GAIL Gas City Project Piping Specification

GAIL GAS LIMITED
CITY GAS DISTRIBUTION PROJECT
CLIENT JOB NO. -

PIPING MATERIAL SPECIFICATION
TOTAL SHEETS 18
DOCUMENT NO 11 0290 02 08 02 001
B 10/08/09 ISSUED FOR APPROVAL GV DDS PKS
A 07/08/09 ISSUED FOR IDC GV DDS PKS
REV DATE DESCRIPTION PREP CHK APPR

TABLE OF CONTENT
CONTENT PAGE No.
GENERAL NOTES 3
DEFINITIONS 3
CODES AND STANDARDS 3
ABBREVIATIONS 4
PIPING CLASS DESCRIPTION 6
PIPING CLASS 1A1 7
PIPING CLASS 3A1 11
PIPING CLASS 6A1 15
Document No. Rev

PIPING MATERIAL SPECIFICATION 11-0290-02-08-02-001 B
SHEET 2 of 18
1.0 GENERAL NOTES
This specification describes the minimum requirements for the design, furnishing of materials,
fabrication, and inspection and testing of pipes, fittings and valves.
All material shall confirm to ASTM, API or BS standards. Design and fabrication shall confirm to ANSI
/ ASME for pressure piping, ANSI B 31.3 – Chemical Plant and petroleum Refinery Piping, and ANSI
B 31.8 – Gas transmission and Distribution piping system.
2.0 DEFINITIONS
Shall : This verbal form indicates requirements strictly to be followed in order

to confirm to the standards and from which no deviation is permitted.
Should : This verbal form indicates that among several possibilities one is
particularly suitable without mentioning or excluding others or that a
certain course of action is preferred but not necessarily required.
May : This verbal form indicates a course of action permissible within the
limits of this standard.
Can : This verbal form is used for statements of possibility & capability,
whether material, physical or casual.
3.0 CODES AND STANDARDS
The latest revision of the following shall be considered as part of this specification.
ASME B 16.5 Steel Pipe Flanges and Flanged Fittings
ASME B 16.9 Factory made Wrought Steel Buttwelding Fittings
ASME B 16.11 Forged Steel Fittings, Socket Welding and Threaded
ASME B 16.20 Metallic Gaskets for Pipe Flanges.
ASME B 16.21 Non-Metallic Flat Gasket for Pipe Flanges
ASME B 16.47 Large Diameter Steel Flanges (26” throu 60”)
ASME B 31.3 Process Piping
ASME B 31.4 Pipeline Transportation system for Liquid hydrocarbons & other Liquids
ASME B 31.8 Gas Transmissions and Distribution Piping System
ASME B 36.10 Welded and Seamless Wrought Steel Pipe
ASME B 46.1 Surface Texture
API 5L Line Pipe
API 6D Pipeline Valves
API 590 Steel Line Blank
Document No. Rev

SHEET 3 of 18
API 600 Steel Gate Valves Flanges and Buttwelding Ends
API 602 Compact Steel Gate Valves
MSS SP 44 Steel Pipe line Flanges
MSS SP 75 Specification for High Test Wrought Butt Welding Fittings
MSS SP 97 Integrally Reinforced Forged Branch Outlet Fitting – Socket Welding,

Threaded and Buttwelding Ends
ASTM A 105 Forging, Carbon Steel for Piping Components
ASTM A 193 Alloy Steel and Stainless Steel bolting Materials for High temp Service.
ASTM A 194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and High
Temperature Service
ASTM A 320 Standard Specification for Alloy Steel and Stainless Steel Bolting
Materials
ASTM A 216 Steel Casting, Carbon, Suitable for Fusion Welding, for High
Temperature Service.
ASTM A 234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate
and Elevated Temperature
ASTM A 285 Pressure Vessel Plates, Carbon Steel, Low and Intermediate Tensile
Strength.
ASTM A 694 Forging, Carbon and Alloy Steel, for Pipe Flanges, Fitting, Valves and
Parts for High Pressure Transmission Service.
ASTM A 333 Low temperature service seamless pipe.
ASTM A 350 Forged Carbon and Low Alloy Steel requiring Notch Toughness Testing
for Piping Components
ASTM A 420 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low
Temperature Service.
ASTM A 860 Standard Specification for Wrought High Strength Low Alloy Steel Butt
Welding Fittings
4.0 ABBREVIATIONS
4.1 Flange Facing
RTJ - Ring Type Joint

FF - Flat Face
RF - Raised Face
Document No. Rev

SHEET 4 of 18
4.2 Fittings
PE - Plain End
BE - Bevel End
BW - Butt Weld
PBE - Plain Both End
POE - Plain One End
TBE - Threaded Both End
TOE - Threaded One End
LR - Long Radius
SR - Short Radius
4.3 Connections
BW - Butt-Weld
FLGD - Flanged
SCRD - Screwed
SO - Slip-On
SW - Socket Weld
THRD - Threaded
WN - Weld Neck
4.4 Wall Thickness
SCH - Schedule in accordance with ANSI B 36.10 or B 36.19

STD - Standard Weight Wall Thickness
XS - Extra Strong Wall Thickness
XXS - Double Extra Strong Wall Thickness
4.5 Valve Description
BC - Bolted Cap
BB - Bolted Bonnet
ES - Extension Stem
FB - Full Bore
MO - Motor Operated
GO - Gear Operated
NRS - Non-Rising Stem (with inside screw)
OS&Y - Outside Screw and Yoke
RB - Reducer Bore
RS - Rising Stem
SC - Screwed Cap
UB - Union Bonnet
UC - Union Cap
WB - Welded Bonnet
4.6 Pipes Description
BE - Beveled End
CS - Carbon Steel
ERW - Electric Resistance Welded
EFW - Electric Fusion Welded
FS - Forged Steel
HFI - High Frequency Induction
KCS - Killed Carbon Steel
KFS - Killed Forged Steel
OH - Open Hearth
SAW - Submerged Arc Welded
SMLS - Seamless
Document No. Rev
SHEET 5 of 18
5.0 PIPING CLASSES DESCRIPTION
Piping Classes assigned for the project are based on the following 2-digit system.
First Digit
Numerical, denoting the basic system rating or flange class
i.e. 1 = ASME Class 150
3 = ASME Class 300
6 = ASME Class 600
9 = ASME Class 900
Second Digit
Letter, denoting the material
A - Carbon Steel
C - Stainless Steel
F - Fiberglass Reinforced plastic/epoxy (FRP)
G - Galvanized
P - Plastic (PEHD)
S - Stainless Steel
V - PVC
Third Digit
Sequential number to differentiate two or more piping classes of the same rating and same
material but presenting some difference related to the handled fluid.
Fourth Digit
Letter, denoting the aboveground and underground
U = Underground
Document No. Rev

SHEET 6 of 18
PIPING SPECIFICATION RATING 150#
1A1 CODE ANSI B 31.8
GAIL GAS LIMITED
TEMPERATURE ( 0 TO 60 °C) BASIC MATERIAL
PRESSURE (18.75 bar g) CORROSION ALL. 0.5 mm
ITEM SHORT SIZE DESCRIPTION RATING DIMENSION MATERIAL REMARKS
CODE FROM- AND/OR STANDARD

THRU SCHED.
PIPELINE PL 2"-4" BE 6.4 mm API 5L API 5L Gr. X42
6"-14" BE 6.4 mm API 5L API 5L Gr. X42
PIPES P 0.50" - 1.50" PE, SEAMLESS S160 ANSI B36-10 ASTM A 106 Gr.B
2" BE, SEAMLESS S80 ANSI B36-10 ASTM A 106 Gr.B
3" - 14" BE, SEAMLESS STD ANSI B36-10 ASTM A 106 Gr.B
ELBOWS 90 LR E 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
2" - 14" BW, 1.5D M ANSI B16.9 ASTM A 234 Gr WPB
ELBOWS 45 LR E45 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105

REDUCERS RC 2" - 14" BW - ANSI B16-25 MXM ANSI B16-9 ASTM A 234 Gr WPB
CONCENTRIC
REDUCERS RE 2" - 14" BW - ANSI B16-25 MXM ANSI B16-9 ASTM A 234 Gr WPB
ECCENTRIC
TEES EQUAL T 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
2" - 14" BW M ANSI B16.9 ASTM A 234 Gr WPB
TEES RED TR 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
2" - 14" BW MXM ANSI B16.9 ASTM A 234 Gr WPB
SOCKOLET S 0.50" - 1.50" SW 6000# MSS-SP 97 ASTM A105
WELDOLETS W 2" - 14" BW - ANSI B16-25 M X XXS MSS-SP 97 ASTM A105
CAPS C 0.50" - 1.50" SCRF 6000# ANSI B16.11 ASTM A105
2" - 14" BW ANSI B16-9 ASTM A 234 Gr WPB
NIPPLES NA 0.50" - 1.50" PBE, SEAMLESS M ANSI B36-10 ASTM A 106 Gr.B
FULL
COUPLINGS ANSI B16-11 ASTM A105
FC 0.50" - 1.50" SW 6000#
HALF HC 0.50" - 1.50" SW 6000#

ANSI B16-11 ASTM A105
COUPLINGS
NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

Document No. Rev
Sheet 7 of 18
GAIL GAS LIMITED
TEMPERATURE( 0 TO 60 °C) BASIC MATERIAL
PRESSURE (18.75 bar g) CORROSION ALLOWANCE 0.5 mm
THRU SCHED.
WN FLANGES FW 0.50"-14" RF,125 AARH 150# ANSI B16-5

ASTM A105
BLIND FB 0.50"-14" RF,125 AARH 150# ANSI B16-5

ASTM A105
FLANGE
FLANGES FF 0.5" - 14" RF,125 AARH 150# ANSI B16-48

ASTM A105
FIG 8
SPCR & FSB 10" - 14" RF,125 AARH 150# ANSI B16-48
ASTM A105
BLND
STUD BOLTS B 0.5" - 14" ANSI B18-2 Bolt: A193 B7
Nut: A194 Gr.2H
GASKETS G 0.5" - 14" 150#, SPIRAL B-16.20 - SP. WND

metallic with
SPIRAL ANSI B16.5 Graphite Filler
WOUND (5 mm thick)
GATE VG 0.50 - 1.50 SW 800# API 602 ASTM A 216 Gr WCB
VALVE B16.11
0.50 - 1.50 SW,BS-5353 800# ANSI B16.10 ASTM A105

PLUG
PV
VALVE
2''-14'' FLG/BW,API6D 150# ANSI B16.10 ASTM A 216 Gr WCB
Document No. Rev.

Sheet 8 of 18
GAIL GAS LIMITED
PRESSURE (18.75 bar g) CORROSION ALLOWANCE 0.5 mm
THRU SCHED.
BALL VBA 0.50'' - 1.50'' SW:ANSI B16-5 800# ANSI B16-10 BODY: FULL BORE
VALVES ASTM A105 FIRE SAFE
BALL: WRENCH OPERATED.
SS 316
2"-3" BW:ANSI B16-5 150# ANSI B16-10 BODY: FULL BORE
ASTM A216 Gr. WCB FIRE SAFE

(A 216 Gr. WCB)
+ 0.003" ENP
4"-10" BW:ANSI B16-5 150 # ANSI B16-10 BODY: FULL BORE
ASTM A216 Gr. WCB FIRE SAFE
BALL: GEAR OPERATED.

(A 216 Gr. WCB)
+ 0.003" ENP
12"-14" BW:ANSI B16-5 150# ANSI B16-10 BODY: DOUBLE BLOCK AND BLEED
ASTM A216 Gr. WCB FULL BORE
BALL: FIRE SAFE
(A 216 Gr. WCB)

GEAR OPERATED.
+ 0.003" ENP
GLOBE VGL 0.50'' - 1.50'' SW 800# ANSI B16-10 BODY: HANDWHEEL
VALVES ANSI B16-5 ASTM A 105 FIRE SAFE
TRIM:
ASTM A182 F6
2" - 14" FLGD RF 150# ANSI B16-10 BODY: HANDWHEEL
ANSI B16-5 ASTM A 216 Gr. WCB FIRE SAFE
TRIM:
ASTM A182 F6
LIFT CHECK 0.50'' - 1.50'' SW 800# ANSI B16-10 BODY: HORIZONTAL INSTALLATION
VALVES ANSI B16-5 ASTM A 105
TRIM:
ASTM A182 F6
VCH
2"-14" FLGD RF 150# ANSI B16-10 BODY: HORIZONTAL INSTALLATION
ANSI B16-5 ASTM A 216 Gr. WCB VERTICAL INSTALLATION FLOW

SWING CHECK
VALVE
TRIM: UPWARDS
ASTM A182 F6
Document No. Rev.

Sheet 9 of 18
GAIL GAS LIMITED
PRESSURE (18.75 bar g) CORROSION ALW 0.5 mm
BRANCH TABLE
B R A N C H S I Z E
1/2" 3/4" 1" 1.1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 30" 32" 36"
1/2" T
3/4" T T
1" T T T
1.1/2" T T T T
2" S S S T T
3" S S S S T T
4" S S S S T T T
H 6" S S S S W T T T
E 8" S S S S W W T T T
A 10" S S S S W W T T T T
D 12" S S S S W W W T T T T
E 14" S S S S W W W T T T T T
R 16" S S S S W W W W T T T T T
18" S S S S W W W W T T T T T T
S 20" S S S S W W W W W T T T T T T
I 24"
Z 28"
E 30"
32"
36"
LEGEND
T : TEE
S: SOCKOLET - SW
W : WELDOLET - BW
Document No. Rev.

Sheet 10 of 18
GAIL GAS LIMITED
PRESSURE (49 bar g) CORROSION ALLOWANCE 0.5 mm
THRU SCHED.
PIPES P 0.50" - 1.50" PE, SEAMLESS S160 ANSI B36-10 ASTM A 106 Gr.B
2" BE, SEAMLESS S80 ANSI B36-10 ASTM A 106 Gr.B
3" - 10" BE, SEAMLESS STD ANSI B36-10 ASTM A 106 Gr.B
12"- 14'' BE, SEAMLESS S40 ANSI B36-10 ASTM A 106 Gr.B
ELBOWS 90 LR E 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
ELBOWS 45 LR E45 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
REDUCERS RC 2" - 14" BW - ANSI B16-25 MXM ANSI B16-9 ASTM A 234 Gr WPB
CONCENTRIC
REDUCERS RE 2" - 14" BW - ANSI B16-25 MXM ANSI B16-9 ASTM A 234 Gr WPB
ECCENTRIC
TEES EQUAL T 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
TEES RED TR 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105
SOCKOLET S SW 6000# MSS-SP 97 ASTM A105

0.50" - 1.50"
WELDOLETS W 2" - 14" BW - ANSI B16-25 M X XXS MSS-SP 97 ASTM A105
CAPS C 2" - 14" BW ANSI B16-9 ASTM A 234 Gr WPB
NIPPLES NA 0.50" - 1.50" PBE, SEAMLESS M ANSI B36-10 ASTM A 106 Gr.B
FULL FC 0.50" - 1.50" SW 6000# ANSI B16-11 ASTM A105
COUPLINGS
HALF HC 0.50" - 1.50" SW 6000# ANSI B16-11 ASTM A105
COUPLINGS
Document No. Rev.

Sheet 11 of 18
GAIL GAS LIMITED
THRU SCHED.
WN FLANGES FW 2"-14" RF, 125 AARH 300# ANSI B16-5

ASTM A105
FLG SW FS 0.50 - 1.50 RF, 125 AARH 300# ANSI B16-5

ASTM A105
BLIND FB 0.50"-14" RF, 125 AARH 300# ANSI B16-5

ASTM A105
FLANGE
FLANGES FF 0.5" - 14" FF, 125 AARH 300# ANSI B16-48

ASTM A105
FIG 8
SPCR & FSB 10" - 14" FF, 125 AARH 300# ANSI B16-48
ASTM A105
BLND
STUD BOLTS B 0.50" - 14'' ANSI B18-2 Bolt: A193 B7
Nut: A194 Gr.2H
GASKETS G 0.5" - 14" SPIRAL, 300# B-16.20 - SP. WND

metallic with
WOUND (5 mm thick)
GATE VG 0.50 - 1.50 SW 800# API 602 ASTM A105
VALVE B16.11
2" - 14" FLGD, B-16.5, 300# API 600 ASTM A 216 Gr WCB
RF/125 AARH
PLUG VP 0.50" - 1.50" SW, BS -5353 800# ANSI B16-10 ASTM A105
VALVE 2" - 14" FLG/ BW, API 6D 300# ANSI B16-10 ASTM A 216 Gr WCB
Document No. Rev.

Sheet 12 of 18
GAIL GAS LIMITED
THRU SCHED.
BALL VBA 0.50 - 1.50 FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: FULL BORE
VALVES 125 AARH BS 5351 ASTM A105 FIRE SAFE
BALL:SS 316 WRENCH OPERATED.
BODY SEAT: RPTFE

2" FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: FULL BORE, FIRE SAFE, WRENCH OPERATED
or BW :ANSI B16-5 BS 5351 ASTM A216 Gr. WCB
BALL:
(A 216 Gr. WCB)
+ 0.003" ENP
BODY SEAT: RPTFE
3" - 4" FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: DOUBLE BLOCK AND BLEED
or BW :ANSI B16-5 BS 5351 ASTM A216 Gr. WCB FULL BORE

(A 216 Gr. WCB)
+ 0.003" ENP FIRE SAFE
BODY SEAT: RPTFE WRENCH OPERATED.
6"-14'' FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: DOUBLE BLOCK AND BLEED
or BW :ANSI B16-5 BS 5351 ASTM A216 Gr. WCB FULL BORE

BALL:
(A 216 Gr. WCB) FIRE SAFE
BODY SEAT: RPTFE GEAR OPERATED.
GLOBE VGL 0.50 - 1.50 FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: HANDWHEEL
VALVES BS 5352 ASTM A 216 Gr. WCB FIRE SAFE
TRIM:
ASTM A182 F6
2" - 4" FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: HANDWHEEL
BS 1873 ASTM A 216 Gr. WCB FIRE SAFE
TRIM:
ASTM A182 F6
6" - 14" FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: GEAR OPERATED
BS 1873 ASTM A 216 Gr. WCB FIRE SAFE
TRIM:
ASTM A182 F6
LIFT CHECK 0.50 - 1.50 FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: HORIZONTAL INSTALLATION
VALVES BS 5352 ASTM A 105 VERTICAL INSTALLATION FLOW UPWARDS
TRIM:
ASTM A182 F6
2"-14'' FLGD RF:ANSI B16-5 300# ANSI B16-10 BODY: HORIZONTAL INSTALLATION
VCH
BS 1868 ASTM A 216 Gr. WCB VERTICAL INSTALLATION FLOW UPWARDS
SWING
TRIM:
CHECK
VALVE ASTM A182 F6
Document No. Rev.

Sheet 13 of 18
GAIL GAS LIMITED
TEMPERATURE ( 0 TO 60°C) BASIC MATERIAL
DESIGN PRESSURE (98 bar g) CORROSION ALLOWANCE 0.5 mm
THRU SCHED.
PIPES P 0.50" - 1.50'' PE, SEAMLESS S160 ANSI B36-10
2" BE, SEAMLESS S80 ANSI B36-10

ASTM A 106 Gr.B
3" BE, SEAMLESS STD ANSI B36-10
4" - 10" BE, SEAMLESS XS ANSI B36-10
12" - 14" BE, SEAMLESS Sch 60 ANSI B36-10 ASTM A 106 Gr.B
ELBOWS 90 LR E 0.50" - 1.50" SW 6000# ANSI B16-11 ASTM A105
2" - 14" BW, 1.5D M ANSI B16-9 ASTM A 234 Gr WPB
ELBOWS 45 LR E45 0.50" - 1.50'' SW 6000# ANSI B16-11 ASTM A105
2" - 14" BW, 1.5D M ANSI B16-9 ASTM A 234 Gr WPB
TEES EQUAL T 0.50" - 1.50'' SW 6000# ANSI B16-11 ASTM A105
2" - 14" BW - ANSI B16-25 MXM ANSI B16-9 ASTM A 234 Gr WPB
TEES RED TR 0.50" - 1.50'' SW 6000# ANSI B16-11 ASTM A105
2" - 14" BW - ANSI B16-25 MXM ANSI B16-9 ASTM A 234 Gr WPB
SOCKOLET S 0.50" - 1.50'' SW 6000# MSS-SP 97 ASTM A105
WELDOLETS W 2" - 14" BW - ANSI B16-25 M X XXS MSS-SP97 ASTM A105
CAPS C 0.50" - 1.50'' SCRF 6000# ASME B16-11 ASTM A105
2" - 14" BW ASME B16-9 ASTM A 234 Gr WPB
PLUG P 0.50" - 1.50'' SCRM 6000# ASME B16-11 ASTM A 234 Gr WPB
NIPPLES NA 0.50" - 1.50'' PBE, SEAMLESS M ANSI B36-10 ASTM A 106 Gr.B
FULL CF 0.50" - 1.50'' SW 6000#

COUPLINGS
HALF HC 0.50" - 1.50'' SW 6000#

COUPLINGS
Document No. Rev.

