flange dimensions


24” and smaller ASME B16.5
26” to 60” ASME B16.47 series B according to Item description
Above 24” water service only ASME/AWWA C207 – Class D (175-150 psi) / Class E (275 psi)
according to item description
Dimensional tolerances shall be within the limit specified in the applicable standards (ASME/API).

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

6.4.2 Flange facing finish


Unless otherwise specified, machining shall be in accordance with the referenced standard.
Facing of galvanized flanges
After galvanizing, facing will show a regular aspect without any over thicknesses. Serrated aspect
will remain visible.
Hardness of flange facing
Flange facing which are to receive ring type joints (RTJ) shall feature the following minimum
hardness values (BHN):
ƒ Carbon steel = 120
ƒ Austenitic stainless steel AISI 304L, 316L = 150
ƒ Austenitic stainless steel AISI 304, 316, 321, 347 = 160
ƒ Low temperature carbon steel (down to –46°C) = 120
ƒ Allow Steel (Cr < = 5%) = 150

6.4.3 Welding neck flanges


For Welding neck flanges, weld bevel end shall be prepared in accordance with ASME B16.25 Figure
2a for pipe wall thickness 22 mm and smaller, And Figure 3a for pipe wall thickness greater than 22
mm. Wall thickness specified in ITEM description shall be in accordance with ASME B36.10M and
ASME B36.19M.
End preparation shown on Figure 2a for pipe wall thickness 22 mm and smaller, And Figure 3a for
pipe wall thickness greater than 22 mm in ASME.

6.4.4 Orifice Flanges


Orifice flanges shall conform to ASME B16.36.
Quantities shown on Material Requisition must be understood as “pair” of orifice flanges supplied
with assembly bolting, pressure taps equipped with a pipe plug and a machine bolt for use as a
jackscrew. Jackscrew details and pressure taps details are as per the item description.

6.4.5 Face finish and end connection of Flanges.


End flange facing shall be finished as follows:
• TFE sheet and other Non-asbestos gasket 125 to 500 AARH
• Spiral wound gaskets 125 to 250 AARH
• Ring type joint groove facing 63 AARH (Roughness shall not exceed
lb side wall surface of the gasket groove)
Unless otherwise specified, end connections shall be as follows:
• Threaded: Internal taper pipe threads to ASME Bl.20.1

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

• Socket welding: ASME B16.11


• Beveled End: preparation shown on Figure 8 for wall thickness 22mm and smaller, and Figure 9 for
wall thicknesses greater than 22mm in ASME B16.5.
Outside diameters and wall thicknesses of pipes connected shall refer to ANSI B36.10 or ANSI
B36.19.

6.5 Gaskets
All gaskets material shall be asbestos free.
Non-metallic Flat gasket:
ƒ Dimensions shall be in accordance with ASME B16.21
ƒ Diameters 26” to 60” shall conform to ASME B16.47 B or ASME/AWWA C207 – Class D (only
for water service) according to Item description
ƒ Thickness shall be 2 mm, all diameters
ƒ Full faced gasket shall have bolt hole punched out.
ƒ All gaskets shall be treated antistic both sides for the full range of temperature they are designed
to be used
ƒ Large flat gaskets made with several bonded segments are allowed only after Purchaser approval

Spiral wound gaskets


ƒ All spiral wound gaskets shall be supplied with a centering ring and inner ring according to item
description.
ƒ Spiral wound gaskets shall conform to ASME B16.20
ƒ Diameters above 24” shall conform to ASME B16.47 series B or ASME/AWWA C207 – Class
D (only for water service) according to Item description
Ring joint (RTJ)
ƒ Ring joint gaskets shall be according to Item description. If not specified octagonal type shall be
used.
ƒ Ring joint shall conform to ASME B16.20
ƒ Hardness of RTJ gasket shall be 20 BHN (Minimum) less than the corresponding flange groove
hardness.
ƒ Above mentioned HB shall be verified by hardness test.

6.6 Bolting
ƒ Stud bolts shall be threaded full length and chamfered both ends. Length tolerance shall be in
accordance with the requirement of table F2 of Annexure 6 of ASME B16.5

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

ƒ The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by
the hot forged process.
ƒ Heads of jack screws and M/C bolts shall be heavy hexagonal type. Jack screw end shall be
rounded.
ƒ Threads shall be unified (UNC for; 1" dia and 8UN for> 1" dia) as per ASME B1.1 with class 2A
fit for Studs, M/C Bolts and jack screws, and class 2B fit for nuts.
ƒ Length for standard flange assembly shall be in accordance with ASME B16.5 (length of stud-
bolt does not include the height of the points, whatever is the thread).
ƒ Length for special flange assembly (eg. Wafer valve, spectacle blind, …) is specified in the
Material Requisition
ƒ Stud bolts shall be supplied with 2 Heavy Hex nuts.
ƒ Machine bolts shall conform to ASME B18.2.1 Heavy Hex head and shall be supplied with 1
Heavy Hex nut and Nuts shall conform to ASME B18.2.2
ƒ Tops and Bearing Surface of Nuts in size 5/8-inch nominal size and smaller shall be double
chamfered. Larger size nuts shall be double chamfered or have washer faced bearing surface and
chamfered top.
ƒ When an external coating is required (galvanisation, ceramic, …) coating thickness must be
included in the final dimensions such as defined in the applicable standard.

