Vol

D:\TS\Flow Tees - 011 - TS.doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI – 110 092

TECHNICAL SPECIFICATIONFOR

FLOW TEES

SPECIFICATION NO. : MEC/TS/05/62/011, Rev-0

MECON LIMITEDREGD. OFF RANCHI

PROCESS & PIPINGDESIGN SECTION

NEW DELHI

TECHNICAL SPECIFICATIONFLOW TEES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/011 REV-0 Page 1 of 8


C O N T E N T S

Sl.No. Description

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MANUFACTURER'S QUALIFICATION

4.0 MATERIALS

5.0 DESIGN AND CONSTRUCTION REQUIREMENTS

6.0 INSPECTION AND TESTS

7.0 TEST CERTIFICATES

8.0 PAINTING, MARKING AND SHIPMENT

9.0 WARRANTY

10.0 DOCUMENTATION

Revision No. Date Revised by Checked by Approved by

PREPARED BY : CHECKED BY : APPROVED BY :



NEW DELHI




1.0 SCOPE

This specification covers the basic requirements for the design, manufacture andsupply of carbon steel flow tees to be installed in pipeline system for handlinghydrocarbons in liquid or gaseous phase.


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

a) ASME B 31.4 : Liquid Transportation Systems forHydrocarbons, Liquid Petroleum Gas,Anhydrous Ammonia and Alcohols.

b) ASME B 31.8 : Gas Transmission and Distribution PipingSystem

c) ASME B 16.9 : Factory made wrought steel butt weldingfittings.

d) ASME Sec. VIII : Boiler & Pressure Vessels Code-Rules for theconstruction of pressure vessels.

e) ASME Sec. IX : Boiler & Pressure Vessel Code-Welding &Brazing Qualifications.

f) ASTM A 370 : Mechanical Testing of Steel Products

g) MSS-SP-53 : Quality Standard for Steel Castings andForgings for Valves, Flanges and fittings andother Piping components and - MagneticParticle Examination Method.

h) MSS-SP-75 : Specification for High Test Wrought ButtWelding Fittings

i) API 1104 : Specification for Welding Pipeline and RelatedFacilities

j) SSPC-VIS-1 : Steel Structures Painting Council



NEW DELHI




In case of conflict between the requirement of this specification and the codes,standards and specifications referred above, the requirements of thisspecification shall govern.

3.0 MANUFACTURER'S QUALIFICATION

Manufacturer who intend bidding for flow tees must possess the records of asuccessful proof test for tees used in the fabrication of flow tees, in accordancewith the provisions of ASME B16.9/ MSS-SP-75. These records shall be submittedat the time of bidding.

4.0 MATERIALS

4.1 Material for the pressure containing parts of the flow tees shall be indicated inthe data sheet. Other parts shall be as per manufacturer's standard suitable forthe service conditions indicated in data sheet and shall be subjected to approvalby Purchaser.

4.2 Fully killed Carbon steel shall be used in the manufacture of flow tees.

4.3 Each heat of steel used for the manufacture of pressure containing parts of theflow tees shall have carbon equivalent (CE) not greater than 0.45 calculated fromthe check analysis in accordance with the following formula.

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

4.4 When specified in Data sheet, Charpy V-notch test shall be conducted for eachheat of steel used in manufacture of pressure containing parts of flow tee. Testshall conform to the provisions of ASTM A-370 and at a temperature of 0°C forpressure containing parts material. The Charpy impact test specimen shall betaken in the direction of principal grain flow and notched perpendicular to theoriginal surface of the plate or forging. The average impact energy values of fullsized three specimens shall be as follows, unless indicated otherwise in the datasheets :

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

For all sizes 27 27



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Minimum impact energy value of any one specimen shall not be less than 80%of the above average values.

4.5 When specified in the data sheet, hardness test shall be carried out as per ASTMA 370 for each heat of steel used. The maximum hardness of base metal, weldmetal and HAZ of all pressure containing parts shall be 248 HV10, unlessotherwise specified.


5.1 Flow tees shall be designed and manufactured in accordance with the provisionsof codes and standards referred in Section 2.0 of this specification. Design factorand corrosion allowance indicated in data sheet shall be taken into account fordesign of flow-tees.

5.2 Flow tees shall generally conform to the figure shown in the data sheet and shallmeet following requirements as minimum :

a) An internal pipe having the same diameter as the connecting pipelineallowing the passage of scraper/ instrumented pigs, provided withholes/slots located in the centre line of the branch. The holes shall bedesigned to prevent the pig getting stuck or damaged without affectingthe flow through the branch line. The area of the holes/slots shall beatleast equal to the internal area of branch size.

b) A forged/ submerged arc welded `tee' as per ASME B 16.9/ MSS-SP-75enclosing the internal pipe fixed to it by suitably shaped forged steel rings.Machined steel rings shall not be used. Circumferential welding on thebranch outlet is not acceptable. Pup shall not be provided either at therun or at the branch.

5.3 Butt weld ends shall be beveled as per MSS-SP-75.

5.4 All flow tees shall be completely stress relieved as per MSS-SP-75.

5.5 Stub-in or pipe to pipe connection shall not be used in the manufacture of flowtees. Flow tees shall be manufactured by forging or extrusion methods. In caseflow tees are manufactured using welded tees, the longitudinal weld seam shallbe at least 90° to the branch connection.



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5.6 All welds shall be made by welders and welding procedures qualified inaccordance with ASME Section-IX. The welding procedure qualification test shallbe include charpy impact test and hardness test and shall meet the requirementsof cllause 4.3 and 4.5 of this specification respectively.

5.7 Repair by welding on parent metal is not allowed. Repair of welds shall becarried out only after specific approval by Purchaser's Representative for eachrepair. The repair welding shall be carried out by the welders and weldingprocedures duly qualified as per ASME Section-IX and records for each repairshall be maintained.


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

6.1.1 All flow tees shall be visually inspected.

6.1.2 Dimensional checks shall be carried out as per the approved drawing.

6.1.3 Chemical composition and Mechanical properties shall be checked as per MSS-SP-75 and this specification for each heat of steel used.

6.1.4 Non destructive examination of individual flow tees shall be performed as givenbelow:

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

b) Welds which in Purchaser's Representative's opinion cannot be inspectedby radiographic methods shall be checked by ultrasonic or magneticparticle methods. Acceptance criteria shall be as per ASME Section VIIIAppendix-12 and Appendix-6 respectively.

c) All finished wrought weld ends shall be 100% ultrasonically tested forlamination type defects for a distance of 25mm from the end. Anylamination larger than 6.35mm shall not be acceptance.



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d) All forgings shall be wet magnetic particle examined on 100% of theforged surfaces. Method and acceptance shall comply with MSS-SP-53.

6.2 Purchaser's Representative shall also perform stagewise inspection and witnesstests as indicated in clause 6.1 at manufacturer's works prior to shipment.Manufacturer shall give reasonable notice of time and shall provide withoutcharge reasonable access and facilities required for inspection, to the Purchaser'sRepresentative.

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


7.1 Manufacturer shall submit following certificates to Purchaser's Representative :

a) Test certificates relevant to the chemical analysis and mechanicalproperties of the materials used for construction as per this specificationand relevant standards.

b) Test reports on radiographic and ultrasonic inspection and wet magneticparticle examination.

c) Certificates for each flow tee stating that it is capable of withstandingwithout leakage for a test duration of 15 minutes and test pressure whichresults in a hoop stress equivalent to 90% of the specified minimum yieldstrength and for the pipe with which the flow tee is to be attachedwithout impairing its serviceability.

d) Test reports on heat treatment carried out.


8.1 Flow tees entire surface shall be thoroughly cleaned, freed from rust and greaseand applied with sufficient coats of corrosion resistant paint, after all the requiredtests have been performed and accepted by Purchaser's Representative. Thesurface preparation shall be carried out by shot blasting to SP 6 in accordancewith "Steel Structures Painting Council - Visual Standard - SSPC-VIS-1".



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8.2 Manufacturer shall indicate the type & recommended coats of corrosion resistantpaint used, in the drawing submitted for approval.

8.3 Flow tees shall be marked with indelible paint with the following data :

a) Manufacturer's Nameb) Nominal diameter in inches D1 x D2c) End thickness in mm T1 x T2d) Materiale) Tag numbers

8.4 Flow tees shall be suitably protected to avoid any damage during transit. Metallicor high impact plastic bevel protectors shall be provided for weld ends.

9.0 WARRANTY

Purchaser will be reimbursed by Manufacturer for any flow tee furnished to thisspecification which fails under field hydrostatic testing or does not performsatisfactory during the pigging operation and if such failure or non-performanceis caused by a defect in the flow tees which is outside the acceptance limits ofthis specification. The reimbursement cost shall include cost of flow tee, labourand equipment rental for finding, excavating, cutting, and installation of replacedflow tee in position.

10.0 DOCUMENTATION

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

a) General arrangement drawing of flow tees with overall dimensions anddetails of internal sleeve and cross sectional drawings.

b) Reference list of previous supplies of flow tees of similar specification withrelevant details viz Project, Year of supply, Client, size, Rating and servicefor the last five years.

c) Clausewise list of deviation from this specification, if any.d) Records of successful proof test for tees used for fabrication of flow tees,

qualifying the range of sizes quoted.e) Brief description of the manufacturing, heat treatment and quality control

facilities of the manufacturer’s work.f) Quality Assurance Plan (QAP) enclosed with this tender duly signed,

stamped and accepted..



NEW DELHI




10.2 Within two weeks of placement of order, the manufacturer shall submit fourcopies, of but not limited to, the following drawings, documents andspecifications for approval.

a) Fabrication drawings and relevant calculations for pressure containingparts.

b) Calculation for the holes/slots sizes/ flow area.

c) Method of manufacture, welding procedure and heat treatment details.

d) Quality control Manual.

Once the approval has been given by Purchaser, any change in design, materialmethod of manufacture shall be notified to Purchaser whose approval in writingof all changes shall be obtained before the flow tees are manufactured.

10.3 Within four weeks from the approval date Manufacturer shall submit onereproducible and six copies of the approved drawings, documents andspecification as stated in clause 10.3 of this specification.

10.4 Prior to shipment, Manufacturer shall submit one reproducible and six copies oftest certificates as listed in clause 7.0 of this specification.

10.5 All documents shall be in English Language.

D:\old data\FATEH\IPPs-KG Basin\Tender RFQ\Bare Line Pipes\VD55-Part-C\Vol II of II - Line Pipe\TS for Line pipe (012D).doc

OIL & GAS PIPELINE SBULong Distance Pipe Line Section

MECON LIMITEDDELHI – 110 092

TECHNICAL SPECIFICATION FORLINEPIPE

(ONSHORE)

SPECIFICATION NO.: MEC/TS/05/21/012D, Rev-0

MECON LIMITEDDelhi

LONG DISTANCEPIPELINE SECTION

TECHNICAL SPECIFICATIONFOR LINEPIPE (ON SHORE)

TECHNICAL SPECIFICATION NO. : MEC/TS/05/21/012D REV-0 Page 1 of 46


C O N T E N T SSl.No. Description

1.0 SCOPE

2.0 REFERENCES

5.0 PROCESS OF MANUFACTURE AND MATERIAL

6.0 MATERIAL REQUIREMENTS

7.0 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

9.0 INSPECTION AND TESTING

10.0 MARKING

11.0 COATING AND PROTECTION

12.0 DOCUMENTS

13.0 PIPE LOADING

14.0(New) INSPECTION OF FIELD TEST AND WARRANTY

APPENDIX-B : REPAIR OF DEFECTS BY WELDING (NORMATIVE)

APPENDIX-C : REPAIR WELDING PROCEDURE (NORMATIVE)

APPENDIX-F : SUPPLEMENTARY REQUIREMENTSR-5 :SR-6 : DROP WEIGHT TEAR TESTING (DWTT) ON WELDED PIPESR-17 : NON DESTRUCTIVE INSPECTION OF WELDS IN ELECTRIC WELDED PIPES AND

LASER WELDED PIPESSR-19 : ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-

NOTCH) FOR PSL 2 PIPE

APPENDIX-H : PURCHASER INSPECTION (NORMATIVE)

ANNEXURE-I (NEW) : MANUFACTURING PROCEDURE SPECIFICATIONANNEXURE-II (NEW) : FIRST DAY PRODUCTION TESTSANNEXURE-III (NEW) : INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING

FIGURE : 6.2.6.1FIGURE : 6.2.6.2(a)FIGURE : 6.2.6.2(b) FIGURE : 6.2.7FIGURE : 7.8.3

MECON LIMITEDDelhi





1.0 SCOPE

1.1 Purpose and Coverage

This specification establishes the minimum requirements for the manufacture ofSeamless, Electric Welded and Submerged Arc Welded Steel line pipes in accordancewith the requirements of API (American Petroleum Institute) Specification 5L, FortyThird Edition, March, 2004 and makes restrictive amendments/ supplements to aforesaid API Spec. 5L. Unless modified (amended and/ or supplemented) and referredby this Specification, the requirements of API Spec. 5L shall be valid.

The sections, paragraphs and appendices contained herein have the same numberingas that of API Spec. 5L, in order to facilitate reference. Additional requirements, whichare not specified in API Spec. 5L, have also been numbered and marked as "(New)".

The coverage by this specification is limited to line pipe to be used in onshore pipelinestransporting non-sour hydrocarbons in liquid or gaseous phase.

The Manufacturer shall have a valid license to use API Monogram for Manufacturing ofline pipe in accordance with the requirements of API Spec. 5L, Forty Third Edition,March, 2004

1.2 Product Specification Level (PSL)

Line pipes supplied to this specification shall conform to Product SpecificationLevel PSL-2.

1.3 Grades

This specification is applicable to PSL-2 line pipes of grade B through X70.

2.0 REFERENCES

The latest edition of following additional references are included in this Specification :

ASTMASTM E 92 : Test Method for Vickers Hardness of Metallic Materials.ASTM E 112 : Standard Test Methods for Determining Average Grain Size.

BSBS 5996 : Specification for the Acceptance Level for Internal Imperfection

in Steel Plate, Strip and Wide Flats based on Ultrasonic Testing.

MECON LIMITEDDelhi





5.0 PROCESS OF MANUFACTURE AND MATERIAL

5.1 Process of Manufacture

Line pipe furnished to this Specification shall be from steel produced in basic oxygen orelectric arc furnace. The steel used for Manufacture of pipes shall be fully killed and finegrained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel shall be made bycontinuous casting only.

5.1.1 Seamless Process

Cold sizing and straightening of pipe is permissible provided the total strain does notexceed 3.0%.

5.1.2 Welding Processes

5.1.2.1.1 Continuous Welding

Not acceptable.

5.1.2.2.1 Submerged Arc Welding (SAW)

All weld shall be done by automatic welding.

5.1.2.2.2 Gas Metal Arc Welding (GMAW)

This process is only acceptable for tack welding pipes which will subsequently bewelded by the SAW process.

5.1.3 Types of Pipes

5.1.3.2 Continuous Welded Pipe

Not acceptable.

5.1.3.3 Electric Welded Pipe

Only EW pipe manufactured from hot rolled coil is acceptable.

A normalising heat treatment of the weld and heat affected zone shall always becarried out, irrespective of grade and chemical composition. Full body normalising isalso acceptable.

MECON LIMITEDDelhi





5.1.3.3.2 PSL 2 Electric Welded Pipe

Electric welding shall be performed with a minimum welder frequency of 200 kHz. Thewelding system shall have an integrated control in which following data, as a minimumshall be monitored.

• Time• Welding Speed• Current and Voltage• Heat Treatment Temperature

The weld seam and the entire heat affected zone (HAZ) shall receive a normalising heattreatment in order to control the structure so that no untempered martensite remain inthe weld seam and the HAZ and the mechanical properties of heat treated zone isapproximately that of the parent metal.

5.1.3.5 Longitudinal Seam Submerged Arc Welded Pipe

The full length of the weld seam shall be made by automatic submerged arc welding,using run-on and run-off tabs. The welding procedure shall be approved by thePurchaser. Welding shall be checked at regular intervals to ensure that current,voltage and travel speed remain within the ranges of the welding procedure.

5.1.3.6 Gas Metal Arc Welded Pipe

Not acceptable.

5.1.3.7 Combination GMAW and SAW pipe.

GMAW is only acceptable for making a continuous tack weld in SAW pipe. This pipe isfurther considered as SAW pipe.

5.1.3.8 Double Seam SAW pipe

Not acceptable.

5.1.3.9 Double Seam GMAW Pipe

Not acceptable.

5.1.3.10 Double Seam Combination GMAW and SAW pipe

Not acceptable.

MECON LIMITEDDelhi





5.1.3.11 Helical Seam Submerged Arc Welded Pipe (HSAW)

HSAW is only acceptable if it meets all the requirements for SAW welding andinspection indicated in this specification.

Each edge of the strip shall be ultrasonically examined for laminations over a width of25mm along its longitudinal edges prior to welding.

Welds shall be inspected on their full length by ultrasonic method as per section9.8.5.1.

The transition between parent metal and weld deposit shall not display undercutting.

The over thickness of the weld deposit shall not exceed 2% for the pipe wallthickness is lesser than 15mm.

5.1.4 Types of Seam Welds

5.1.4.5 Skelp End Weld

Not acceptable.

5.1.4.6 Jointer Weld

Not acceptable.

5.1.4.7 Tack Weld

Tack welds shall be made in accordance with a qualified tack welding procedureusing automatic SAW, GMAW, gas shielded FCAW, or shielded metal arc weldingusing low hydrogen electrodes. When low hydrogen electrodes are used the diffusiblehydrogen content of the resulting weld metal shall not exceed 10ml/ 100g ofdeposited metal.