Sheet 15 of 18
GAIL GAS LIMITED
THRU SCHED.
WN FLANGES FW 2" - 14" RF, 125 AARH 600# ANSI B16-5 ASTM A105
FLG SW FS 0.50 - 1.50 RF, 125 AARH 600# ANSI B16-5

ASTM A105
BLIND FB 0.50"-14" RF, 125 AARH 600# ANSI B16-5

ASTM A105
FLANGES
FLANGES FF 0.5" - 14" FF, 125 AARH 600# ANSI B16-48

ASTM A105
FIG 8
SPCR & FSB 10" - 14" FF, 125 AARH 600# ANSI B16-48
ASTM A105
BLND
STUD BOLTS B 0.50" - 14'' ANSI B18-2 Bolt: A193 B7
Nut: A194 Gr.2H
GASKETS G 0.5" - 14" SPIRAL, 600# B-16.20 - SP. WND

metallic with
WOUND (5 mm thick)
GATE VG 0.50 - 1.50 SW 800#, 3000# API 602 ASTM A105
VALVE B16.11
PLUG VP 0.50" - 1.50" SW 800# ANSI B16.10 ASTM A105

BS -5353
VALVE
2" - 14" FLG/ BW 600# ANSI B16.10 ASTM A 216 Gr WCB

API 6D
Document No. Rev.

Sheet 16 of 18
GAIL GAS LIMITED
THRU SCHED.
BALL VBA 0.50 - 1.50 FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: FULL BORE
VALVES ASTM A105 FIRE SAFE
SS 316
2" BW :ANSI B16-5 600# ANSI B16-10 BODY: FULL BORE, FIRE SAFE, WRENCH OPERATED
ASTM A216 Gr. WCB
BALL:
(A 216 Gr. WCB)

+ 0.003" ENP
3" - 4" FLGD RF:ANSI B16-5 600 # ANSI B16-10 BODY: DOUBLE BLOCK AND BLEED
ASTM A216 Gr. WCB FULL BORE
BALL: FIRE SAFE

(A 216 Gr. WCB)
+ 0.003" ENP WRENCH OPERATED.
6"-14'' FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: DOUBLE BLOCK AND BLEED
or BW :ANSI B16-5 ASTM A216 Gr. WCB FULL BORE

BALL: FIRE SAFE
(A 216 Gr. WCB)
+ 0.003" ENP GEAR OPERATED.
GLOBE VGL 0.50 - 1.50 FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: HANDWHEEL
VALVES ASTM A 105 FIRE SAFE
TRIM:
ASTM A182 F6
2" - 4" FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: HANDWHEEL
ASTM A 216 Gr. WCB FIRE SAFE
TRIM:
ASTM A182 F6
6" - 14" FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: GEAR OPERATED
ASTM A 216 Gr. WCB FIRE SAFE
TRIM:
ASTM A182 F6
LIFT CHECK VCH 0.50 - 1.50 FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: HORIZONTAL INSTALLATION
VALVES ASTM A 105 VERTICAL INSTALLATION FLOW UPWARDS
TRIM:
ASTM A182 F6
2"-14'' FLGD RF:ANSI B16-5 600# ANSI B16-10 BODY: HORIZONTAL INSTALLATION
ASTM A 216 Gr. WCB VERTICAL INSTALLATION FLOW UPWARDS

SWING CHECK
VALVE TRIM:
ASTM A182 F6
Document No. Rev.

Sheet 17 of 18
GAIL GAS LIMITED
DESIGN PRESSURE (98 bar g) CORROSION ALL. 0.5 mm
BRANCH TABLE
B R A N C H S I Z E
1/2" 3/4" 1" 1.1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 30" 32" 36"
1/2" T
3/4" T T
1" T T T
1.1/2" T T T T
2" S T T T T
3" S S S S T T
4" S S S S T T T
H 6" S S S S W T T T
E 8" S S S S W W T T T
A 10" S S S S W W T T T T
D 12" S S S S W W W T T T T
E 14" S S S S W W W T T T T T
R 16" S S S S W W W T T T T T T
18" S S S S W W W W T T T T T T
S 20" S S S S W W W W T T T T T T T
I 24" S S S S W W W W T T T T T T T T
Z 28" S S S S W W W W T T T T T T T T T
E 30" S S S S W W W W T T T T T T T T T T
32" S S S S W W W W T T T T T T T T T T T
36" S S S S W W W W T T T T T T T T T T T T
LEGEND
T : TEE
S: SOCKOLET - SW
W : WELDOLET- BW
Document No. Rev.

Sheet 18 of 18
GAIL GAS LIMITED
TECHNICAL SPECIFICATION CLIENT JOB NO. -

FOR
BALL VALVES TOTAL SHEETS 16
DOCUMENT NO 11 0290 02 08 02 002

TABLE OF CONTENT
1.0 SCOPE ........................................................................................................................... 3
2.0 REFERENCE DOCUMENTS.......................................................................................... 3
3.0 DEFINITIONS ................................................................................................................. 4
4.0 INSTRUCTIONS............................................................................................................. 5
5.0 MATERIALS................................................................................................................... 5
6.0 DESIGN AND CONSTRUCTION .................................................................................. 6
7.0 INSPECTION AND TESTS.......................................................................................... 10
8.0 TEST CERTIFICATES.................................................................................................. 12
9.0 PAINTING, MARKING AND SHIPMENT .................................................................... 12
10.0 SPARES AND ACCESSORIES .................................................................................. 13
11.0 DOCUMENTATION 13
ANNEXURE A - DATA SHEET
ANNEXURE B - QUALITY ASSURANCE PLAN
ANNEXURE C - PIPING MATERIAL SPECIFICATION
Document No. Rev

TECHNICAL SPECIFICATION
FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 2 of 16
1.0 SCOPE
This specification provides minimum requirement for design, manufacturing, Inspection, Testing and
supply of Carbon steel Ball Valves covering sizes ½” NB through 36”NB( 900mm) for ANSI pressure
classes # 150 through # 900 to be used in cross country Gas pipeline(onshore) and City Gas distribution
for handling non-sour hydrocarbon in liquid or gaseous phase.
2.0 REFERENCE DOCUMENTS
The following Standard includes provision which, through reference in this text constitute provision of this
Standard. Latest revision of this standard shall be used unless otherwise specified.
API 6D : Specification for Pipeline Valves.
API 605 : Large Diameter Carbon steel Flanges.
API 6FA : Specification for Fire Test for Valves.
API 5L : Specification for Line Pipe.
API 1104 : Specification for Welding Pipelines and related facilities.
ASME 16.10 : Face to Face and End to End Dimensions of Valves
ASME 16.20 : Metallic gasket for pipe flanges – Ring joint or spiral wounds and
jacketed.
ASME 16.21 : Non Metallic Gaskets for pipe flanges.
ASME B 16.5 : Steel Pipe Flanges and Flanged Fittings.
ASME B 16.34 : Valves - Flanged, Threaded and Welding Ends.
ASME B 31.3 : Process Piping.
ASME B 31.8 : Gas Transmission and Distribution Piping Systems.
ASME Sec VIlI Div.I/Div.II : Boiler and Pressure Vessel Code – Rules for Construction of
Pressure Vessels.
ASTM A370 : Standard Test Methods and Definitions for Mechanical Testing of Steel
Products.
ASTM B 733 : Auto catalytic Nickel Phosphorous Coating on Metals.
BS 6755-1 : Testing of Valves. Specification for production pressure testing

requirements.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 3 of 16
EN 1004511 : Metallic products: Charpy Impact test – test methods (U & V Notches)
BS 6755-2 : Testing of Valves. Specification for fire type-testing requirement.
EN 10204 : Metallic Materials – Types of Inspection documents.
MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges and Connecting -
end Flanges of Valves and Fittings.
MSS-SP-25 : Standard marking system for Valves, Fittings, Flanges and Union.
MSS-SP-44 : Steel Pipeline Flanges.
MSS-SP-53 : Quality Std for Steel Casting & Forgings for Valves, Flanges & Fittings &
Other Piping Components – Magnetic Particle Examination Method.
MSS-SP-55 : Quality Standard for Steel casting of valves, Flanges, Fittings & other
Piping components (Visual Method)
MSS-SP-72 : Ball Valves with Flanged or Butt welding ends for General Service.
ISO 5208 : Industrial Valves – Pressure Testing of Valves
ISO 10497 : Testing of Valves – fire type testing requirements.
ISO 13623 : Petroleum & Natural Gas Industry – pipeline transportation system.
ISO 14313 : Petroleum & Natural Gas Industry. Pipeline transportation system –
pipeline Valves
SSPC-VIS-1 : Steel Structures Painting Council Visual Standard.
In case of contradiction the most stringent shall apply.
3.0 DEFINITIONS
Purchaser : The Company which makes purchase order.
Manufacturer : Manufacturer who receives the purchase order.
Shall : This verbal form indicates requirements strictly to be followed in order to confirm to the
standards and from which no deviation is permitted.
Should : This verbal form indicates that among several possibilities one is particularly suitable
without mentioning or excluding others or that a certain course of action is preferred
but not necessarily required.
May : This verbal form indicates a course of action permissible within the limits of this
standard.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 4 of 16
Can : This verbal form used for statements of possibility & capability, whether material,
physical or casual.
4.0 INSTRUCTIONS
4.1 Eventual Interpretations and deviations to this specification by the manufacturer shall be
requested by writing in his offer with detailed justification and approved by the purchaser or
purchaser’s representative before the eventual order to the manufacturer.
4.2 The specifications of the steel used shall be mentioned by the material manufacturer and all
potential sub contractors (such as forging plant, casting plant and fabrication unit etc) will be
described in the offer. After order no change will be accepted except for justified. In that case the
asked changes shall be supported by a technical file submitted to the purchaser and the
purchaser’s representative for approval.
4.3 The manufacturer shall provide a technical description of the manufacturing methods that might
influence the quality of material.
4.4 The purchaser/ purchaser’s representative keeps the right to audit the manufacturer’s and sub
contractors manufacturing and control methods. All costs for such an audit shall be borne by the
manufacturer except the wages, travel expenditure, lodging and boarding of the auditors
supported by the purchaser/ purchaser’s representative.
4.5 The purchaser/ purchaser’s representative shall have at any time free access to all parts of the
manufacturer’s facilities and to all his sub contractors involved in the order manufacturing.
4.6 A copy of ISO 9001 Certificate shall be included in the offer.
4.7 An approval of documents can never be considered as acceptance of deviations or relaxation to

requirements. A deviation is only possible after specific request to purchaser and purchaser’s
representative.
4.8 Purchaser/ purchaser’s representative may verify the control equipment of the manufacturer, its
calibration and the points at which it is located. If during the production certain problem arises,
the purchaser/ purchaser’s representative may demand supplementary tests.
5.0 MATERIALS
5.1 Material for major components of the valves shall be as indicated in Valve Data Sheet.
In addition, the material shall also meet the requirements specified herein. Other components
shall be as per Manufacturer’s standard (suitable for service conditions as indicated in valve data
sheet), which shall be subjected to approval by Purchaser / Purchaser’s representative.
5.2 Carbon steel used for the manufacture of valves shall be fully killed.
5.3 The carbon equivalent (CE) of valve end connections which are subject to further field welding
by Purchaser shall not exceed 0.45% on check analysis for each heat of steel used and shall be
calculated by the following formula:
CE = C + Mn + Cr + Mo + V + Ni + Cu
6 5 15
5.4 The steel used shall be suitable for field welding to pipes, flanges or fittings manufactured under
ASTM – 53, A – 105, A – 106, A – 234, A – 350, A – 352, A – 694, A – 420, A – 333, and
API – 5L etc.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 5 of 16
5.5 When the ball of valve is manufactured out of C.S, it shall be subjected to 75μm (0.003”) thick
Electrolysis nickel plating as per ASTM B733 with following classification SC2, type II, class-2.
For Ball made of S.S material, ENP is not mandatory.
The hardness of plating shall be minimum 50 RC.
5.6 For valves specified to be used for Gas service or High Vapor Pressure (HVP) liquid service;
Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 7.5
for all pressure containing parts such as body, end flanges and welding ends as well as bolting
material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall
be conducted at 0°C. The Charpy V-notch test specimen shall be taken in the direction of
principal grain flow and notched perpendicular to the original surface of plate or forging. The
minimum average absorbed energy per set of three specimens shall be 35 J with an individual
minimum per specimen of 27J. Test procedure shall conform to ASTM A 370 or ISO 148.
For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements
stated above are not applicable, unless required by the specified material standard as a
mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard
shall be complied with.
5.7 Valves shall be subjected to hardness test on base material for each heat for pressure containing
parts. A full thickness cross section shall be taken for this purpose and the maximum hardness
shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire
thickness.
6.0 DESIGN AND CONSTRUCTION
6.1 a) Valve design shall be as per API 6D and suitable for the process conditions indicated in the
Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used
to design the valve body. Allowable stress requirements shall comply with the provisions of
ASME B31.3 and B31.8. In addition, corrosion allowance indicated in Valve Data Sheet shall
be considered in valve design. However, the minimum wall thickness shall not be less than the
minimum requirement of ASME B16.34.
b) Corrosion Allowance for all valves to be used in sweet gas services shall be considered nil.
c) The manufacturer shall have valid license to use API monogram on valves manufactured
as per API 6D.
6.2 Fully welded valves shall be used for main line aboveground/underground services. Other
aboveground valves may be of welded or bolted type with 2 piece/3 piece construction. Threaded
body joints shall not be accepted.
6.3 Ball shall be of single piece, solid type construction.
6.4 Valves shall be Full bore or Reduce bore . Full bore valves shall be suitable for the passage
of all types of pipeline scraper and inspection pigs on regular basis without causing damage to
either the valve component or the pig. The full bore valve shall provide an unobstructed profile for
pigging operations in either direction. Full bore valves shall be designed to minimize
accumulation of debris in the seat ring region to ensure that valve movement is not impeded.
6.5 Reduced bore valves shall be provided if specifically mentioned in data sheet. Valve body shall
be manufactured by casting or forging.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 6 of 16
6.6 All valves 4”NB and above shall be trunion mounting type. Valves below 4” shall be floating type
unless specifically mentioned in data sheet otherwise.
6.7 Valve seats shall be with primary metal to metal contact. O - Rings or other seals if used for drip
tight sealing shall be encased in a suitable groove in such a manner that it can not be removed
from seat ring and there is no extrusion during opening or closing operation at maximum
differential pressure. The seat rings shall be designed so as to ensure sealing at low as well as
high differential pressures. Seat design with PTFE inserts is not acceptable.
6.8 All valves shall have two seating surfaces which in close position blocks the flow from both
ends. The cavity between the seating surfaces is vented through a bleed connection
provided on the body cavity i.e. the valves shall be Double Block & Bleed (DBB).
6.9 Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in
both open and closed positions.
6.10 All valves of nominal valve size 200 mm (8”) NB & above shall have provision for secondary
sealant injection under full line pressure for seat and stem seals. All sealant injection connections
shall be provided with an internal Non-return valve. Valve design shall have a provision to
replace the sealant injection fitting under full line pressure.
6.11 All valves shall be provided with a vent and drain connection. These connections shall be welded
type as per Fig. 6.11 A/B. Body vent and drain shall be provided with valves (Ball or Plug type).
All these vents & drain connection shall be provided with isolation ball valve as shown in Fig
6.11 A/B. The end connection of vent & drain line to valve body or isolation valves shall be
welded type at underground location and threaded type for above ground location.
6.12 Valve design shall ensure repair of stem seals/packing under full line pressure.
6.13 a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt welded
as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged body valves shall
be integrally cast/ forged with the body of the valve. Face to face/end to end dimensions shall
conform to API 6D.
b) The length of butt welding ends shall be sufficient to allow welding and heat treatment without
damage of the internal parts of the valves.
c) Flanged end, if specified shall have dimensions as per ASME B 16.5 for valve sizes up to DN
600 mm (24”) excluding DN 550 mm (22”) and as per MSS-SP-44/ASME B16.47Series A for
Valve sizes DN 550 mm (22 inches) and for DN 650mm (26”) and above. Flange face shall be
either raised face or ring joint type as indicated in Valve Data Sheet. In case of RTJ flanges,
the groove hardness shall be minimum 140 BHN. All flanged face shall have concentric
serration with 125 AARH finish.
d) Butt welding end preparation shall confirm to ASME B 16.25. Incase of difference in thickness
of valve body & mating pipelines, the bevel end of valve shall be as per ASME B 31.8 or
ASME B 31.4 as applicable. The end preparation shall take care of outside diameter of
connecting pipe, wall thickness, material grade, SMYS & Special chemistry of welded material
as indicated in the data sheet.
6.14 The temperature and pressure range of the valves shall be in accordance with the indicated
values on the relevant piping specification and valve data sheet.
6.15 Wall thickness of parts used for the welding connection with the line pipe shall meet the
following requirements:
a) The maximum allowable stress in the material of butt-weld connection for butt welding shall be
equal to 50% of the minimum yield strength guaranteed by the specification of steel used.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 7 of 16
b) The minimum wall thickness for butt welding connection must be greater than or equal to the
largest value of either the calculated minimum thickness of butt welding connections or the
nominal thickness of pipe as indicated on data sheet.
c) If the butt welding connections has a yield strength lower than the yield strength of the pipe to
which it is intended to be welded, the wall thickness in each zone of the butt welding
connection is at least equal to the specified pipe wall thickness times the ratio of minimum
yield strength guaranteed by the specification of the steel of the pipe to minimum yield strength
guaranteed by the specification of the steel of the butt welding connection.
d) The specified pipe wall thickness and grade with which the valve is intended to be used is
specified in the data sheet.
e) All valves under this specification shall be designed to withstand a field hydrostatic test
pressure with non corrosive water. After installation during 24 hours when the ball is partially
or fully open at a pressure level
P = 1.4 X MOP
P = hydrostatic test pressure (bar)
MOP = Maximum operating pressure at 38 ºC
6.16 Valve shall be provided with ball position indicator and stops of rugged construction at the fully
open and fully closed positions.
6.17 Valves of nominal size, DN 200 mm (8”) and larger, shall be equipped with support foot and
lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot
shall be kept minimum. The lifting lugs shall be stamped with safe working load.
6.18 In order to avoid stress induced crack and soft seat damage during direct field welding operation
to valve body, all valves shall be supplied with welded pups at both ends which shall be
considered as an integral part of the valves and also the ID of the pup shall match with pipe ID.
The pup piece welding shall be carried out in controlled condition of temperature at
manufacturer’s workshop. Field welding of pup piece shall not be allowed. Material & length of
pup piece shall be as per Data sheet.
6.19 When indicated in Material Requisition, valves shall have locking devices to lock the valve
either in full open (LO) or full close (LC) positions. Locking devices shall be permanently
attached to the valve operator and shall not interfere with operation of the valve. Locking device
shall be such that the valve shall operate when the differential pressure across the valve
is ≤ 3bar.
6.20 Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high alloy
steel components in the assembly. Accordingly, Suitable insulation shall be provided as required.
6.21 The valve stem shall be capable of withstanding the maximum operating torque required to
operate the valve against the maximum differential pressure as per the appropriate class.
The combined stress shall not exceed the maximum allowable stresses specified in ASME
Section VIII, Division 1. The design shall take into account a safety factor of 1.5 based on the
maximum output torque of the operating mechanism. The valve Manufacturer shall guarantee
that the breakaway torque after long periods of non- movement can not exceed the normal
short term breakaway torque by a factor more than 1.25, and that the safety factor specified
above is not compromised.
6.22 The valve stem shall have anti-blowout feature with antistatic device conforming to BS 5351
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 8 of 16
6.23 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions:
a) Valves provided with stem extension shall have water proof outer casing. The Length of
stem extension shall be as indicated on the Valve Data Sheet. The length indicated
corresponds to the distance between centerline of the valve opening and the centerline of
the rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a horizontal
shaft.
b) Manual override devices shall be provided on all valves
c) Vent, drain and sealant connections shall be terminated adjacent to the valve operator by
means of suitable piping anchored to the valve body.
d) The stem extension shall be self relieving.
e) Outer casing of stem extension shall have 3/8” or 1/2” NPT plugs at the top and bottom, for
draining and filling with oil to prevent internal corrosion
6.24 Operating Devices
a) All valves of size > 12”NB shall be manually operated & hydraulically actuated. In case of
manual operator, valve sizes, 100 mm (NPS 4”) and below shall be wrench/ lever operated.
For Valves from 6” - 12” shall be gear operated.
Valve design shall be such that damage due to malfunctioning of the operator or its control
gear train or power cylinder and other damaged parts can be replaced without the valve cover
being removed.
b) The power actuator shall be in accordance with the Purchaser Specification issued for the
purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as
indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open
/full open to full close under maximum differential pressure corresponding to the valve rating.
For actuated valves, the actuator’s rated torque output shall be 1.25 times the break torque
required to operate the ball valve under the maximum differential pressure corresponding to
the Valve Class Rating.
c) For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, the total force
required to operate the valve does not exceed 350N. Manufacturer shall also indicate the
number of turns of hand wheel (In case of gear operators) required for operating the valve
from full open to full close position. The wrench length or hand wheel diameter shall be in
accordance with API 6D requirements. The manufacturer shall indicate the number of turns
of the hand wheel (for gear operators), required for operating the valve from fully open to the
fully closed position.
d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing
the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully encased
in water proof/splash proof enclosure and shall be filled with suitable grease.
6.25 Welding including repair welding of pressure retaining parts shall be as per welding
procedure qualification specified in ASME Section IX. The procedure qualification shall also
Include impact test and hardness test when required as per Clause 5.6, 5.7, 7.5 and 7.6 of this
specification and shall meet the requirements as specified therein.
6.26 The welders involved in welding shall be qualified in accordance with ASME Section IX.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 9 of 16
6.27 Repair by welding is not permitted for forged body valves. However repair by welding as per
ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat
treatment of casting is done. Repair welding procedure qualification shall also include impact test
and hardness test when required as per Clause 5.6, 5.7, 7.5 and 7.6 of this specification and
shall meet the requirements as specified therein.
6.28 The tolerance on internal diameter and out of roundness at the ends for welded ends valves
shall be as per connected pipe specification as indicated in the Valve Data Sheet.
6.29 When specified on the Valve Datasheet, Ball Valves shall be “fire safe” in accordance with
API 6FA, for which qualifying certificates, covering the range of items offered, shall be supplied
by the Manufacturer.
7.0 INSPECTION AND TESTS
The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests
shall be, but not limited to, the following:
7.1 The valve manufacturer must deliver a Certificate EN 10204 3.2 stating the quality, the
mechanical properties (yield strength, tensile strength, and impact test at 0 º C), the chemical
analysis the process of manufacture and the marking (for ex: - heat number of material)
A new chemical analysis (upgradation) shall be done on specimen of valve in presence of TPIA.
7.2 All valves shall be visually inspected. The external and internal surfaces of the valves shall be
free from any arc strikes, gouges and other detrimental defects.
7.3 Dimensional check on all valves shall be carried out as per the Purchaser’s approved drawings.
7.4 Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.
7.5 Pressure containing parts of all valves such as body, bonnet, flange, welding ends and balls etc
shall be subjected to impact test on each heat of base material as per API 6D CL.7.5.
7.6 Notch toughness properties Charpy V: The standard impact test temperature is 0 ºC. The
average value per series of 3 test specimen shall be equal to 35 J/cm². The minimum value per
test specimen shall be equal to 35 J/cm²; this value may drop to 27 J/cm² per test specimen
per series.
7.7 Non Destructive Examination
a) Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer. All castings shall be wet magnetic particle inspected 100% of the internal
surfaces. Method and acceptance shall comply with MSS-SP-53.
b) Body castings of all valves shall be radio graphically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B 16.34. For all sizes, body casting
shall be subjected to 100% radiography.
c) All forgings shall be ultrasonically examined in accordance with the procedure and acceptance
standard of Annexure E of ASME B 16.34. All forgings shall be subjected to wet magnetic
particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with
MSS-SP-53.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 10 of 16
d) Bodies and bonnets made by welded assembly of segments of castings, forgings,
combinations thereof shall be examined, as applicable, by methods of 7.7 (b) for cast
components or 7.7 (c) for forged components and plates.
7.8 Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.3 or ASME B31.8 as applicable and API 1104.
7.9
a) All finished weld ends subject to welding in field shall be 100% ultrasonically tested for
lamination type defects for a distance of 50 mm from the end. Laminations shall not be
acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100% radio graphically
examined and acceptance criteria shall be as per ASME B16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet -
magnetic particle methods. All defects longer than 6.35 mm shall be rejected. Rejectable
defects must be removed. Weld repair of bevel surface is not permitted.
7.10 All valves shall be tested in compliance with the requirements of API 6D. During pressure
testing, valves shall not have sealant lines and other cavities filled with sealant, grease or
other foreign material. The drain, vent and sealant lines shall be either included in the
hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic
testing. The body cavity self-relieving feature meeting the requirements of clause 6.8 of this
specification shall also be checked.
7.11 A supplementary air seat test as per API 6D, Appendix C, Para C3.3 Type II shall be carried
out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is
allowed. Test pressure shall be held for at least 15 minutes.
7.12 Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6, API 6D
under hydraulic pressure equal to maximum differential pressure corresponding to the valve
rating. For manually operated valves, it shall be established that the force required to operate
the valve does not exceed the requirements stated in section 6.24 (c) of this specification.
7.13 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve
Manufacturer’s works. At least five Open-Close-Open cycles without internal pressure and
five Open-Close-Open cycles with maximum differential pressure corresponding to the valve
rating shall be performed on the valve actuator assembly. The time for Full Open to Full
Close shall be recorded during testing. If required, the actuator shall be adjusted to ensure
that the opening and closing time is with in the limits stated in Valve Data Sheet. The Hand
operator provided on the actuator shall also be checked after the cyclic testing, for
satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the
same size, rating and the actuator model/type. In case, the tests do not meet the
requirements, retesting/rejection of the lot shall be decided by the Purchaser’s Inspector.
7.14 Subsequent to successful testing as specified in clause 7.10, 7.11, 7.12 and 7.13 above,
one(1) valve out of the total ordered quantity shall be randomly selected by the Company
Representative for cyclic testing as mentioned below:
a) The valve shall be subjected to at least 5 Open-Close-Open cycles with maximum