7. INSPECTION AND TESTS

7.1 General requirements


Unless otherwise indicated, all pipe and piping components are subject to inspection during
fabrication and to final acceptance tests.
A pre-inspection meeting, at Purchaser request, shall be held before starting of fabrication activity.
Unless additional inspection is specified in the material requisition, inspection and test shall be as a
minimum, in accordance with the referred standard.
Inspection and testing will be performed according to this specification and to the relevant codes
indicated in the corresponding ITEM DESCRIPTION.
If no specific testing prescriptions are available, the Supplier must in any case submit his internal
standard test procedure and limits of acceptance for Purchaser's approval.
Inspection and tests are at Manufacturer's care and charge.
The extent of PURCHASER's and/or other bodies' activities (inspection, witnessing of tests and/or
review of certification) is indicated on the pertinent Inspection and Test Plan (I.T.P.), attached to the
MR.
All pipe and piping components prepared for Purchaser's inspection shall have passed a preliminary
inspection made by the Manufacturer's Quality Control.

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

Transverse tension test shall be carried out on pipes of nominal size 8” and above and thickness of
Sch.120 and above as per supplementary requirements of respective standards.
Check analysis shall be carried out as per ASTM-A-530 for pipes as per ASTM-A-312 and pipe size
> 8” and thickness > Sch.120, Check analysis shall also be carried out as per supplementary
requirement S1 of ASTM-A-312.
For seamless pipes, each length of pipe with following specifications shall be ultrasonically tested as
per ASTM E 213 or ASTM A 388.
(a) Size up to 4 inches and Sch. > 120
(b) Size > 5 inches and thk. > 12 mm.
Any defects producing signal greater than the appropriate reference groove shall be unacceptable.
The allowable defect shall be longitudinal flat bottom groove on the outside or inside surface of the
pipes and length not greater than 25 mm, width not greater than 1.6 mm and depth not greater than
the smaller of 1 mm or 5% of the wall thickness.

7.2 Material Inspection


All mill test certificates and SUPPLIER's test certificates, if any, shall be verified.
Chemical and mechanical characteristics, hydraulic tests and recorder diagrams of heat treatment, if
any, shall be according to those provided in the relevant Codes, Standards and/or Specifications.
For materials requiring additional testing, for example, impact tests, mill test reports shall be
provided in addition to the documents required by the mentioned material standard. These reports
shall include the impact test results.
The PURCHASER’S Inspector has the right to carry out any check test in order to verify the certified
values in any case of doubt or dispute concerning the results obtained.
Should the results not be according to Specification, re-testing costs shall be at SUPPLIER's charge.

7.3 Visual Inspection


Visual inspection shall be according to the relevant Codes, Standards and Specifications.
Furthermore, all surfaces should be sound, clean and free of flaws, corrugated cracks and/or other
defects that can be detrimental for the use of the piping components.
For machined surfaces, the following shall be verified:
Flange facing
End preparation for welding, if any
Threading, if any
Burrs are not accepted.

7.4 Dimensional Inspection


Unless otherwise specified, tolerances in dimensions shall be according to the relevant Codes,
Standards and Specifications.
In particular, the following shall be checked:

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

- thickness
- diameters
- bevel threaded dimensions
- roundness
- straightness
- end to end dimensions
- flange facing
- bolt hole
- diameter of bolt circle and number of holes

7.5 Hydrostatic Test


Hydrostatic tests shall be applied to each length of pipe and be in accordance with the requirements
of ASTM A530/A530M, unless otherwise specified.
The test fluid used for hydrostatic testing (if any) shall be hydraulic oil or an emulsion of water with
a water-soluble oil to prevent rust. After hydrostatic tests, material shall be carefully drained.
Water for hydrostatic test of austenitic stainless steel pipes shall not contain chlorides more than 50
ppm in weight.

7.6 Welded Items


Welded items shall be fabricated to comply with design codes (ASME B31.3 or ASME B31.1)
requirements.
Unless otherwise stated in the order, welded items shall be furnished only when specifically provided
for by the ITEM DESCRIPTION or accepted in writing by PURCHASER.
For any welded item, the SUPPLIER shall submit the following documents to PURCHASER for
approval:
Weld Key Form
WPSs - Welding Procedure Specifications
PQRs Procedure Qualification Records
WPQs Welder Performance Qualifications

These Documents shall be supplied for ALL welded materials, also if not required in the others
referenced Detailed Supply Specification.