5.2 Cold Expansion

EW pipe shall not be cold expanded.

LSAW Pipes shall be mechanically cold expanded for full length. The expansionmeasured on the circumference shall range between 0.8 to 1.5% of the value measuredbefore the expansion. The expansion shall be measured and recorded for one out ofevery 50 pipes.

MECON LIMITEDDelhi





5.4 Heat Treatment

Seamless pipe shall be furnished in the hot formed, normalized and tempered orquenched and tempered condition. For hot formed pipe, the finishing temperatureshall be greater than 780°C. Pipe finished at a lower temperature than 780°C shall besubjected to a further normalizing heat treatment with a minimum holding time of 30minutes.

For Welded Pipes, the pipes shall be produced from skelp which shall be quenched andtempered or controlled rolled or combined controlled rolled and accelerated cooled toimpart uniformly fine ferritic grain structure to the finished steel. Other types of heattreatment shall be agreed upon between Purchaser and Manufacturer.

The heat treating process shall be performed in accordance with a documentedprocedure. The Manufacturer shall also establish and follow procedures formaintaining heat and/or lot identity.

6.0 MATERIAL REQUIREMENTS

6.1 Chemical Properties

6.1.1 Chemical Composition

The chemical composition of each heat of steel on product analysis shall be inaccordance with Table-2B and notes given below. Table-2B of API Spec. 5L iscancelled.

For each order the Manufacturer shall propose a chemical composition for the pipe tobe supplied. This composition shall be contained in the manufacturing procedurespecification and, as determined by product analysis, shall comply with the maximumallowable limits specified in Table-2B. The limitations on heat and product analysisare those agreed following acceptance of the manufacturing procedure specification(Annexure-I).

MECON LIMITEDDelhi





Table-2B : PSL 2 - Chemical requirements for Heat and Product Analysis

Maximum Permitted Alloy Content, Wt. %Element SMLS EW SAWC 0.16 0.15 0.16

Mn 1.601.5 (For Gr. B to X-52)

1.6 (For Gr. X-56 to X-70)

1.5 (For Gr. B to X-52)

1.6 (For Gr. X-56 to X-70)

Si 0.45 0.45 0.45

P 0.02 0.02 0.02

S 0.01 0.010 0.015

V 0.08 0.05 0.08

Nb 0.05 0.05 0.05

Ti 0.04 0.1 0.1

Cr 0.20 0.20 0.20

Mo 0.25 0.08 0.10

Ni 0.30 0.20 0.20

Cu 0.25 0.35 0.35

Al 0.06 0.07 0.07

N 0.012 0.012 0.012

B 0.0005 0.0005 0.0005

Ca 0.006 0.006 0.006

Note: g(New)1. V+Nb+Ti shall not exceed 0.15%.2. Cu+Ni shall not exceed 0.4%.3. The AL/N ratio shall not be less than 2:1

NOTE: h (New)If alloying elements other than those specified in Table 2B above are added to thesteel, the limits of the additional components shall be agreed with the Purchaser.

6.1.2 Elements Analysed

For heat analysis and product analysis, all the elements listed in Table-2B of thisspecification shall be analysed and reported, even if those are not purposely added butare present as residuals only.

MECON LIMITEDDelhi





6.1.3 Carbon equivalent (PSL 2 Only)

6.1.3.1 Calculations of Carbon Equivalent

Boron content shall be considered in CE (Pcm) formula even if it is less than 0.001%.

6.1.3.2 Maximum Carbon Equivalent

For pipes of all grades,, size and wall thickness, carbon equivalent shall comply thefollowing limits:

CE (Pcm) ≤ 0.20CE (IIW) ≤ 0.40

6.2 Mechanical Properties

6.2.1 Tensile Properties

The ratio between the measured value of the yield strength (YS) at 0.5% elongationof the gauge length as determined by an extensometer and ultimate tensile strength(UTS) for the body of each test pipe (product pipe) on which YS and UTS aredetermined shall not exceed 0.85 for grades X60 or lower; for grades X65 to X70, thesame ratio shall not exceed 0.90.

The ratio between yield strength and ultimate tensile strength of finished pipe shallbe < 0.85 for grade X-60.

The ratio between yield strength and ultimate tensile strength of finished pipe shallbe < 0.90 for grades X-65 and X-70.

The actual yield strength shall be as close as possible to the specified minimum yieldstrength (SMYS) but in no case it shall exceed the limits specified here under:

API Spec. 5L Grade Permissible in excess of SMYS, psi (Mpa)Upto X-46 19,000 (131)X-46 and above 22,000 (152)

Table 3B of API Spec. 5L stands modified accordingly.

The minimum elongation of base metal shall be determined in accordance with theformula given in foot note (a) of Table-3B and shall comply with the minimum values ofAPI Spec. 5L Appendix D. However elongation in no case shall be less than 20%. APISpec. 5L Appendix D stands modified accordingly.

The ultimate tensile strength of the weld shall be equal to or better than the specifiedminimum tensile strength of the base metal.

MECON LIMITEDDelhi





6.2.5 Fracture Toughness Tests

6.2.5.2 Charpy Impact Tests for PSL 2

For pipes of all grades and wall thicknesses, Charpy V-notch impact test in accordancewith SR5 (Appendix-F) shall be performed.

e. Additionally, for SAW pipes of all sizes and specified wall thicknesses,additional fracture(New) toughness requirements as per Supplementary Requirements SR 19 of API Spec. 5L

and as modified in this specification shall be applicable for body, weld and heat affectedzone.

6.2.5.3 Supplementary Fracture Toughness Tests

For EW Pipes

For pipe sizes 16 and larger, Drop Weight Tear Test in accordance with SupplementaryRequirements SR 6 of API Spec. 5L and as modified herein shall also be performed.

For SAW Pipes

Wherever line pipes are specified for hydrocarban service in gaseous phase and HighVapour Pressure (HVP) service in Purchase Order, Drop Weight Tear Test inaccordance with Supplementary Requirements SR 6 of API Spec. 5L and as modifiedin this specification shall be also performed for all pipe size, grade and wall thickness.

6.2.6 Metallographic Examination

6.2.6.1 For EW Pipes(New)

A test specimen for Metallographic & hardness examination shall be taken transverseto the weld, from one finished pipe from each lot of 50 pipes per heat or at least onceper working shift (12 hours maximum) which ever is occurring more frequently andwhenever changes in grade, diameter or wall thickness are made or when significantexcursions from operating heat treatment conditions are encountered. The specimenshall be suitably ground, polished and etched to reveal the microstructure. Thespecimen shall be visually examined using adequate magnification to provide evidencethat heat treatment of weld zone is adequate and there is no untempered martensiteleft. In case defects are observed, it will become a cause of revaluation of weldingparameters and heat treatment as deemed necessary by Purchaser's Representative.

For SAW Pipes

A test specimen for Metallographic & hardness examination shall be taken transverseto the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at

MECON LIMITEDDelhi





least once per operating shift (12 hours maximum) which ever is occurring morefrequently and whenever changes in grade, diameter or wall thickness are made orwhenever significant excursions from operating heat treatment conditions areencountered. The specimen extraction shall be as per Fig. 6.2.6.1 of this specification.The specimen shall be suitably ground, polished and etched to reveal themicrostructure. The specimen shall be visually examined using a minimum 10Xmagnification to provide evidence that proper fusion has been obtained for the fullthickness, and there is proper interpretation of passes, their alignment and texture ofweld zone. In case defects are observed, it will become a cause of revaluation ofwelding parameters and heat treatment as deemed necessary by Purchaser'sRepresentative.

6.2.6.2 For EW Pipes(New)

Vickers hardness tests shall be carried out on each specimen taken for macroscopicexamination in accordance with ASTM E-92, at locations indicated in figure 6.2.6.2 (a).The resulting Vickers hardness value at any point shall not exceed 248 HV10. Themaximum difference in hardness between the base material and any reading taken onthe weld or heat affected zone shall be less than 80 HV10. Modalities of retest shall bein accordance with para 9.12.2 of API Spec. 5L.

For SAW Pipes

Vickers hardness tests shall be carried out on each specimen taken for metallographicexamination in accordance with ASTM E-92, at locations indicated in figure 6.2.6.2(b)this specification. Indentation in the Heat Affected Zone shall start as close to thefusion line as possible. The resulting Vickers hardness value at any point shall notexceed 248 HV10. Modalities of retest shall be in accordance with para 9.12.2 of APISpec. 5L.

6.2.7 Reverse Bend Test (For EW Pipes only)(New)

6.2.7.1 Reverse bend test shall be executed with the same number of tests and retests(New) specified for flattening tests in para 9.3.2 of API Spec. 5L. Ring Specimen, 100mm to

115mm wide, taken from the pipe, shall be reverse bend tested according to theprocedure given below and Fig. 6.2.7.

6.2.7.2 Selection of Mandrel(New)

The reverse bend test shall be carried out with a mandrel, whose radius (R), or width(A) shall be calculated for any combination of diameter, wall thickness and grade withthe following formula.

MECON LIMITEDDelhi





1.4 (D-t)tA = 2R = ------------------------ - t

e (D-2t) - 1.4t

WhereD - Outside diameter of pipe, mmt - Wall thickness of pipe, mm1.4 - Peaking factore - Strain

Minimum values of è' shall be as follows :Grades of Steel Min è' valueGr.B 0.1425X-42 0.1375X-46 0.1325X-52 0.1250X-60 0.1125X-65 0.1100X-70 0.1075

6.2.7.3 Procedure(New)

The Mandrel shall be plunged into the specimen, with the weld in contact with themandrel, to such a depth that the angle of engagement between mandrel andspecimen reaches 60° (see Fig. 6.2.7). If the combination of diameter and wallthickness of pipe, and radius of mandrel is such that the angle of engagement does notreach 60° the mandrel shall be plunged into the specimen until opposite walls of thespecimen meet.

6.2.7.4 Acceptance Criteria(New)

A specimen which fractures completely prior to the specified engagement of mandreland specimen, or which reveals cracks or ruptures in the weld or heat affected zonelonger than 4mm, shall be rejected. Cracks less than 6mm long at the edges of thespecimen shall not be cause for rejection.

7.0 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

7.1 Measuring equipment for inspection and testing shall be selected such that it has aresolution and accuracy at least five times (5X) finer than the tolerance of theparameter being measured. Similarly, standards against which a piece of equipmentis calibrated shall be at least five times as accurate as the equipment beingcalibrated.

MECON LIMITEDDelhi





Only measuring equipment which can be demonstrated to have been previouslycalibrated satisfactorily and still be within its documented calibration period (interval)shall be used for inspection and testing.

Note: These requirements apply to all inspections and tests performed to verifycompliance with this specification (not only dimensions and weights)

7.2 Diameter

Pipe Body

The outside diameter of pipe body (for welded pipes), as determined by taping thecircumference, shall not deviate by more than the value given from that given in TableE-6B and E-6C Appendix E. API Spec. 5L Table-7 stands modified accordingly.

Pipe Size Value≥ 4½ and < 20 ± 0.75% of specified OD or ± 3mm whichever is smaller≥ 20 and ≤ 36 + 3mm, -0.25% of specified OD> 36 ±3mm

Pipes Ends

Diameter tolerances for the pipe ends indicated in API Spec. 5L Table-8 shall beapplicable on inside diameter for sizes ≥ 14” and on outside diameter for pipesizes ≤ 12”.

The specified inside diameter, based on circumferential measurement, over a length of100mm from the end shall comply with the tolerances specified in API Spec. 5L.Specified inside diameter is defined as ID=(OD-2WT) where ID, OD & WT are thespecified inside diameter, specified outside diameter and specified wall thicknessrespectively.

Out of Roundness

Out of Roundness i.e., the difference between the maximum and minimum diameter(inside for pipe size ≥ 14 and outside for pipe size ≤ 12) at pipe shall comply with thefollowing limits. Out of roundness tolerance indicated at API Spec. 5L Table 8 standsdeleted.

For pipe size ≤ 10¾ - 3mm (Note “a” of API Spec. 5L Table 8 applicable)For pipe size ≥ 12¾ - 5mm (Note “a” of API Spec. 5L Table 8 applicable)

Each pipe shall be measured for conformance to above requirements. All dimensionsand tolerances shall be recorded at least 3 times per operating shift (12 hrs maximum).

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7.3 Wall Thickness

In addition to API requirements, the wall thickness of each pipe shall be checked alongthe circumference at both ends and at the mid location of pipe body at 12 o’clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerances shall comply therequirements of this specification.

The tolerances on specified wall thickness shall be (+) 10 percent and (-) 5 percent. However, in case of EW Pipes specified wall thickness tolerance upto (+) 15 percent fora distance of 25 mm on either side of longitudinal weld seam is also acceptable. APISpec. 5L Table 9 stands cancelled.

Wall thickness measurements shall be recorded at least 3 times per operating shift (12hours maximum).

7.5 Length

All pipes shall be supplied with length between 11.5m and 12.5m. The minimumaverage length of the entire order shall be 12.0m. API Spec. 5L Table-11 shall not beapplicable.

Each pipe shall be measured for conformance to above requirements and allmeasurements shall be recorded.

7.6 Straightness

The deviation from a straight line for all diameters shall not exceed 20mm. Each pipeshall be checked for conformance to the requirements. Straightness shall be measuredand recorded at least 3 times per operating shift (12 hours maximum).

7.7 Jointers

Jointers on pipes are not permitted.

7.8 Workmanship and defects

7.8.1 Dents

Allowable dent size shall be as per API Spec. 5L. Disposition of dents shall be carriedout in accordance with API Spec. 5L para 9.9(c) or (d). Dents on weld and heataffected zone (HAZ) are not acceptable.

7.8.2 Offset of Plate Edges

All pipes shall be checked for offset of skelp plate edges and offset shall be measuredand recorded three times per operating shift (12 hour maximum).

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7.8.3 Out-of-Line weld bead for pipe with filler metal welds

A misalignment of weld seam exceeding 3.5mm shall be rejected. The misalignmentshall be measured on radiographic film and calculated using the formula (a+b)/2 whereà’ and `b’ are the relative offsets of the outside edges of the seam (refer Figure 7.8.3of this specification). All pipes shall be checked for out-of-line weld bead and shall bemeasured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.4 Height of Outside and Inside Weld Beads – Submerged Arc Welds

The maximum height of outside and inside weld bead shall not be more than 3.18mm(1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead heightusing a template having a cut out for weld bead and shall be measured and recorded atleast 3 times per operating shift (12 hours maximum).

7.8.5 Height of Flash of Electric Welded Pipe

The inside flash of EW pipe shall not extend above the prolongation of the originalinside surface by more than 0.5mm + 5% of nominal wall thickness.

7.8.7 Trim of Inside Flash of Electric welded pipe

In any case, the groove shall not cause the remaining thickness to be less than thatallowed by Section 7.3.

7.8.8 Hard Spots

Any hard spot having a minimum dimensions greater than 2 inch (50.8 mm) in anydirection and a hardness greater than 248 HV10 shall be rejected. The section of pipecontaining the hard spot shall be removed as a cylinder.

7.8.9 Cracks, Sweats and Leaks

Sections of the pipe containing cracks, sweats and leaks shall be cut off as per therequirements of API Spec. 5L para 9.9(c) or (d).

7.8.10 Laminations

Any lamination or inclusion extending into the face or bevel of the pipe is consideredunacceptable defect and pipe containing such defects shall be cut back until suchdefects are eliminated.

The acceptance limit and disposition of lamination type defects on the skelp/ pipe bodyshall be as per Para 9.8.5.4 of this specification.

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7.8.11 Arc Burns

Arc burns produced during the manufacturing of pipes are injurious defects and shallbe disposed off in accordance with the requirements of API Spec. 5L para 9.9 (c) or(d). As a reference method for conforming the existence of an arc burn, the area shallbe buffed with wire brush or sanding disc and etched with 5 percent nital solution.However, arc burns can also be considered for acceptance, in case the same isrecrystallised by seam heat treatment. In such case, the Manufacturer shalldemonstrate the recrystallisation to Purchaser by taking a sample as per para 6.2.6.1.

7.8.12 Undercuts

b. Undercutting not classified as minor shall be considered a defect. Dispositionshall be as follows :1. Undercut defects not exceeding 1/32 in (0.79mm) in depth and not

exceeding 12½% of the specified wall thickness shall be removed bygrinding in accordance with API Spec. 5L para 9.9 (a) and as modified inthis specification.

Disposition of undercuts greater in depth than 1/32 in. (0.79 mm) or 12½% ofthe specified wall thickness shall be in accordance with API Spec. 5L para 9.9(c) or (d).

7.8.14 Other Defects

Any imperfection (measured from the surface) with a depth greater than 5 percent ofthe specified thickness of the pipe is considered unacceptable and shall be repaired inaccordance with para 9.9 and as modified herein.

7.8.15 Peaking(New)

In respect of SAW Pipes, deviation from the circular arc at the weld seam at pipeends shall not exceed 1.6mm. Each pipe shall be checked for conformance to aboverequirement. Peaking shall be measured and recorded at least 3 times per operatingshift (12 hours maximum). Pipes not complying to these requirements shall bedisposed off as per API Spec. 5L para 9.9 (c) or (d).

7.9 Pipe Ends

7.9.1 General

Pipes shall be furnished with plain ends.

7.9.3 Plain Ends

Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L.

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In removing the inside burrs at the pipe ends, care shall be taken not to remove excessmetal and not to form an inside cavity or bevel. Removal of excess metal beyond theminimum wall thickness as indicated in para 7.3 of this specification, shall be a causefor rebevelling. In case root face of bevel is less than that specified, the pipe ends shallbe rebevelled and rectification by filing or grinding shall not be done.