differential pressure corresponding to the valve rating.
b) Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 7.10 and 7.11.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 11 of 16
In case this valve fails to pass these tests, the valve shall be rejected and two more valves
shall be selected randomly and subjected to testing as indicated above. If both valves pass
these tests, all valves manufactured for the order (except the valve that failed) shall be
deemed acceptable. If either of the two valves fails to pass these tests, all valves shall be
rejected or each valve shall be tested at the option of manufacturer.
Previously carried out prototype test of similar nature shall not be considered acceptable in
place of this test.
7.15 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated
in clauses 7.1 to 7.14 above at Manufacturer’s works prior to shipment. Manufacturer shall
give reasonable access and facilities required for inspection to the Purchaser. Purchaser or
Purchaser’s representative reserves the right to require additional testing at any time to
confirm or further investigate a suspected fault. The cost incurred shall be borne to
Manufacturer.
In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves .
Inspection and tests performed/witnessed by the Purchaser’s Inspector shall in no way

relieve the Manufacturer’s obligation to perform the required inspection and tests.
8.0 TEST CERTIFICATES
Manufacturer shall submit the following certificates:
a) Mill test certificates relevant to the chemical analysis and mechanical properties of the
materials used for the valve construction as per the relevant standards.
b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and
pressure of each test.
c) Test reports of radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 7.12, 7.13 and 7.14 of this
specification.
e) All other test reports and certificates as required by API 6D, this specification and data sheets.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only those valves
which have been certified by Purchaser’s Inspector shall be dispatched from Manufacturer’s
works.
9.0 PAINTING, MARKING AND SHIPMENT
9.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by
shot blasting to SP- 6 in accordance with “Steel Structures Painting Council - Visual
Standard SSPC-VIS-1”. For the valves to be installed underground, when indicated
in Valve Data Sheet, the external surfaces of buried portion of the valve shall be
painted with three coats of suitable coal tar epoxy resin with a minimum dry film
thickness of 300 microns.
9.2 All valves shall be marked as per API 6D. The units of marking shall be metric except
nominal diameter, which shall be in inches.
9.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces,
Document No. Rev
FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 12 of 16
securely attached to the valves. Bevel ends shall be protected with metallic or high impact
plastic bevel protectors.
9.4 All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
9.5 Packaging and shipping instructions shall be as per API 6D and procurement documentation.
All valves shall be transported with ball in the fully open condition.
9.6 On packages, following shall be marked legibly with suitable marking ink:
a) Order Number
b) Manufacturer’s Name
c) Valve size and rating
d) Tag Number
e) Serial Number
10.0 SPARES AND ACCESSORIES
10.1 Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning.
10.2 Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves.
10.3 Manufacturer shall quote for spares and accessories as per Material Requisition.
11.0 DOCUMENTATION
11.1 At the time of bidding, Manufacturer shall submit the following documents:
a) Filled in Data Sheet
b) General arrangement/assembly drawings showing all features and relative positions and
sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts
together with overall dimension.
c) Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be furnished
complying with the requirement of Clause 6.7 of this specification.
d) Reference list of similar ball valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating, service
etc.
e) Torque curves for the power actuated valves along with the break torque and maximum
allowable stem torque. In addition, sizing criteria and torque calculations shall also be
submitted for power actuated valves.
f) Clause wise list of deviations from this specification, if any.
g) Descriptive technical catalogues of the manufacturer.
h) Installation, Operational and Maintenance Manual.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 13 of 16
i) Copy of valid API 6D Certificate.
j) Details of support foot including dimensions and distance from valve centerline to bottom
of support foot.
11.2 Within three weeks of placement of order, the Manufacturer shall submit four copies of, but not
limited to, the following drawings, documents and specifications for Purchaser’s approval:
a) Detailed sectional drawings showing all parts with reference numbers and material
specifications.
b) Assembly drawings with overall dimensions and features. Drawing shall also indicate
the number of turns of hand wheel (in case of gear operators) required for operating the
valve from full open to full close position and the painting scheme. Complete dimensional
details of support foot (where applicable) shall be indicated in these drawings.
c) Welding, heat treatment and testing procedures (Quality Assurance Plan).
d) Details of corrosion resistant paint to be applied on the valves.
Manufacturing of valves shall commence only after approval of the above documents. Once the
approval has been given by Purchaser, any changes in design, material and method of
manufacture shall be notified to Purchaser whose approval in writing of all changes shall be
obtained before the valve is manufactured.
11.3 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the
following:
a) Test certificates as per clause 8.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions including a list of
recommended spares for the valves.
11.4 CD containing all docs in 11.2 & 11.3 shall be submitted within 30 days from the approval date,
Manufacturer shall submit to Purchaser one reproducible and six copies of the approved
drawings, documents and specifications as listed in clause 11.2 above.
11.5 All documents shall be in English language only.
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 14 of 16
FIG - 6.11 A
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 15 of 16
FIG - 6.11 B
Document No. Rev

FOR 11-0290-02-08-02-002 B
BALL VALVES
SHEET 16 of 16
CLIENT
GAIL GAS LIMITED PROJECT: CITY GAS DISTRIBUTION PROJECT
SIZE/QUANTITY **
GENERAL SPECIFICATION
Process Fluid NG ANSI Rating 300#
Design Temperature ( 0 to 60 deg C) Design Pressure 49 barg
Design Standard API 6D Piping Class 3A1
Size, mm (inch) 2" to 12"
Full Bore/Reduce Bore**

Body Type
End Connection Type ** Standard ASME B16.25/ASME B16.5
Flange Face Finish RF 125AARH Vent, drain & Sealant connection

Special Requirement Anti Blow out system
Locking Device Reqd As per Technical Spec.
VALVE DESIGN CONDITIONS
Corrosion Allowance 0.5 mm Design Factor 0.5
Installation ** Stem Ext Length, mm 800 approx(wherever applicable)

CONNECTING PIPE DETAILS
Diameter, mm (inch) 10"/8"/6"/4" MATERIAL API 5L Gr X42(6.4mm thickness)
Diameter, mm (inch) 2" MATERIAL ASTM A 106 Gr.B (Schedule 80)
VALVE OPERATION
Actuation Type As per Technical Spec.
Type of Actuator Not Applicable

VALVE MATERIAL SPECIFICATION
PART DISCRIPTION SPECIFIED
Body A 216 Gr. WCB
Ball (A 216 Gr. WCB) + 0.003" ENP
Seat Rings AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410

Seat Seal VITON
Stem AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410
Stem Seal PTFE/ VITON
Stud Bolts ASTM A 193 Gr. B7
Nuts A194 Gr. 2H
TESTING REQUIREMENT
Hydrostatic Test Pressure Body: 74 barg Seat: 54 barg
Air Test Pressure 7barg
Anti-Static Testing Requirement As per API 6D Latest Edition
Hardness Test 248 HV10
Charpy Impact Test/ Temperature Yes (at 0 deg C)
Document No. Rev.

DATA SHEET FOR BALL VALVES
11-0290-02-08-03-002 B
(2"-12," 300#)
SHEET 1 of 2
CLIENT
SIZE/QUANTITY
**
Fire Safe Test As per API 6FA

Valve Painting Specification Suitable for Corrosive Industrial Environment
Manufacturer's Painting Specification Number *
Notes
1. This Data Sheet Shall be read in conjunction with the Material Requsition, Technical Specification, M.T.O.(if any)
and PMS which are enclosed along with this requisition.
* To be filled by Vendor ** Refer MR
Legend: B.W - Butt welded, RF - Raised Face
Document No. Rev.

DATA SHEET FOR BALL VALVES 11-0290-02-08-03-002 B
(2"-12", 300#)
SHEET 2 of 2
CLIENT
SIZE/QUANTITY **
Size, mm (inch) 2" to 12"
Full Bore/Reduce Bore**

Body Type
End Connection Type ** Standard ASME B16.25/ASME B16.5
Flange Face Finish RF 125AARH Vent, drain & Sealant connection

Special Requirement Anti Blow out system
Locking Device Reqd As per Technical Spec. Retrofit arrangement
Installation ** Stem Ext Length, mm 800 approx(wherever applicable)
Diameter, mm (inch) 10"/8"/6"/4" MATERIAL API 5L Gr X42 (6.4mm thickness)
Diameter, mm (inch) 2" MATERIAL ASTM A 106 Gr.B(Schedule 80)
VALVE OPERATION

Body A 216 Gr. WCB
Ball (A 216 Gr. WCB) + 0.003" ENP
Seat Rings AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410

Seat Seal VITON
Stem AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410
Nuts A194 Gr. 2H
TESTING REQUIREMENT
Air Test Pressure 7 barg
Document No. Rev.

11-0290-02-08-03-016 B
(2"-12",150#)
SHEET 1 of 2
CLIENT
SIZE/QUANTITY
**

Notes
Document No. Rev.

(2"-12",150#)
SHEET 2 of 2
CLIENT
SIZE/QUANTITY **
Size, mm (inch) Below 2"
Reduce Bore
Body Type
End Connection Type FLG Standard ASME B16.5
Flange Face Finish RF 125AARH

Special Requirement Floating Ball Design
Installation Above Ground Stem Ext Length, mm Not Applicable

VALVE OPERATION

Body A 105
Ball S.S.316
Seat Rings PTFE/ VITON
Seat Seal VITON
Stem S.S.316

Nuts A194 Gr. 2H
TESTING REQUIREMENT
Document No. Rev.

(Below 2",300#) 11-0290-02-08-03-019 B
SHEET 1 of 2
CLIENT
SIZE/QUANTITY
**

Notes
Document No. Rev.

(Below 2",300#)
SHEET 2 of 2
CLIENT
SIZE/QUANTITY **
Size, mm (inch) Below 2"
Reduce Bore
Body Type
End Connection Type FLG Standard ASME B16.5

Special Requirement Floating Ball Design
Installation Above Ground Stem Ext Length, mm Not Applicable

VALVE OPERATION

Body A 105
Ball S.S.316
Seat Rings PTFE/ VITON
Seat Seal VITON
Stem S.S.316

Nuts A194 Gr. 2H
TESTING REQUIREMENT
Document No. Rev.

(Below 2",150#) 11-0290-02-08-03-018 B
SHEET 1 of 2
CLIENT
SIZE/QUANTITY
**

Notes
Document No. Rev.

(Below 2",150#)
SHEET 2 of 2
PROJECT: CITY GAS DISTRIBUTION PROJECT QAP NO: 11-0290-02-08-10-002
REV NO: B
CLIENT: GAIL GAS LIMITED ITEM DESCRIPTION/ QUANTITY: BALL VALVE
CONSULTANT: WGI JOB NO.: 110290
VENDOR: PAGE NO: 1 of 3
INSPECTION
QUANTAM OF REFERENCE FORMAT OF
SR. NO. COMPONENTS & OPERATIONS TYPES OF CHECK ACCEPTANCE NORMS
CHECK DOCUMENT RECORD SUBVENDOR/
TPI WGI/GGL
VENDOR
1 RAW MATERIAL
CHEM. TEST PER HEAT MOC MOC 3.2 Certificate P/R R R
PHY. TEST PER HEAT MOC MOC 3.2 Certificate P/W W W
1. BODY & BONET

VISUAL 100% MSS-SP-75 − INTERNAL Q.C P/W R R
( REFER NOTE-1)
IMPACT TEST ( 35J AVERAGE VALUE /

PER HEAT ASTM A 370 T.C. P/W W W
0 DEG C ) 28J (ONE SPECIMEN)
INSPECTION
RADIOGRAPHY 100% ASTM A 16.34 ASTM A 16.34 REPORT/RT P/W R R
FILMS
INSPECTION
MPT 100% ASTM A 16.34 ASTM A 16.34 P/W W R
REPORT
CHEM. TEST PER HEAT MOC MOC SUPPLIER T.C. P/W R R
PHY. TEST PER HEAT MOC MOC SUPPLIER T.C. P/W W W

2. DISC & SEAT RING
10% WITNESS &
VISUAL − P/W W R
100% REVIEW
IMPACT TEST 35J AVERAGE VALUE / INSPECTION

PER HEAT ASTM A 370 P/W W RW
( 0 DEG C ) 28J (ONE SPECIMEN) REPORT
CHEM. TEST PER HEAT MOC MOC LAB T.C. P/R R R
3. SPINDLE
PHY. TEST PER HEAT MOC MOC LAB T.C. P/W W R
REV NO: 0
CLIENT: GAIL GAS LTD. ITEM DESCRIPTION/ QUANTITY: BALL VALVE
CONSULTANT: WGI JOB NO.:110290
INSPECTION
QUANTAM OF REFERENCE ACCEPTANCE FORMAT OF
SR. NO. COMPONENTS & OPERATIONS TYPES OF CHECK SUBVENDOR
CHECK DOCUMENT NORMS RECORD TPI WGI/GGL
/VENDOR
INPROCESS INP
2
TRANSFER OF INSPECTION
100% − − P/W W R
HEAT NO. REPORT
1. BODY & BONET
INSPECTION
DIMENSIONS 100% APPVD.DRG APPVD.DRG P/W W R
REPORT
2. DISC & SEAT RING DIMENSIONS 100% -DO- -DO- -DO- P/W R R
3. SPINDLE DIMENSIONS 100% -DO- -DO- -DO- P/W R R
ASTM B 16.34 350 to INSPECTION

4. HARD FACING HARDNESS & D.P. 100% ASTM B 16.34 P/W W RW
450 BHN REPORT
BROUGHTOUT ITEM
3
ASTM A 193 Gr. B7 & ASTM A 193 Gr. B7 &

CHEMICAL PER LOT P R R
A 194 Gr. 2H A 194 Gr. 2H
ASTM A 193 Gr. B7 & ASTM A 193 Gr. B7 &

PHYSICAL PER LOT P R R
A 194 Gr. 2H A 194 Gr. 2H
INSPECTION
REPORT
1. FASTNERS
DIMENSIONS 10% − − P R R
3.2 Certificate
35J AVERAGE
IMPACT TEST
PER LOT ASTM A 370 VALUE / 28J (ONE P W R
( 0 DEG C )
SPECIMEN)
REV NO: B
CLIENT: GAIL GAS LIMITED. ITEM DESCRIPTION/ QUANTITY: BALL VALVE
SR.
INSPECTION
COMPONENTS & QUANTAM OF REFERENCE ACCEPTANCE FORMAT OF
TYPES OF CHECK
OPERATIONS CHECK DOCUMENT NORMS RECORD SUBVENDOR/
TPI WGI/GGL
NO. VENDOR
4 FINAL INSPECTION
VISUAL 100% - - - P W R
APPVD.DRG & APPVD.DRG & INSPECTION

DIMENSIONS 100% P/W W RW
API 598 API 598 REPORT
APPVD.DRG & APPVD.DRG &
HYD. BODY TEST 100% -DO- P/W W RW
API 598 API 598
HIGH PRESSURE CLOSER APPVD.DRG & APPVD.DRG &

100% -DO- P/W W RW
( SEAT) TEST API 598 API 598
ASPER API 598
( REF.ANNEXURE-1 )
LOW PRESSURE CLOSER APPVD.DRG & APPVD.DRG &
100% -DO- P/W W R
(SEAT) TEST API 598 API 598

BACKSEAT TEST 100% -DO- P/W W R
API 598 API 598
PERFORMANCE TEST 100% API 598 API 598 -DO- P/W W RW
HIGH PRESSURE
100% API 598 API 598 -DO- P/W W RW
PNEUMATIC SHELL TEST
10% WITNESS &
VISUAL - - - P R R
100% REVIEW
SURFACE PREPARATION SPEC 60-80μ INSPECTION
100% SPEC P W R
5 PAINTING SA 2¹/² ROUGH REPORT
SPEC 60-80μ EACH
PRIMER & FINISH COAT PAINT.INSP.
100% SPEC COAT & TOTAL P W R
(EACH TWO COAT) REPORT
WITHIN 300μ
AS PER AS PER
REVIEW 100% Final dossier - IRN, P R R
SPEC./APPD.DRG. SPEC./APPD.DRG.
3.2 Certificate, Insp &
6 FINAL DOCUMENTS
AS PER SPEC./MSS AS PER SPEC./MSS test report, Drawing
MARKING/TAG DETAILS 100% etc P R R
SP25 SP 25
LEGEND: W - WITNESS, R - REVIEW, TPI - THIRD PARTY INSPECTION, RW - RANDOM WITNESS,MOC-MATERIAL OF CONSTRUCTION
NOTES : 1. ALL INSTRUMENTS & EQUIPMENT SHALL HAVE VALID CALIBRATION CERTIFICATE TO BE REVIEWED BY TPI.
2. MATERIAL TEST CERTIFICATE OF CASTING AND FASTENERS SHALL BE IN 3.2 AS PER EN-10204.
3. TPIA TO ISSUE 3.2 CERTIFICATE AS PER EN 10204 SPEC.
GAIL GAS LIMITED
CLIENT JOB NO.