7.6.1 Weld Key Form


The weld key form shall provide on matrix table the list of all WPS intended to be used with the
following information:

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

ƒ Supporting PQR and qualification range


ƒ Welding consumables brand name and designation
ƒ Post Weld Heat Treatment requirement
ƒ Parent material grade to be welded

7.6.2 Welding Procedure Specification “WPS”


WPS's shall be written on the ASME form or approved equal.
All filler metals shall be shown according to the AWS classifications.

7.6.3 Procedure Qualification Record “PQR”


Each PQR shall be witnessed by an independent and recognized authority.
Existing PQR's shall be accepted only if in agreement with all requirements of the project.
PQR’s shall include also all laboratory test reports, heat treatment diagram chart and all Filler Metal
Certificates used to produce PQR.
All documentation shall be written in the official project language (English).
If PQR's are written in a different language, a copy of the same with an attached translation in the
official language may be accepted.
If all or part of the supply is sub ordered or subcontracted, each vendor or sub vendor shall submit
the relevant documentation to PURCHASER for approval.
When an impact test is required for base materials, all the PQR's shall provide an impact test on weld
metal and heat affected zone, even if not required by the applicable code.

7.6.4 Welder Performance Qualification “WPQ”


Each WPQ shall be witnessed by an independent authorized authority.
Existing WPQ's shall be accepted only if in accordance with the applicable project code.

7.6.5 Owner Approved Inspection Authority


Owner approved inspection agencies are
ƒ M/s. Lloyds, TUV & BVIS Inspection Agency are approved for overseas vendors for Non-
IBR items.
ƒ M/s. LRIS, RW - TUV & BVIS Inspection Agency are approved for Indigenous vendors
for Non-IBR items.
ƒ For IBR Items
- Indigenous (Indian) supply, only IBR is the inspection authority.
- Non - indigenous supply, IBR inspection shall be carried out by the inspection
agencies approved by IBR.

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

8. DOCUMENTATION
The Material Requisition defines the documentation to be delivered by the SUPPLIER.
Documentation will clearly mention SUPPLIER’s name, Project identification and Material
Requisition number.
MATERIAL DOCUMENTATION SHALL BE CONSIDERED AS AN INTEGRAL PART OF
THE SUPPLY.
Material Certificates:
Traceability and proper identification of all materials is required.
All materials shall be supplied with their relevant original certification covering mechanical and
chemical properties.
Certification shall include the certificate of the raw material.
All certificates shall be issued in English language.
Certificates shall represent the material in the final condition, or at least in a condition after operations
which can affect any of the properties being reported.
Type of inspection documents shall conform to EN 10204:
ƒ Material certificates
3.1 For all metallic components including bolting materials, RTJ gaskets and
Galvanised piping
2.2 For other metallic gaskets
2.1 for all non-metallic components and malleable iron threaded fittings
ƒ Test certificates
3.1 Pressure tests and non-destructive tests.
Mill test certificates indicating the following and duly signed by the inspecting authority along
with supply of materials
- Purchase order no.
- Material test certificates (Material specification, grade, physical property, chemical
composition & heat treatment report) shall also be furnished for the flanges supplied.
- Size and Sch. No. /thickness
- Quantity
- Heat and lot no.
- Results of Chemical analysis
- Mechanical test results (as per applicable Clause).
- Results of impact test where applicable.
- Non-destructive test results (as per applicable clause)

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

IBR Documentation
Pipes: Pipes meant for steam service shall be supplied with 3 copies of I.B.R. certificates in Form
IIIA duly signed by IBR inspecting authority along with supply of materials. In addition 8 copies
shall be sent to Owner / Contractor for final compilation.
Fittings: Fittings meant for steam service shall be supplied with 3 copies of I.B.R. certificates in
Form IIIC duly signed by IBR inspecting authority along with supply of materials. In addition 8
copies shall be sent to Owner / Contractor for final compilation.
Flanges: Flanges meant for steam service shall be supplied with 3 copies of I.B.R. certificates in
Form IIIC duly signed by IBR inspecting authority along with supply of materials. In addition 8
copies shall be sent to Owner / Contractor for final compilation.