7.9.6 Bevel Protectors(New)

Both pipe ends of all pipes shall be provided with metallic or high impact plastic bevelprotectors as per Manufacturer's standard. Bevel protectors shall be of a design suchthat they can be re-used by coating contractor for providing on coated pipessubsequent to coating of line pipes.

9.0 INSPECTION AND TESTING

9.2.1 Heat Analyses

Where the steel mill is not a part of an integrated pipe mill, heat analysis shall bereported by the Manufacturer prior to start of production.

9.2.2 Product Analyses

9.2.2.1 Sampling Frequency

Two pipes per inspection lot shall be analysed. Inspection lot shall be 50 pipes perheat. Pipes selected shall be such that one at the beginning of the heat and one at theend of the heat is also represented.

9.2.2.2 Sampling Method

9.2.2.2.2 Welded Pipe

Product analysis shall be carried out from finished pipes. Product analysis from skelp isalso acceptable provided that the tracebility is guaranteed.

9.3 Testing of Mechanical Properties9.3.1 Tensile Tests

Tensile properties shall be determined from specimen removed from pipe which hasbeen subjected to all mechanical and heat treatment operations.

9.3.1.2 Tensile Testing Frequency

Tensile test shall be performed on samples taken from two pipes per inspection lot.Inspection lot shall be 50 pipes per heat. API Spec. Table 13 stands modifiedaccordingly.

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9.3.1.4 Transverse Tensile Tests

The transverse tensile tests shall be carried out on flattened rectangular specimen.

9.3.1.5 Weld Tensile Tests

For EW Pipes

Inside and outside flash of weld in excess of pipe wall thickness shall be removed fromthe specimen either by grinding or machining. Specimen shall be tested for ultimatetensile strength only. The testing frequency shall be one test per inspection lot.Inspection lot shall be 50 pipes per heat.

For SAW Pipes

Inside and outside weld reinforcement in excess of pipe wall thickness shall beremoved from the specimen either by grinding or machining. Specimen shall be testedto determine ultimate tensile strength only.

A cylindrical all weld tensile test shall be carried out at the time of first day productionas specified in Annexure-I of this specification to determine the yield strength, UTS &elongation.

The cylindrical all weld specimen shall have gauge length, L=5d, where

L = gauge length (mm)d = diameter of the test specimen (mm)

The results of the test shall meet the minimum requirements of the plate/ skelp withregard to yield, tensile and elongation parameters.

The testing frequency shall be one test per inspection lot. Inspection lot shall be 50pipes per heat.

9.3.5 Fracture Toughness Tests

9.3.5.1 Charpy Test Specimens

In addition to the specimen taken from the body of the pipe, three transversespecimens with weld in middle and three specimens with heat affected zone (HAZ) inthe middle shall also be taken.

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9.3.5.2 Charpy Testing Frequency

The minimum test frequency shall be one test (a set of three specimens each for body,Weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specifiedwall thickness.

9.4 Hydrostatic Tests

9.4.1 Hydrostatic Test Requirement

Test pressure shall be held for a minimum period of 15 seconds for all sizes and gradesof pipes.

9.4.2 Verification of Hydrostatic Test

The pressure gauge used for hydrostatic testing shall be calibrated with a “DeadWeight” tester and the record shall be maintained. Calibration records shall be furnishedto purchaser’s Representative on request.

9.4.3 Test Pressure

The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibrestress) generated is at least 90% of SMYS, computed based on the formula mentionedin API Spec 5L para 9.4.3 (Note 2)

9.5 Dimensional Testing

The measuring equipment requiring calibration or verification under the provisions ofAPI 5L shall be calibrated with manual instruments at least once per operating shift (12hours maximum). Such calibration records shall be furnished to Purchaser’sRepresentative on request.

9.7 Visual Inspection

The full body and welds (if applicable) of every pipe shall be examined, internally andexternally, for surface defects. For internal examination of pipe DN 600 (24 inch OD)and larger, the inspector shall pass through the bore of the pipe. Adequateillumination shall be provided to enable proper inspection.

9.8 Non-Destructive Inspection

9.8.3 Methods of Inspection

Refer a) Non destructive inspection of welds in welded pipe shall be done after coldexpansion, heat treatment, hydrostatic testing and straightening operation of pipe.

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Following will also be noted.

i) All personnel performing NDT activities shall be qualified in the techniqueapplied, in accordance with ISO 9712 or equivalent.

ii) For UT at least one level-III qualified inspector shall be available to the mill(on call) for overall supervision. A level II inspector is required for shiftsupervision, manual weld inspection and calibration of all systems (bothmanual and automatic).

iii) A level I inspector is acceptable for all other NDT methods. A level IIinspector is acceptable for supervision of all other NDT methods.

iv) All NDT shall be performed in accordance with written procedures. Theseprocedures shall have the prior approval of Purchaser.

v) NDT for acceptance of the pipe (final inspection) shall take place after all heattreating and expansion operations and, for welded pipe, after hydrostatictesting of the pipe. It may, however, take place before cropping, bevellingand end sizing.

9.8.3.1 Pipe End Weld Inspection

Submerged arc welds shall be inspected over their entire length, for both longitudinaland transverse defects, using ultrasonic examination in accordance with (Sections9.8.5.1 through 9.9). In addition, each end of the weld seam in SAW and SPW pipeshall be examined radiographically for a distance of at least 200 mm.

If skelp end welds are permitted for spiral welded pipes (Section 5.1.4.5), these shallbe inspected by the same methods as used for the spiral weld.

EW pipe welds shall be examined for longitudinal defects over their entire length byultrasonic methods in accordance with Sections 9.8.5.1 to 9.9.

9.8.3.3 Lamination Detection(New)

Each plate or strip rolled> shall be ultrasonically tested for laminations using anoscillating scanning pattern. The scanning coverage using this technique shall be aminimum of 12.5%. Alternatively, the scanning shall be executed along straight,evenly distributed parallel lines with a scanning coverage of at least 25%. Coil for EWpipe may be tested after welding of the longitudinal seam by rotary ultrasonic testingof the pipe body. The coverage in this case shall be 100%.

In addition, the longitudinal edges of a plate or coiled strip shall be 100%ultrasonically tested, over a width of at least 25mm from the trimmed plate/coil edge.This may be performed either before or after pipe forming. For EW pipe subjected to100% rotary ultrasonic testing of the pipe body, strip edge testing is not required.

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9.8.3.4 Seamless Pipe(New)

Ultrasonic lamination testing of each seamless pipe body shall be performed using ahelical pattern with at least 25% scanning coverage of the pipe surface.

Ultrasonic thickness testing of the pipe body and ends of seamless pipe shall beperformed by scanning along a helical or straight pattern in such a way that at least10% of the pipe surface is covered.

The body and ends of all seamless pipe shall be 100% ultrasonically tested for insideand outside surface defects as well as transverse, longitudinal and inclined embeddeddefects.

EMT may be applied for nominal wall thickness less than 6 mm.

9.8.4 Radiological Inspection - Weld Seams9.8.4.1 Radiological Inspection Equipment

The radiographic examination shall be executed with X-ray equipment using fine -grain type film (e.g. Gevaert type D7 or equivalent) and lead intensifying screens.

For acceptance of the radiographic films, the technique used shall result in asensitivity better than 2% of the thickness of the weld metal and in a relative filmdensity of 2.0 to 3.5 in the weld metal.

The Manufacturer shall record on a review form accompanying the radiograph orwithin the mill computer system. The interpretation of each radiograph anddisposition of the pipe inspected.

9.8.5 Ultrasonic and Electromagnetic Inspection

9.8.5.1 Equipment

The automatic ultrasonic equipment shall incorporate:

1. A device which monitors the effectiveness of the coupling.

In the case where a zero degrees compression wave probe is used to monitorcoupling, or where a through transmission technique is used for seamless orHEW pipe, loss of coupling exists when the sensitivity (echo height) decreasesby more than 10 dB relative to the static calibration.

In the case where a through transmission technique through the weld seam isused for SAW linepipe, loss of coupling exists when the signal drops belowthe electronic noise level pIus 10 dB at the position of the throughtransmission signal.

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A clear acoustic warning system and an automatic paint spray system (orequivalent) shall be activated when loss of coupling occurs.

2. An automatic paint-spraying device, or equivalent system, which is activatedwhen the received ultrasonic echo exceeds the preset acceptance limit. Thisalarm shall operate without any interference of the ultrasonic operator andshall be applied within 25mm advancement past the detected defect. Thereset time of the alarm system, after detection of a defect, to be againavailable for detection, shall be shorter than the time needed for 25mmadvancement in the scanning direction.

3. An automatic weld tracking system for correct positioning of thecrystals/probes with respect to the weld centre of all welded pipe.

Entrance angles of shear wave probes shall be as follows:

Seamless pipe : 45 (40 - 48) degreesEW pipe : 50-70 degreesSAW and SPW pipe longitudinal defect detection : 45 (40 – 48) degrees (on

weld bead)SAW and SPW pipe transverse defect detection : 50 - 70 degrees (X or K

transmission)

Lamination testing may be performed in pulse echo or transmission mode; wallthickness only in pulse echo mode. The probe(s) used for wall thickness/laminationcheck should satisfy the following requirements:

- Twin crystal probes : The focal length should be 50% of thewall thickness.

- Single crystal probesin be better pulse echo mode : The near surface resolution should be

25% of the wall thickness, measured atthe primary reference sensitivity level.

The transducer arrangement shall be such that the sound intensity in both thelongitudinal and circumferential directions does not decrease by more than 3 dB atany point in the pipe wall; referred to the maximum sound intensity adjusted in thestatic calibration.

The equipment shall be checked with an applicable reference standard (test piece) asdescribed in (Section 5) at least every four hours and at the beginning and end of abatch in order to demonstrate the effectiveness of the inspection procedures andshow that the equipment is functioning correctly.

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In case discrepancies of more than 3 dB occur, then all pipes inspected since theprevious check shall be reinspected. Proper functioning of the UT equipment and thelinearity of the electronic instrumentation shall be checked at least once every sixmonths or if a change is made to the equipment.

From each pipe under test, an automatic “on-line” record shall be made withoutoperator intervention. For every pipe, a summary record shall be made showing pipeidentification number, time and examination results, including reexaminations.

If parts of the ultimate pipe ends are not covered by an automatic UT system(untested area), manual ultrasonic shall be carried out using approved procedures formanual ultrasonic examination based on the requirements given above.

The complete circumference of seamless pipe ends or rotary tested HEW pipe ends,shall be tested manually over the length of the untested area pIus 25mm overlap ofthe automatically tested area.

9.8.5.1.1 Electromagnetic Equipment(New)

If permitted by the Purchaser, EMT methods such as eddy current testing ormagnetic flux leakage testing may be applied for surface defect detection in seamlesspipe.

EMT shall be performed in accordance with ASTM F 309 or ASTM E 570. Testing shallbe performed by automatic equipment over the entire surface of the pipe.

If parts of the ultimate pipe ends are not covered by an automatic EMT system(untested area), then manual ultrasonic shall be carried out using approvedprocedures for manual ultrasonic examination based on the requirements givenabove. The complete circumference of the pipe ends shall be tested by manual UT,over the length of the untested area plus 25mm overlap of the automatically testedarea.

9.8.5.2 Ultrasonic and Electromagnetic Inspection Reference Standards

Following will also be noted.

The reference (calibration) standard shall have the same specified diameter andthickness as the product being inspected and shall be of sufficient length to permitcalibration of ultrasonic inspection equipment at the speed to be used in production.The reference standard shall also be of the same material type and have the samesurface finish and heat treatment as the product to be inspected. It shall be free fromdiscontinuities or other conditions producing indications that may interfere withdetection of the reference reflectors. The reference standard shall contain notches(N5 or N10) or radially drilled holes (3.2mm).

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The Manufacturer may use a type of reference reflector not specified above providedhe can demonstrate to Purchaser that the examination is at least as sensitive asprescribed in this specification. In such cases, the Manufacturer shall obtain approvalfrom Purchaser.

The Primary reference sensitivity level shall be adjusted on the following referencereflectors :

Type of PipeExamination TypeSMLS SAW/SPW EW

Lamination Detection FBH 6.3 mm FBH 6.3 mm FBH 6.3 mmSurface Defect Detection Notch N5Defect Detection Body and Pipe End Notch N5Defect Detection Welds RDH 3.2 mm Notch N10Defect Detection Plate and Axial Defect Notch N5

For all reference reflectors except for RDH 3.2mm, the acceptance limit signal shallbe equal to the primary reference sensitivity level, i.e. equal to the height of thesignal produced by the reference reflector. For the RDH 3.2mm reference reflector,the acceptance limit signal shall be 10 dB below the primary reference sensitivitylevel.

All sensitivity adjustments shall be carried out dynamically

Flat bottomed holes for lamination detection shall be drilled to the midwall position.

9.8.5.4 Acceptance Limits

Following also to be noted.

For all examination types, indications exceeding the acceptance limit signal areunacceptable.

For lamination detention in plate coil, seamless pipe body and pipe ends, theacceptance limits shall be based on the lamination size and frequency and be inaccordance with the classification of SEL-072, as described below:

Location SEL - 072 Lamination Acceptance LevelsPlate/Coil Body Table 1. Class 3Plate/Coil Edges Table 2. Class 1

Seamless pipe body Table 1 Class 3

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9.8.6 Magnetic Particle Inspection

9.8.6.2 Equipment


MT shall be performed in accordance with the requirements of ASTM E 709.

Prior to the inspection, the surface to be examined and all adjacent areas within25mm shall be dry and free of all dirt, grease, lint, scale, welding flux and spatter, oilor other extraneous matter that could interfere with the examination.

9.9 Disposition of Pipe Containing Defects


In all cases where grinding repairs are made as a result of imperfections beingdisclosed by NDT, the part of the pipe containing such repairs shall be subjected toadditional NDT using the same technique, and MT, after the grinding operation.

9.10 Test Methods

9.10.4 Charpy Test

Individual test value for any specimen shall not be less than 80% of the requiredminimum average absorbed energy value as per this specification.

9.12 Retests

9.12.1 Recheck Analyses

Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot beingtested (refer para 9.2.2.1). However, during individual testing, each pipe shall be fullyanalysed to meet the requirement of Tables 2B of this specification.

9.12.6 Charpy Retests

In the event that a set of charpy test fails to meet the acceptance criteria, themanufacturer may elect to replace the lot of material involved or alternatively to testtwo more lengths from that lot. If both the new tests meet the acceptance criteria,then all pipe in that lot with the exception of the original selected length, shall beconsidered to meet the requirement.

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9.13 Reprocessing

This para stands cancelled.

10.0 MARKING

10.1 General

Marking specified in API Paragraphs and otherwise specified in the Purchase Order shallbe in English language and international system (SI) of units. Marking shall also includeAPI Monogram, Purchase Order number, item number, heat number and weight.

10.2 Location Of Markings

Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis.Stencil marking shall be placed on the inside surface length except that on pipe sizesmaller than 16, marking may either be placed on inside or outside.

10.3 Sequence Of Markings

10.3.4 Specified Dimension

Actual pipe weight in kg shall also be marked.

10.3.5 Grades and Class

A colour code band shall be marked on inside surface of finished pipe for identificationof pipes of same diameter but different wall thickness, as indicated in the PurchaseOrder. The colour code band shall be 50mm wide and shall be marked at a distance of150mm from the pipe ends.

10.5 Length

Actual length shall be marked in metres.

10.7 Die Stamping

Additionally, the pipe number shall be placed by cold rolling or low stress dot markingon the outside surface of the pipe at an approximate distance of 50 mm from bothends. In case of non availability of either cold rolling or low stress dot marking facility inpipe mill, an alternative marking scheme of a permanent nature may be proposed byManufacturer at bidding stage.

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11.0 COATING AND PROTECTION

11.1 Coatings

Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare,free of any trace of oil, stain, grease and paint. Varnish coating shall be applied onthe marking area. Bevels shall be free of any coating.

12.0 DOCUMENTS 12.1.2 PSL 2 Certification requirements

The Manufacturer shall furnish to Purchaser a certificate of compliance including therequirements of (Appendix F, SR15).

The certificate shall comply with ISO 10474 type 3.1.c. For tests witnessed by thePurchaser, type 3.1.c. certificates shall be issued.

12.2 Retention of Records

In addition to the records indicated in APL Spec 5L Table 27, the Manufacturer shallretain the records of all additional tests mentioned in this specification including thehard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends.

12.3 Production Report(New)

The Manufacturer shall provide six copies of production report in English languageindicating at least the following for each pipe. International system of units (SI) shall beadopted.

- Pipe number- Heat number from which pipe is produced- Pipe length and weight- Pipe grade

The Manufacturer shall provide six copies of acceptance certificates which shall includethe results of all tests required as per this specification and performed on deliveredmaterial giving details of, but not limited to, the following.

- All test certification as per SR 15.1 of Appendix-F.- Certified reports of dimensional. Workmanship and defect inspection.- Data on test failures, rejected heats/lots etc.- Information on production and shipping.- All other reports and results required as per this specification.

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The certificates shall be valid only when signed by the Purchaser’s Representative. Onlythose pipes which have been certified by the Purchase’s Representative shall bedispatched from the pipe mill.

In the event of small quantities of pipes supplied this specification the productionreport may consist of only test certificates required as per SR 15 of API Spec 5L andother test report/results required as per this specification.

12.4 Line Pipe Tracking Data(New)

The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc(CD). The specific data to be recorded shall be agreed between Purchaser and theManufacturer and shall include, but not limited to, the following:

- All marking information- Data of skelp and pipe manufacture- All mechanical properties from test results- All dimensional records- All workmanship and defects inspection records- Final inspection and release date- Description and disposition of repairs- Load-out /despatch date- Destination- Consignment details.