FOR PLUG VALVES
TOTAL SHEETS 12
DOCUMENT NO 11 0290 02 08 02 004
A 24/08/09 ISSUED FOR IDC APPROVAL GV DDS PKS

CONTENTS PAGE NO.
1.0 SCOPE 3
2.0 REFERENCEE DOCUMENTS 3
3.0 DEFINITIONS 4
4.0 MATERIALS 4
5.0 DESIGN AND CONSTRUCTION 5
6.0 INSPECTION AND TESTS 7
7.0 TEST CERTIFICATES 9
8.0 PAINTING, MARKING & EQUIPMENT 9
9.0 SPARES AND ACCESSORIES 10
10.0 DOCUMENTATION 10
ANNEXURE A - DATA SHEET
ANNEXURE B - QUALITY ASSURANCE PLAN
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 2 of 12
1. SCOPE
This Specification covers the minimum requirements for design, manufacture and supply of carbon steel
plug valves of size DN 50 mm (2 inch) and above and ANSI class 150# thru 900# for use in onshore
pipeline systems handling non sour hydrocarbons in liquid phase or gaseous phase including Liquefied
Petroleum Gas (LPG).This specification does not cover plug valves for sour hydrocarbons (liquid/gas)
service as defined in NACE Standard MR-0l-75.
2. REFERENCE DOCUMENTS
ASME 16.20 : Metallic gasket for pipe flanges – Ring joint or spiral wounds and jacketed.
ASME Sec VIlI Div.I/Div.II : Boiler and Pressure Vessel Code – Rules for Construction of Pressure Vessels.
ASTM A3 70 : Standard Test Methods and Definitions for Mechanical Testing of Steel
Products.
BS 6755-1 : Testing of Valves. Specification for production pressure testing requirements.
MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges and Connecting - end
Flanges of Valves and Fittings.
MSS-SP-25 : Standard marking system for Valves, Fittings, Flanges and Union.
MSS-SP-53 : Quality Standard for Steel Casting and Forgings for Valves, Flanges and
Fittings and Other Piping Components – Magnetic Particle Examination
Method.
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 3 of 12
ISO 14313 : Petroleum & Natural Gas Industry. Pipeline transportation system – Valves.
3. DEFINITIONS

May : This verbal form indicates a course of action permissible within the limits
of this standard.
Can : This verbal form used for statements of possibility & capability, whether
material, physical or casual.
4. MATERIALS
4.1 Material for major components of the valves shall be as indicated in Valve Data Sheet. In
addition, the material shall also meet the requirements specified herein other components shall
be as per Manufacturer’s standard, which shall be subject to approval by Purchaser.
4.2 Carbon steel used for the manufacture of valves shall be-fully killed.
4.3 The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by
Purchaser shall not exceed 0.45 in check analysis for each heat of steel used, as calculated by
the following formula:
6 5 15
4.4 For valves specified to be used for Gas service or High Vapor Pressure (HVP) liquid service;
Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 3.7
for all pressure containing parts such as body, end flanges and welding ends as well as bolting
material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall
be conducted at 0 °C. The Charpy V-notch test specimen shall be taken in the direction of
principal grain flow and notched perpendicular to the original surface of plate or forging. The
minimum average absorbed energy per set of three specimens shall be 27 J with an individual
minimum per specimen of 22J.
For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements
stated above are not applicable, unless required by the specified material standard as a
mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard
4.5 When the plug of valve is manufactured out of C.S, it shall be subjected to 75μm/0.003” thick
Electroless nickel plating as per ASTM B733 with following classification SC2, type II, class-2. For
Ball made of S.S material, ENP is not mandatory.
Hardness of Plating shall be minimum 50 RC.
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 4 of 12
4.6 Valves shall be subjected to hardness test on base material for each heat for pressure containing
parts. A full thickness cross section shall be taken for this purpose and the maximum hardness
shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire
thickness.
5.1 a) Valve design shall be as per API 6D and suitable for the process conditions indicated in the
Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used
to design the valve body. Allowable stress requirements shall comply with the provisions of
ASME B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be
considered in valve design. However, the minimum wall thickness shall not be less than the
minimum requirement of ASME B16.34.
b) Corrosion Allowance for all valves to be used in sweet gas services shall be considered nil.
c) The manufacturer shall have valid license to use API monogram on valves manufactured
as per API6D.
5.2 Valve pattern area shall be as specified in the following table: -
ANSI Rating Size Range, DN mm ( inch ) Pattern

50-100 (2-4) Short
150 150-300 (6-12) Regular
350 (14) & above Venturi
50-100 (2-4) Short
300 150-250 (6-10) Regular
50-250 (2-10) Regular
600
50-250 (2-10) Regular
900
5.3 Valves shall have an inherent feature using line pressure to ensure that the line pressure cannot
cause taper locking of the plug / plug movement into the taper, i.e. valves shall be of “pressure -
balanced” design.
5.4 Cover shall be bolted to the body and screwed connections are not acceptable.
5.5 Soft seats to achieve a seal between plug and body are not permitted.
5.6 When specified in the Vale Data Sheet, valves shall be designed to withstand a sustained internal
vacuum of at least 1 (one) milli-bar in both open and closed position.
5.7 Valve design shall ensure repair of gland packing under full line pressure.
5.8 a) Valve ends shall be either flanged or butt-welded or one end flanged and one end butt-welded
as indicated in the Valve Data Sheet. Flanges of the flanged end cast body valves shall be
integrally cast with the body of the valve. Face to face/end to end dimensions shall conform to
API 6D.
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 5 of 12
b) Flanged end, if specified shall have dimensions as per ASME B 16.5 for valve sizes up to DN
600 mm (24”) excluding DN 550 mm (22”) and as per MSS-SP-44/ASME B16.47Series A for
Valve sizes DN 550 mm (22 inches) and for DN 650mm (26”) and above.. In case of RTJ
flanges, the groove hardness shall be minimum 140 BHN. All flanged face shall have
concentric serration with 125 AARH finish
c) Butt welding end preparation shall confirm to ASME B 16.25. Incase of difference in thickness
of valve body & mating pipelines, the bevel end of valve shall be as per ASME B 31.8. The
end preparation shall take care of outside diameter of connecting pipe, wall thickness, material
grade, SMYS & Special chemistry of welded material as indicated in the data sheet.
5.9 Valves shall be provided with plug position indicator and stops of rugged construction at the fully
open and fully closed positions.
5.10 When indicated in Material Requisition, valves shall have locking devices to lock the valve either
in full open (LO) or full close (LC) position. Locking devices shall be permanently attached to the
valve operator and shall not interfere with operation of the valve.
5.11 Valves shall be suitable for either buried or aboveground installation as indicated in Valve Data
Sheet.
5.12 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions: -
a) Valves provided with stem extension shall have waterproof outer casing. Length of stem
extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the
distance between centre line of the valve opening and the centerline of the rim of the hand
wheel on a vertical shaft or centerline of the hand wheel on a horizontal shaft.
b) Vent, drain and sealant connections shall be terminated adjacent to the valve operator by
means of suitable piping anchored to the valve body.
c) Stem extension and stem housing design shall be such that the complete assembly will form a
rigid unit giving positive drive under all conditions with no possibility of free movement
between valve body, stem extension or its operator.
d) Outer casing of stem extension shall have 3/8“ or 1/2” NPT plugs at the top and bottom, for
draining and filling with oil to prevent internal corrosion.
5.13 Operating Devices
a) Valves shall have a power actuator or manual operator as indicated in the Valve Data Sheet.
In case of manual operator, valve sizes < DN 100 mm (4”) shall be wrench operated and valve
sizes > DN 150 mm (6”) shall be gear operated. Each wrench operate valve shall be supplied
with wrench. Valve design shall be such that damage due to malfunctioning of the operator or
its controls will only occur in the operator gear train or power cylinder and that damaged parts
can be replaced without the valve cover being removed.
b) The power actuator shall be in accordance with the Purchaser specification issued for the
purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as
indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full
open/full open to full close under maximum differential pressure corresponding to the valve
rating. For actuator valves, the actuator rated torque output shall be at least 1.25 times the
break torque required to operate the valve under maximum differential pressure corresponding
to the valve class rating.
c) For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, total force
required to operate the valve does not exceed 350N. Manufacturer shall also indicate the
number of turns of hand wheel (in case of gear operator) required to operate the valve from
full open to full close position.
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 6 of 12
d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing
the valve.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully encased
in water proof/splash proof enclosure and shall be filled with suitable grease.
5.14 Repair by welding is not permitted for fabricated and forged body valves. However repair by
welding as per ASME BI 6.34 is permitted for cast body valves. Repair shall be carried out before
any heat treatment of casting is done. Repair welding procedure qualification shall also include
impact test and hardness test when required as per Clause 4.6, 6.4 and 6.5 of this specification
and shall meet the requirements as specified therein.
5.15 The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall
be as per connected pipe specification as indicated in the Valve Data Sheet.
5.16 Valve stem shall be capable of withstanding the maximum operating torque required to operate
the valve against the maximum differential pressure corresponding to applicable class rating. The
combined stress shall not exceed the maximum allowable stresses specified in ASME section
VIII, Division 1.
For Power Actuated Valves, the valve stem shall be designed for maximum output torque of the
selected power actuator (including gear box, if any) at the valve stem..
The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests
6.1 All valves shall be visually inspected.
6.2 Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.
6.3 Chemical composition and mechanical properties shall be checked as per relevant material
6.4 Pressure containing parts of all valves such as body, bonnet, flange, welding ends and balls etc
shall be subjected to impact test on each heat of base material as per API6D CL.3.7.
6.5 All Valves shall be impact tested at -20°C. The average energy absorbed shall be 35J and min.
28J.
6.6 Non Destructive Examination
a) Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer. All castings shall be wet magnetic particle inspected 100% of the internal
surfaces. Method and acceptance shall comply with MSS-SP-53.
b) Body castings of all valves shall be radio graphically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B 16.34. For all sizes body casting
shall be subjected to 100% radiography.
c) All forgings shall be ultrasonically examined in accordance with the procedure and acceptance
standard of Annexure E of ASME B 16.34. All forgings shall be subject to wet magnetic
particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with
MSS-SP-53
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 7 of 12
Bodies and bonnets made by welded assembly of segments of castings, forgings, combinations
there of shall be examined, as applicable, by methods of 6.6 (b) for cast components or 6.6 (c) for
forged components and plates.
6.7 Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.3 or ASME B31.8 as applicable and API 1104.
6.8
a) All finished wrought weld ends subject to welding in field shall be 100% ultrasonically tested
for lamination type defects for a distance of 50 mm from the end. Laminations shall not be
acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100% radio graphically
examined and acceptance criteria shall be as per ASME B 16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet - magnetic
particle methods. All defects longer than 6.35 mm are rejected, as are the defects between
6.35 mm and 1.59 mm that are separated by a distance less than 50 times their greatest
length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted.
6.9 All valves shall be tested in compliance with the requirements of API 6D. During pressure
testing, valves shall not have sealant lines and other cavities filled with sealant, grease or other
foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic shell
test or tested independently. No leakage is permissible during hydrostatic testing. The body cavity
self-relieving feature meeting the requirements of clause 5.8 of this specification shall also be
checked.
6.10 A supplementary air seat test as per API 6D shall be carried out for all valves. A bubble tight
seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be
held for at least 15 minutes.
6.11 Valves shall be subjected to Operational Torque Test as per clause C4 of API 6D under
hydraulic pressure equal to maximum differential pressure corresponding to the valve rating.
For manually operated valves, it shall be established that the force required to operate the
valve does not exceed the requirements stated in section 5.22 (c) of this specification.
6.12 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve
Manufacturer’s works. At least five Open-Close-Open cycles without internal pressure and five
Open-Close-Open cycles with maximum differential pressure corresponding to the valve
rating shall be performed on the valve actuator assembly. The time for Full Open to Full Close
shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the
opening and closing time is with in the limits stated in Valve Data Sheet. The Hand operator
provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual
over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same
size, rating and the actuator model/type. In case, the tests do not meet the requirements,
retesting/rejection of the lot shall be decided by the Purchaser’s Inspector.
6.13 Subsequent to successful testing as specified in clause 6.9, 6.10, 6.11 and 6.12 above, one (1)
valve out of the total ordered quantity shall be randomly selected by the Company Representative
for cyclic testing as mentioned below:
a) The valve shall be subjected to at least 500 Open-Close-Open cycles with maximum
differential pressure corresponding to the valve rating.
b) Subsequent to the above, the valve shall be subjected to hydrostatic test and supplementary
air seat test in accordance with clause 6.9 and 6.10.
In case this valve fails to pass these tests, the valve shall be rejected and two more
Document No. Rev
FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 8 of 12
valves shall be selected randomly and subjected to testing as indicated above. If
both valves pass these tests, all valves manufactured for the order (except the valve
that failed) shall be deemed acceptable. If either of the two valves fails to pass these
tests, all valves shall be rejected or each valve shall be tested at the option of
manufacturer.
Previously carried out prototype test of similar nature shall not be considered
acceptable in place of this test.
6.14 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in
clauses 6.1 to 6.13 above at Manufacturer’s works prior to shipment. Manufacturer shall give
reasonable access and facilities required for inspection to the Purchaser. Purchaser reserves the
right to require additional testing at any time to confirm or further investigate a suspected fault.
The cost incurred shall be to Manufacturer’s account.
In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves.
Inspection and tests performed/witnessed by the Purchaser’s Inspector shall in no way relieve the
Manufacturer’s obligation to perform the required inspection and tests.
a) Mill test certificates relevant to the chemical analysis and mechanical properties of
the materials used for the valve construction as per the relevant standards.
b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and
pressure of each test.
c) Test reports of radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 6.11, 6.12 and 6.13 of this
specification.
e) All other test reports and certificates as required by API 6D, this specification and data
sheets.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only those valves
which have been certified by Purchaser’s Inspector shall be dispatched from Manufacturer’s
works.
8.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot
blasting to SP-6 in accordance with “Steel Structures Painting Council - Visual Standard
SSPC-VIS-1”. For the valves to be installed underground, when indicated in Valve Data Sheet,
the external surfaces of buried portion of the valve shall be painted with three coats of suitable
coal tar epoxy resin with a minimum dry film thickness of 300 microns.
8.2 All valves shall be marked as per API 6D. The units of marking shall be metric except nominal
diameter, which shall be in inches.
8.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces, securely
attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel
protectors.
Document No. Rev
FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 9 of 12
8.4 All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
8.5 Packaging and shipping instructions shall be as per API 6D and procurement documentation.
All valves shall be transported with ball in the fully open condition.
8.6 On packages, following shall be marked legibly with suitable marking ink:
a) Order Number
b) Manufacturer’s Name
c) Valve size and rating
d) Tag Number
e) Serial Number
9.1 Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning.
9.2 Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves.
9.3 Manufacturer shall quote for spares and accessories as per Material Requisition.
10.0 DOCUMENTATION
10.1 At the time of bidding, Manufacturer shall submit the following documents:
a) Filled Data Sheet
b) General arrangement/assembly drawings showing all features and relative positions and
sizes of vents, drains, gear operator/ actuator, painting, coating and other external
parts together with overall dimension.
b) Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be furnished
complying with the requirement of clause 4.6 of this specification.
c) Reference list of similar ball valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating, service
etc.
d) Torque curves for the power actuated valves along with the break torque and maximum
allowable stem torque. In addition, sizing criteria and torque calculations shall also be
submitted for power actuated valves.
e) Clause wise list of deviations from this specification, if any.
f) Descriptive technical catalogues of the manufacturer.
g) Installation, Operational and Maintenance Manual.
h) Copy of valid API 6D Certificate.
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 10 of 12
i) Details of support foot including dimensions and distance from valve centerline to bottom
of support foot.
10.2 With in three weeks of placement of order, the Manufacturer shall submit four copies of, but not
limited to, the following drawings, documents and specifications for Purchaser’s approval:
a) Detailed sectional drawings showing all parts with reference numbers and material
specifications.
b) Assembly drawings with overall dimensions and features. Drawing shall also indicate
the number of turns of hand wheel (in case of gear operators) required for operating the
valve from full open to full close position and the painting scheme. Complete
dimensional details of support foot (where applicable) shall be indicated in these
drawings.
c) Welding, heat treatment and testing procedures.
d) Details of corrosion resistant paint to be applied on the valves.
Manufacturer of valves shall commence only after approval of the above documents. Once the
approval has been given by Purchaser, any changes in design, material and method of
manufacture shall be notified to Purchaser whose approval in writing of all changes shall be
obtained before the valve is manufactured.
10.3 CD containing all docs in 10.2 & 10.4 shall be submitted within 30 days from the approval date,
Manufacturer shall submit to Purchaser one reproducible and six copies of the approved
drawings, documents and specifications as listed in clause 10.2 above.
following:
a) Test certificates as per clause 7.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions including a list of
10.5 All documents shall be in English language only.
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 11 of 12
Fig 5.6
Document No. Rev

FOR PLUG VALVES 11-0290-02-08-02-004 B
SHEET 12 of 12
CLIENT GAIL GAS LIMITED PROJECT:CITY GAS DISTRIBUTION PROJECT
SIZE/QUANTITY
**
Process Fluid NG/ R-LNG ANSI Rating 300#
Design Standard API6D / BS 5353 Piping Class 3A1
Size, mm (inch) 2" & above

Valve Pattern Regular
End Connection ** Standard ASME B16.25/ASME B16.5

Special Requirement
Locking Device Reqd NA
Installation Aboveground Stem Ext Length, mm N.A.
Opening/Closing time NA
Diameter, mm (inch) 2"
Material ASTM A 106 Gr.B (Schedule 80)
Out of roundness Not Applicable

VALVE OPERATION
Actuation Reqd As per tech. spec.
Type of Actuator Manual

Body ASTM A 216 Gr WCB
Plug (Lubricated) ASTM A 216 Gr WCB + 0.003”ENP
Cover ASTM A 216 Gr WCB
Stem AISI 4140 + 0.03" ENP/ AISI 410
Stem Seal PTFE/ Graphite
Lubricant Screw Manufacturer's Standard
TESTING REQUIREMENT
Air Test Pressure 7 bar
Document No. Rev.

DATA SHEET FOR
11-0290-02-08-03-004 B
PLUG VALVES
SHEET 1 of 2
CLIENT GAIL GAS LIMITED PROJECT: CITY GAS DISTRIBUTION PROJECT
SIZE/QUANTITY
**

Notes
1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along
with this requisition.
2. Stem packing shall be renewable with valve open on stream.
3. All valves shall be provided with valve position indicator.
4. Valve shall be "pressure balanced design ". i.e It shall have an inherent feature using the line pressure to ensure that the
line pressure cannot cause taper locking of the plug/plug movement into the taper.
Abbreviations: SB - BW - Butt welded, FLG - Flange
Document No. Rev.