9. MARKING

9.1 General
Marking shall conform to requirements of the Material Requisition
Marking may be applied by stencilling on ferrous materials with a thickness less than 5 mm,
austenitic stainless steel below 10 mm, and all nonferrous materials.
When stencilling is not used, marking shall be applied by low-stress hard-die stamping on a painted
background, unless otherwise approved by Purchaser.
Low-stress stamps shall be round nosed with a radius of 0.25 mm minimum. Casting shall have the
charge or heat number cast in the material. The other required markings also to be cast-in, in an order
of preference.
As a minimum, marking shall be in accordance with:
ƒ Requirements of the applicable standard,
ƒ MSS SP 25 for other materials than pipe,
ƒ Purchaser Ident Code
ƒ Purchaser Ident code can be omitted for components of nominal size 1 ½” and smaller provided
marking is transferred on the packing box
ƒ Colour code for piping identification shall be confirm to 077625-C00-JSD-2310-0001_RevA for
TechnipFMC and confirm to 077625-C00-PP-0000-5505 for LTHE.

9.2 Other requirements


Marking paint or ink to be used shall not contain chlorides, fluorides, any harmful metal, or metal
salts, such as zinc, lead, sulphur or copper which could cause corrosive attack on heating.

10. PREPARATION FOR SHIPMENT


As a minimum and unless otherwise specified, the following measures to prevent the rust, corrosion
and mechanical damage during transportation, shipment and storage shall be performed:

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

Carbon and alloy steel pipes (excluding stainless steel or higher alloys and galvanized steel) shall be
protected by mill finish products.
SUPPLIER shall use an easily removable rust preventive compound, that can guarantee the shipment
and 1 year of outdoor storage without detrimental effect, taking into account the type of transport
and site climatic conditions.
Stainless steel and nickel alloy pipes shall be protected from ferritic contamination and chloride
attack such as might occur from exposure to sea water or sea water spray by means of jute, plastics,
etc.
Protection for bevel ends shall be agreed with the Purchase Order. Rust preventive shall not
detrimental to welding.
Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum
solvent, and the same shall not be harmful to welding.
After inspection and before dispatch, flanges and fittings shall be thoroughly dried and cleaned. All
flanges except SS flanges shall be coated with hard film type of rust preventive to protect against
rusting during transit and storage

10.1 Pipe
Threaded or beveled ends of pipes shall be protected with plastic, metal or wood covers.
SUPPLIER shall ensure adequate protection from damage during shipment to any coating and
wrapping on pipes.
For large diameter pipes, in particular when thin wall manufactured, SUPPLIER shall provide
suitable reinforcements to avoid buckling and ends ovalization.
The smaller pipes may be bundled together but limited to the same item code number.

10.2 Fittings
Arrangement will avoid water retention (particularly for elbows).

10.3 Flanges
Machined surfaces shall be protected with an easy removable rust preventive compound, or by
strippable products. In addition, flange facings shall be duly protected from damage during shipping
and storage, using suitable packing and heavy-duty plastic or wood flange facing protectors.
Each couple of orifice flanges shall be shipped complete with bolts and plugs, and assembled with
gasket contact surface protected by suitable packing.

10.4 Gasket
Packed in closed box

10.5 Bolting
Packed in closed box and protected by a non-corrosive oil or grease

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

11. ATTACHMENTS
1. TECHNICAL NOTES – UREA GRADE PIPING MATERIAL.

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

ATTACHMENT – I
TECHNICAL NOTES – UREA GRADE PIPING MATERIAL

1.0 GENERAL

1.1 Scope and field of application

This specification covers the requirements for austenitic stainless steel materials and
relevant welds in contact with the process fluid in the high-pressure section of urea
plants. These requirements shall be considered in addition to the ones of the codes and
standards applicable to the product in question (equipment, piping components, plates,
materials, testing, etc.). In case of conflict with any of the above standards, this document
prevails.

1.1.2 This specification takes into consideration both the 316L UG stainless steel (UNS
S31603) and the 25Cr-22Ni-2Mo type stainless alloy (UNS S31050).

1.2 Definitions

Supplier Before placing the order it means each of the potential


supplier(s)contacted; after placing the order, it means
the selected supplier(s)
316L UG Urea grade modified‫ ۅ‬316L type austenitic stainless steel that
shall meet all the requirements of the AISI 316L (UNS
S31603) material specification and all the additional
requirements mentioned in this specification.
Sample the piece of semi-finished/ finished product (tube, plate,
W.O., etc.) From which the specimens to be tested are taken
out
Specimen a piece of material obtained from the sample and subjected
to the destructive tests described below (corrosion test,
metallography, etc.).

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

1.3 ABBREVIATIONS

AISI American Iron and Steel Institute


ASME The American Society of Mechanical Engineers
ASTM American Society for Testing and Material
AWS American Welding Society
DIN Deutsches Institut fur Nürmung
IIW International Institute of Welding
UG Urea Grade alloy
UNS Unified Numbering System
W.O. Weld Overlay Deposit

1.4 REFERENCED CODES (ALWAYS LATEST REVISION)

ASME Sect. VIII Boiler and pressure vessel code - Pressure Vessel
ASME Sect. IX Boiler and pressure vessel code- Welding
and Brazing qualifications
ASME Sect.V Non Destructive Examination.