13.0 PIPE LOADING

Manufacturer shall prepare and submit the loading diagram which detail how the pipe isarranged, protected and secured on trucks, barges or ocean going vessels. All relevantloading calculation shall be submitted to the Purchaser as a Part of ManufacturingProcedure Specification (Refer Annexure I of this specification)

14.0 INSPECTION OF FIELD TEST AND WARRANTY(New)

Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this orderthat fails under field hydrostatic test if such failure is caused by amaterial/manufacturing defect in the pipe. The reimbursement cost shall include pipe,labour and equipment rental for finding, excavating, cutting out and installation ofreplaced pipe in position. The field hydrostatic test pressure will not exceed thatvalue which will cause a calculated hoop stress equivalent to 95 percent of specifiedminimum yield strength.

In case Manufacturer so desires, he will be advised at least two week in advance sothat his representative may witness the hydrostatic test in field. However, the testingand leak finding (if any) and repair operation shall not be postponed because ofabsence of the Manufacturer’s Representative.

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APPENDIX-B

REPAIR OF DEFECTS BY WELDING (NORMATIVE)

B.1 .2 Weld Seam of Welded Pipe

Delete existing clause and replace with the following:

a) Repair of the weld seam or heat treated region of EW pipe is not acceptable.

b) Repair of the weld seam of SAW pipe is not acceptable within 300mm of thebevel ends.

c) The nature of any weld defect indicated by non-destructive inspection shall beascertained before any repair is performed. Where necessary, complementaryultrasonic and radiographic inspections shall be carried out to characterize thedefect. Repair welding to rectify pipe welds containing cracks is not permitted.

d) Repairs to the weld seam shall be limited to three per pipe. The length ofrepair weld shall not exceed 5% of the total weld length on each pipe.

e) Weld repairs shall not be carried out after cold expansion or hydrostatictesting of a pipe.

f) Repair welding shall be executed only after specific approval by PurchaserRepresentative for each repair.

g) No repair of a repaired weld is permitted.

h) The repair weld shall be performed with a minimum of two passes.

B.2 Procedure for Repair By Welding Of Seamless Pipe And Parent Metal OfWelded Pipe

Delete existing section and replace with the following:

Repair welding on seamless pipe and on parent metal of welded pipe is notacceptable.

B.3 Procedure for Repair Of Submerged Arc and Gas Metal Arc Welds

B.3.1 The defective part of the weld shall be clearly marked on the pipe so that the defectcan be easily located and repaired.

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B.3.4 Repair welding shall be executed using qualified procedures and in accordance with(New) the requirements of Appendix C.

The repaired area shall be non-destructively tested by RT, manual UT and MT.

B.3.5 The Manufacturer shall also maintain a record of repairs carried out. The records(New) shall include number, pipe identification number, welding procedure applicable and

NDT details.

B.4 Procedure for Repair of Electric and Laser Welds Repair welding of EW welds is notacceptable.

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APPENDIX-C

REPAIR WELDING PROCEDURE (NORMATIVE)

C.2 Repair Welding Procedure Qualification

C.2.2 Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test

The radius of male member of the jig used for guided bend tests shall be RA=2.25t,where “t” is specified wall thickness of pipe.

C.2.2.5 For all pipes where fracture toughness test is specified, Charpy V-Notch impact test(New) as specified shall be included in the Repair Welding Procedure Qualification.

C.2.2.6 Hardness test as specified in para 6.2.6 of this specification shall be included in(New) the procedure qualification. The location of the hardness measurements is to be

indicated taking into account the new HAZ of the repaired area.

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APPENDIX-F

SUPPLEMENTARY REQUIREMENT SR5

SR.5.1 Delete this section and replace with the following

The fracture toughness of the pipes shall be determined by Charpy V-notch impacttesting in accordance with ASTM A370. The impact test temperature shall be lowerthan or equal to that specified in the table below :-

Nominal Wall Thickness, wt (mm) Test Temperature (°C)(maximum 0°C)

wt<16.0 T16.0<wt<25 T-1025<wt<32 T-20

t>32 T-30

T is the minimum design temperature, which shall be specified in the purchase order.If no minimum design temperature is indicated, it shall be taken as 0°C.

SR5.4 Delete existing section and replace with the following

Impact testing shall be carried out using l0 x 10, l0 x 7.5 or l0 x 5mm cross sectionspecimens. The largest possible specimen shall be used. Where the nominal pipedimensions are insufficient to extract a 10 x 5mm specimen, impact testing is notrequired.

For pipes of DN 250 (10 inch) or less, impact test specimens shall be taken parallel tothe axis of the pipe (i.e. longitudinal specimens shall be taken).

For pipes greater than DN 250 (10 inch), impact test specimens shall be takentransverse to the axis of the pipe, except where the wall thickness preventsextraction of a l0 x 5mm specimen, in which case longitudinal specimens shall betaken.

For weld centreline and HAZ impact tests, only transverse specimens shall be used.

SR5B.2 One set of three specimens shall be taken from the mid-thickness location in the pipewall at the following positions:

Seamless pipe - Pipe bodySAW Pipe - Pipe body at 90 degrees to the weld

- Weld centreline- Fusion line

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- Fusion line + 2mm- Fusion line + 5mm

HFW - Pipe body at 90 degrees to the weld- Weld centreline

SR5B.3 Delete existing section and replace with the following

The minimum absorbed energy requirements for full size (10 x 10) specimens takentransverse to the pipe axis are given in the table below.

Grade Minimum Average Value (J) Minimum IndividualValue (J)

B 27 22X42 27 22X46 32 24X52 36 27X56 39 29X60 41 31X65 45 34X70 48 36

For other specimen sizes and orientations, the values above shall be multiplied by thefollowing factors:

Size Orientation Factor10x 10 Longitudinal 1.510x 7.5 Transverse 0.7510x 7.5 Longitudinal 1.12510x5 Transverse 0.510x 5 Longitudinal 0.75

The shear area at the fracture surface of the test specimens shall be recorded. Eachsample shall exhibit not less than 50% fibrous shear.

MECON LIMITEDDelhi





APPENDIX-F

SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR 6 DROP WEIGHT TEAR TESTING (DWTT) ON WELDED PIPE

SR 6.1 Fracture toughness for pipe sizes 16" and larger, all grades, and wall thickness shall bedetermined by Manufacturer using Drop Weight Tear Test (DWTT) in accordance withthe requirements of SR 6.2 through SR 6.8.

SR 6.2 Two transverse specimen shall be taken from one length of pipe per inspection lot.Inspection lot shall be 100 pipes per heat. Unless specified otherwise, the test shall beconducted at –32°F (0°C).

Full transition curves shall be established for one heat out of ten, with a minimum ofone.

SR 6.4 At least 80 percent of the heats shall exhibit a fracture appearance shear area of 75percent or more for the specified test temperature.

Note: Acceptance criteria for retesting indicated in API Spec. 5L para SR6.5 standsmodified based on above mentioned requirements. Wherever `heat’ indicated inAPI Spec. SR6.5 shall be replaced by `lot’. Lot shall be as per SR6.2 as above.

MECON LIMITEDDelhi





APPENDIX-F


SR 17 NON DESTRUCTIVE INSPECTION OF WELDS IN ELECTRIC WELDED PIPESAND LASER WELDED PIPES

SR 17.1 Supplementary Non Destructive Inspection

The weld in electric welded pipe shall be inspected full length for surface andsubsurface defects and laminations by ultrasonic methods using automatic ultrasonicequipment.

SR 17.2 Equipment and Reference Standards

The equipment for ultrasonic inspection shall meet the requirements of 9.8.5.1 and9.8.5.2 of this specification. The detailed procedure shall be approved by Purchaser'sRepresentative.

SR 17.3 Acceptance Limits

If during production repeated ultrasonic indications occur requiring re-inspection byother methods and it appears that the nature of defects causing ultrasonic indicationscan not be definitely established, the Manufacturer shall prove by other inspectionmethods (such as making cross-sections as per para 6.2.6.1 of this specification) thatthese defects are not injurious defects as stipulated in this specification.

SR 17.4 Disposition

Disposition of defects shall be in accordance with API Spec. 5L para 9.9 (c) or (d).

MECON LIMITEDDelhi





APPENDIX-F


SR 19 ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSECHARPY V-NOTCH) FOR PSL 2 PIPE

SR 19.1 Except as allowed by SR 19.2 of API Spec. 5L, fracture toughness testing shall beperformed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of APISpec. 5L and as modified in this specification, with a test temperature of 32°F (0°C) orat a lower temperature as specified in the Purchase Order. The required minimum all-heat average full size absorbed energy value for body specimen shall be the greater ofSR 19.1 (a) and SR 19.1 (b) of API Spec. 5L. The required minimum average full sizeabsorbed energy value of weld and HAZ specimen shall also be the greater of SR 19.1(a) and SR 19.1 (b) of API Specification.

MECON LIMITEDDelhi





APPENDIX-H

PURCHASER INSPECTION (NORMATIVE)

H.4 Rejection

If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shallbe adequate reason to refuse final inspection of subsequent pipes until the cause hasbeen investigated and corrective action taken.

H.5 Purchaser shall specify if, and to what extent, he will monitor the Manufacturer’s(New) production, quality control and inspection.

Sufficient fluorescent lighting both overhead and at pipe ends shall be provided atthe inspection area. Facilities shall be provided for rolling each pipe joint forinspection. The Manufacturer shall make ultrasonic or other suitable equipmentavailable for use by the Purchaser to check the remaining wall thickness where anydefects have been ground out of the pipe.

MECON LIMITEDDelhi





ANNEXURE-I (NEW)

MANUFACTURING PROCEDURE SPECIFICATION

A Manufacturing Procedure Specification (MPS) outlining the successive steps and associatedinspection procedures from steel making to finished line pipe shall be prepared and submitted toPurchaser for approval at least two weeks prior to start of production. Manufacture of pipes shall startonly after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall bestrictly followed in all phases of the production of pipes.

The Manufacturing procedure shall as a minimum include the following information.

• Steel/ skelp maker and plant at which steel is produced.

• Steel making process with details of secondary refining & degassing processes and continuouscasting process, nominal weight of each heat.

• Target chemistry, chemical range of intentionally added elements, limits on heat and productanalysis to be placed on steel maker.

• Skelp rolling procedure indicating number of passes, their temperature and thickness reductionin each pass required by Controlled Rolling Procedure and the finishing temperature.

• Heat treatment procedure document established as per para 5.4.

• Ultrasonic testing of skelp and pipes using automatic and manual equipment including detailsof equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, referencestandard for calibration, dynamic calibration procedure, method of marking defects andindicating loss of coupling, inspection and recording.

• Pipe making procedure including skelp edge preparation, forming and any other specialprocess proposed.

• Production welding procedure giving details of welding speed, current and voltage, weldingtemperature, heat treatment temperature etc.

• Ultrasonic testing of weld seam of pipe using automatic equipment including details ofequipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent ofweld length at pipe ends not covered by all probes, method of marking defect and indicatingloss of coupling, inspection and records.

• For seamless pipes, the pipe forming procedure, pipe heat treatment procedure, hydrostatictest procedure & NDT procedure details.

MECON LIMITEDDelhi





• Dimensional tolerances, frequency of checking, measurement and record in a tabular formincluding details of instruments and equipments proposed.

• Detail of techniques proposed for measurement of end squareness and peaking at the welds.

• Hydrostatic testing including details of testing equipment, procedure and the relevant testpressure calculations.

• Marking details.

• Handling, storage and shipment procedure.

• Production Report Formats.

• Complete details of computerised pipe tracking system.

Note: In the event of small quantities of pipe ordered against this specifications, the requirements ofsubmission of manufacturing procedure details can be moderated subject to agreementbetween Purchaser and Manufacturer.

MECON LIMITED Delhi

LONG DISTANCE PIPELINE SECTION

TECHNICAL SPECIFICATION FOR LINEPIPE (ON SHORE)


D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\SUPPLY\MAINLINE\WORD,ACAD\012D - TS for Line pipe (012D).doc

ANNEXURE-II (NEW) FIRST DAY PRODUCTION TESTS Two lengths, each from two different heats (i.e. a total of four pipe lengths) from first day's mill 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 or 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 as deemed necessary by Purchaser’s Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. The Manufacturer shall submit to Purchaser a report giving the, results of all tests mentioned below. The report shall be agreed and signed by Purchaser’s Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends

and other similar applications, as specifically called out in the purchase order, the 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. a. Visual Examination All pipes shall be examined visually for dimensional tolerance and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically. c. Radiographic Examination The weld seams of all SAW Pipes shall be radiographically examined throughout their full length

in accordance with sections 9.8.4 to 9.8.4.9. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of the

relevant sections of this specification. Purchaser will select the places in pipe from where the test specimens shall be removed.

The following tests shall be conducted :

MECON LIMITEDDelhi





The following tests shall be conducted :

i. Two flattening test specimens shall be removed : one specimen shall be tested withweld at 0° and other at 90°. In case it is not possible to take transverse specimen forsmaller diameter pipes, longitudinal specimen may be taken.

ii. Two transverse base material specimens and two transverse weld test specimen fortensile test shall be tested. In case it is not feasible to obtain transverse specimen,longitudinal specimen may be taken.

iii. Six weld cross section specimens shall be taken at equally spaced points along the pipelength. They shall be polished and etched to show the metallurgical structure. Two ofthese specimens shall be tested for hardness at room temperature after light etching.Manufacturer shall propose alternative scheme of location of six specimens whichensure similar coverage for checking the weld quality. For SAW pipes, this examinationshall provide evidence that proper fusion has been obtained throughout the fullthickness of the joint, the extent of interpenetration and the alignment of internal andexternal weld passes. For EW pipe, this examination shall provide proof that heattreatment of the weld zone has been adequate.

For Seamless Pipes, three specimens from one pipe shall be extracted from locations120° apart from a position chosen by the Purchaser, polished and etched forexamination and checked for microstructure. A hardness survey shall be made onone of the above specimens selected by the Purchaser. Three traverses shall bemade, one 2 mm from the outer edge, the second across the centre and the third 2mm from the inner edge. A minimum of 12 readings shall be taken at 5 mm intervals.

iv. Three fracture toughness test specimens shall be taken from pipe transverse to pipeaxis out of base metal at 90° from weld and tested at specified temperature. Bothshear and absorbed energy values shall be determined.

Three weld specimens shall be removed perpendicular to and across weld with V-notchin the middle of the weld and shall be tested at the same specified temperature. Thespecimen shall be according to para SR 5.4 of this specification.

v. Two reverse bend test specimens shall be removed and tested.

vi. At points selected by Purchaser, 12 DWTT specimen shall be removed from base metalin a transverse direction. The sets of 3 base metal specimen shall be tested at -40, -10,0, +20°C for shear area. The value at the specified test temperature mentioned in SR 6of this specification shall be used to evaluate the test.

e. In addition, all the tests and inspections required to be conducted on each pipe as per thisspecification shall be conducted on all the pipes selected for testing during first day productiontest.

f. In case of any test failure, no re-testing shall be allowed and the entire first day productionshall be rejected.

MECON LIMITEDDelhi





ANNEXURE-III (NEW)

INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING

The following information as applicable shall be furnished at Bid stage with respect to line pipe to besupplied.

• Name(s) of proposed Manufacturer(s)

• Authorisation letter(s) from Manufacturer(s) where applicable.

• Authorisation letter(s) from Manufacturer(s) of skelp/ plates, in case skelp manufacturingfacility is not an integral part of the Supplier's pipe mill.

• Record of similar supplies made earlier by the Manufacturer for both skelps and pipes, givingcomplete details of diameter, thickness, length, grade of plate/ pipe, service, year, name ofproject, name of client, and contact person.

In particular, details of similar supplies made over the last five years shall be furnished.

• Descriptive technical catalog(s) of the proposed Manufacturer(s) clearly indicating the millcapacity, existing range of production, facilities at pipe mill, etc.

Pipe manufacturing facilities/ equipment details viz.

• Welding system having integrated control as per Cl. 5.1

• Heat treatment facilities as per Cl. 5.1

• Automatic ultrasonic testing for skelp, pipe body and weld as per Cl. 9.8.5.

• Copy of valid certificate of Authority to use API monogram as per clause 1.2 of thisspecification.

• A clause wise list of technical deviations, if considered unavoidable, from the requirements ofthis specification shall be furnished in the proforma enclosed with the Enquiry. Deviationsindicated anywhere else in the offer shall not be considered valid. In case of no deviations,Bidder shall write "NO DEVIATIONS" in the said proforma.

MECON LIMITEDDelhi





FIGURE 6.2.6.1

MECON LIMITEDDelhi





FIGURE 6.2.6.2(a)

MECON LIMITEDDelhi





FIGURE 6.2.6.2(b)

MECON LIMITEDDelhi





FIGURE 6.2.7

MECON LIMITEDDelhi





FIGURE 7.8.3

D:\TS\Lond Redius Bends - 015-R1.doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI - 110 092


LONG RADIUS BENDS



MECON LIMITEDDELHI


STANDARD SPECIFICATION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 1 OF 8

MEC/TS/05/62/015 REVISION 1

C O N T E N T S

1.0 SCOPE


3.0 MATERIAL

4.0 MANUFACTURE


6.0 MARKING, PACKING AND SHIPMENT

7.0 WARRANTY

8.0 DOCUMENTATION


PREPARED BY : CHECKED BY : APPROVED BY :


MECON LIMITEDDELHI





1.0 SCOPE

This specification covers long radius steel pipe bends to be manufactured inaccordance with the requirements of MSS-SP (Manufacturers StandardisationSociety – Standard Practice) – 75, latest edition, to be used in pipeline systemhandling Natural Gas. The selection of options permitted by MSS-SP-75 shall beas described below. All applicable requirements contained in the MSS-SP-75shall be fully valid unless cancelled, replaced or amended by morerequirements as stated in this specification. In case of conflict between therequirements of this specification and MSS-SP-75, the requirements of thisspecification shall govern.