DATA SHEET FOR
PLUG VALVES 11-0290-02-08-03-004 B
SHEET 2 of 2
CLIENT: GAIL GAS LIMITED REV NO: B
CONSULTANT: WGI ITEM DESCRIPTION/ QUANTITY: PLUG VALVE
VENDOR: JOB NO.: 110290
PAGE NO: 1 of 3
INSPECTION
TYPES OF QUANTAM OF REFERENCE ACCEPTANCE FORMAT OF
SR. NO. COMPONENTS & OPERATIONS
CHECK CHECK DOCUMENT NORMS RECORD SUBVENDOR/
TPI WGI
VENDOR
1 RAW MATERIAL
ASTM A 216 Gr
CHEM. TEST PER HEAT ASTM A 216 Gr WCB WCB 3.2 Certificate P/R R R
EN 10204/3.1B
ASTM A 216 Gr
PHY. TEST PER HEAT ASTM A 216 Gr WCB WCB 3.2 Certificate P/W W W
EN 10204/3.1B
VISUAL 100% MSS-SP-75 − INTERNAL Q.C P/W R R
1. BODY & BONET ( 35J AVERAGE
REFER NOTE-1) IMPACT TEST VALUE / 28J
PER HEAT ASTM A 370 T.C. P/W W W
( 0 DEG C ) (ONE
SPECIMEN)
INSPECTION
FILMS
INSPECTION
REPORT
ASTM A 216 Gr
CHEM. TEST PER HEAT ASTM A 216 Gr WCB SUPPLIER T.C. P/W R R
WCB
ASTM A 216 Gr
PHY. TEST PER HEAT ASTM A 216 Gr WCB SUPPLIER T.C. P/W W W
WCB
2. PLUG & SEAT RING 10% WITNESS &

VISUAL − P/W W R
100% REVIEW
35J AVERAGE
IMPACT TEST VALUE / 28J INSPECTION
PER HEAT ASTM A 370 P/W W RW
( 0 DEG C ) (ONE REPORT
SPECIMEN)
AISI 4140/AISI
CHEM. TEST PER HEAT AISI 4140/AISI 410 LAB T.C. P/R R R
3. SPINDLE 410
AISI 4140/AISI
PHY. TEST PER HEAT AISI 4140/AISI 410 LAB T.C. P/W W R
410
PAGE NO: 2 of 3
INSPECTION
SR. NO. TYPES OF CHECK SUBVENDOR
OPERATIONS CHECK DOCUMENT NORMS RECORD TPI WGI
/VENDOR
INPROCESS INP
2
100% − − P/W RW R
HEAT NO. REPORT
1. BODY & BONET
INSPECTION
DIMENSIONS 100% APPVD.DRG APPVD.DRG P/W RW R
REPORT
2. PLUG & SEAT RING DIMENSIONS 100% -DO- -DO- -DO- P/W R R
ASTM B 16.34 INSPECTION

350 to 450 BHN REPORT
BROUGHTOUT ITEM
3
A193 B7 A193 B7
PER LOT & & P R R
CHEMICAL A194 Gr.2H A194 Gr.2H
A193 B7 A193 B7
PER LOT & & INSPECTION P R R
PHYSICAL A194 Gr.2H A194 Gr.2H REPORT
1. FASTNERS
10% − − P R R
DIMENSIONS 3.2 Certificate
35J AVERAGE
IMPACT TEST VALUE / 28J
PER LOT ASTM A 370 P W R
( 0 DEG C ) (ONE
SPECIMEN)
PAGE NO: 3 of 3
SR.
INSPECTION
TYPES OF CHECK
TPI WGI
NO. VENDOR
4 FINAL INSPECTION
VISUAL 100% - - - P W R


API 598 API 598
HIGH PRESSURE APPVD.DRG & APPVD.DRG &

100% -DO- P/W W RW
ASPER API 598 CLOSER ( SEAT) TEST API 598 API 598
( REF.ANNEXURE-1 )
100% -DO- P/W W R

API 598 API 598
HIGH PRESSURE
100% API 598 API 598 -DO- P/W W RW
10% WITNESS &
VISUAL - - - P R R
100% REVIEW

100% SPEC P W R
SPEC 60-80μ EACH

WITHIN 300μ
AS PER AS PER Final dossier - IRN,

REVIEW 100% 3.2 Certificate, Insp & P R R
6 FINAL DOCUMENTS SPEC./APPVD.DRG. SPEC./APPVD.DRG.
test report, Drawing
AS PER SPEC./MSS AS PER SPEC./MSS
SP25 SP 25
LEGEND: W - WITNESS, R - REVIEW, TPI - THIRD PARTY INSPECTION, RW - RANDOM WITNESS
2. MATERIAL TEST CERTIFICATE OF CASTING AND FASTENERS SHALL BE IN 3.2 AS PER EN-10204.
GAIL GAS LIMITED
TECHNICAL SPECIFICATION CLIENT JOB NO. ----

FOR CHECK VALVES
TOTAL SHEETS 09
DOCUMENT NO 11 0290 02 08 02 005
B 27/08/09 ISSUED FOR APPROVAL AS DDS PKS
A 26/08/09 ISSUED FOR IDC AS DDS PKS

TABLE OF CONTENTS
CONTENTS PAGE NO.
1.0 SCOPE ………………………………………………………..3
2.0 REFERENCEE DOCUMENTS……………………………..3
3.0 DEFINITIONS……………………………………………......4
4.0 MATERIALS……………………………………………….. ..5
5.0 DESIGN AND CONSTRUCTION.………..........................5
6.0 INSPECTION AND TESTS……………………………… 6
7.0 TESTS CERTIFICATE……………………………..………..7
8.0 PAINTING, MARKING AND SHIPMENT………………… 7
9.0 SPARES AND ACCESSORIES.………………………….. 8
10.0 DOCUMENTATION………………………………………… 8
Document No. Rev

FOR CHECK VALVES 11-0290-02-08-02-005 B
SHEET 2 of 9
1.0 SCOPE
This specification provides minimum requirement for Design, Manufacturing, Inspection, Testing and
Supply of Carbon steel Check Valves covering sizes 2” NB(15mm) through 36”NB( 900mm) for pressure
class 150 # to class 900 # to be used in on-shore pipeline systems handling non- sour hydrocarbons in
liquid or gaseous phase, including Liquid Petroleum Gas (LPG).
API 6D : Specification for Pipeline Valves.
API 6FA : Specification for Fire Test for Valves.
ASME 16.20 : Metallic gasket for pipe flanges – Ring joint or spiral wounds and
jacketed.
ASME Sec VIlI Div.I/Div.II : Boiler and Pressure Vessel Code – Rules for Construction of Pressure
Vessels.
ASTM A370 : Standard Test Methods and Definitions for Mechanical Testing of Steel
Products.
BS 6755-1 : Testing of Valves. Specification for production pressure testing

requirements.
Document No. Rev

SHEET 3 of 9
BS 5352 : Specification for Steel, Wedge Gate, Globe and Check Valves 50 mm
and smaller for the Petroleum, Petrochemical and Allied Industries
BS 1873 : Steel Globe and Globe Stop and Check Valves (Flanged and Butt-
Welding Ends) for the Petroleum, Petrochemical and Allied Industries
MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges and Connecting -
end Flanges of Valves and Fittings.
MSS-SP-25 : Standard marking system for Valves, Fittings, Flanges and Unio
MSS-SP-53 : Quality Standard for Steel Casting and Forgings for Valves, Flanges
and Fittings and Other Piping Components – Magnetic Particle
Examination Method.
ISO 14313 : Petroleum & Natural Gas Industry. Pipeline transportation system –
pipeline Valves
3.0 DEFINTIONS

May : This verbal form indicates a course of action permissible within the
Limits of this standard.
Can : This verbal form used for statements of possibility & capability, whether
material, physical or casual.
Document No. Rev

SHEET 4 of 9
4.0 MATERIALS
4.1 Material for major components of the valves shall be as indicated in Valve Data Sheet. Other
components shall be as per Manufacturer’s standards which will be subject to approval by Purchaser.
4.2 Carbon steel used for the manufacture of valves shall be fully killed.
4.3 The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by
Purchaser, shall not exceed 0.45% (as calculated by the following formula) on check analysis for each
heat of steel used :
6 5 15
4.4 Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 7.5, for all
pressure containing parts such as body, end flanges and welding ends as well as bolting material for
pressure containing parts. Unless specified otherwise, the Charpy impact test shall be conducted at 0°C.
The Charpy impact test specimen shall be taken in the direction of principal grain flow and notched
perpendicular to the original surface of plate or forging.
The minimum average absorbed energy per set of three specimens shall be 35 J with an individual
minimum per specimen of 28 J. No specimen shall exhibit less than 80 percent shear area.
4.5 All process — wetted parts, metallic and non-metallic, shall be suitable for the fluids and service specified
by the Purchaser.
5.1 Following types of check valves, meeting the requirements of applicable standards (refer clause 2. of this
specification) are acceptable:
a) Swing Check Valve
b) Dual Plate Check Valve
c) Axial Flow (Nozzle) Check Valve
Valve design shall be suitable for the service conditions indicated in Valve Data Sheet. Corrosion
allowance indicated in Valve Data Sheet shall be considered in valve design.
5.2 In case of swing check valves, the disc hinge shall be mounted on the valve body and shall not be
attached to the valve body cover. Valve body cover joint shall be of bolted design. Screwed covers shall
not be used.
5.3 Valves shall be provided with non-renewable integral type seats as indicated in Valve Data Sheet. Non-
renewable seats shall be of a design which does not require renewal over the design life of the valve.
Document No. Rev

SHEET 5 of 9
5.4 Valves shall be provided with drain connection as per the Manufacturer’s standard. Drain tapping shall be
provided in a position suitable to completely drain the valve with valve in horizontal position.
5.5 Valve ends shall be either flanged or butt welded or one end flanged and one end butt welded as
indicated in Valve Data Sheet. Flanged end shall have dimensions as per ASME B 16.5 for sizes upto
DN 400mm (16”). Flanges of the flanged end cast body valves shall be integrally cast with the body of the
valve.
5.6 Butt weld end preparation shall be as per ANSI B16.25. The thickness of the pipe to which the valve has
to be welded shall be as indicated in Valve Data Sheet. Valves shall be without transition pups. In case
difference exists between thickness of valve neck end and connecting pipe, the bevel end of valve shall
be prepared as per ANSI B31.8 or ANSI B31 .3, as applicable.
5.7 Valves of size DN 200mm (8”) and above shall be equipped with lifting lugs. Tapped holes and eye bolts
shall not be used for lifting lugs.
5.8 An arrow indicating the direction of flow shall be embossed or cast on the body of all valves.
5.9 All welds shall be made by welders and welding procedures qualified in accordance with the provisions of
ASME Section IX. The welding and repair welding procedure qualification shall include impact test and
shall meet the requirements of clause 3.4 of this specification.
5.10 Repair by welding is permitted for cast body valves subject to written approval by Purchaser and shall be
carried out as per ANSI B16.34. Repair shall be carried out before any heat treatment of casting is done.
6.1 The Manufacturer shall perform all inspection and tests as per the requirements of this specification and
the relevant codes, prior to shipment at his works. Inspection certification shall be confirmed to EN-10204
3.2 Such inspection and tests shall be, but not limited to, the following:
6.1 .1 All valves shall be visually inspected.

6.1 .2 Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.
6.1 .3 Chemical compositions and mechanical properties shall be checked as per relevant material standards
and this specification, for each heat of steel used.
6.1.4 a) Where applicable, the body castings of valves shall be radio graphically
examined on 90% of the surface of critical areas as per ANSI B16.34.
Procedure and acceptance criteria shall be as per ANSI B16.34.
b) Where applicable, valve body made by forging and plate components shall be
ultrasonically examined in accordance with procedure and acceptance standard of
Annexure E of ANSI B16.34.
c) The extent of radiography/ultrasonic examination shall be as follows:
ANSI Class 300 - All sizes - 90%
Document No. Rev

SHEET 6 of 9
6.1.5 All valves shall be tested in compliance with the requirements of applicable standard (refer clause 2.0).
6.2 Purchaser reserves the right to perform stage-wise inspection and witness tests as indicated in clause
6.1 above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and
facilities required for inspection to the Purchaser’s Inspector.
Purchaser reserves the right to require additional testing at any time to confirm or further investigate a
suspected fault. The cost incurred shall be to Manufacturer’s account.
In no case shall any action of Purchaser or its Inspector relieve the Manufacturer of his responsibility for
material, design, quality or operation of valves.
Inspection and tests performed/witnessed by the Purchaser’s Inspector shall in no way relieve the
a) Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used
for the valve construction as per the relevant standards.
b) Hydrostatic test certificates complete with records of timing and pressure of each test.
c) Test reports of radiograph and ultrasonic inspection, as applicable.
d) All other tests reports and certificates as required by applicable standard and this specification.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only those valves which have
been certified by Purchaser’s Inspector shall be dispatched from Manufacturer’s works.
8.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of
corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance
with “Steel Structures Painting Council — Visual Standard SSPC-VlS-1 “.
8.2 All valves shall be marked as per applicable standard. The units of marking shall be metric except
nominal diameter, which shall be in inches.
8.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined
surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All
valves shall be provided with suitable protectors for flange faces, securely attached to the valves.
8.4 Packaging and shipping instructions shall be as per applicable standard.
8.5 On packages, the following shall be marked legibly with suitable marking ink:
Document No. Rev

SHEET 7 of 9
a) Order Number
b) Manufacturer’s Name and trade mark.
c) Valve Size and Rating
d) Tag Number.
e) Minimum & maximum operating temperature.
f) Body material designation.
g) Maximum operating pressure
9.1 Manufacturer shall recommend and quote separately the commissioning and two years of normal
operation.
10.0 DOCUMENTATION
a) General arrangement drawings showing all features together with overall dimensions and actual valve
bore size.
b) Sectional drawing showing major parts with reference numbers and material specification and Quality
assurance plan (QAP).
c) Details of corrosion resistant paint proposed to be applied.
d) Reference list of similar supplies of check valves, including project, year, client, location, size, rating, the
Manufacturer shall furnish services, etc. for the last three years. (The valves shall be proven for service
indicated in Valve Data Sheet).
10.2 Within three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to,
the following drawings, documents and specifications for Purchaser’s approval.
a) Detailed sectional drawings showing all parts with reference numbers and material specification.
b)Assembly drawings indicating overall dimensions, features and painting scheme.

Once the approval has been given by Purchaser, any changes in design, material and method of
manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained
before the valve is manufactured.
Document No. Rev

SHEET 8 of 9
10.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six
copies of all approved drawings, documents and specifications as listed in clause 8.2 above.
following:
a) Test certificates as listed in clause 6.0 of this specification.

b) Manual for installation, erection, maintenance and operation instructions, including a list of
10.5 All documents shall be in English language.
Document No. Rev

SHEET 9 of 9
CLIENT PROJECT: CITY GAS DISTRIBUTION PROJECT
GAIL GAS LIMITED
DEWAS
SIZE/QUANTITY
**
Process Fluid NG/ R-LNG ANSI Rating 300#
Size, mm (inch) 2" & above

Type Swing check
End Connection Type FLG Standard ASME B16.5, B16.47
Flange Face Finish RF 125AARH Special Requirement

Installation Aboveground Stem Ext Length, mm N.A.
Opening/Closing time *
VALVE OPERATION
Actuation Requirement Not Applicable
PART DISCRIPTION SPECIFIED MATERIAL OFFERED
Body ASTM A216 Gr.WCB *
Wedge ASTM A216 Gr.WCB *
Disc ASTM A216 Gr.WCB *
Hinge Pin ASTM A 182 F6 *
Gasket Graphite *
Stud Bolts A193 B7 *
Nuts A194 Gr.2H *
TESTING REQUIREMENT
High Pressure Closure Test API 598
Low Pressure Closure Test API 598
Leak Test API 598
Document No. Rev.

DATA SHEET FOR
11-0290-01-08-03-005 B
CHECK VALVES
SHEET 1 of 2
CLIENT
GAIL GAS LIMITED
PROJECT: CITY GAS DISTRIBUTION PROJECT, DEWAS
SIZE/QUANTITY

PAINTING A/G U/G

Surface Preparation SA 2.5 SA 2.5
Primer 30-40 micrometer 30-40 micrometer
2 - layers polyurethane
Finish 30-40 micrometer
- 1000 microns
Notes
1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along
with this requisition.
2. Valve shall be provided with a pup piece integrally welded (in controlled factory conditions only) to the valve whose
strength shall be equivalent to attached pipe specification.

3. Unless otherwise stated, all tests will be witnessed by the purchaser/ control authority
* To be filled by Vendor ** Refer MTO

Legend: B.W - Butt welded, FLG - Flange,
Document No. Rev.

DATA SHEET FOR
11-0290-01-08-03-005 B
CHECK VALVES
SHEET 2 of 2
REV NO: B
CLIENT: GAIL GAS LIMITED ITEM DESCRIPTION/ QUANTITY: CHECK VALVE
INSPECTION
SR. COMPONENTS & TYPES OF QUANTAM OF REFERENCE ACCEPTANCE FORMAT OF
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD SUBVENDOR/
TPI WGI
VENDOR
1 RAW MATERIAL
ASTM A 216 Gr.
CHEM. TEST PER HEAT ASTM A 216 Gr. WCB WCB 3.2 Certificate P/R R R
EN 10204/3.1B
ASTM A 216 Gr.
PHY. TEST PER HEAT ASTM A 216 Gr. WCB WCB 3.2 Certificate P/W W W
EN 10204/3.1B
1. BODY & BONET VISUAL 100% MSS-SP-75 − INTERNAL Q.C P/W R R
( REFER NOTE-1)
INSPECTION
FILMS
INSPECTION
REPORT
ASTM A 216 Gr.
CHEM. TEST PER HEAT ASTM A 216 Gr. WCB SUPPLIER T.C. P/W R R
WCB
ASTM A 216 Gr.
2. DISC & SEAT RING PHY. TEST PER HEAT ASTM A 216 Gr. WCB SUPPLIER T.C. P/W W W
WCB
10% WITNESS
VISUAL − P/W W R
& 100% REVIEW
REV NO: B
CLIENT: GAIL GAS LIMITED ITEM DESCRIPTION/ QUANTITY: CHECK VALVE
INSPECTION
SR. COMPONENTS & QUANTAM OF REFERENCE ACCEPTANCE FORMAT OF
TYPES OF CHECK SUBVENDOR
NO. OPERATIONS CHECK DOCUMENT NORMS RECORD TPI WGI
/VENDOR
INPROCESS INP
2
100% − − P/W W R
HEAT NO. REPORT
1. BODY & BONET
INSPECTION
DIMENSIONS 100% APPVD.DRG APPVD.DRG P/W W R
REPORT
2. DISC & SEAT RING DIMENSIONS 100% -DO- -DO- -DO- P/W R R
ASTM B 16.34 INSPECTION

350 to 450 BHN REPORT
BROUGHTOUT ITEM
3
A 193 Gr.B7 & A A 193 Gr.B7 & A
PER LOT P R R
CHEMICAL 194 GR 2H 194 GR 2H
INSPECTION
A 193 Gr.B7 & A A 193 Gr.B7 & A REPORT
1. FASTNERS PER LOT P R R
PHYSICAL 194 GR 2H 194 GR 2H
3.2 Certificate
10% − − P R R
DIMENSIONS
CONSULTANT: WGI ITEM DESCRIPTION/ QUANTITY: CHECK VALVE
PAGE NO: 3 of 3
SR.
INSPECTION
TYPES OF CHECK
TPI WGI
NO. VENDOR
4 FINAL INSPECTION
VISUAL 100% - - - P W R


API 598 API 598
HIGH PRESSURE APPVD.DRG & APPVD.DRG &

100% -DO- P/W W RW
ASPER API 598 CLOSER ( SEAT) TEST API 598 API 598
( REF.ANNEXURE-1 )
100% -DO- P/W W R

API 598 API 598
HIGH PRESSURE
100% API 598 API 598 -DO- P/W W RW
10% WITNESS &
VISUAL - - - P R R
100% REVIEW

100% SPEC P W R
SPEC 60-80μ EACH

WITHIN 300μ
AS PER AS PER
REVIEW 100% Final dossier - IRN, P R R
SPEC./APPVD.DRG. SPEC./APPVD.DRG.
3.2 Certificate, Insp &
6 FINAL DOCUMENTS
test report, Drawing
AS PER SPEC./MSS AS PER SPEC./MSS
SP25 SP 25
LEGEND: W - WITNESS, R - REVIEW, TPI - THIRD PARTY INSPECTION, RW - RANDOM WITNESS
GAIL GAS LIMITED
CLIENT JOB NO. -

TECHNICAL NOTES FOR VALVES
TOTAL SHEETS 11
DOCUMENT NO 11 0290 02 08 02 007

TABLE OF CONTENT
1. GENERAL 3
2. DOCUMENTATION 3
3. DESIGN AND CONSTRUCTION 3
4. OPERATION 7
5. INSPECTION & TESTING 8
6. RADIOGRAPHY OF CAST VALVES 9
7. IBR CERTIFICATION 9
8. MARKING 10
9. DESPATCH 10
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 2 of 11
TECHNICAL NOTES FOR VALVES
1.0 GENERAL
1.1 Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries, if any,
such as gear operator, bypasses, drains etc. wherever specified in the specification sheets, subject notes
and other enclosures to the material requisition (MR).
1.2 Vendor shall quote in strict accordance with the valve data / specification sheets, subject technical notes
and all other enclosures to the MR. Deviations to the specification / data sheets, subject technical notes
and other enclosures of the MR, if any, shall be asked as explained in clause 2.0.
1 .3 All codes and standards for manufacture, testing, inspection etc. shall be of latest editions.
2.0 DOCUMENTATION
2.1 Vendor shall submit the following with the offer:
2.1.1 Manufacturer’s complete descriptive and illustrative catalogue I literature.
2.1.2 Detailed dimensioned cross section drawing with parts/material lists, weight etc. for the ball valves, plug
valves, butterfly valves, diaphragm valves and valves to manufacturer’s standard.
2.1.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator, motor, extension
bonnet, extended stems with stands, bypass etc. giving major salient dimensions.
2.1 .4 One copy of the valve specification sheets signed as “Accepted” by the manufacturer with all deviations
marked clearly.
2.1.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve specification
sheets as “Regret” or “No Deviation”.
2.1.6 For subject notes, if there is any deviation, the same shall be listed clausewise.
Even clauses which are acceptable shall be categorically confirmed as “Accepted”.
2.1.7 On failure to submit documents as specified in clauses 2.1.1 to 2.1 .6 above, the offer is likely to he
rejected.
2.2 The following documents shall be submitted after placement of the order
2.2.1 Vendor shall submit for approval drawings mentioned in clauses 2.1.2 & 2.1.3 before start of
manufacture. No other drawing shall be submitted for approval.
2.2.2 Test report shall he supplied for all mandatory tests as per the applicable code. Test reports shall also be
furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.
2.2.3 Material test certificates (physical properties, chemical composition & heat - treatment report) of the
pressure containing parts shall he furnished for the valves supplied. Material test certificates for the other
parts shall also he furnished for verification during inspection.
3.1 Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing
standards, design codes and standards (latest editions) indicated in the respective valve specification
sheets. Any conflict between the requisition, enclosures, specification sheets and referred standard
codes shall be brought to the notice of the purchaser for clarifications. But generally, specification sheets
and enclosures of the requisition including subject notes shall govern. After issue of the Purchase
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 3 of 11
Requisition (PR). no deviation to specification/standards shall be permitted through vendor drawing
approval. Approval of drawings shall be valid only for design / constructional features.
3.2 All flanged valves shall have flanges integral (except forged valves) with the valve body. Flange face
finish shall be normally specified in the valve specification sheet as serrated finish, 125 AARH etc. The
interpretation for range of face finish shall be as follows:
Stock finish : 1000 u in AARH max
Serrated finish / smooth
finish / 125 AARH : serrations with 125 to 250 u m in AARH
Extra Smooth Finish / 63 AARH : 32 to 63 u in AARH
3.3 All weld end valves with bevel end as per ASME B16.25. the contour of bevel shall be as follows:
Material Wall Thickness Weld Contour
Upto 22 mm Figure 2 Type A