ASME Sect. II Parts A & D Materials

ASME Sect. II Part C Specification for welding rods, electrodes and filler
metals
EN 10204 Metallic materials - Types of inspection documents

ASTMA262 Standard Practices for Detecting Susceptibility to


Intergranular Attack in Austenitic Stainless Steels
ASTM E562 Standard Test Method for Determining Volume
Fraction by Systematic Manual Point Count
AD MERKBLATTER Complete Technical Rules for Pressure Vessels
(English Edition)

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

2.0 MATERIALS

2.1 General

2.1.1 The list of suppliers and sub-vendors of plates, forgings, bars, piping and tubes for High
Pressure Urea equipment and piping to be operated in contact with the urea process
fluid shall be submitted to OWENER/PMC for acceptance.

2.1.2 All semi-finished products shall be supplied in the solution annealed condition. No
heating over 400 °C shall be allowed during machining or any other manufacturing
activity, except welding. If heating above 400 °C cannot be avoided, a new solution
annealing heat treatment shall then be performed and new samples shall be taken and
tested as described in para 4.

2.1.3 If, after solution annealing heat treatment, forgings or bars are submitted to machining
and more than 5 mm depth is removed from the side in contact with the process fluid, then
a new solution annealing heat treatment is required except for the 25Cr-22Ni-2Mo alloy
provided that the samples taken after machining satisfy the test requirements as per para
4.

2.1.4 All tubes and pipes shall be seamless type. For welded fittings, special requirements
of welding have to be pre-approved by OWNER/PMC.

2.1.5 Cast parts and rod bars are not permitted unless approved by OWENER/PMC.

2.1.6 When 316L UG material is required, the use of 25Cr-22Ni-2Mo material is allowed as
an alternative.

2.2 316L UG stainless steel (UNS S31603)

2.2.1 Stainless steel 316L UG type shall be in accordance with the ASME-(SA) specifications
applicable to the relevant semi- finished products; it shall also meet the additional
requirements detailed in para 3 and 4.
2.3 25Cr-22Ni-2Mo alloy (UNS S31050)

2.3.1 Stainless steel 25Cr-22Ni-2Mo type shall be in accordance with the ASME-(SA)
specifications applicable to the relevant semi- finished products; it shall also meet the

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JOB SPECIFICATION FOR SUPPLY- PIPE AND PIPING COMPONENTS

additional requirements detailed in para 3 and 4.

3.0 ADDITIONAL REQUIREMENTS

3.1 Chemical analysis

In the following paragraphs the chemical or additional chemical requirements for 316
UG stainless steel and 25Cr-22Ni-2Mo alloy are reported. Any deviation from these
requirements shall be subject to OWNER / PMC acceptance.

3.1.1 316L UG stainless steel

The 316L UG stainless steel base material shall have the following additional
chemical requirements:

C = 0.020 % max.
P = 0.015 %max.
S = 0.010 % max.
Ni > 13%
N = 0.10 % max.

The carbon content restriction above does not apply to forgings provided no
welding is performed after the solution annealing heat treatment, not even for installation
purposes.

3.1.2 25Cr-22Ni-2Mo stainless steel

The 25Cr-22Ni-2Mo stainless steel base material shall have the following chemical
Composition:

Cr = 24 ÷ 26 % C = 0.020 % max.
Ni = 21 ÷ 23.5 % P = 0.020 % max.
Mo = 2 ÷ 2.6 % S = 0.010 % max.
Mn = 1.5 ÷ 2.0 % Si = 0.40 % max.
N = 0.10 ÷ 0.15 % B = 0.0015 % max.

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3.1.3 W.O. deposit shall meet the following requirements for a depth of at least 3 mm from
the ʊas welded‫ ۅ‬or machined surface:

Material type 316L UG:

C = 0.030 % max. (SAW-ESW-GTAW)


C = 0.040 % max. (SMAW)
Cr = 16.5 % min.
Ni = 15 % min.
Mo = 2.2 % min.

Material type 25Cr-22Ni-2Mo:

C = 0.030 % max. (SAW-ESW-GTAW)


C = 0.040 % max. (SMAW)
Cr = 24 % min.
Ni = 21 % min.
Mo = 1.9 % min.
And

Cr eq = % Cr +% Mo +1. 5 % Si

Ni eq = % Ni +30 % C +0. 5 % Mn

3.1.4 Chemical analysis at depth of 1 mm and 2 mm shall also be performed and reported
for information.

3.2 Mechanical properties

The mechanical properties of 25Cr-22Ni-2Mo stainless steel, at room temperature, shall


be as Follows:

Tensile strength 580 N/mm² min.

Yield strength(0,2% offset)


270 N/mm² min.

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Elongation (l=5d) 30% min.

3.2.1 Short Time Tensile Test shall be performed/ certified at the design temperature for each
heat of Urea Stripper heat exchanger tubes.