Reference has also been made in this specification to the latest edition of thefollowing codes, standards and specifications.

a) ANSI B31.8 : Gas Transmission and Distribution PipingSystem.

b) ASME – Sec. VIII : Boiler and Pressure Vessel CodeDiv. 1

c) ASME – Sec IX : Boiler & Pressure Vessel CodeWelding and Brazing Qualifications

d) API Spec. 5L : Line Pipe

e) ASTM Part-I : Steel – Piping, Tubing, Fittings

In case of conflict between the above reference documents and thisspecification, the requirements of the specification shall prevail.

3.0 MATERIALS

3.1 Bends shall be fabricated from bare steel line pipe (to be issued as free issueitem by Purchaser). The details of free issue line pipe material is givenseparately in LR Bend Data Sheet & Purchase Requisition.


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3.2 All mechanical properties of the bends after finishing shall be same as pipespecification as referred in section 3.1. The following tests shall be conductedon finished bends and test procedures shall be as per pipe specification asreferred in para 3.1.

3.2.1 One transverse tensile test will be conducted to establish the yield strength,ultimate tensile strength and elongation of :

a) Base material at inside radius of the bend.b) Base material at outside radius of the bend.

3.2.2 One all weld tensile test will be conducted (wherever applicable) to establishyield strength, ultimate tensile strength and elongation of weld material onbend.

3.2.3 Three transverse Charpy-V-notch impact tests shall be conducted on full sizedspecimen of the same heat in accordance with ASTM A370 at 0°C for each ofthe following :

a) Base material at outside radius of the bend.b) Weld material of bend

3.2.4 Guided Bend Tests

One face and one root guided bend weld test shall be performed on samplescut from one bend per heat of steel. The dimensions À’ in guided bend testshall not exceed 4.0 times the nominal wall thickness and dimension `B’ shallbe equal to A + 2t + 3.2mm.

4.0 MANUFACTURE

4.1 Bends shall be manufactured by hot bending of pipe applying induction heatingonly.

The adopted procedure shall be completed by suitable heat treatment toachieve the required mechanical and chemical properties of the finished bendsand is accepted only after written approval of the Purchaser. The procedureshall ensure uniform bending without any defects other than those allowed inthis specification and pipe specification as referred in para 3.1.


MECON LIMITEDDELHI





4.2 When bending, the weld wherever applicable shall be located at approx. 10° fromthe neutral zone, measured at outside of the bend as indicated in figure below.

1 0 °

W E L D H E R EO R

H E R E

B E N D

B E N D IN G P L A N E

1 0 °

4.3 Bevels at the ends shall be as specified in MSS-SP-75 unless otherwise specifieddifferently in the material/ purchase requisition.

4.4 Bends shall not have any circumferential joint.

4.5 No repair by welding is allowed on any part of the bends.

4.6 The cooling of the bend immediately after bending shall be an interval cooling,alternatively with water and air at a minimum pressure of 2 atmospheres.

4.7 The procedure shall be such which shall not require any additional heat –treatment after bending. If such a heat treatment is required, it is permitted onlyafter the written approval of purchaser and shall be carried out at Manufacturer’sexpense.

4.8 Bulges, dents and flat areas shall not appear within 100mm from end of the bend.

For the remaining part of the bend these deviations from the original contour ofthe pipe are permitted but the same shall be repaired, provided these deviationsshall not exceed 6.5% of nominal wall thickness in height/ depth and the sameshall not extend (in any direction) over a distance of more than 25% of nominaldiameter.

4.9 The excess weld material wherever applicable at the inside of the bend shall beremoved over a distance of 100mm at both ends.

4.10 TolerancesThe dimensions of bends shall be controlled to make sure that they aremanufactured according to the tolerances indicated below over and above therequirements of MSS-SP-75


MECON LIMITEDDELHI





4.10.1 Minimum Inside Diameter : -2.5% of inside nominaldiameter except 200mm from ends

Bend Angle : ±1°

Bend Radius : ± 1% of bending nominalDiameter

4.10.2 The manufacturer shall check the wall thickness of the pipe before and afterbending along the outside radius either at distances approximately equal topipe diameter or 300mm whichever is less. The measured wall thickness shallbe atleast equal to :

tmin = 0.95 (tnom. - t)

tnom = nominal wall thickness as specified in thematerial/ purchase requisition.

t = 0.35mm for a wall thickness smaller than10mm.

t = 0.50mm for a wall thickness 10mm or more.

4.10.3 Ovality may be defined as :

OD max. – OD min OD nom.

The above value shall be < 1% within 100mm from each end and < 6% forremaining part of the bend. The measurement shall be made over thecircumference of the bend either at distance approximately equal to pipediameter or 300mm whichever is less.

4.10.4 Wrinkles

Measurements of the outside diameter shall be taken in the plane of the bendat locations where wrinkles are present (OD max.) and at locations wherewrinkles are not present (OD min,). The acceptance limit shall be as definedbelow.

OD max. – OD min------------------------- < 1%

OD nom.


MECON LIMITEDDELHI






5.1 The manufacturer shall perform all inspection and tests as per therequirements of this specification and MSS-SP-75 prior to shipment at hisworks. Such inspection and tests shall be, but not limited to, the following :

a) Verify that the unfinished product arriving at manufacturer’s shop is infull compliance with the pipe specification as referred in para 3.1.

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) Material properties shall be checked to meet the requirements of section

3.0 of this specification.g) The non-destructive inspection on the finished bend shall be carried out

as given below :

• All longitudinal seam welds shall be fully radiographed andacceptance limits shall be as per pipe specification as referred inpara 3.1.

• The full circumference of both ends of each bend after bevellingshall be ultrasonically tested for laminations over a length of 25mmand acceptance limits shall be as per pipe specification as referred inpara 3.1.

5.2 Purchaser’s Representative reserves the right to perform stagewise inspectionand witness tests on all bends as indicated in para 5.1 at Manufacturer’sworks, prior to shipment.

Manufacturer shall give reasonable notice of time and shall provide withoutcharge reasonable access and facilities required for inspection, to thePurchaser’s Representative. Inspection and test performed or witnessed byPurchaser’s Representative shall in no way relieve the Manufacturer’sobligation to perform the required inspection and tests. Under nocircumstances any action of the Purchaser’s Representative shall relieve theManufacturer of his responsibility for the material, design, quality andoperation of the equipment.


MECON LIMITEDDELHI





5.3 Test Certificates

The Manufacturer shall produce the Certificates (in original) for all, but notlimited to, the following :

a) Certificates of chemical analysis and mechanical tests carried out onpipe and bends separately.

b) Certificates of required non-destructive test inspection.

c) Certificates of heat treatments, if any.

d) Certificates of all other tests as required in this specification.

In case any of the above said certificates are not available during the finalinspection, the supply shall be considered incomplete.

6.0 MARKING, PACKING AND SHIPMENT

6.1 All bends shall be marked as per MSS-SP-75.

6.2 All loose and foreign material i.e. rust, grease, etc. shall be removed frominside and outside of the bends.

6.3 All bends except bevelled ends shall be coated internally and externally with athin film of zinc chromate red oxide paint for protection against corrosionduring transit and storage. The coating shall be easily removable in the field.Manufacturer shall furnish the details for the same.

6.4 Both ends of all bends shall be suitably protected to avoid any damage duringtransit by means of metallic bevel protectors.

6.5 Package shall be marked legibly with suitable marking to indicate thefollowing:

a) Order Numberb) Package Numberc) Manufacturer’s Named) Size (Inches) and wall thickness (mm)


MECON LIMITEDDELHI





7.0 WARRANTY

Purchaser will be reimbursed by Manufacturer for any bend furnished on thisorder that fails under field hydrostatic test if such failure is caused by a defectin the bend which is outside the acceptance limits of this specification. Thereimbursement cost shall include bend cost, labour cost and equipment rentalfor searching, excavation, cutting out and installation of replaced bend inposition. The field hydrostatic test pressure will not exceed that value whichwill cause a calculated hoop stress equivalent to 100% of specified minimumyield strength of the attached pipe.

8.0 DOCUMENTATION

8.1 All documents shall be in English language.

8.2 At the time of bidding, bidder shall submit the following documents :

a) Reference list of previous supplies of bends of similar specifications.

b) Clause-wise list of deviation from this specification, if any.

c) Brief description of manufacturing and quality control facilities of theManufacturer’s works.

8.3 Within one week of placement of order the Manufacturer shall submit fourcopies, of the manufacturing process and quality assurance plan for pipe andbends.

Once the approval has been given by Purchaser any change in material andmethod of manufacture and quality control shall be notified to Purchaserwhose approval in writing of all such changes shall be obtained before thebends are manufactured.

8.4 Within four weeks from the approval date Manufacturer shall submit onereproducible and six copies of the documents as stated in para 8.3 of thisspecification.

8.5 Prior to shipment, the Manufacturer shall submit one reproducible and sixcopies of test certificates as listed in para 5.3 of this specification.

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\SUPPLY\TERMINALS\MECHANICAL\WORD,ACAD\025 - TS - Seamless Fittings & Flanges - R1.doc

PROCESS & PIPING DESIGN SECTION

MECON LIMITED DELHI 110 092

TECHNICAL SPECIFICATION

FOR SEAMLESS FITTINGS AND FLANGES

UPTO 400mm (16”) NB


MECON LIMITED Delhi


TECHNICAL SPECIFICATION FOR

SEAMLESS FITTINGS AND FLANGES UPTO 400mm (16”) NB



C O N T E N T S Sl.No. Description Page No. 1.0 SCOPE 2 2.0 REFERENCE DOCUMENTS 2 3.0 MANUFACTURER’S QUALIFICATION 3 4.0 MATERIALS 3 5.0 DESIGN AND MANUFACTURE 4 6.0 INSPECTION AND TESTS 4 7.0 TEST CERTIFICATES 5 8.0 MARKING 5 9.0 DOCUMENTATION 6 Revision No. Date Revised by Checked by Approved by

1 Gurdeep Singh A.K. Sarkar A.K. Johri

PREPARED BY :

GURDEEP SINGH

CHECKED BY :

A.K. SARKAR

APPROVED BY :

A.K. JOHRI

MECON LIMITED Delhi






1.0 SCOPE This specification covers the minimum requirements for the design,

manufacture and supply of following items to be installed in pipeline system handling hydrocarbons in liquid or gaseous phase: - Seamless fittings 400 mm (16”) NB and smaller, such as tees, elbows,

reducers and caps. - Flanges 400 mm (16”) NB and smaller, such as welding neck flanges

and blind flanges.

The specification does not cover the above mentioned items which are to be installed in pipeline system handling sour hydrocarbons (liquid/ gas) service as defined in NACE standard MR-01-75-98.

2.0 REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition of the

following codes, standards and specifications: a) ASME B 16.5 - Steel Pipe Flanges and Flanged Fittings b) ASME B 16.9 - Factory-Made Wrought Steel Butt Welding Fittings c) ASME B 16.11 - Forged Steel Fittings, Socket Welding

and Threaded d) ASME B 31.4 - Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols e) ASME B 31.8 - Gas Transmission and Distribution

Piping Systems f) ASTM A 370 - Mechanical Testing of Steel Products

g) API 590 - Steel Line Blanks h) MSS-SP-25 - Standard Marking System for Valves,

Fittings, Flanges and Unions

MECON LIMITED Delhi






i) MSS-SP-44 - Steel Pipeline Flanges j) MSS-SP-75 - Specification for High Test Wrought Welded Fittings k) MSS-SP-97 - Forged Carbon Steel Branch Outlet

Fittings-Socket Welding, Threaded and Butt Welding Ends

3.0 MANUFACTURER’S QUALIFICATION

Manufacturer who intends bidding for fittings, must possess the records of a successful proof test, in accordance with the provisions of ASME B 16.9/ MSS-SP-75, as applicable. These records shall be submitted at the time of bidding.

4.0 MATERIALS 4.1 The basic material for fittings and flanges shall be as indicated in the Material

Requisition. Additionally, the material shall also meet the requirements specified hereinafter.

4.2 Each heat of steel used for the manufacture of fittings and flanges shall have

carbon equivalent (CE) not greater than 0.45% calculated from check analysis in accordance with following formula :

Mn Cr + Mo + V Ni + Cu

CE = C + ------- + --------------------- + --------------- 6 5 15

Carbon contents on check analysis shall not exceed 0.22%. 4.3 Unless specified otherwise, Charpy V-notch test shall be conduced for each

heat of steel, in accordance with the impact test provision of ASTM A370 at 0°C temperature. The average absorbed impact energy values of three full-sized specimens shall be 27 joules.

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

MECON LIMITED Delhi






4.4 Steel used shall be fully killed. 4.5 Hardness testing shall be carried out by Manufacturer in accordance with

ASTM A 234. Hardness testing shall cover at least 10% per item, per size, per heat per manufacturing method.

5.0 DESIGN AND MANUFACTURE 5.1 Flanges such as welding neck flanges and blind flanges shall conform to the

requirements of ASME B 16.5. Spectacle blind, spacer & blind shall conform to API 590.

5.2 Fittings such as tees, elbows and reducers shall be seamless type and shall

conform to ASME B 16.9 for sizes 50 mm (2”)NB and above and ASME B16.11 for sizes below 50mm(2”)NB.

5.3 Fittings such as weldolets, sockolets, nippolets, etc., shall be manufactured in

accordance with MSS-SP-97. 5.4 Type, face and face finish of flanges shall be as specified in Material

Requisition. 5.5 Stub-in or pipe to pipe connection shall not be used in the manufacture of

tees. Tees shall be manufactured by forging or extrusion methods. The longitudinal weld seam shall be kept at 90° from the extrusion. Fittings shall not have any circumferential joint .

5.6 All butt weld ends shall be beveled as per ASME B16.25. 5.7 Repair by welding on flanges and parent metal of the fittings is not allowed.

6.0 INSPECTION AND TESTS 6.1 The Manufacturer shall perform all inspection and tests as per the requirement

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:

6.1.1 Visual inspection. 6.1.2 Dimensional checks.

MECON LIMITED Delhi






6.1.3 Chemical composition, mechanical properties and hardness examination.

6.1.4 All finished wrought weld ends shall be 100% ultrasonically tested for

lamination type defects. Any lamination larger than 6.35 mm shall not be acceptable.

6.1.5 All other tests not specifically listed but are required as per applicable

standard/ specification. 6.2 Purchaser’s Inspector may also perform stage-wise inspection and witness

tests as indicated in Clause 6.1 at Manufacture's Works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable access and facilities required for inspection to the Purchaser’s Inspector.

Inspection and tests performed/ witnessed by the Purchaser’s Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests.

7.0 TEST CERTIFICATES Manufacturer shall submit following certificates to Purchaser’s Inspector:

a) Test certificates relevant to the chemical analysis and mechanical properties of the materials used for construction as per this specification and relevant standards.

b) Test reports on non-destructive testing.

8.0 MARKING

Each item shall be marked with indelible paint with the following data:

a) Manufacturer's marking

b) Material Specification

c) Size and schedule number

d) Heat number

MECON LIMITED Delhi






9.0 DOCUMENTATION 9.1 At the time of bidding, Manufacturer shall submit the following documents: a) Reference list of previous supplies of similar fittings of similar specification. b) Clausewise list of deviations from this specification, if any. c) Brief description of the manufacturing and quality control facilities at

Manufacturer's works. d) Manufacturer's qualification requirement as per clause 3.0 of this

specification. e) Quality Assurance Plan (QAP) enclosed with this tender duly signed,

stamped and accepted. 9.2 Prior to shipment, Manufacturer shall submit six copies of test certificates as

listed in clause 7.0 of this specification. 9.3 All documents shall be in English language.

D:\Technical Specifications & Standards\048 - Pig Signaller - TS.doc

SPECIFICATIONFOR

PIG SIGNALLERS

SPECIFICATION NO. : MEC/S/05/62/048, Rev-0

MECON LIMITEDDELHI - 110 092



NEW DELHI

STANDARD SPECIFICATIONPIG SIGNALLERS

TECHNICAL SPECIFICATION NO. : MEC/S/05/62/048 REV-0 Page 1 of 6


C O N T E N T S

Sl.No. Description

1.0 SCOPE

2.0 MATERIALS





7.0 SPARES AND ACCESSORIES

8.0 GUARANTEE

9.0 DOCUMENTATION

PREPARED BY CHECKED BY APPROVED BY



NEW DELHI




1.0 SCOPE

This specification covers the basic requirements for the design andmanufacture testing & supply of pig signallers, used for the detection ofpassage of scraper and instrumented gauging pigs, to be installed in pipelinesystems handling hydrocarbons in liquid or gaseous phase including LiquefiedPetroleum Gas (LPG). This specification does not cover pig signallers for sourhydrocarbons (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 pigsignallers shall be as indicated in the data sheets. Other components shall be asper manufacturer's standard suitable for the service conditions indicated inAnnexure – I and data sheets which will be subject to approval by Purchaser.

2.2 Scarfed welding base, shall have Carbon Equivalent (CE) not greater than 0.45on check analysis, calculated as per the following formula :

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

6 5 15

2.3 Fully skilled carbon steel shall be used in the manufacture of pig signallers.

2.4 The maximum hardness of the base material, weld metal heat affected zone ofthe pressure ciontaining parts shall be 248 HV10. Hardness test shall be carriedout as per ASTM A370 for each heat of steel used.


3.1 Pig signallers shall be bi-directional type having pivot-less tumbler mechanismand laminated trigger blades.

3.2 Pig signallers 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 signallers shall be such that any possibility of signaller beingoperated by line pressure is eliminated.