Carbon Steel (Except low Temp. Carbon Steel)
> 22 mm Figure 3 Type A
Upto 10 mm Figure 4
Alloy Steel. Stainless Steel &

Low temp. Carbon Steel > 10mm & Upto
Figure 5 Type A
25 mm
3.4 For flanged valves with ring joint flanges, the hardness shall be as follows
Flange Material Mm. Hardness of Groove (BHN)
Carbon Steed 140
1% Cr to 5 Cr 150
Type 304, 316, 321, 347 160
Type 304L, 316L. 140
3.5 Following requirements for check valves shall be met over and above the valve spec sheet requirements:
3.5.1 Unless specified otherwise in the data sheet all check valves 3” & above (except in 900#, 1500# & 2500#
rating) shall have a drain boss at location “G” (Refer Fig. No. 1 of ASME B16.34). A tapped drain hole
with plug shall be provided as per ASME B16.34. Threads shall be as per ASME B1.20.l (Taper) NPT.
3.5.2 Wherever check valve disc assembly is supported from the cover of the check valves the following shall
be ascertained.
i) Positive location / positioning of cover must he provided to ensure correct alignment of the valve
disc.
ii) Hinge pin design must permit accurate alignment of the disc and valve seat.
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 4 of 11
3.5.3 For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and other such
standard devices.
3.6 If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion resistance of the
seat ring base material shall be at least equal to the corrosion resistance of the material of the shell.
3.7 Following valve bypass requirements shall be met
3.7. 1 By-pass requirement for (Gate valves is indicated in the respective data sheets. As a rule, the following
shall be followed
ANSI 150 Class On sizes 26” and above

ANSI 600 Class On sizes 6’ and above
ANSI 2500 Class On sizes 3’ and above
3.7.2 The by-pass piping arrangement shall be such that clearance between main valve body and by-pass
assembly shall be the minimum possible for layout reasons.
3.7.3 By-pass valve shall be a globe valve. The sizes shall be as under
On main valve 4” : 1/2” or more

On main valve > 4” but < 10” : 3/4” or more
On main valve > 10” : 1” or more
3.7.4 Vendor shall supply the by-pass valve duly tested and fitted to the main valve.
Valves with by-pass shall have the direction of flow marked on the main valve. Bypass attachment to the
main valve body shall not be screwed. All fillet welds for bypass installation shall be 100% examined by
DP/MP test.
3.8 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but
not vice-versa.
3.9 Material of construction of yoke shall be minimum equivalent to body / bonnet material.
3.10 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However, integral
stem of cast stainless steel ball valve is acceptable.
3.11 Stelliting / hardfacing by deposition shall be minimum 1.6 mm. Renewable seat rings shall be seal
welded.
3.12 Valves under “NACE” category shall meet the requirements specified in MR-0l-75 unless otherwise
specified.
3.13 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted as per the
following
3.14.1 ASTM A262 Practice “B” with acceptance criteria of “60 mils/year (max” for all materials - forged, rolled,
wrought and casting.
Or
ASTM A262 Practice “E” with acceptance criteria of “No cracks as observed from 20X magnification” for
all materials other than castings. “Microscopic structure to be observed from 250X magnification” in
addition.
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 5 of 11
3.14.2 When specifically asked for in MR for high temperature application of some grades of austenitic stainless
steel (e.g. SS309, 310, 316, 316H etc.) ASTM A262 Practice 7 “C” with acceptance criteria of “15
mils/year (max.)” shall he conducted.
3.14.3 For the IGC test as described in Clauses 3.14.1 & 3.14.2, two sets of samples shall be drawn from each
solution annealing lot. One set shall correspond to the highest Carbon content and the other to the
highest pressure rating. When testing is conducted as per practice “E”, photograph of the microscopic
structure shall be submitted for record.
3.15 All types of 321 or 347 stainless steel valves shall be in a stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature
and holding time for stabilizing heat treatment shall be 900°C and 4 hours respectively.
3.16 Spiral wound bonnet gaskets are to he provided with inner/outer ring except when encapsulated gaskets
type body-bonnet joints are employed. Outer ring may be avoided in case of non-circular spiral wound
gasket used in 150# valve provided the outermost layer of spiral touches the bolts ascertaining the
centering.
3.17 Ball / Plug / Butterfly Valves
3.17.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS 6755 Part 117 shall he carried out on
soft seated ball, plug & butterfly valves and also on lubricated plug valves. The test shall be witnessed
and certified by a third party inspection agency like Lloyds, B.V, DNV.The vendor has to submit test
certificate for the particular design of the valve offered.
3 17.2 Each valve shall he supplied with a lever / wrench except the gear operated / motor operated valves.
3.17.3 Soft-seated ball, plug & butterfly valves shall he supplied with antistatic devices.
3. 17.4 Soft-seated BW / SW end ball valves shall have a 100 mm long seamless pipe nipple welded to each end
of the valve. Nipples are to be welded prior to assembling Teflon seats / seals. Specifications of the
nipples shall be as indicated in the MR.
3.17.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the corresponding
ANSI class (except 10” onwards in Class 150 where the face to-face dimensions shall be as per API 6D
long pattern).
3.17.6 The ball of ball valve shall not protrude outside the end flanges of valve.
3.17.7 Ball valves shall be of floating ball/trunnion mounted type as per following:
8” & below
Floating ball
150#
10’ & above Trunnion mounted
4” & below Floating ball

300#
Trunnion mounted
6” & above
1.5” & below Floating ball

600#
& above
Trunnion mounted
2” & above
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 6 of 11
3.17.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall he limited to one
size lower than the nominal bore.
3.18 The MOVs are to be installed in an open area and the actuators shall be suitable for all weather
conditions. The testing of complete assemblies of MOVs along with the actuators shall be done by the
supplier at his works. Torque details for MOVs shall be furnished by the bidder/supplier.
4.0 OPERATION
4.1 Generally the valves are hand wheel or lever operated. Gear operation shall be provided as under
Size Requiring Gear-

Valve Type Class
Operator
150 Class 14” and larger

Gate Valve & Diaphragm Valve
900 Class 6’ and larger
300 & 600

6” and larger
Class

Globe Valve
Ball Valve/Plug Valve (Other than pressure

balance plug valves)
150, 300
Butterfly Valve 6” and larger
Class
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 7 of 11
For sizes lower than these ranges, hand wheel / lever / wrench shall he provided. For pressure balance
plug valves manufacturer’s recommendation shall be acceptable provided the requirements specified in
clause 4.6 are met.
4.2 Gear operator shall be as under with position indicators for open /close positions and with limit stops.
(Limit stops are not applicable for gate and globe valves).
For Gate / Globe I Totally enclosed bevel gear in grease case with
Diaphragm Valves grease nipples / plugs.
Totally enclosed helical worm or combination of

For Ball! Plug I
helical worm and spur gear in grease case with
Butterfly Valves
grease nipples I plugs.
4.3 Where gear operator is not called for as per Clause 4, 1 but vendor recommends a gear operator, he
shall highlight such case(s).
4.4 Gear operator shall be so designed as to operate effectively with the differential pressure across the
closed valve equal to the cold non-shock pressure rating.
4.5 Ball, plug and butterfly valves, even with wrench or lever operators shall have “Open” position indicators
with limit stops.
4.6 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either side.
Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing to meet the above
requirements, vendor shall offer gear operated valve and quote as per clause 4.3.
5.0 INSPECTION AND TESTING
5.1 Every valve shall he subjected to all the mandatory tests and checks called in the respective codes / data
sheet by WGI inspection or any third party as approved by the purchaser.
5.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks
called for in the respective codes, data sheets etc. by the manufacturer.
5.3 Though the extent of inspection shall be as under, exact extent with hold points shall he decided by WGI
regional inspection and recorded in the form of inspection plan. In case of third party inspection, the
inspection plan shall be approved by the purchaser.
Forged Valves:
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Any mandatory or supplementary test.
4. Hydrostatic test on 10% valves selected on random basis.
5. Strip check is required for 1 % of total ordered quantity of valves (min. 1 No.) against each sheet
no.
Cast Steel Vales
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Review of radiographs/radiographic reports or any other NDT tests wherever applicable as per
data sheet.
4. Any mandatory or supplementary test.
5. Hydrostatic test 100% for body, 10% other test.
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 8 of 11
6. Strip check is required for 1% of total ordered quantity of valves (min. 1 No.) against each sheet
no. Samples for strip check shall be selected at random and shall generally be in the highest size
in the lot.
5.4 In case of motor operated or actuator operated valves, functional / operational checks as per the
requirements of the specifications shall be made on each valve.
5.5 Positive Material Identification (PMI) shall be performed as per the scope and procedures as defined in
the ‘Specification for Positive Material Identification (PMI) at Vendor’s Works’
6.0 RADIOGRAPHY OF CAST VALVES
6.1 Valve castings shall undergo radiographic examination as specified below. However, for sizes 24” &
below in 150# and 16” & below in 300#, radiography percentage specifically mentioned in individual valve
material spec sheet shall govern.
Rating Size Range Radiography

Material
24” and below NIL
150#
26” and above* 100%
All
16” and below NIL
300#
18” and above 100%
600# & above All sizes 100%
*No radiography is required for valves of size > 26” in cooling water service.
Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies 10% or
20% etc. of number of valves ordered against each item number with a minimum of one valve against
each item.
6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B16.34 and
acceptance criteria shall be as per ASME B16.34 Annexure-B. However for areas of casting to be
radiographed for types of valves not covered in ASME B 16.34, vendor shall enclose details of areas to
be radiographed in line with ASME B16.34.
6.3 For random radiography wherever specified in individual data sheets, the sampling shall he per size of
the quantity ordered for each foundry.
6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray/gamma-
ray to get the required sensitivity.
7.0 IBR CERTIFICATION
7.1 For valves described “IBR”, valves shall be in accordance with the latest IBR (Indian Boiler Regulation)
including the requirements specified in the specification.
7.2 For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to the following
Carbon (Max) 0.25%
others (S. P, Mn): As per IBR regulations
The above composition is not valid for non-IBR valves.
7.3 Valves coming under the purview of “IBR” (Indian Boiler Regulations) shall each be individually
accompanied by IBR certificate original in Form Ill-C duly approved by IBR authority / local authority
empowered by the Central Boiler Board of India. Photocopy of original certificate duly attested by the
local boiler inspector where the supplier is located is the minimum requirement for acceptance.
Document No. Rev
TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 9 of 11
7.4 All “IBR” valves shall be painted red in body-bonnet / body-cover joint.
8.0 MARKING
8.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard
referred in specification sheet as applicable. Vendor’s name, valve rating, material designation, nominal
size, direction of flow (if any) etc. shall be integral on the body.
8.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely attached to the
valve body.
8.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper
which cause corrosive attack on heating.
8.4 Carbon Steel I Alloy Steel valves shall he painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).
9.0 DESPATCH
9.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
9.2 Valves shall be protected from rust, corrosion and any mechanical damage during transportation,
shipment and storage.
9.3 Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent
or shall not be harmful to welding.
9.4 Each end of valve shall be protected with the following materials
Flange Face : Wood or Plastic Cover
Beveled End : Wood or Plastic Cover
SW & SCRD : End Plastic Cap
9.5 End protectors of wood/plastic to be used on flange faces shall be attached by at least three bolts and
shall not be smaller than the outside diameter of the flange. However plastic caps for SW & SCRD, end
valves shall be press fit type.
9.6 End protectors to be used on beveled end shall be securely and tightly attached.
9.7 For special service valves additional requirement of dispatch shall be prescribed in data sheet.
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 10 of 11
NOTES
1. The orientation & location of hand wheel of bevel gear operator & the bypass arrangement shall be
strictly as per this sketch.
2. The bypass pipe ends shall be socket/butt welded to the body wall of the main valve.
3. The bypass arrangement shall he properly clamped to & supported by the body of the main valve.
4. Basic design of bypass shall he to MSS-SP-45 & ASME B16.34
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 11 of 11
5. Material of bypass pipe & 90° elbows shall be same or equivalent to the body material.
6. This sketch is applicable for both BGO & NON-BGO Valves.
7. Vendor shall furnish dimensions L1 to L8.
Document No. Rev

TECHNICAL NOTES
FOR VALVES 11-0290-02-08-02-007 B
SHEET 12 of 11
GAIL GAS LIMITED
CLIENT JOB NO.

TECHNICAL SPECIFICATION FOR FLANGES
TOTAL SHEETS 6
DOCUMENT NO 11 0290 02 08 02 010
B 26/08/09 ISSUED FOR CLIENT’S REVIEW GV RM DDS
A 25/08/09 ISSUED FOR IDC GV RM DDS

TABLE OF CONTENT
1.0 SCOPE ..................................................................................................................................... 3
2.0 REFERENCE DOCUMENTS.................................................................................................... 3
3.0 MANUFACTURER’S QUALIFICATION .................................................................................. 3
4.0 MATERIALS ............................................................................................................................ 4
5.0 DESIGN AND MANUFACTURE.............................................................................................. 4
6.0 INSPECTION AND TESTS ...................................................................................................... 5
7.0 TEST CERTIFICATES ............................................................................................................. 5
8.0 MARKING ................................................................................................................................. 5
10.0 PACKING, SHIPPING & HANDLING...................................................................................... 5
Document No. Rev

TECHNICAL SPECIFICATION FOR
FLANGES 11-0290-02-08-02-010 B
SHEET 2 of 6
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture and supply of
following carbon steel flanges of size to be installed in pipeline systems handling hydrocarbons
in liquid or gaseous phase including Liquefied Petroleum Gas (LPG):
- Flanges such as weld neck flanges, blind flanges, spectacle blinds, spacers and blinds, etc.
This 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.
Reference has been made in this specification to the latest edition of the following codes,
standards and specifications:
CODES AND STANDARDS:
ASME B3 1.3 - Process Piping
ASME B3 1.4 - Pipeline Transportation System for Liquid Hydrocarbons and Other
Liquids
ASME B3 1.8 - Gas Transmission and Distribution Piping Systems
ASME B 16.5 - Pipe Flanges and Flanged Fittings
ASME B 16.9 - Factory Made Wrought Steel Butt Welding Fittings (1/2” to 24”)
ASME B 16.25 - Butt-welding Ends
ASME B16.47 - Large Diameter Steel Flanges (26” to 60”)
ASME B 16.48 - Steel Line Blanks
ASME Sec VIll/IX - Boiler and Pressure Vessel Code
ASTM A 370 - Standard Test Methods and Definitions for Mechanical Testing of Steel
Products.
MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges and Unions
MSS-SP-75 - Specification for High Test Wrought Welded Fittings.
MSS-SP-97 - Forged Carbon Steel Branch Outlet Fittings- Socket Welding, Threaded
and Butt Welding Ends.
In case of conflict between various requirements of this specification and reference standard
mentioned above, the more stringent requirement shall apply.
3.0 MANUFACTURER’S QUALIFICATION
Manufacturer, who intends bid for flanges, must possess the records of a successful
proof test, in accordance with the provisions of ASME B 16.9/ MSSSP- 75, as applicable. These
records shall be submitted at the time of bidding.
Document No. Rev

FLANGES 11-0290-02-08-02-010 B
SHEET 3 of 6
4.0 MATERIALS
4.1 The basic material for flanges shall be as indicated in the Material Requisition
Additionally; the material shall also meet the requirements specified hereinafter.
4.2 The Carbon steel used for the manufacture of Flanges shall be fully killed.
4.3 Each heat of steel used for the manufacture of flanges shall have carbon equivalent (CE) not
greater than 0.45 %calculated from check analysis in accordance with following formula:
CE = C + Mn + Cr + Mo +V + Ni +Cu
6 5 15
Carbon contents on check analysis shall not exceed 0.22%.
4.4 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 35 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.
For flanges specified to be used for other hydrocarbon service, the Charpy V-notch test
requirements as stated above are not applicable, unless required by the specified material
standard as a mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition for
flanges, the Charpy V-notch test requirements of applicable material standard shall be complied
with.
4.5 For flanges specified to be used for Gas service or High Vapour Pressure (HVP) liquid service,
hardness test shall be carried out in accordance with ASTM A 370. Hardness testing shall cover
at least 10% per item, per size, per heat, per manufacturing method. A full thickness cross
section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10.
For welded portion maximum difference in hardness of base material, weld material and heat
affected zone shall be less than 80 points in Vickers HV10.
4.6 In case of RTJ flanges, the groove hardness shall be minimum 140 BHN
5.0 DESIGN AND MANUFACTURE
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the requirements of ASME
B16.5 upto sizes DN 600 mm (24”) excluding DN 550 mm (22”), and for sizes DN 550 mm (22”),
DN 650mm (26”) and above ASME B 16.47 (Series B) shall be used.
5.2 Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.3 Flanges manufactured from bar stock is not acceptable.
5.4 All welds shall be made by welders and welding procedures qualified in accordance with
provisions of ASME Sec. IX. The procedure qualification shall include Charpy V-notch test for
weld/heat affected zone and hardness test in accordance with clause 4.4 and 4.5 of this
specification.
5.5 Repair by welding on flanges and parent metal of fittings is not permitted. Repair of weld seam
by welding shall be carried out by welders and welding procedures duly qualified as per ASME
Section IX and records for each repair shall be maintained. Repair welding procedure
qualification shall include all tests, which are applicable for regular production welding procedure
qualification.
Document No. Rev
FLANGES 11-0290-02-08-02-010 B
SHEET 4 of 6
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
6.1.1 All flanges shall be visually inspected. The internal and external surfaces of the
fittings shall be free from any earth strikes, gauges and other detrimental defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5/MSS-SP-
44/ASME B16.47 as applicable for flanges, ASME B 16.48 for spacers and blinds and ASME
B16.9/MSS-SP-75/MSS-SP-97 as applicable for fittings and as per this specification.
6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material
6.2 Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests, as
- indicated in clause 6.1 of this specification at Manufacturer’s Works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable
access and facilities required for inspection, to the Purchaser’s Inspector.
Inspection and tests performed/witnessed by Purchaser’s Inspector shall in no way relieve the
Manufacturer 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 radiography, ultrasonic inspection and magnetic particle examination.
c) Test reports of heat treatment carried out as per the specification.
d) Welding procedures and welders qualification reports.
e) EN 10204 3.2 Certificate stating the quality of relevant Flanges.
8.0 MARKING
8.1 All Flanges shall be marked with:
• PO Number
• Item Code
9.0 DOCUMENTATION
9.1 Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in
clause 7.0 of this specification.
9.2 All documents shall be in English Language only.
10.0 PACKING, SHIPPING & HANDLING
10.1 After all inspection and tests required have been carried out; all external surfaces shall be
thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill
Document No. Rev

FLANGES 11-0290-02-08-02-010 B
SHEET 5 of 6
coating for protection against corrosion during transit and storage. The coating shall be easily
removable in the field.
10.2 Ends of all weld neck flanges shall be suitably protected to avoid any damage during transit.
Metallic or high impact plastic bevel protectors shall be provided for fittings and flange.Flange
face shall be suitably protected to avoid any damage during transit.
Document No. Rev

FLANGES 11-0290-02-08-02-010 B
SHEET 6 of 6
GAIL GAS LIMITED

FOR SEAMLESS FITTINGS
TOTAL SHEETS 06
DOCUMENT NO 11 0290 02 08 02 017
B 27/08/09 ISSUED FOR CLIENT’S REVIEW GV RM DDS
A 26/08/09 ISSUED FOR IDC GV RM DDS