3.2.2 If the design is carried out in accordance with ASME code BPVC section VIII, for
forgings the code itself shall be applicable with reference to CODE CASE 2038.

3.2.3 For other requirements, the relevant material/ product SA (ASME) specification shall
be applied.

4.0 TESTING AND CERTIFICATION OF MATERIAL


4.1 General criteria for sampling

Product Sampling for corrosion test Sampling for metallographic examination

PLATES One sample for each heat One sample for each plate
One sample form each lot of One sample form each lot of no more than
PIPING, FORGING no more than 50 pieces of 50 pieces of each heat and same heat
each heat and same heat treatment (1)
treatment (1)
One sample form each lot even if of no
BOLTS, NUTS, One sample for each heat more than 50 pieces of each heat and
SMALL-SIZE same heat treatment (1) for bolts, nuts, and
FORGING forgings of small size (Dia.”219.1mm )
One sample form each lot of 200 pieces of
EXCHANGER TUBES One sample for each heat
each heat and same heat treatment (1)

NOTE (1): definition of same heat treatment:


-If final heat treatment is in a batch-type furnace = in the same furnace charge
If final heat treatment is in a continuous furnace = in the same furnace at the
same temperature, time at heat, and furnace speed.

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4.2 TEST SAMPLES AND SPECIMENS

4.2.1 Samples for corrosion tests and micro structural examination shall be taken as per
the above table (base material) and from each weld test during the welding procedure
qualification. Overheating shall be avoided when cutting the specimens (thermal-cutting
is not allowed). Each sample shall be marked, by stamping, with proper identification
traceability number.

4.2.2 The area of each sample shall be of 180 cm2 as a minimum (if not otherwise specified
in this document) and shall permit to take out with sufficient allowance the following
specimens:

1 for check (chemical) analysis


1 for corrosion test (see para. 4.4)
1 for corrosion re-testing (if required)
3 for microstructure examination (see para. 4.3) 1 for metallography re-testing (if required)

4.2.3 Each specimen shall include the side that will be in contact with the process fluid if
known (consequently liner plates shall then be installed by exposing to the process fluid
the side that has been actually tested with positive results). Specimens for the corrosion
test shall have an area of approximately 30 - 32 cm2, weight of 40 g minimum (100 g
maximum) and, when feasible, an approximately rectangular shape with dimensions of
about 50 x 25 x 5 mm.

4.2.4 In the case of plates with thickness over 7 mm, the specimen shall be reduced to 5 mm
by machining material in excess on the opposite side from that (those) in contact
with the process fluid (avoiding overheating).

4.2.5 In the case of tubes with outside diameter less than 30 mm, the sample shall have
a cylindrical shape. In the case of tubes or pipes with outside diameter • 30 mm, the
sample shall be taken with length "a" approximately equal to arc "b".

4.2.6 If the pipe or tube thickness is over 7 mm, the specimen thickness shall be reduced to
5 mm by machining material in excess on the opposite side from that (those) in contact
with the process fluid (avoiding overheating).

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4.2.7 In the case of forgings or bars, if it is not possible to take a sample with the surface to be
in contact with the process fluid, the sample shall be taken from the core of the forging
bar. Test specimens shall be taken from the forging extension or by a representative
specimen with the same heat and heat treatment having maximum treated thickness
size of those forgings.
4.2.8 In the case of special pieces (valves, thermocouples, fittings, instrument separators, etc.)
the supplier shall submit to OWNER / PMC for acceptance an overall drawing showing
the location of the sample(s).
4.2.9 In the case of welding procedure qualification tests for SAW / ESW / SMAW weld
overlay (see Attachment 1) three samples shall be taken:
- sample S1 (Attachment 2) which shall include at least 2 bead overlap of adjacent beads
- sample S2 (Attachment 3) which shall include stop and restart point of a bead
- sample S3 (Attachment 4) which shall include beads deposited by manual welding
with SMAW and/ or GTAW on the automatic overlay, simulating repair if any.

4.2.10 The specimens obtained from each of the above samples shall be used as follows:
- specimen(s) labeled “A” are to be used for metallographic analysis (one is for re-
testing if required)
- specimen(s) labeled “B” are to be used for corrosion test
- specimen labeled “B1” is to be used for corrosion re-testing if required
- specimen labeled “C” is to be used for macro graphic examination
- specimen labeled “D” is for chemical check analysis.

4.2.11 In the case of welding procedure qualification tests for additional automatic GTAW weld
overlay on liner plates or SAW / ESW / SMAW weld overlay, a sample of S1 type including
at least 2 bead overlap of adjacent beads (see Attachment 2) shall be taken out.