NEW DELHI




3.4 Design of pig signallers shall also be such that repair and installation of internals/accessories are possible under pressure, without removing the unit from the line.

3.5 Pig signallers shall be provided with a visual indicator to indicate the passageof pigs, by means of spring loaded metal shaft. The arm shall lock in downposition when manually reset.

3.7 Pig signallers shall be fitted with sealed, weather proof and explosion proofmicroswitch for remote signal indication. The area classification and rating ofmicroswitch shall be as indicated in data sheet. Suitable for installation in NECclass I Division 1, hazardous area. Microswitch shall have the following rating:

2 Amp, 24 Volts, 50 Hz.Type : SPDT.Contacts : 2 NO and 2 NC

3.8 All welds shall be made by welders and welding procedures qualified inaccordance with the provision of ASME Section IX.

The procedure qualification shall include hardness test and shall meet therequirements of clause 2.4 of this specification

3.9 Whenever specified in the data sheet, pig signallers shall be provided withextension, suitable for installation on underground pipeline.


4.1 Manufacturer shall perform all inspection and tests required to supply thesignallers as per the requirements of this specification.

4.2 All pig signallers shall be visually inspected.

4.3 Chemical composition & mechanical properties including hardness shall bechecked 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 circumferencefor lamination type defects. Any lamination larger than 6.35 mm shall not beacceptable.



NEW DELHI




4.6 Hydrostatic test shall be conducted at a pressure equal to 1.5 times the designpressure. Hydrotest duration shall be 15 Minutes.

4.6 Manufacturers shall perform functional tests to establish satisfactoryperformance of both manual and electrical indications


5.1 Manufacturer shall supply the test certificates for material compliance as per therelevant Material Standards.

5.2 Certificate for hydrostatic test and functional test

5.3 Test reports on heat treatment carried out, if any.


6.1 Exterior surface of the pig signallers shall be thoroughly cleaned, freed from rustand grease and applied with sufficient coats of corrosion resistant paint.Manufacturer shall indicate the type and corrosion resistant paint used in thedrawings submitted for approval. In case of pig signallers with extension, theburried portion shall be coated with three coats of coal tar epoxy resin. Theminimum dry film thickness shall be 300 microns.

6.2 A corrosion resistant metal tag shall be permanently attached with each unit,with the following marking:-

i) Manufacturer’s name

i) Suitable for installation in_______mm dia. pipeline

ii) ANSI Rating

iii) Tag No.



NEW DELHI




6.3 Each unit shall be suitably protected to avoid any damage during transit. Careshall be exercised during packing to prevent any damage to the welding ends. Allmachined surfaces subject to corrosion shall be well protected by a coat ofgrease or other suitable materials.

7.0 SPARES AND ACCESSORIES

7.1 Manufacturer shall furnish list of recommended spares and accessories for PigSignallers required during start up and commissioning. Cost of such spares shallbe included by the Manufacturer in the item rates indicated in PurchaseRequisition.

7.2 Manufacturer shall furnish separately a list of recommended spares andaccessories required for two years of normal operation and maintenance of PigSignallers.

8.0 GUARANTEE

8.1 Manufacturer shall guarantee that the pig signallers comply with therequirements stated in this specification and in the purchase order. Manufacturershall replace or repair all parts found to be defective due to inadequateengineering or quality of material. Manufacturer shall replace the signallerwithout delay, if the defect or malfunctioning cannot be eliminated.

8.2 Any defects occuring within the time period specified elsewhere shall be repairedmaking all necessary modifications and repair of defective parts free of charge tothe purchaser.

9.0 DOCUMENTATION

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

a) General Arrangement drawing with overall dimensions.b) Clause wise list of deviation from this specification, if any.c) Reference list of similar supplies of pig signaller shall be furnished

including project, year of supply, client, size, rating and service for lastfive years.

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



NEW DELHI




9.2 Within two weeks of placement of order, the manufacturer shall submit fourcopies, but not limited to, of the following drawings, documents andspecifications for approval.

a) Fabrication drawings/ sectional arrangement drawings showing all partswith reference numbers and material specification.

b) Assembly drawing with overall dimension.

c) Welding and testing procedure.

e) Cable connection details and cable specification.

Once the approval has been given by Purchaser, any change in design, material,etc. shall be notified to the Purchaser whose approval in writing for all changesshall be obtained before Pig Signallers are manufactured.

9.3 Within four weeks from the approval date, Manufacturer shall submit onereproducible and six copies of the approved drawings and specifications as listedin 9.2 of this specification.

9.4 Prior to shipment, Manufacturer shall submit one reproducible and six copies offollowing :

a) Test certificates as per clause 5.0 of this specification.

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

9.5 All documents shall be in English Language.

D:\TS\PSV - TS - 056 (R-1).doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI – 110 092


PRESSURE SAFETY VALVES


MECON LIMITEDDelhi






C O N T E N T S

Sl.No. Description Page No.

1.0 GENERAL 2

2.0 VALVE SIZING 5

3.0 VALVE CONSTRUCTION 5

4.0 NAMEPLATE 7

5.0 INSPECTION & TESTING 7

6.0 SHIPPING 9

7.0 GUARANTEE 9

8.0 REJECTION 9


1 K.P. Singh A.K. Johri Niraj Gupta

PREPARED BY :

K.P. SINGH

CHECKED BY :

A.K. JOHRI

APPROVED BY :

NIRAJ GUPTA

MECON LIMITEDDelhi






1.0 GENERAL

1.1 Scope

1.1.1 This specification together with the attached data sheets covers the requirements forthe design, materials, nameplate marking, testing and shipping of pressure safetyvalves.

1.1.2 The related standards referred to herein and mentioned below shall be of the latesteditions prior to the date of the Purchaser's enquiry :

ASME B 1.20.1 : Pipe threads

ASME B 16.5 : Pipe flanges and flanged fittings

ASME B 16.20 : Ring joint gaskets and grooves for steel pipe flanges

ASME Sec.VIII : Boiler & pressure vessels codes for unfired pressure vessel

API RP 520 : Sizing, selection and installation of pressure relieving(Part-I & II) devices in refineries

API RP 521 : Guide for pressure relieving and depressurisingsystems

API 526 : Flanged steel safety-relief valves

API 527 : Commercial seat tightness of refineries relief valvewith metal to metal seats

DIN 50049 : Document on material testing

IBR : Indian boiler regulations

1.1.3 In the event of any conflict between this specification, data sheets, related standards,codes etc, the Vendor should refer the matter to the Purchaser for clarifications andonly after obtaining the same, should proceed with the manufacture of the items inquestion.

1.1.4 Purchaser's data sheets indicate the selected valve's relieving area, materials for thebody, bonnet, disc, nozzle, spring, indicative inlet/outlet connection sizes, bellows etc.However, this does not relieve the Vendor of the responsibility for proper selection withrespect to the following :

MECON LIMITEDDelhi






a) Sizing calculations and selection of valve with proper relieving area to meet theoperating conditions indicated.

b) Selection of materials for all parts of the valve suitable for the fluid and itsconditions indicated.

1.1.5 All process-wetted parts, metallic and non-metallic, shall be suitable for the fluids andservice specified by the Purchaser. The service gas composition shall be as given inAnnexure-I.

1.2 Bids

1.2.1 Vendor's quotation shall include a detailed specification sheet for each pressure safetyvalve which shall provide all the details regarding type, construction materials, relievingarea, relieving capacity, orifice letter designation, overpressure, blowdown, operatingpressure, etc., and any other valve accessories.

1.2.2 All the units of measurement for various items in the Vendor's specification sheets shallbe to the same standards as those in Purchaser's data sheets.

1.2.3 All the material specifications for various parts in the Vendor's specification sheets shallbe to the same standards as those in Purchaser's data sheets.

1.2.4 Deleted.

1.2.5 Vendor shall enclose catalogues giving detailed technical specifications and otherinformation for each type of pressure safety valve covered in the bid.

1.2.6 Vendor's quotation, catalogues, drawings, operating and maintenance manual, etc.,shall be in English.

1.2.7 Vendor’s quotation shall include detailed sizing calculation for each pressure safetyvalve. Published data for certified discharge coefficient and certified flow capacities andactual discharge area shall be furnished. Data used by Vendor without the abovementioned supported documentation shall, on prima-facie basis, be rejected.

1.2.8 All valves shall have been type tested for capacity as per ASME. A copy of the certificateshall be provided.

1.2.9 Vendor shall also quote separately for the following :

a) Two years recommended operational spares for each pressure relief valve andits accessories. List of such spares without price shall be indicated alongwithtechnical bid and separately with price.

b) Any specific tools needed for maintenance work.

MECON LIMITEDDelhi






1.2.10 Vendor’s quotation shall include general arrangement and sectional drawings showingall features and major parts with reference numbers and material specification.

IMPORTANT

The drawings to be submitted alongwith the bid shall be in total compliancewith the requirement of technical specification and data sheets of the valveswith no exception & deviation.

1.2.11 Vendor’s quotation shall include Quality Assurance Plan (QAP) enclosed with this tenderduly signed, stamped & accepted.

1.3 Drawings and Data

1.3.1 Detailed drawings, data, catalogues required from the Vendor are indicated by thePurchaser in this specification. The required number or reproducibles and prints shouldbe dispatched to the address mentioned, adhering to the time limits indicated.

1.3.2 Within two weeks of placement of order, Vendor shall submit six copies of certifieddrawings and specification sheets for each pressure safety valve for Purchaser’s finalapproval. These documents shall specially include the following :

a) Flange face to face dimension.b) Height of the complete valve assembly.c) Weight of the complete valve assembly.d) Cold bench set pressure for the valve to be tested at atmospheric temperature

and back pressure.e) The cold test medium to be used for bench test in case it is different from air.f) Horizontal reaction force at center line of valve outlet.g) Relieving capacity of the valve under the same operating conditions.h) Over pressure and blowdown/ reclosing pressure for each valve.

1.3.3 Vendor shall provide test certificates for all the tests indicated in clause 5.0 of thisspecification. In addition Vendor shall provide the Manufacturer’s certificate ofconformity to Purchaser’s specifications as per clause 2.2 of Din 50049.

1.3.4 Within 30 days from the approval date, Manufacturer shall submit to Purchaser onereproducible and six copies of the approved drawings, documents and specifications aslisted in clause 1.3.2 above.

1.3.5 Prior to shipment, Manufacturer shall submit one reproducible and six copies of thefollowing:

MECON LIMITEDDelhi






a) Test certificates for all the tests indicated in clause 5.0 of this specification.b) Manual for installation, erection, maintenance and operation instructions,

including a list of recommended spares for the valves.

2.0 VALVE SIZING

2.1 Sizing shall be carried out using the formulae mentioned in the following standards,whenever the sizing code mentioned in the Purchaser's data sheets refers to them:

Sizing Code Standard

API API RP 520 Part-I

ASME ASME boiler and pressure vessel code section VIII titled- Unfired pressure vessels

IBR Indian Boiler Regulations Paragraph – 293

2.2 Discharge co-efficient of Vendor's pressure safety valves shall be minimum 0.975 as perAPI – 520. However, for valves covered under IBR, regulations of IBR shall govern.

2.3 For flanged pressure safety valves, the orifice letter designation and the correspondingrelieving area indicated in the Purchaser's data sheet shall be as per API 526. For avalve of given inlet and outlet sizes and letter designation, relieving area of the valvesoffered by Vendor shall meet those in API-526, as a minimum.

2.4 The discharge capacity of selected pressure safety valves shall be calculated based oncertified ASME capacity curves or by using ASME certified discharge coefficient andactual orifice area. Higher valve size shall be selected in case pressure relief valvedischarge capacity is less than the required flow rate.

2.5 The definitions of various terminologies used in Purchaser's data sheets are as perparagraph 3.1 of API RP 520 Part-I.

3.0 VALVE CONSTRUCTION

3.1 Body

3.1.1 Unless otherwise mentioned end connection details shall be as below :-

a) Threaded end connections shall be to NPT as per ASME B 1.20.1.b) Flanged end connections shall be as per ASME B 16.5.

MECON LIMITEDDelhi






c) Flanged face finish shall be serrated concentric to paragraphs 6.3.4.1, 6.3.4.2and 6.3.4.3 of ASME B 16.5. The face finish as specified in data sheets, shallhave serrations as follows.

Serrated : 250 to 500 microinches AARH125 AARH : 125 to 200 microinches AARH63 AARH : 32 to 63 microinches AARH

3.1.2 For flanged valves, inlet and outlet sizes & ratings and center to flange face dimensionsshall be in accordance with API-526. Dimensional tolerances shall be as mentionedtherein.

3.1.3 Body drain with a plug shall be provided as a standard feature on every pressure safetyvalve.

3.2 Trim

3.2.1 The term `trim' covers all the parts of the valves exposed to and in contact with theprocess fluid except for the body and bonnet assembly.

3.2.2 Valves shall in general be of the full nozzle full lift type, unless otherwise specified.

3.2.3 Wherever stelliting of disc and nozzle has been specified, it stands for stelliting of theseat joint and the entire disc contour, unless otherwise mentioned.

3.2.4 Resilient seat/ seal or Ò’ rings wherever used shall be suitable for pressure andtemperature conditions specified.

3.3 Bonnet and Spring

3.3.1 All valves shall be provided with a cap over the adjusting bolt.

3.3.2 Lifting lever shall be provided whenever the fluid to be relieved is steam or air.

3.3.3 Valve spring design shall permit an adjustment ± 5% of the set pressure as a minimum.

3.3.4 Carbon Steel spring shall be cadmium/ nickel plated.

3.3.5 The allowable tolerances in set pressures are as below :

± 0.14 kg/cm2(g) for set pressures upto and including 5 kg/cm2(g);±3% for set pressure above 5 kg/cm2(g).

3.3.6 Bonnet shall be of the enclosed type in general. Open type of bonnet may be used onlyfor non-toxic fluids.

MECON LIMITEDDelhi






3.4 Pilot

3.4.1 Wherever pilot operated valves are specified, pilot shall be non-flowing type and shallbe designed fail safe.

3.4.2 All accessories like back flow preventer, pilot filter etc. required for proper operation ofpilot operated valves as per indicated service conditions shall be included.

3.4.3 Wherever the body is part of flow path, body material shall be same as trim material, asa minimum.

4.0 NAMEPLATE

4.1 Each pressure safety valve shall have a S.S. nameplate attached firmly to it at a visibleplace, furnishing the following information:

a) Tag number as per Purchaser's data sheets.b) Manufacturer's serial no. or model no.c) Manufacturer's name/ trade mark.d) Nominal flanged size in inches and rating in lbs. for both inlet and outlet.e) Orifice letter designation.f) Valve set pressure.g) Cold bench test set pressure.

Unit of the above pressures shall be marked in the same units as those followed inPurchaser's data sheets.

5.0 INSPECTION & TESTING

5.1 Unless otherwise specified, Purchaser reserves the right to test and inspect all the itemsat the Vendor’s works.

5.1.1 Purchaser's Inspector shall perform inspection and witness test on all valves asindicated in the Quality Assurance Plan (QAP) attached with this specification.

5.2 Vendor shall submit the following test certificates and test reports for Purchaser’sreview:

a) Material test certificate from the foundry (MIL certificate) for each valve bodyand bonnet castings, nozzle, disc etc.

b) Certificate of radiography / x-ray for valve castings. 100% radiography shall becarried out for all valve castings with body rating of 600# and above. Aminimum of two shots shall be taken for all curved portion of the body andbonnet.

MECON LIMITEDDelhi






c) Hydrostatic test reports for all valve bodies and functional test reports for allvalves as per clause 5.3 and 5.4 of this specification.

d) IBR certificate in Form III item 11 and shall be furnished for all safety valves insteam service in addition to Form III C. Form III C shall also be furnished forpressure relief valves in distribution network.

5.3 Hydrostatic Test

5.3.1 Each pressure safety valve body and nozzle shall undergo hydrostatic test as per outletflange and inlet flange ANSI rating, respectively. However all the safety valves castingscovered under IBR shall be tested as per IBR regulations. There shall not be any visibleleakage during this test.

5.4 Functional Tests

5.4.1 Assembled valves shall be subjected to functional tests as below :

a) Cold bench set pressure test

Pressure relief valve shall be tested for opening at specified set pressure andalso for seat tightness.

b) Seat Leakage test as per API

Whenever the specified set pressure is less than or equal to 70 kg/cm2g, thevalve shall meet the seat tightness requirements specified in API RP-527. Themaximum permissible leakage rates for conventional and balanced bellow valvesagainst various sizes shall be as specified therein. Whenever the specified setpressure exceeds 70 kg/cm2g, the Vendor shall submit the leakage rates ofvalves for approval by the Purchaser.

Where bubble tightness has been specified, there shall be no leakage or bubblesof air at the specified percentage of set pressure.

c) Valve lift test

5.5 Witness Inspection

All pressure safety valves shall be offered for pre-despatch inspection for following as aminimum :

a) Physical dimensional checks and workmanshipb) Hydrostatic test as per clause 5.3 of this specification.c) Functional test on representative samples.d) Review of all certificate and test reports as indicated in clause 5.2 of this

specification.

MECON LIMITEDDelhi






In the event of tests being not witnessed by Purchaser, the tests shall anyway becompleted by the Vendor and documents for same submitted for scrutiny.

6.0 SHIPPING

6.1 Valves shall be supplied as a whole, complete with all the accessories like cap, liftinglever, test gag, etc.

6.2 All threaded and flanged opening shall be suitably protected to prevent entry of foreignmaterial.

7.0 GUARANTEE

7.1 Manufacturer shall guarantee that the materials and machining of valves and fittingscomply with the requirements in this specification and in the Purchase Order.