TABLE OF CONTENTS
1.0 SCOPE ........................................................................................................................................... 3
2.0 REFERENCE DOCUMENTS ......................................................................................................... 3
3.0 MANUFACTURE’S QUALIFICATION........................................................................................... 3
4.0 MATERIAL ..................................................................................................................................... 4
5.0 DESIGN AND MANUFACTURE.................................................................................................... 4
6.0 INSPECTION AND TESTS ............................................................................................................ 4
7.0 TEST CERTIFICATES ................................................................................................................... 5
8.0 PAINTING, MARKING AND SHIPMENT....................................................................................... 5
9.0 WARRANTY................................................................................................................................... 6
10.0 DOCUMENTATION........................................................................................................................ 6
Document No.
Rev
11-0290-02-08-02-017 B
SHEET 2 of 6
1.0 SCOPE
1.1 This specification covers the minimum requirements for the design, manufacture and
supply of following fittings in size NB 600mm and smaller to be installed in natural gas
or liquid hydrocarbon pipelines and piping system
1.1.1 Fittings such as tees, elbows, caps etc. shall conform to the requirements of MSS-
SP-75, latest edition. Dimensions standard for Screwed/SW fittings shall be as per
ANSI B16.11.
1.2 All requirements contained in the above standards shall be fully valid unless
cancelled, replaced or amended by more requirements as stated in this specification.
This specification does not cover the above-mentioned items, which are to be
installed in pipeline handling sour hydrocarbon (liquid/gas) service as defined in
NACE standard MR-0175-98.
2.1 Reference has also been made in this specification to the latest edition of the
following codes, standards and specifications:
a) ASME B 31.8 : Gas Transmission and Distribution Piping System
b) ASME B 31.4 : Liquid transportation system for hydrocarbon liquid

petroleum gas, anhydrous ammonia and alcohols
c) ANSI B 16.25 : Butt – Welding Ends
d) ASME B 16.9 : Factory made wrought steel butt welding fittings
e) ASME B 16.11 : Forged Steel Fittings, Socket Welding and Threaded
f) ASTM A 370 : Mechanical Testing of Steel Products
g) ASTM Part-1 : Steel Piping, Tubing, Fittings
h) MSS-SP-25 : Standard marking system for valves, fittings, flanges

and unions.
i) MSS-SP-75 : Specification for High Test Wrought Welding Fittings
j) MSS-SP-97 : Forged carbon steel branch outlet fittings – socket

welding, threaded and butt welding ends.
2.2 In case of conflict between the requirement of MSS-SP-75, & above reference
documents and this specification, the requirements of this specification shall govern.
3.0 MANUFACTURE’S QUALIFICATION
Manufacturer who intends bidding for fittings must possess the records of a
successful proof test in accordance with the provisions of relevant MSS-SP-75 and/or
ANSI B16.9/ANSI B16.11 as applicable. These records shall be submitted at the time
of bidding.
Document No.
Rev
11-0290-02-08-02-017 B
SHEET 3 of 6
4.0 MATERIAL
4.1 The basic material for fittings shall be as indicated in the Purchase Requisition
Additionally, the material shall also meet the requirements specified hereinafter.
4.2 Steel used shall be fully killed.
4.3 Each heat of steel used for the manufacture of fittings shall have carbon equivalent
(CE) not greater than 0.45 calculated from check analysis in accordance with the
following formula:
Mn Cr + Mo + V NI + Cu
CE = C + ------- + ------------------- + ----------------
6 5 15
Carbon contents on check analysis shall not exceed 0.22%.
4.4 Unless specified otherwise, Charpy V-notch test shall be conducted for each heat of
steel, in accordance with the impact test provisions of ASTM A370 at temperature of
0ºC. The average absorbed impact energy values of three full-sized specimens shall
be 35 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.
4.5 Hardness testing shall be carried out by Manufacturer in accordance with applicable
ASTM code.
5.0 DESIGN AND MANUFACTURE
5.1 Fittings such as tees, elbows and reducers shall be seamless type and shall conform
to ASME B16.9 for sizes 50mm (2”) NB and above ASME B16.11 for sizes below
50mm (2”) NB.
5.2 Fittings such as weldolets, sockolets, etc. shall be manufactured in accordance with
MSS-SP-75.
5.3 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 90º from the extrusion. Fittings shall not have any circumferential
joints.
5.4 All butt weld ends shall be bevelled as per ASME B16.25.
5.5 Repair by welding on parent metal of the fittings is not allowed.
6.1 The Manufacturer shall perform all inspection and tests as per the requirements of
this specification and the relevant codes, prior to shipment, at his works. Such
inspection and tests shall be, but not limited to the following:
Document No.
Rev
TECHNICAL SPECIFICATION 11-0290-02-08-02-017 B
SHEET 4 of 6
6.1.1 Visual inspection.
6.1.2 Dimensional checks as per MSS-SP-75 for fittings/applicable standards.
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 Para 6.1 at manufacturer’s works prior to shipment. Manufacturer shall
give reasonable notice of time and shall provide without charges reasonable access
and facilities required for inspection to the Purchaser’s Inspector
Inspection and tests performed/witnessed by Purchaser’s Inspector shall in no way

relieve the Manufacturer’s obligation to perform the required inspection and test.
Manufacturer shall produce the certificates (in original) for all, including, but not
limited, the following tests:
a) Certificates of chemical analysis and mechanical properties of the material used for
construction as per this specification and relevant standards.
b) Certificates of required non-destructive tests inspections.
c) Certificates of all other tests as required in this specification.
d) In case any of the said certificates is not available during the final test, the supply
shall be considered incomplete.
8.1 All fittings shall be marked as per MSS-SP-25.
8.2 All loose material and foreign material i.e. rust, grease, etc. shall be removed from the
inside and outside of the fittings.
8.2 Ends of all fittings shall be suitably protected to avoid any damage during transit.
Metallic bevel protectors shall be used for fittings of size 18” and larger each item
shall be marked with indelible paint with the following data:
a) Manufacturer marking
b) Material Specification
c) Size & Sch.
d) Heat No.
8.4 Package shall be marked legibly with suitable marking ink to indicate the following:
a) Order Number
b) Package Number
c) Manufacturer’s Name
Document No.
Rev
SHEET 5 of 6
d) Type of Fitting
e) Size (inches) and Wall Thickness (mm)
9.0 WARRANTY
Manufacturer will reimburse purchaser for any fitting furnished on this order that fails
under field hydrostatic test if such failure is caused by a defect in the fitting, which is
outside the acceptance limits of this specification. The reimbursement cost shall
include fitting, labour and equipment rental for finding, excavation, cutting out and
installation of replaced fitting in position. The field hydrostatic test pressure will not
exceed that value which will cause a calculated hoop stress equivalent to 100% of
specified minimum yield strength for the pipe with which the fitting is to be attached
without impairing its serviceability.
10.0 DOCUMENTATION
10.1 All documents shall be in English Language.
10.2 At the time of bidding bidder shall submit the following documents:
a) Reference list of previous supplies of similar fittings of similar specification.
b) Clause wise list of deviation from this specification, if any.
c) Brief description of the manufacturing and quality control facilities of the

Manufacturer’s work.
d) Manufacturer’s qualification requirement as per section 3.0 of this specification.
e) Quality Assurance Plan (QAP).
10.3 Within two weeks of placement of order, the manufacturer shall submit four copies of
method of manufacture and quality control procedure for raw material and finished
product.
Once the approval has been given by Purchaser, any change in material, method of
manufacture and quality control procedure shall be notified to Purchaser whose
approval in writing of all changes shall be obtained before the fittings are
manufactured.
10.4 Within four weeks from the approval date, Manufacturer shall submit six copies of the
approved documents as stated in Para 10.3 of this specification.
10.5 Prior to shipment, Manufacturer shall submit six copies of test certificates as listed in
Para 7.0 of this specification.
Document No.
Rev
SHEET 6 of 6
GAIL GAS LIMITED
TECHNICAL SPECIFICATION CLIENT JOB NO. -

FOR
ASSORTED PIPES TOTAL SHEETS 08
DOCUMENT NO 11 0290 02 08 02 006

TABLE OF CONTENT
1.0 GENERAL 3
2.0 IBR PIPES 4
3.0 HYDROSTATIC TEST 5
4.0 MARKING AND DISPATCH 5
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 2 of 8
1.0 GENERAL
1.1 All pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment,
hydro test and other testing and marking requirements shall conform to the latest codes and standards
.Deviation(s), if any, shall be clearly highlighted in the offer.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable Material specifications. Test
reports shall also be furnished for any supplementary tests as specified in theClauses 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 employ automatic welding.
1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to14 meters, respectively
Seamless and E.R.W. pipes shall not have any circumferential seam joint in a random length. However,
in case of E.FS.W. pipe, in one random length one welded circumferential seam same quality as
longitudinal weld is permitted. This weld shall be at least 2.5 m from either end.
1.5
a) The longitudinal seams of the two portions shall be staggered by 90°. Single random length in such
cases shall be 5 to 7m.
b) Unless otherwise mentioned in the respective material code, E.FS.W. pipes < 36” shall not have
more than one longitudinal seam joint and E.FS.W. pipes >36” shall not have more than two
longitudinal seam joints.
1.6 Pipe with screwed ends shall have NPT external taper pipe threads conforming to ASME/ ANSI
B1.20.1upto 1.5” NB & IS:554 for 2” to 6” NB.
1.7 Pipe with bevelled ends shall be in accordance with ASME B16.25. Weld contours shall be as follows

Carbon Steel (Except Low Temp. Carbon Steel) Upto 22mm Figure 2 Type A
> 22mm Figure 3 Type A
Alloy Steel Stainless Steel & Low Temp. Carbon
Upto 10 mm Figure 4
Steel
>10 mm & Upto 25 mm Figure 5 Type A
>25mm Figure 6 Type A
1.8 Galvanized pipes shall be coated with zinc by hot dip process conforming to IS: 4736/ ASTM A 153.
1.9 All austenitic stainless steel pipes shall be supplied in solution annealed condition.
1.10 I.G.C. Test for Stainless Steels
1.10.1 For all austenitic stainless steel pipes, intergranular corrosion test shall have to be conducted as
per following:
ASTM A262 practice “B “with acceptance criteria of “60 mils/ year (max.)”
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 3 of 8
OR
ASTM 262 practice “E” with acceptance criteria of “No cracks as observed from 20X magnification” &
“Microscopic structure to be observed from 250X magnification”.
1.10.2 When specifically asked for high temperature application of some grades of austenitic stainless steel (eg
.SS 309, 310, 316, 316H etc.), ASTM A262 practice “C” with acceptance criteria of “15 mils/ year
(max.)” shall have to be conducted.
1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from each solution
annealing lot; one set corresponding to highest carbon content and the other corresponding to the
highest pipe thickness. When testing in is conducted as per Practice “E”, photograph of microscopic
structure shall be submitted for record.
1.11 All welded pipes indicated as ‘CRYO’ & ‘LT’ in shall be impact tested per requirement and acceptance
criteria of ASME B31.3. The impact test temperature shall be —196° C & 0° C for stainless steel and
carbon steel, respectively, unless specifically mentioned otherwise in MR.
1.12 Specified heat treatment for carbon steel & alloy steel and solution annealing for stainless steel pipes
shall be carried out after weld repairs. Number of weld repairs at the same spot shall be restricted to
maximum two by approved repair procedure.
1.13 For black or galvanised pipes to IS: 1239, the minimum percentage of elongation shall be 20%.
2.0 IBR PIPES
2.1 IBR Documentation
2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form lilA, duly approved
and counter signed by IBR authority local authority empowered by the Central Boiler Board of India.
Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is
located is the minimum requirement for acceptance.
2.1.2 For materials 1 1/4 Cr- 1/2 Mo (ASTM A335 Gr. P11 A691 Gr. 1 1/4 Cr) & 2 1/4 Cr-iMo (ASTM
A335r.P22/ A691 Gr. 2 1/4 Cr.), from Ill-A approved by IBR shall include the tabulation of E , S & Sr
values for the entire temperature range given below. Et, S & Sr values shall be such that throughout the
temperature range.
E t / 1.5 ≥ Sa
Sr/1.5 ≥ Sa
Sc ≥ Sa
where,
Sa : Allowable stress at the working metal temperature.
Et : Yield point (0.2% proof stress at the working metal temperature.
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. at the working metal temperature and in
no case more than 1.33 times the lowest stress to produce rupture at this temperature.
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 4 of 8
SA (psi) Temperature (°F)
Material 500 600 650 700 750 800 850 900 950 1000 1050 1100
A335 Gr. P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
A 691 Gr. 1½
18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
Cr
A335 Gr. P2/
A691 Gr. 2 17900 17900 17900 17900 17900 17800 14500 12800 10800 7800
5100 3200
1/4 Cr
Note : Sa values given above are as per ASME B31.3-1999. Values shall be as per the latest
edition prevailing.
2.2 For carbon steel pipes under IBR, the chemical composition shall conform to the following:
Carbon (max.): 0.25%
Others (S, P, Mn): As prescribed in IBR regulation.
The chemical composition as indicated in this clause is not applicable for pipes 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, the item code & special conditions like “IBR”, “ CRYO”, “NACE”,
etc., shall also be marked.
4.2 Pipes under “IBR”, “CRYO”, & “NACE” shall be painted in red stripes, light purple brown stripes & canary
yellow stripes, respectively, longitudinally throughout the length for easy identification.
4.3 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead or copper
which cause corrosive attack on heating.
4.4 Pipes shall be dry, clean and free from from moisture, dirt and loose foreign materials of any kind.
4.5 Pipes shall be protected from rust, corrosion and mechanical damage during transportation, shipment
and storage.
4.6 Rust preventive used on machined surfaces to be welded shall be easily removable with petroleum
solvent and the same shall not be harmful to welding.
4.7 Both ends of the pipe shall be protected with the following material:
Plain end : Plastic cap

Bevel end : Wood, Metal or Plastic cover
Threaded end : Metal or Plastic threaded cap
4.8 End protectors to be used on bevelled ends shall be securely and tightly attached with belt or wire.
4.9 Steel end protectors to be used on galvanised pipes shall be galvanized.
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 5 of 8
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 Standard

ASTM A 106 Gr. B ASTM A 530
API 5L Gr. B, Seamless API 5L
API 5L, E.R.W. API 5L
API 5L, Spiral API 5L
ASTM A333 Gr.3 & 6, Seamless ASTM A 530
ASTM A 333 Gr. 3 & 6, E.R.W. ASTM A 530
b) Seamless Alloy Steel

ASTM A335 GR.P1, P12, P11, P22, P5 P9 ASTM A 530
ASTM A268 TP 405, TP41O ASTM A 530
c) Seamless Stainless Steel

ASTM A312 GR.TP304,304L,304H,
ASTM A 530
316,316L, 316H, 321,347
d) Seamless Nickel Alloy

ASTM B161 UNS No.2200 ASTM B161
ASTM B407 UNS No. 8800 ASTM B407
e) Welded Nickel Alloy

ASTM B725 UNS No.2200,4400 ASTM B725
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 6 of 8
3.2.2 Electric Fusion Welded
a) Carbon Steel & Alloy Steel E.FS.W. (16” & above )

API 5L Gr.B P=2ST / D
S=90% OF SMYS (except for
ASTM A 671 Gr. CC65, 70 (Cl.32)
API 5L Gr.B)
ASTM A 672 Gr.C60,65,70 (Cl.12,22)
S=85% of SMYS for API 5L
ASTM A 671 Gr.CF60,65,66,70 (Cl.32)
Gr.B
ASTM A 691 Gr. ½ Cr, 1Cr, 1 1/4Cr ,2
T=Nominal Wall Thickeness
1/4Cr,5Cr,9Cr (Cl.42)
D=O.D. of pipe
b) Stainless Steel E.FS.W. ( 2” to 6”)
The hydrostatic test pressure in kg /cm² for the following materials shall be as given below:
Material Gr.1: ASTM A312 TP304/ 304H/ 316/ 316H/ 321/347 welded
Material Gr.2: ASTM A312 TP 304L/ 316L welded
Pipe Schedule: S l0 Pipe Schedule: S 40 Pipe Schedule: S 80

Size
Material Material Material Material Material Material
Gr.1 Gr.2 Gr.1. Gr.2 Gr.1 Gr.2
2” 100 80 155 130 230 190
3” 80 60 155 130 230 190
4” 80 50 155 130 230 190
6” 65 35 90 75 155 130
c) Stainless Steel E.FS.W. ( 8” and above)
Material Standard Test Pressure standard
ASTM A358 TP P=2ST/D

304L,304,304H,316L,316,316H,321,347 S=85% of SMSYS
(Classes 1, 3 & 4) T=Nominal wall thickness
D=O.D. of pipe
ASTM A358 TP 304L, 304, 304H, 316L, P=2ST/D

316 S=72% of SMYS
316H, 321, 347 (Classes 2 & 5) T=Nominal Wall thickness
D=O.D. of pipe
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 7 of 8
3.2.3 Carbon Steel Pipes to IS Standards

IS : 1239 IS : 1239
IS : 3589 IS : 3589
Document No. Rev

FOR 11-0290-02-08-02-006 B
ASSORTED PIPES
SHEET 8 of 8
GAIL GAS LIMITED
CLIENT JOB NO. -

TECHNICAL NOTES FOR BOLTS, NUTS & GASKETS
TOTAL SHEETS 05
DOCUMENT NO 11 0290 02 08 02 009

TABLE OF CONTENT
1.0 TECHNICAL NOTES FOR BOLTS AND NUTS 3
2.0 TECHNICAL NOTES FOR GASKETS 4
Document No. Rev

TECHNICAL NOTES FOR BOLTS,
NUTS & GASKETS 11-0290-02-08-02-009 B
SHEET 2 of 5
Abbreviations:
AARH : Average Arithmetic Root Height

BHN : Brinnel Hardness Number
CS : Carbon Steel
MR : Material Requisition
PMI : Positive Material Identification
RTJ : Ring Type Joint
1.0 TECHNICAL NOTES FOR BOLTS AND NUTS
1.1 The process of manufacture, heat treatment, chemical & mechanical requirements and marking for all
stud bolts, bolts, jack screws & nuts shall be in accordance with the codes/standards and specifications
given in the requisition. The applicable identification symbol in accordance with the material specification
shall be stamped on each bolt and nut. Vendor shall strictly comply with MR/PR stipulations and no
deviations shall be permitted.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material specifications.
1.2.2 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and Mechanical
Requirement)
1.2.3 PMI shall be performed as per the scope and procedures defined in the Specification for PMI at
Vendor’s Works.
1.2.4 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453 bolting
material irrespective of the temperature.
1.3 All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jackscrews and ANSI B18.2.2 for nuts.
1.4 Threads shall be unified (UNC for 1” dia and 8UN for > 1” dia) as per ANSI B.1.1 with class 2A fit for
studs, M/c bolts and jackscrews and class 2B fit for nuts.
1.5 Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall be in
accordance with the requirement of ANSI B 16.5.
1.6 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot
forged process and stamped as per respective material specification.
1.7 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be rounded.
1.8 Each size of studs & rn/c bolts with nuts and jackscrews shall be supplied in separate containers marked
with size and material specifications. ‘CRYO’ shall be marked additionally in case ‘CRYO’ is specified in
the requisition.
1.9 All items shall be inspected and approved (stagewise) by Wood Group Engineering India Pvt Ltd.
1.10 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
1.11 All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition unless
specified otherwise in the material specification.
Document No. Rev

NUTS & GASKETS 11-0290-02-08-02-009 B
SHEET 3 of 5
1.12 Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material specification and
also where the material specification is indicated as “CRYO”. For S.S. nuts and bolts minimum impact
energy absorption shall be 27 Joules and test temperature shall be - 196°C unless mentioned otherwise.
For other materials impact energy and test shall be as per respective code.
1.13 Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested as per supplementary
requirement S3 of ASTM A 193.
1.14 When specified as galvanized, the studs, M/C bolts and nuts shall be ‘hot dip zinc coated’ in accordance
with requirements of ‘class C’ of ‘ASTM A 153’. As an alternative, electrogalvanizing as per IS 1573,
‘Service Grade Number 2’ is also acceptable.
1.15 All Stud Bolts of Bolt diameter size 1” and above shall be provided with three nuts irrespective of
whatever has been specified elsewhere in the MR.
2.0 TECHNICAL NOTES FOR GASKETS
2.1 All gaskets shall conform to the codes/standards and technical specifications as given. Vendor shall
strictly comply with technical specification and no deviations shall be permitted.
2.2 Process of manufacture, dimensions and tolerances not specified in specification shall be in accordance
with the requirements of the manufacturer’s standards.
2.3 Testing
2.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the codes & standards specified
in this technical specification.
2.3.2 Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test reports on
samples.
2.3.3 For Spiral wound material following shall be furnished:
a) Manufacturer’s test certificate for filler material and spiral material as per the relevant material
specifications.
b) Manufacturer’s test certificate for raw materials and tests for compressibility/ seal-ability & recovery
as per the relevant material specifications.
2.4 Full face gaskets shall have bolt holes punched out.
2.5 Filler material for spiral wound gaskets shall not have any colour or dye.
2.6 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall be CS unless
otherwise specified.
2.7 For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip material. In
addition to the requirements as per code and standard as specified in the technical specification. Inner
rings shall be provided for the following:
a) Sizes 26” and above.
b) Class 900 and above.
2.8 Hardness of metallic RTJ gaskets shall not exceed the values specified below:
Document No. Rev

NUTS & GASKETS 11-0290-02-08-02-009 B
SHEET 4 of 5
Ring Gasket Material Maximum Hardness (BHN)
Soft Iron 90
Carbon steel 120
5Cr.1/2Mo 130
2.9 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.
2.10 Gaskets of different types and sizes shall be placed in separate shipping containers and each container
clearly marked with the size, rating, material specification and item code.
2.11 All items shall be inspected and approved by WGI / owner / TPI
2.12 Any additional requirements specified in this technical specification, shall be fully complied with.
2.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto 24” (except 22”
size) and to ASME B 16.47B above 24” unless specified otherwise. For 22” size, the matching flange
standard shall be ASME B 16.47B unless specified otherwise.
2.14 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto 24” (except
22”size) and to ASME B16.47B above 24” unless specifically mentioned otherwise. For 22”
size, the matching flange standard shall be ASME B 16.47B unless specified otherwise.
Document No. Rev

NUTS & GASKETS 11-0290-02-08-02-009 B
SHEET 5 of 5
GAIL GAS LIMITED
CLIENT JOB NO.