4.2.12 In the case of welding procedure qualification test for butt joints, the sample shall be as
wide as the face of weld in contact with the process fluid plus 12 mm (6 mm each side)
and 5 mm thick (see Attachment 6).
4.2.13 In the case of procedure qualification tests for welds between tube and tube-sheet, no. 2 mock-

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up shall be prepared. From the first one the specimens for corrosion test and
metallographic examination shall be obtained and they shall include 3 tubes in central position.
One central tube shall be used for the corrosion test, one shall be used for the metallographic
examination, one is for re-testing, if required (see Attachment 7 for details). The second mock-
up shall be prepared following Attachment 9 and it will be subject only to the flaw assessment
test as detailed in para 4.5.

4.2.14 The metallographic examination of the first mock-up shall be performed on the central
tube assembly previously longitudinally sectioned following 4 perpendicular directions
starting from the second weld pass stop as follows:
a) on 4 of the 8 surfaces obtained from the sectioning a macro graphic examination shall
be performed in order to determine the extension of weld fusion (which shall not exceed
at any point 75 % of wall tube thickness), weld throat thickness (minimum weld throats of
all sections shall be not less than the specified tube wall thickness) and penetration.

b) the 4 remaining surfaces shall be used for the microstructural examination (one surface
for each of the 3 required etchings plus one for re-testing if required).

4.2.15 The surface to be in contact with the process fluid and the opposite one if not machined
shall remain in the "as received" condition.

4.2.16 The specimens shall not be subjected to any heat treatment before the test.

4.2.17 The remaining part of each sample after taking out the specimens, with the identification
number, shall be made available for five years (ex-work delivery) at Supplier‘s care for further
OWNER / PMC investigation.
4.2.18 All tests described below (macro graphic and micrographic examination, corrosion test,
flaw assessment, etc.) shall be performed and certified by a laboratory approved by OWNER
/ PMC. Laboratory shall officially inform OWNER / PMC about any inconvenience (e.g.
deviations from the material requirements etc.) encountered during the tests as well as in case
of re-testing.
4.3 MICROSTRUCTURE EXAMINATION
4.3.1 The material (base, welds and weld overlay) used in contact with the process fluid shall
be subject to metallographic analysis following the methods detailed below. 3 (three)

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metallographic specimens, each for any required etching, shall be obtained from each of
the sample(s) as detailed in para. 4.2.2 and 4.2.10. A fourth specimen shall be retained for
retesting (if required). The re-use of the same metallographic specimen for two or more
different etchings is not allowed.

4.3.2 The metallography shall be considered preliminary to the corrosion test.


4.3.3 Presence of ferrite shall be evaluated by means of a ferritometer on each of the 3 specimens
before etching. Ferrite content shall not be greater than 0.6 % in all specimens except
for SMAW welds for which 1% is allowed.

4.3.4 The material microstructure shall be determined following ASTM A262 Practice A. Only a
fully austenitic step structure as defined in the above standard shall be considered
acceptable. The presence of any structure other than the step structure (e.g. ditch
structure, interdendritic ditches, end-grain pitting type I or II) is not allowed.

4.3.5 Presence of sigma phase shall be checked at 100x and 500x after electrolytic etching
with NaOH 10N at 3 V and 0.5 to 1 A/cm2 for 2 to 5 sec. Sigma phase shall be absent.

4.3.6 An etching with oxalic acid (10%, 6 V DC, 0.5 - 1 A/cm2, 15 sec.) shall be performed and
the specimen shall be examined at 100x and 500x. Presence of any intergranular or
intragranular compounds or phases other than the austenitic phase is not allowed
whatever their composition might be and irrespective of their quantity, with the exception of
the ferrite phase within the limits stated in para. 4.3.3.

4.3.7 The material not in compliance with the above requirements shall be rejected.

4.4 CORROSION TEST PROCEDURE

4.4.1 The corrosion test, Huey type, shall be performed on the sample material that already resulted
acceptable after the microstructure examination detailed in para 4.3.
4.4.2 AISI 316L UG specimens shall be subjected to 5 test periods and the acid shall be renewed
each time. Each period shall last 48 hours actual boiling. 25Cr-22Ni-2Mo alloy shall be
subjected to 10 test periods at the same conditions as above.
4.4.3 The corrosion test shall follow the ASTM A262 Practice C with the following additions:

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4.4.4 Only one specimen shall be tested in each flask.


4.4.5 A finger type refrigerator shall be used and it is necessary to check, by litmus paper, that no
acid vapours are released during testing.

4.4.6 The ratio of the solution volume to the sample area shall be 20 ml/cm² as a minimum.
4.4.7 The flasks for Huey test shall be used only for this purpose.

4.4.8 The flask, refrigerator and specimen shall be carefully rinsed after each test cycle to remove all
the corrosion products (by means of a nonmetallic brush).