7.2 Manufacturer is bound to replace or repair all valve parts which should result defectivedue to inadequate engineering or to the quality of materials and machining.

7.3 If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace thevalve without delay,

7.4 Any defect occurring during the period of Guarantee shall be attended to by making allnecessary modifications and repair of defective parts free of charge to the Purchaser asper the relevant clause of the bid document.

7.5 All expenses shall be to Manufacturer’s account.

8.0 REJECTION

8.1 Vendor shall make his offer in detail with respect to every item of the Purchaser'sspecifications. Any offer not conforming to this shall be summarily rejected.

\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\59A assorted pipe spec\Specification for Assorted Pipes 59A.doc

PROCESS & PIPING DESIGN SECTIONMECON LIMITEDDELHI 110 092


ASSORTED PIPES

SPECIFICATION NO. : MEC/TS/05/62/59A, R-0

MECON LIMITEDDelhi



ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 1 OF 9


C O N T E N T S

Sl.No. Description Page No.

1.0 GENERAL 2

2.0 IBR PIPES 4

3.0 HYDROSTATIC TEST 5

4.0 MARKING & DESPATCH 5

ANNEXURE-I : HYDROSTATIC TEST 7

Prepared By : Checked By : Approved By :

MECON LIMITEDDelhi



ASSORTED PIPES



1.0 GENERAL

1.1 All pipes and their dimensions, tolerances, chemical composition, physicalproperties, heat treatment, hydrotest and other testing and markingrequirements shall conform to the latest codes and standards specified inthe Material Requisition (MR). Deviation(s), if any, shall be clearlyhighlighted in the offer.

1.2 Testing

1.2.1 Test reports shall be supplied for all mandatory tests as per the applicablematerial specifications. Test reports shall also be furnished for anysupplementary tests as specified in the MR & Clauses 1.10 & 1.11.

1.2.2 Material test certificates (physical property, chemical composition &treatment report) shall also be furnished for the pipes supplied.

1.3 Manufacturing Processes

1.3.1 Steel made by Acid Bessemer Process shall not be acceptable.

1.3.2 All longitudinally welded pipes other than IS:3589 should employautomatic welding.

1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to14 meters, respectively.

1.5 a) Seamless and E.R.W. pipes shall not have any circumferential seamjoint in a random length. However, in case of E.FS.W. pipe, in onerandom length one welded circumferential seam of same quality aslongitudinal weld is permitted. This weld shall be at least 2.5 mfrom either end. The longitudinal seams of the two portions shallbe staggered by 90°. Single random length in such cases shall be 5to 7m.

b) Unless otherwise mentioned in the respective material code,E.FS.W. pipes < 36” shall not have more than one longitudinalseam joint and E.FS.W. pipes ≥ 36” shall not have more than twolongitudinal seam joints.

MECON LIMITEDDelhi



ASSORTED PIPES



1.6 Pipe with screwed ends shall have NPT external taper pipe threadsconforming to ASME/ ANSI B1.20.1 upto 1.5” NB & IS:554 for 2” to 6” NB.

1.7 Pipe with bevelled ends shall be in accordance with ASME B16.25. Weldcontours shall be as follows:

Material Wall Thickness Weld ContourUpto 22mm Figure 2 Type ACarbon Steel (Except Low

Temp. Carbon Steel) > 22mm Figure 3 Type AUpto 10 mm Figure 4>10 mm & Upto 25 mm Figure 5 Type A

Alloy Steel Stainless Steel &Low Temp. Carbon Steel

> 25 mm Figure 6 Type A

1.8 Gavanished pipes shall be coated with zinc by hot dip process conformingto IS:4736/ ASTM A 153.

1.9 All austenitic stainless steel pipes shall be supplied in solution annealedcondition.

1.10 I.G.C. Test for Stainless Steels

1.10.1 For all austenitic stainless steel pipes, intergranular corrosion test shallhave to be conducted as per following:

ASTM A262 practice “ B “ with acceptance criteria of “60 mils/ year(max.)”

OR

ASTM 262 practice “ E’’ with acceptance criteria of “ No cracks asobserved from 20X magnification” & “Microscopic structure to be observedfrom 250X magnification”.

1.10.2 When specifically asked for in MR for high temperature application ofsome grades of austenitic stainless steel (eg.SS 309, 310, 316, 316H etc.),ASTM A262 practice “C” with acceptance criteria of “15 mils/ year (max.)”shall have to be conducted.

1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shallbe drawn from each solution annealing lot; one set corresponding tohighest carbon content and the other corresponding to the highest pipe

MECON LIMITEDDelhi



ASSORTED PIPES



thickness. When testing in is conducted as per Practice “E”, photograph ofmicroscopic structure shall be submitted for record.

1.11 All welded pipes indicated as ‘CRYO’ & ‘LT’ in MR shall be impact testedper requirement and acceptance criteria of ASME B31.3. The impact testtemperature shall be –196° C & -45° C for stainless steel and carbonsteel, respectively, unless specifically mentioned otherwise in MR.

1.12 Pipes under ‘NACE’ category shall meet the requirements given inMR-01-75.

1.13 Specified heat treatment for carbon steel & alloy steel and solutionannealing for stainless steel pipes shall be carried out after weld repairs.Number of weld repairs at the same spot shall be restricted to maximumtwo by approved repair procedure.

1.14 For black or galvanised pipes to IS:1239, the minimum percentage ofelongation shall be 20%.

2.0 IBR PIPES

2.1 IBR Documentation

2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificateoriginal in Form IIIA, duly approved and countersigned by IBR authority/local authority empowered by the Central Boiler Board of India. Photocopyof the original certificate duly attested by the local boiler inspector wherethe supplier is located is the minimum requirement for acceptance.

2.1.2 For materials 1 ¼ Cr- ½ Mo (ASTM A335 Gr. P11/ A691 Gr. 1 ¼ Cr) & 2¼ Cr-1Mo (ASTM A335 Gr.P22/ A691 Gr. 2 ¼ Cr.), from III-A approvedby IBR shall include the tabulation of Et , Sc & Sr values for the entiretemperature range given below. Et , Sc & Sr values shall be such thatthroughout the temperature range

Et / 1.5 ≥Sr / 1.5 ≥ Sa

Sc ≥where,SA : Allowable stress at the working metal temperature.Et : Yield point (0.2% proof stress at the working metal

temperature).

MECON LIMITEDDelhi



ASSORTED PIPES



Sc : The average stress to produce elongation of 1% (creep) in 1,00,000 hrs at the working metal temperature.

Sr : The average stress to produce rupture in 1,00,000 hrs. atthe working metal temperature and in no case more than1.33 times the lowest stress to produce rupture at this temperature.

SA (psi) Temperature (°F)

Material 500 600 650 700 750 800 850 900 950 1000 1050 1100A335 Gr. P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800A 691 Gr. 1½ Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800A335 Gr. P2/A691 Gr. 2 ¼ Cr

17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200

Note: SA values given above are as per ASME B31.3-1999. Values shall be as perthe latest edition prevailing.

2.2 For carbon steel pipes under IBR, the chemical composition shall conformto 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 forpipes other than IBR services.

3.0 HYDROSTATIC TEST

Refer Annexure – I.

4.0 MARKING AND DESPATCH

4.1 All pipes shall be marked in accordance with the applicable codes,standards and specifications. In addition, the purchase order number, theitem code & special conditions like “IBR”, “ CRYO”, “NACE”, etc., shall alsobe marked.

4.2 Pipes under “IBR”, “CRYO”, & “NACE” shall be painted in red stripes, lightpurple brown stripes & canary yellow stripes, respectively, longitudinallythroughout the length for easy identification.

4.3 Paint or ink for marking shall not contain any harmful metal or metallicsalts such as zinc, lead or copper which cause corrosive attack on heating.

MECON LIMITEDDelhi



ASSORTED PIPES



4.4 Pipes shall be dry, clen and free from from moisture, dirt and looseforeign materials of any kind.

4.5 Pipes shall be protected from rust, corrosion and mechanical damageduring transportation, shipment and storage.

4.6 Rust preventive used on machined surfaces to be welded shall be easilyremovable with a petroleum solvent and the same shall not be harmful towelding.

4.7 Both ends of the pipe shall be protected with the following material:

Plain end : Plastic capBevel end : Wood, Metal or Plastic coverThreaded end : Metal or Plastic threaded cap

4.8 End protectors to be used on bevelled ends shall be securely and tightlyattached with belt or wire.

4.9 Steel end protectors to be used on galvanised pipes shall be galvanised.

MECON LIMITEDDelhi



ASSORTED PIPES



ANNEXURE–I

3.0 HYDROSTATIC TEST

3.1 All pipes shall be hydrostatically tested.

3.2 The mill test pressure shall be as follows:

3.2.1 Seamless, E.R.W. & Spiral Welded

a) Carbon Steel

Material Standard Test Pressure StandardASTM A 106 Gr. B ASTM A 530API 5L Gr. B, Seamless API 5LAPI 5L, E.R.W. API 5LAPI 5L, Spiral API 5LASTM A333 Gr.3 & 6, Seamless ASTM A 530ASTM A 333 Gr. 3 & 6, E.R.W. ASTM A 530

b) Seamless Alloy Steel

Material Standard Test Pressure StandardASTM A335 GR.P1, P12, P11, P22, P5,P9

ASTM A 530

ASTM A268 TP 405, TP410 ASTM A530

c) Seamless Stainless Steel

Material Standard Test Pressure StandardASTM A312 Gr.TP304, 304L, 304H, 316,316L, 316H, 321, 347

ASTM A 530

d) Seamless Nickel Alloy

Material Standard Test Pressure StandardASTM B161 UNS No.2200 ASTM B161ASTM B165 UNS No.4400 ASTM B165ASTM B167 UNS No.6600 ASTM B167ASTM B407 UNS No.8800 ASTM B407

MECON LIMITEDDelhi



ASSORTED PIPES



e) Welded Nickel Alloy

Material Standard Test Pressure Standard

ASTM B725 UNS No.2200, 4400 ASTM B725

ASTM B517 UNS No.6600 ASTM B517

ASTM B514 UNS No.8800 ASTM B514

3.2.2 Electric Fusion Welded

a) Carbon Steel & Alloy Steel E.FS.W. (16” & above)

Material Standard Test Pressure Standard

API 5L Gr.BASTM A 671 Gr.CC65, 70 (Cl.32)ASTM A 672 Gr.C60, 65, 70 (Cl.12,22)ASTM A 671 Gr.CF60, 65, 66, 70 (Cl.32)ASTM A 691 Gr. ½ Cr, 1Cr, 1 ¼Cr, 2¼Cr, 5Cr, 9Cr (Cl.42)

P=2ST/ DS=90% of SMYS (except for API 5LGr.B)S=85% of SMYS for API 5L Gr.BT=Nominal Wall ThicknessD=O.D. of Pipe

b) Stainless Steel E.FS.W. (2” to 6”)

The hydrostatic test pressure in kg/ cm2 for the following materialsshall be as given below:

Material Gr.1: ASTM A312 TP304/ 304H/ 316/ 316H/ 321/ 347 welded

Material Gr.2: ASTM A312 TP 304L/ 316L welded

Pipe Schedule: S10 Pipe Schedule : S40 Pipe Schedule : S80Size Material

Gr.1Material

Gr.2Material

Gr.1Material

Gr.2Material

Gr.1Material

Gr.22” 100 80 155 130 230 1903” 80 60 155 130 230 1904” 80 50 155 130 230 1906” 65 35 90 75 155 130

MECON LIMITEDDelhi



ASSORTED PIPES



c) Stainless Steel E.FS.W. (8” and above).

Material Standard Test Pressure StandardASTM A358 TP 304L, 304, 304H,316L, 316, 316H, 321, 347(Classes 1, 3 & 4)

P = 2ST/DS = 85% of SMYST = Nominal Wall ThicknessD = O.D. of Pipe

ASTM A358 TP 304L, 304, 304H,316L, 316, 316H, 321, 347(Classes 2 & 5)

P = 2ST/DS = 72% of SMYST = Nominal Wall ThicknessD = O.D. of Pipe

3.2.3 Carbon Steel Pipes to IS Standards

Material Standard Test Pressure StandardIS :1239 IS :1239IS :3589 IS :3589

GUJRAT STATE PETRONET LIMITED

PARTICULAR TECHNICAL SPECIFICATIONOF

CO2 FLOODING SYSTEM

MECON LIMITEDSCOPE TWIN TOWER, (NORTH TOWER - 1st.Floor),LAXMI NAGAR DISTRICT CENTRE, DELHI - 110 092

SPEC. NO. MEC/05/14/23JT/01 JANUARY, 2007

Gujarat State Petronet Ltd.

PADMALA – GODHARA GASPIPELINE PROJECT

Tender Document for EPC ContractsTender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-II of V MECON LIMITED

CONTENTS

SL.NO. ITEMS PAGENO.

01.00 BRIEF TECHNICAL SCOPE OF WORK 1

02.00 GENERAL REQUIREMENTS 1

03.00 HEAT DETECTORS 1

04.00 MANUAL CALL POINTS 2

05.00 ELECTRONIC HOOTER (SOUNDER) 2/AUDIO VISUAL ALARM

06.00 REMOTE RESPONSE INDICATOR 3

07.00 CONTROL PANEL 3

08.00 EXTINGUISHING SYSTEM FIRING UNIT 4

09.00 LOCAL CONTROL PANELS /FLOOR PANELS 5/ REPEATER PANELS

10.00 POWER BACK-UP INCLUDING BATTERIES, 5CHARGER UNIT

11.00 ELECTRICAL CABLES, WIRING & CONDUITING 5

12.00 CARBON DIOXIDE GAS EQUIPMENT 6

13.00 PRINCIPLE OF SELECTIVE DISCHARGE 7

14.00 SOR FOR CO2 FLOODING SYSTEM 11

PREPARED BY CHECKED BY APPROVED BY





Page 1

1.0 BRIEF TECHNICAL SCOPE OF WORK

1.1 The work under this section shall consist of furnishing all labour, material,equipment and appliances necessary and required to completely installAutomatic Fire Detection, Alarm and Co2 extinguishing system as required by thedrawings and specified hereinafter or given in the schedule of quantities.

1.2 Without restricting to the generality of the foregoing, the Fire Detection, Alarmand Co2 flooding system shall include the following:

a) High pressure seamless cylinders, pilot cylinders, manifolds, seamless piping, Co2

nozzles, directional valves, rate of rise-cum-fixed temperature heat detectors,manual call points, electronic hooter / sounders, response indicators andaccessories as specified.

b) Metallic conduits (rigid / flexible), PVC insulated copper conductor cables,armored cables, glands, tees, bends, special fittings, junction boxes etc. asspecified.

c) Main control panels with gas discharge firing units, repeater panels, batteries,battery charger etc. as specified.

2.0 GENERAL REQUIREMENTS

2.1 All materials shall be of the best quality confirming to specifications and subjectto the approval of the consultant.

2.2 All Co2 pipes, conduits, pipes / cables shall be fixed truly vertical, horizontal or inslopes as required in a neat workmen like manner.

2.3 All Co2 pipes, conduits, cables, junction boxes etc. shall be securely fixed to brick/ RCC walls and ceilings by suitable clamps at regular intervals. Only approvedtype of anchor fasteners shall be used.

2.4 Control panels shall be so located that they are easily accessible for operations,repairs and maintenance.

2.5 Detectors shall be provided at appropriate spacing as given in IS: 2189-1988.The spacing shall also be in conformity with the drawings and properly co-ordinated with electrical fixtures, air-conditioning ducts / grills, beams and otherceiling services. Tenderer shall submit detailed layout drawings to consultant forapproval before commencement of work.

2.6 CO2 nozzles shall be provided at appropriate spacing as given in IS: 6382-1984 &NFPA-12. The spacing shall also be in conformity with the drawings and properlycoordinated with the electrical fixtures, air-conditioning ducts / grills, beams andother ceiling services. Tenderer shall submit detailed layout drawings toconsultants for approval before commencement of work.

3.0 HEAT DETECTORS

3.1 The heat detectors shall be combined rate of rise-cum-fixed temperature re-





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settable type preferably operating on twin thermistor principle where onethermistor is exposed and is therefore in good thermal contact with thesurrounding air and responds quickly to changes in air temperature and theother is thermally insulated from the surrounding air and responds less quicklyresulting in electrical imbalance. The detector shall operate at 60`C. Thesensitivity of the detectors shall be as per requirements of IS: 2175 for Grade-Iheat detectors.

3.2 The heat detectors shall incorporate response indicator with provision forconnecting remote response indicator and operate on a two-wire system on D.C.low voltage. It shall be possible to loop the heat detector with smoke detectorsand manual push buttons in the same circuit. The detectors shall be UL / FMlisted or LPC approved.

4.0 MANUAL CALL POINTS

4.1 Each manual call point unit shall comprise of a push button of reputed makeenclosed in a M.S. Box with provision for cable or conduit coupling. The manualpush button shall have the words prescribed in clear bold letters on facialwindow “In case of fire break glass”. Installation of the manual push button shallbe as per IS: 2189. The push button shall not be shrouded and the same shallbe projecting out of the surface of the M.S. Box.

4.2 It shall be provided with a push button of 300 volts 3 amp. Rating and withminimum 1 NC + 1 NO contacts. The whole assembly of push button is to beenclosed in the M.S. box enclosure with all sides covered except the front side.

The front side shall be sealed with breakable glass cover using neoprene orequivalent gasket. The glass surface should be minimum 30 sq. cm. In area andglass thickness should not exceed 2mm.

4.3 The M.S. Box enclosure shall be completely dust, vermin, damp & weather proofand provided with chain and hammer attached to it. It shall be made of at least16SWG sheet steel. The complete unit shall be suitable for wall / columnmounting with necessary mounting accessories. The complete unit push buttonshall be painted signal red (Shade No. 537 as per IS: 5). The internal surface ofthe M.S. enclosure of the box shall be painted white in colour. The externalpainting shall be of synthetic enamel (Signal Red).

5.0 ELECTRONIC HOOTER (SOUNDER) /AUDIO VISUAL ALARM

The Audio – Visual Alarm Unit shall be located at the respective zones atconvenient places near the rooms / Panels fitted with Co2 flooding system. Thisunit shall be based on Micro Controller housed in a prefabricated anodizedaluminium rack / MS box. This unit shall monitor the status of all the Co2

cylinders, piping installed in the rooms in that particular zone. The dual toneelectronic hooter shall be provided so that it gives discontinuous / intermittentaudible alarm automatically whenever the automatic / manual detector operatesand is distinct from the background noises in every part of the premises. Themode of the alarm sounders shall be quite distinct from any other sounder to beheard. All hooters shall produce a similar sound and shall maintain the sameduring their operation. In case of fire there will be loud audio – visual alarm and





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the sound level shall be 100 dB. The Unit shall work on isolated 24volt DC supplyprovided from the Master Control Panel. It should have LED indication for Poweron, Fault, Co2 cylinder status, Power back-up status and also switches for Lamp /alarm test, Buzzer mute, Power on and fire acknowledgement. Hooter shall becomplete with electronic oscillations, magnetic coil (sound coil) and accessories,ready for mounting (fixing) and confirming to IS: 2189-1988. It shall be housedin a 16 SWG M.S. sheet Box duly painted signal Red.

6.0 REMOTE RESPONSE INDICATOR

6.1 The remote response indicator shall consist of a steady glowing LED similar tothe one provided at the base of the detector. This LED shall be mounted within aM.S. box of 16 SWG and connected in parallel to the built-in indicator of thedetector by a 2-core cable. The response indicator shall come ‘ON’ as soon asthe detector actuates. The M.S. enclosure shall be painted externally andinternally in synthetic enamel paint of approved shade. The LED shall be soprovided that it is visible from the side also.

7.0 CONTROL PANEL

7.1 Control panel in general shall confirm to IS: 2189. The equipment for the mainboard shall be compact, neatly wired and completely of solid state design. Thepanel shall be of wall and /or floor mounting type, totally enclosed dust andvermin proof type made of 16 SWG dust inhibited MS sheet of suitable size andhaving lockable glass front suitable to accommodate accessories as specified,with oven baked finish duly painted with one coat of anti-corrosive paint and twocoats of synthetic enamel paint.

The primary function of control panel shall be to respond automatically to theoperation of one or more detectors to give fire alarm and to indicate area (zone)where the device (s) are activated. The operation of one or more detectors shallresult in a simultaneous alarm by the following: -

a) The external alarm hooters in the zone of actuation.b) A visible indication on control panel.c) Audible alarm on control panel itself (common to all zones)

7.2 The secondary function of the control panel shall be to indicate the faults withinthe system. An immediate fault warning shall be given by an audible and visualsignal on the control panel. A fault warning shall be given in case of the followingoccurrences:-

a) Failure or disconnection of normal power supply.b) Short-circuit or disconnection of the leads to trigger devices unless the

fault condition reproduce the effect of the operation of a triggereddevice.

c) Removal of any triggered device of the plug-in type or disconnectionfrom its transmitter of power supply.

d) Short-circuit or disconnection of any of the lead to alarm soundersexternal to the control and indicating equipment.

In addition to above, visual warning shall be given on the control panel for





Page 4

failure or dis-connection of stand-by power supply and rupture or disconnectionof any fuse on the operation of any protective devices that would prevent a firealarm being given. The healthiness of battery charging equipment shall beindicated by a charging meter and an LED.

7.3 A facility may also be provided for sending fault signal to remote centers, ifrequired.

7.4 There shall be one indicator for fire and one for fault in the control panelcorresponding to each zone. Each shall have two LEDs for fire / fault indication.Each indicator shall be clearly labeled wit zone no. and inscribed with the “CodeName, i.e. word FIRE” or “FAULT” or “SILENCE”. Separate indicator must beprovided in green for system standby ‘ON’ etc.

7.5 The control panel shall derive 230 volts A.C. power from normal supply and theentire fire alarm and detection system shall be suitable for operation on 24 VD.C. A event of failure of normal supply and shall automatically be connected asto maintain the equipment in condition such that fire alarm originating from theoperation of detector is separate zone can be subsequently given.

8.0 EXTINGUISHING SYSTEM FIRING UNIT

8.1 The main fire alarm control panel shall also incorporate fire extinguishingsystem-firing units to actuate the extinguishing system automatically.

8.2 The unit shall be complete with required solid electronic circuit boards, LEDdisplays, control and loud speakers for the number of zones / areas protected.The unit shall be designed to be connected to the detection control unit in such away that the actuation of one detection circuit shall not trigger the extinguishingagent discharge. Upto 60 sec. Time delay adjustable circuit shall be incorporatedin the extinguisher firing unit. The detectors are to be provided in cross-zoneprincipal and two independent detection circuits must signal a fire conditionbefore the gas discharge timer starts to operate.

8.3 Simultaneously with operation of timer and subsequently with operation of gasactuator warning signs or “time on” and “gas discharge” shall be illuminated outside each area protected by automatic gas extinguishing system.

8.4 Automatic extinguishing system shall be backed up by manual operation. Manualrelease push button shall be connected electrically to control panel so that theoperation of the push button will by-pass all automatic circuitry and immediately,energises the release of gas. Push buttons shall be protected with a glass frontto be released in case emergency.

8.5 The control panel shall also incorporate facility to automatically trip theconnected AHU units, ventilation fan and self-closing door etc.

8.6 The stand by power supply should be capable of maintaining the system innormal operation for a period of not less than 48 hours after the failure ofnormal mains supply. Sufficient capacity would remain be there to provide fullload operation for atleast 30 minutes. The full load would be defined as thatcaused by the operation of all the alarm sounders operating simultaneously





Page 5

operation of a detector in atleast 25 percent of zones (with a minimum of twozones) and the operation of the fault indicator. The operation of trigger devicesin further zones should not result on cancellation of fire alarm existing at thattime.

9.0 LOCAL CONTROL PANELS /FLOOR PANELS / REPEATER PANELS

9.1 These panels shall be similar to main fire alarm panels except that these will nothave their own power supply but draw the power from the main fire alarmpanel.

9.2 Automatic of any zone / detector / fault shall be indicated automatically on thesepanels (Audio / Visual) clearly indicating the relevant zone and shall have all thefeatures including construction details as indicated for main fire alarm controlpanels. However, visual indication shall continue to remain ON till the fault isremoved.

10.0 POWER BACK-UP INCLUDING BATTERIES, CHARGER UNIT

The main control unit / panel should provided with a power back up so that itis operational in case of 230 V-AC power supply failures. The power back upshall be meant for at least 48 hours. Suitable nos. of 12 volt maintenance freebatteries should be connected in series as battery back-up. A built in batterycharging facility is provided using High quality charging IC’s. The systemshould continuously maintain the status of the battery and if the battery levelbecomes less than the predefined level of 20 volt the charger circuit will startcharging the battery at that time charger on indication will be displayed onthe MCU. If at a given time the battery voltage becomes less than 18V, it willgive a battery low indication and also charger on indication. When the batteryvoltage reaches 27volt the charger circuit will display only the fully chargedindication. If the system works on battery than Back up on indication LED’swill glow.

11.0 ELECTRICAL CABLES, WIRING & CONDUITING

11.1 All wires / cables to be used for the system shall confirm to the following:

a) PVC insulated copper conductor cables confirming to and marked IS: 694-1977 having minimum 1.5 sq. mm cross sectional area or as specified. Ifstranded atleast, 0.5 sq. mm. Cross-section should be used.

b) Armoured PVC / Rubber insulated copper conductor cable of above sizeconfirming to and marked IS: 1554 (Part-I) 1976.

11.2 Joints in the cables shall be avoided. Where joints are unavoidable all visibleareas of the junction boxes shall be painted signal red.

11.3 The maximum number of wires that can be drawn in a conduit shall be governedby the CPWD specification for internal electrical works (Part-I) 1972.

11.4 Insulation on the cable should not be less than one mega OHM when tested witha 500 volts megger for any particular section of the wiring.





Page 6

11.5 Conduits shall be of 16 SWG mild steel welded ISI marked and having perfectlycircular tubing and capable of being cleaned and have tight fitting joints.Conduits shall be laid either on surface or in recess as specified and they shall beprotected from rust by one coat of iron oxide and one or more coats of redenamel paint.

12.0 CARBON DIOXIDE GAS EQUIPMENT

12.1 Each room shall be protected by modular type system. In order to maintain adesign concentration of 34% each room shall have 2 cylinders each of 45 kgcapacity. Each area shall be provided by an independent Pilot Cylinder forActuator.

12.2 Each cylinder shall be provided with its own valve with a duo tube extending tothe bottom inside the cylinder and valve discharge head which shall beconnected to a common manifold through high pressure connecting pipes &fittings. Arrangement shall be provided to prevent accidental discharge of CO2

gas due to valve breakage during transportation. The valve shall be suitable forelectrical as well as manual actuation.

12.3 All carbon dioxide cylinders in the battery and the common manifold shall bemounted and suitably supported in a rack provided for the purpose. The rackshall be designed in such a manner that servicing and checking of contents ofindividual cylinders shall be convenient and the cylinders are rigidly held inposition.

12.4 Means shall be provided to automatically prevent the loss of carbon dioxide fromthe manifold if the installation is actuated, when any cylinder is removed duringmaintenance of the installation. Flexible connectors shall be used between eachcylinder and the common manifold. All manifolded systems that are not openended, that are normally closed, must preferably have a vent plug in themanifold. This device releases slow accumulations of pressure in the manifoldcaused by a leak in one of the cylinder valves and prevents the discharge of thesystem caused by a leaky cylinder.

Flexible hoses used for a discharge bend shall preferably be double wire braided(perforated) rubber covered hose suitable to withstand a minimum burstingpressure of 420 Kgf /sq. cm. at 54`C.

12.5 To eliminate any dead period after discharge and also to ensure continuity ofprotection, a reserve battery of 2 cylinders of 45 kg capacity shall also besupplied. This battery of storage cylinders shall have one pilot gas cylinder,which shall be released by operation of solenoid valve, or manually and in turndischarge system shall be activated pneumatically from the pilot cylinder.

12.6 The supporting racks shall be aligned to ensure that the mounting positions ofthe CO2 cylinders shall be parallel. The supporting racks shall be fixed to the floorand wall. The CO2 cylinders shall be provided with a safety device to protectthem against excessive internal pressure and also to prevent their accidentaloperation. Provision for local as well as remote operation from the control roomshall be made.





Page 7

12.7 Discharge nozzles of suitable size for performing the desired duty shall besupplied. All the equipment shall be designed and tested in accordance withNFPA/LPC requirements and shall also be approved by NFPA/LPC.

12.8 Battery of CO2 cylinders is proposed to be accommodated near the risk to beprotected where sufficient area is available for mounting of the battery.

13.0 Principle of selective discharge will be considered for system as illustratedbelow:

13.1 The CO2 cylinder banks shall be installed at suitable location nearby the areas.Schematic arrangement of FDA system and discharge of CO2 gas for the systemshall be indicated in drawings. The tenderer shall ensure that the appropriatelogic is followed for discharge of gas and also opening of the respective pressureoperated valve on receipt of signal from FDA system. Automatic fire detectionand alarm system for the panels shall be designed using Fixed temperature cumrate of rise heat detectors located strategically inside the panels. The tenderershall size the pipe accordingly to maintain the designed concentration of CO2

(34%) in the enclosure.

13.2 Equipment Specification

The system in general shall consist of the equipment not limited to the followingfor successful operation:

- Bank of Carbon Dioxide Cylinders each fitted with cylinder head valveand non- return valve.

- Bank of standby cylinders fitted with - cylinder head valves connectedwith manifold.

- Gas manifold and High Pressure Wire Braided Flexible Discharge Hosessuitable for fixing between cylinder and manifold

- Pressure operated Control Valves

- Pilot cylinders with firing unit (electrical actuator)

- CO2 discharge nozzles

- Manual Release push button

- Pipes and Fittings

- Fire Detection and Alarm system

- Caution Hooters

- Insitu Weighing arrangement for cylinders

- Supports and Fixtures for CO2 piping and other equipments





Page 8

- Caution Boards & evacuation alarm

- Inhibitors

- CO2 control and firing module

- Safety relief valves

- Time Delay mechanism

13.3 Cylinder Bank

The required quantity of Carbon Dioxide gas will be stored in seamless steelcylinders duly approved by CCE, Nagpur. Each cylinder shall be provided withgas release device all suitably connected to the gas manifold, which willdischarge the Carbon Dioxide gas in protected premises in case of any outbreakof fire. The total number of Carbon Dioxide cylinders in the bank shall bedetermined depending upon the area/volume of the protected premises and thecapacity of individual cylinders. All cylinders in the bank shall beinter-changeable. Equal number of standby cylinders shall also be provided to beused after depletion of main cylinder bank.

13.4 Gas Manifold

Each carbon dioxide cylinder in the bank shall be fitted with a discharge head,which shall be connected to a common manifold through high pressureconnecting pipes or tubes. In case rigid pipes are used for the purposeanti-vibration coils shall be provided.

All cylinders in the battery and the common manifold shall be mounted andsuitably supported in a rack provided for the purpose. The rack shall bedesigned in such a manner that servicing and checking of contents of individualcylinders shall be convenient and the cylinders are rigidly held in position. Thedesign shall ensure no chance/minimum possibility of accidental discharge ofcylinders.

13.5 Discharge Heads and Valves

All discharge heads and valves shall be designed taking into consideration thefact that liquefied carbon dioxide expands very rapidly when discharged. Therequirements of minimum flow of gas and the temperature at which these arerequired to operate shall also be taken into consideration.

All valves under constant high pressure shall have a minimum bursting pressureof not less that 420 kgf/sq.cm and those not under constant pressure shall havea bursting pressure of not less than 350 kgf/sq.cm.

Discharge heads and valves shall be designed to permit a minimum discharge of85 percent of the carbon dioxide in the cylinder in not more than 30 second at atemperature of 27 + 1 Deg. C. The discharge rate of carbon dioxide shall be notless than 0.68 kg/second for the first 85 percent of the cylinder's content.





Page 9

All discharge heads and valves shall be so arranged that these shall not besusceptible to mechanical, chemical or other damage.

13.6 Discharge Nozzles

Discharge nozzles shall be sufficient in number and so located that the gasdischarge pattern shall completely cover the protected area house havingadequate concentration in the high hazard locations. Nozzles shall be capable ofwithstanding pressure upto 140kg/sq.cm.

13.7 Direction Valves

If a single battery of carbon dioxide cylinders serves more than one space,direction valves shall be fitted to the manifold. The direction valves shall permitautomatic selection of discharge pipe leading from the manifold to the affectedspace in case of a fire. The linkage between the selector on the direction valvesand the tripping mechanism at the cylinder position shall be arranged so that thedirection valve is selected and opened before the gas is discharged into themanifold. The design shall also provide for the manual selection of the directionvalve in assertion to the automatic device.

13.8 Pipes and Fittings

All the pipes shall be black or galvenised, seamless ASTM A-106. 20mm dia andsmaller pipes shall be schedule 40 and 25mm & higher dia pipe shall be schedule80. All pipes and fittings, including the manifold shall have a minimum burstingpressure of 350 kgf/sq.cm. The complete distribution system shall be free fromleakage when tested at a pneumatic pressure of 140 kg/sq.cm with all nozzlesoutlets closed.

All sections of pipes having dead ends shall be fitted with suitable pressure reliefdevices designed to operate between 168 kg/sq.cm and 210 kg/sq.cm.

The pipes shall be of ASTM A-53 seamless or A-106 type (Seamless Carbon SteelHigh Pressure Schedule 40/80 pipe).

Fittings shall be class 300 malleable or ductile iron fittings shall be used. Flangedjoints upstream of any stop valves shall be class 600. Flanged joints downstreamof stop valves or in system with no stop valves may be class 300. Stainless steelfittings of type 304 or 316, forged (ASTM A-182) shall be used.

13.9 Lock off Device (Inhibitor)

Each system shall incorporate a suitable locking device to make the automaticsystem inoperative before undertaking any repair/ maintenance within theprotected area. The system shall be capable of putting on normal operationafter completion of the repair/maintenance work.

13.10 Caution Sign





Page 10

Necessary caution displays in the form of Audio-Visual type indicating thehazards of carbon dioxide flooding shall be installed at strategic places in andoutside the coolant rooms and hydraulic room and also near the mills.The visual display shall be of flashing type and the audio hooter/siren shall be ofdistinct tone and capable of being heard in the range of 500 m from the source.

13.11 Weight Monitoring System

The weight monitoring system should be designed to monitor the weight of theCo2 gas filled in the Co2 cylinder. It shall consist of a load cell of high quality andprecision with associated electronics and a cylindrical ring for holding the Co2

cylinder in place. The load cell can operate in 5`C to 70`C range. Thetemperature affect on the span shall be 0.06% and the effect on Tare be0.008%. The safe over load provision is 200% of the rated capacity of 100kgs.The protection class code shall be IP-68. The system shall use preferably beamtype load cell. The system shall monitor Co2 gas weight on continuous basis allthe time. In the event of reduction in the weight of the Co2 gas in the cylinder(either due to leakage or release of Co2 gas) beyond the preset limit, theelectronic circuitry provided in the unit shall activate the respective audio-visualalarm unit and annunciates the occurrence of fault or fire.

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