4.4.9 Before corrosion testing, the specimens shall be first degreased in acetone (chlorinated agents
are not allowed), pickled in boiling nitric acid (65%) for thirty minutes, and then rinsed;
the corrosion products shall be removed by nonmetallic brush.
4.4.10 After each test cycle and after rinsing, the specimens shall be dipped in acetone, dried by
hot air, and weighed (when cold).
4.4.11 The time between two cycles shall be as short as possible.
4.4.12 Besides the determination of the corrosion rate (for each cycle and for the overall periods)
obtained by weighting, it is also required to determine the maximum depth of attack by
examining under a microscope the edges of a specimen section (for details see note 5 of
table in para. 4.4.13)
4.4.13 The following table shows both the maximum corrosion rate and depth of attack allowed in
each test cycle and for the average of the results of all cycles, calculated according to ASTM
A262 Practice C:

Corrosion rate Depth of attack


Semi-finished Product Type of Material
(mm/month) (micron)
Plates, sheets, bars, 316L UG 0.025 (1) (2) 90 (4) (5)
tubes, pipes, 25Cr-22Ni-2Mo 0.015 (1) (2) 70 (4) (5)
Forgings
316L UG 0.025 (1) (3) (4) 90 (3) (4) (5)
Welds and W.O.
25Cr-22Ni-2Mo 0.015 (1) (3) (4) 70 (3) (4) (5
surfacing

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NOTES:

General: the above limits are valid for each test cycle and for the average of the result of all
cycles.
1. If the corrosion rate exceeds the rate specified in the table or if the corrosion rate in cycle
5 (cycle 10 for 25Cr-22Ni-2Mo alloy) exceeds the one in cycle 4 (cycle 9 for 25Cr-22Ni-
2Mo alloy) by more than 50%, a second specimen taken from the same sample under
examination shall be re-tested with the same procedure. Only the result of re-testing shall
be taken into consideration. Further re-testings are not allowed.
2. No deviations allowed.

3. The heat affected zone and the bead overlap zone (for W.O.) shall also be examined.
4. Any deviation shall be subject to OWNER / PMC acceptance.
5. Depth of attack shall be determined after completion of the corrosion test by taking a
metallographic sample from the most corroded area, if visible. The value shall be referred
to the deepest attack observed on both the transverse and the longitudinal directions of
the specimen

4.5 FLAW ASSESSMENT TEST

4.5.1 Samples to be tested shall be prepared in formats approved by OWNER/PMC.

4.5.2 The tube protrusion shall be machined down until the contact between tube face and the
upper weld toe. This surface shall be recorded as starting test level. The examination shall
proceed on repeated plane at 1 mm distance from each other till the tube gets lose.
4.5.3 Each level shall be prepared for etching and examined under a binocular microscope
with magnification from x15 to x25.
4.5.4 The following table gives the number and extension of the allowable defects

4.5.5

Defect type Max. allowed number of defects (1) Max. dimensions allowed

Cracks (2) 0 -
Pores 5 0.6
Wormholes 0 -
Slag inclusions 2 0.6

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Fusion defects 2 2
Crater cracks 0 -

Burn through 0 -

Note 1: It is the sum of all defects found on 7 tube welds at all levels
Note 2: Any deviation shall be subject to OWNER / PMC acceptance

4.5.6 The weld fusion depth shall have a regular profile and its extension shall never exceed the
75% of the wall tube thickness at any point
4.5.7 No more than 1 defect per tube and per level is allowed. Any deviation shall be subject
to OWNER / PMC acceptance.

4.5.8 Defects extended on different levels are not allowed.

4.5.9 A photograph shall be taken on each surface (scale 1:1) showing defects location, type
and extension.
4.5.10 Certification of the flaw assessment test shall be in accordance with para. 4.6.

4.6 CERTIFICATION

4.6.1 The laboratory shall certify that the test results are in compliance or not in compliance with
the requirements of the present specification. The certification shall be made available
to OWNER / PMC as soon as the certificate is issued. Certification shall include the following:

4.6.2 A photograph(s) showing the samples as received; the identification stamping on the
sample(s) shall be clearly visible and readable.

4.6.3 The photomicrographs showing the material ‘s microstructure after each etching. The
photos shall be of high quality and fully readable (e.g. laser prints on photographic quality
paper, prints from photo negatives etc.). B/W or color photocopies are not acceptable.

4.6.4 The etching details, the magnifications employed and a short but comprehensive comment by
a metallurgy specialist shall be reported in each caption. The result of the ferrite check on
each specimen shall also be reported.

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4.6.5 The corrosion rates after each testing cycle and the average corrosion rate values shall
be reported.
4.6.6 As an option the testing certificate can be supplied in electronic (PDF) format provided
the above requirements are fully met.
4.6.7 OWNER / PMC reserves the right to require to the Supplier further testing or investigation
whenever OWNER / PMC acceptance is required or the laboratory results are controversial.

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