STANDARD SPECIFICATION FOR INSPECTION, FLUSHING
AND TESTING OF PIPING SYSTEMS
TOTAL SHEETS 08
DOCUMENT NO 11 0290 02 08 02 014

ABBREVIATIONS:
PMI - Positive Material Identification
NDT - Non Destructive Testing
P&ID - Process and Instrumentation Diagram
A.S. - Alloy Steel
C.S. - Carbon Steel
C.I. - Cast Iron
S.S. - Stainless Steel
LTCS - Low Temperature Carbon Steel
NACE - National Association of Corrosion Engineers
Document No. Rev

STANDARD SPECIFICATION FOR
INSPECTION, FLUSHING 11-0290-02-08-02-014 B
SHEET 2 of 8
TABLE OF CONTENT
1.0 SCOPE ........................................................................................................... 4
2.0 DEFINITION 4
3.0 INSPECTION.................................................................................................. 4
4.0 FLUSHING ..................................................................................................... 4
5.0 TESTING ........................................................................................................ 5
Document No. Rev

SHEET 3 of 8
1.0 SCOPE
This specification covers the general requirements for inspection, flushing and testing of piping systems.
However testing of steam lines falling under IBR shall also be governed by Indian Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.
2.0 DEFINITIONS
Shall : This verbal form indicates requirements strictly to be followed in order to confirm to the
standards and from which no deviation is permitted.
Should : This verbal form indicates that among several possibilities one is particularly suitable
without mentioning or excluding others or that a certain course of action is preferred
but not necessarily required.
May : This verbal form indicates a course of action permissible within the limits of this
standard.
Can : This verbal form used for statements of possibility & capability, whether material,
physical or casual.
3.0 INSPECTION
During various stages and after completion of fabrication and erection, the piping system shall be
inspected by the Engineer-In-Charge to ensure that:
- Proper piping material has been used.
- Piping has been erected as per drawings and instructions of Engineer-In-Charge.
- All supports have been installed correctly.
- Test preparations mentioned in this specification have been carried out.
4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not
desirable, to clean the pipe of all dirt, debris or loose foreign material Required pressure for water
flushing shall meet the fire hydrant pressure or utility water pressure.
For air flushing, the line / system will be pressurized by compressed air at the required pressure which
shall be 50 PSI maximum. The pressure shall then be released by quick opening of a valve, already in
line or installed temporarily for this purpose. This procedure shall be repeated as many times as required
till the inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, Rota meters, safety valves and other instruments like
thermo wells which may interfere with flushing shall not be included in flushing circuit.
The screens / meshes shall be removed from all permanent strainers before flushing. Screens/meshes
shall be reinstalled after flushing but before testing.
Document No. Rev

SHEET 4 of 8
During flushing temporary strainers shall be retained. These shall be removed, cleaned and reinstalled
after flushing but before testing.
In case of equipment such as column, vessel, exchanger etc. form part of a piping circuit during flushing,
this shall be done with the approval of Engineer-In-Charge. However, equipments thus included in the
circuit shall be completely drained and dried with compressed air after flushing is completed.
During flushing discharged water/air shall be drained to the place directed by the Engineer-In-Charge. If
Necessary, proper temporary drainage shall be provided by the contractor.
Care shall be taken during flushing so as not to damage/spoil work of other agencies. Precautions shall
also be taken to prevent entry of water/foreign matter into equipments, electric motors, instruments,
electrical installations etc. in the vicinity of lines being flushed.
The contractor shall carry out all the activities required before, during and after the flushing operation,
arising because of flushing requirements, such as but not limited to the following
Dropping of valves, specials, distance pieces, inline instruments and any other piping part before
flushing. The flanges to be disengaged for this purpose shall be envisaged by the contractor and
approved by the Engineer-In-Charge. These flanges shall be provided with temporary gaskets at the time
of flushing.
After flushing is completed and approved, the valve distance pieces, piping specials etc. shall be
reinstalled by the contractor with permanent gaskets. However, flanges at equipment nozzles and other
places where isolation is required during testing, only temporary gaskets shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each piping system for the
flushing done in the Performa provided/approved by the Engineer-in-Charge.
5.0 TESTING
5.1 Extent of Testing
With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be tested
irrespective of whether or not they have been pressure tested prior to site welding of fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be included in the system
with the prior approval of Engineer-In-Charge if the test pressure specified is equal to or less than that for
the vessels and other equipments.
Pumps, compressors and other rotary equipments shall not be subjected to field test pressure.
Lines which are directly open to atmosphere such as vents, drains, safety valves discharge need not be
tested, but all joints shall be visually inspected. Wherever necessary, such lines shall be tested by
continuous flow of fluid to eliminate the possibility of blockade. However, such lines if provided with block
valve shall be pressure tested up to the first block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working pressure
of the valve. Test pressure applied to valves shall not be greater than the manufacturer’s
recommendation nor less than that required by the applicable code. Where allowable seat pressure is
less than test pressure, test shall be made through an open valve.
Instruments in the system to be tested shall be excluded from the test by isolation or removals, unless
approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting and draining such as orifice plates etc. shall not be
installed unless testing is complete.
Document No. Rev

SHEET 5 of 8
Control valves shall not be included in the test system. Where bypasses are provided test shall be
performed through the bypass and necessary spool shall be used in place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test pressure shall not be
installed until the system has been tested. Where piping systems to be tested are directly connected at
the battery limits to piping for which the responsibility rests with other agencies, the piping to be tested
shall be isolated from such piping by physical disconnection such as valve or blinds.
5.2 General Requirements / Test Preparation for Testing
Testing shall be carried out with permanent gaskets installed unless specified otherwise or instructed by
the Engineer-in-Charge.
No pressure test shall be carried out against closed valve unless approved by the Engineer-in-Charge.
The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence and
program, to enable him to be present for witnessing the test. The Contractor shall be fully responsible for
making arrangements with the local boiler inspector to witness the tests for steam lines falling under IBR.
IBR certificates for these tests shall be obtained in the relevant IBR forms and furnished to the Engineer-
in-Charge.
Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale, debris and
other loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points and the systems purged
of air before the test pressure is applied.
Wherever in the line any void exists due to any reasons, like absence of control valves, safety valves,
check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the test. Before
pressuring the lines, each weld joint shall be cleaned by wire brush to free it from rust and any other
foreign matter.
Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted between the
companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable
design code.
Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or
wherever equipment or pipe spools have been recovered or disconnected prior to hydrostatic testing,
shall be blinded off by using standard blind flanges of same rating as the piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest point in the piping
system to be tested, to avoid overstressing of any of the lower portions of the system. For longer lines
and vertical lines, two or more pressure gauges shall be installed at locations decided by the Engineer-in-
Charge.
For lines containing check valves any of the following alternatives shall be adopted for pressure testing:
Whenever possible pressurize up-stream side of valve. Replace the valve by a temporary spool and
reinstall the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line separately and remove
the blind after testing. At these flanges, temporary gaskets shall be provided during testing and shall be
replaced by permanent gaskets subsequently.
For check valves in lines 1 1/2” and below flapper or seat shall be removed during testing (if possible).
After completion of testing the flapper/seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary supports during testing
as directed by the Engineer-in-Charge.
Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of
Document No. Rev
SHEET 6 of 8
the fluid would overload the support. Retaining pins for spring supports shall be removed only after
testing is completed and test fluid is completely drained.
When testing any piping system, air or steam of approximately 2 kg/cm2g may be used as preliminary
test to detect missing gaskets etc. as this avoids the necessity of draining the line to make repairs.
However, steam shall not be used for this purpose, if the steam temperature is more than the design
temperature of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is continuously
jacketed, before it is jacketed. The outer jacket shall be tested separately as a system. For piping with
discontinuous jacketing the core pipe and the jacket shall be tested as separate continuous systems.
5.3 Testing Media, Test Pressure and Test Pressure Gauges
5.3.1 Testing Media
In general all pressure tests shall be hydrostatic using iron free water, which is clean and free of silt.
Maximum chlorine content in water for hydrostatic testing for S.S. piping shall be 15-20 ppm. Air shall be
used for testing only if water would cause corrosion of the system or overloading of supports etc. in
special cases as directed by Engineer-in-Charge.
Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc. shall be
used as the testing medium, with due consideration to the hazards involved. These test fluids shall be
specified in the line list given to the contractor.
5.3.2 Test Pressure
The hydrostatic/pneumatic test pressure shall be as indicated in the line list or as per the instruction of
Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the following:
Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress, maximum length of piping
shall be included in each test.
5.3.3 Test Pressure Gauge
All gauges used for field testing shall have suitable range so that the test pressure of the various systems
falls in 40% to 80% of gauge scale range. Gauge shall be of a good quality and in first class working
condition.
Prior to the start of any test or periodically during the field test program, all test gauges shall be calibrated
using a standard dead weight gauge tester or other suitable approved testing apparatus. Any gauge
showing an incorrect zero reading or error of more than ± 2% of full scale range shall be discarded. The
Engineer-in-Charge shall check the accuracy of master pressure gauge used for calibration.
5.4 Testing Procedure
5.4.1 Hydrostatic Test
All vents and other connections used as vents shall be left open while filling the line with test fluid for
complete removal of air. In all lines for pressurizing and depressurizing the system, temporary isolating
valves shall be provided if valves vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved by the Engineer-incharge.
Document No. Rev
SHEET 7 of 8
Pressure shall be applied by means of a suitable test pump or other pressure source which shall be
isolated from the system as soon as test pressure is reached and stabilized in the system.
A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the
required pressure.
The pump shall be attended constantly during the test by an authorized person. The pump shall be
isolated from the system whenever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all joints
for leakage or signs of failure. Any joint found leaking during a pressure test shall be retested to the
specified pressure after repair. Test period shall be maintained for a minimum of three hours.
The pump and the piping system to be tested are to be provided with separate pressure indicating test
gauges. These gauges are to be checked by the standard test gauge before each pressure test.
Care shall be taken to avoid increase in the pressure due to temperature variation during the test.
5.4.2 Air Test
When testing with air, pressure shall be supplied by means of a compressor. The compressor shall be
portable type with a receiver, after cooler and oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so that the joints can
be examined for leaks.
All other details shall be same as per hydro testing procedure (specified above)
5.5 Completion of Testing
After the hydrostatic test has been completed, pressure shall be released in a manner and at a rate so as
not to endanger personnel or damage equipments.
All vents and drains shall be opened before the system is to be drained and shall remain open till all
draining is complete, so as to prevent formation of vacuum in the system. After draining, lines / systems
shall be dried by air.
After testing is completed the test blinds shall be removed and equipment/ piping isolated during testing
shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for
tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop / circuit
including equipments (except rotary equipments).
Pressure test shall be considered complete only after approved by the Engineer-in-Charge. Defects, if
any, noticed during testing shall be rectified immediately and retesting of the system / line shall be done
by the contractor at his cost.
5.6 Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping system, for the
pressure test done in the Performa provided/approved by the Engineer-in-Charge. Records shall also be
submitted for the PMI.
Document No. Rev

SHEET 8 of 8
GAIL GAS LIMITED
CLIENT JOB NO.

STANDARD SPECIFICATION FOR FABRICATIOIN AND
ERECTION OF PIPING
TOTAL SHEETS 13
DOCUMENT NO 11 0290 02 08 02 012

ABBREVIATIONS:
PMI - Positive Material Identification
NDT - Non Destructive Testing
P&ID - Process and Instrumentation Diagram
A.S. - Alloy Steel
C.S. - Carbon Steel
C.I. - Cast Iron
S.S. - Stainless Steel
LTCS - Low Temperature Carbon Steel
NACE - National Association of Corrosion Engineers
Document No. Rev

FABRICATION AND ERECTION OF
PIPING 11-0290-02-08-02-012 B
SHEET 2 of 13
TABLE OF CONTENT
1.0 SCOPE ...................................................................................................................................... 4
2.0 SCOPE OF WORK OF CONTRACTOR................................................................................... 4
3.0 BASIS OF WORK ..................................................................................................................... 5
4.0 FABRICATION.......................................................................................................................... 6
5.0 ERECTION................................................................................................................................ 9
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 3 of 13
1.0 SCOPE
This specification covers general requirements of fabrication and erection of above ground and trench
piping systems at site. The specification covers the scope of work of contractor, basis of work to be
carried out by contractor and standards, specifications and normal practice to be followed during
fabrication and erection by the contractor.
2.0 SCOPE OF WORK OF CONTRACTOR
Generally the scope of work of contractor shall include the following:
2.1 Transportation of required piping materials (as described in Cl.2.1.1), pipe support (material as described
in Cl. 2.3) and all other necessary piping materials from Owner’s storage point or contractor’s storage
point (in case of contractor’s scope of supply) to work site/shop including raising store requisitions for
issue of materials in the prescribed format & maintaining an account of the materials received from
Owner’s stores.
2.1.1 Piping materials include the following but not limited to the same.
a. Pipes (All sizes and schedule)
b. Flanges (All sizes, types & Pressure ratings).
c. Fittings (All sizes, types and schedule)
d. Valves (All sizes, types and Ratings)
e. Gaskets (All sizes, types & Ratings)
f. Bolts, Nuts or M/C Bolts (All types)
g. Expansion Joint/Bellows (All types)
h. Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air traps etc.
i. Online instruments like control valve, orifice flange, rotameter, safety valves etc.
2.2 Shop & field fabrication and erection of piping in accordance with documents listed under ‘BASIS OF
WORK’ including erection of all piping materials enumerated above.
2.3 Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips, cradles,
hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, teeposts including erection of
spring supports and sway braces.
2.4
2.4.1 Fabrication of piping specials like special radius bends, reducers, miters etc.
2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3 Fabrication of swage nipples as and when required.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 4 of 13
2.4.4 Fabrication of odd angle elbow like 60º, 30° or any other angle from 90/45° elbows as and when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
2.4.6 Fabrication of stub-in connection with or without reinforcement.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/different thickness
wherever required.
2.5 Modifications like providing additional cleats, extension of stem of valve, locking arrangement of valves
etc. as and when required.
2.6 Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines up to 2- 1/2 within the
unit battery limit and get subsequent approval from Engineer-in-Charge as and when called for.
2.7 Obtaining approval for drawings prepared by contractor from statutory authority, if required.
2.8 Spun concrete lining of the inside of pipes 3” NB & above including fittings and flanges as required in
accordance with specification.
2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in specification.
2.11 Performing PMI using alloy analyzers as per Standard Specification at Construction Sites.
2.12 Casting of concrete pedestals and fabrication & erection of small structures for pipe supports including
supply of necessary materials.
2.13 Providing insert plates from concrete structures and repair of platform gratings around pipe openings.
2.14 Making material reconciliation statement and return of Owner’s supply left over materials to Owner’s
storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection, flushing and
testing of piping systems.
2.16 Pickling (as and when applicable) as per standard specification for chemical cleaning of C.S. suction
piping of compressors.
2.17 Submission of job execution procedure for review and approval of Engineer-in-charge covering all above
activities.
3.0 BASIS FOR WORK
3.1 The complete piping work shall be carried out in accordance with the following
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 5 of 13
3.1.1 “Approved for Construction” drawings and sketches issued by J P KENNY to the Contractor - Plans
and/or Isometrics.
3.1.2 “Approved for Construction” drawings and sketches issued by Turn-key bidders to the Contractor - Plans
and/or Isometrics.
3.1.3 Approved Process licensor’s standards and specifications.
3.1.4 Drawings, sketches and documents prepared by contractor duly approved by Engineer-in- Charge (such
as isometrics of small bore piping and offsite piping etc.)
3.1.5 Approved construction job procedures prepared by Contractor as stipulated in 2.16.
3.1.6 J P KENNY specifications/documents as below:
a. Process and Instrument Diagram.
b. Piping Materials Specification.
c. Piping support standards.
d. Line list
e. Piping support indices (only in offsite), if supports are not shown in plan.
f. Standard specification of Non-destructive Requirement of Piping.
g. Welding specification charts for piping classes .
h. Standard specification for Pressure Testing of Erected Piping System.
i. Welding specification for fabrication of piping.
j. Any other J P KENNY or OTHER specifications attached with Piping Material Specification or special
condition of contract (such as standard for cement lining of pipe, standard of jacketed piping, standard
for steam tracing, Dimensional Tolerances etc.)
k. Procedure for storage, preservation and positive identification of materials at Contractors works/
stores.
3.1.7 Following codes, standards and regulations
a. ASME B 31.3 : Process Piping
b. ASME B 31.4 : Pipeline Transportation System for Liquid Hydrocarbons and Other.
c. ASME B 31.8 : Gas Transmission and Distribution Piping Systems
d. ASME Sec. VIII : Code for unfired pressure vessel.
e. IBR Regulations
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 6 of 13
f. IS: 823 : Code for procedure for Manual Metal Arc Welding of Mild Steel (for structural
steel).
g. NACE Std. : Code for Sour Services material requirements MR-0 1-75
Note: All codes referred shall be latest edition, at the time of award of contract.
3.2 Deviations
Where a deviation from the “Basis of Work and approved job procedure described above is required or
where the basis of work does not cover a particular situation, the matter shall be brought to the notice of
Engineer - in - Charge and the work carried out only after obtaining written approval from him in each
case.
4.0 FABRICATION
4.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall be strictly
as per the “Piping Material Specification” for the “Pipe Class” specified for that system. To ensure the
above requirement, all piping material supplied by the Owner/Contractor shall have proper identification
marks as per relevant standards/specifications/Licensors specification. Contractor shall provide
identification marks on left over pipe lengths wherever marked up pipe lengths have been fabricated/
erected. Material traceability is to be maintained for A.S., S.S., NACE, LTCS, material for Hydrogen
service and other exotic materials by way of transferring heat number, etc. (hard punching) as per
approved procedure. This shall be in addition to color coding for all piping materials to avoid mix-up.
For the purpose of common understanding the construction job procedure, to be submitted by the
contractor, shall include proposal for
- Maximizing prefabrication, inspection and testing at fabrication shop with minimum field joints.
- Positive material identification, handling, storage & preservation.
4.2 Dimensional Tolerances
Contractor shall be responsible for working to the dimensions shown on the drawings. However, the
Contractor shall bear in mind that there may be variations between the dimensions shown in the drawing
and those actually existing at site due to minor variations in the location of equipments, inserts, structures
etc. To take care of these variations “Field Welds” shall be provided during piping fabrication. An extra
pipe length of 100 mm over and above the dimensions indicated in the drawing may be left on one side of
the pipe at each of the field welds. During erection, the pipe end with extra length at each field weld shall
be cut to obtain the actual dimension occurring at site. Isometrics, if supplied may have the field welds
marked on them. However, it is the responsibility of the Contractor to provide adequate number of field
welds. In any case no extra claims will be entertained from the Contractor on this account. Wherever
errors I omissions occur in drawings and Bills of Materials it shall be the Contractor’s responsibility to
notify the Engineer-in-Charge prior to fabrication or erection.
4.3 IBR Piping
4.3.1 Contractor shall be supplied generally with all drawings for steam piping falling under the purview of
Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor shall carry out the
fabrications, erection and testing of this piping as per requirements of Indian Boiler Regulations and to
the entire satisfaction of the local Boiler Inspector. The Contractor shall also get the approval of IBR
inspector for all fabrication and testing done by him at his own cost. All certificates of approval shall be in
proper IBR forms.
4.3.2 Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by the
contractor at his own cost.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 7 of 13
4.4 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general, joining of lines 2”
and above in process and utility piping shall be accomplished by butt welds. Joining of lines 1-1/2” and
below shall be by socket welding/butt welding/threaded joints as specified in “Piping Material
Specifications”. However, in piping 1-1/2” and below where socket welding/threaded joints are specified
butt - welds may be used with the approval of Engineer-in-Charge for pipe to pipe joining in long runs of
piping. This is only applicable for non galvanized piping without lining.
Flange joints shall be used at connections to Vessels, Equipment’s, Valves and where required for ease
of erection and maintenance as indicated in drawings.
4.5 Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating, post-heating and
heat treatment shall be as described in the welding specification and NDT specification.
4.6 Screwed Piping
In general, Galvanized piping shall have threads as per IS: 554 or ANSI B2.l NPT as required to match
threads on fittings, valves etc. All other piping shall have threads as per ANSI B2.l, tapered unless
specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed. Threading of
pipes shall be done preferably after bending, forging or heat treating operations. If this is not possible,
threads shall be gauge checked and chased after welding heat treatment etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly cleaned of
cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with thread sealant and
the joint tightened sufficiently for the threads to seize and give a leak proof joint.
Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and made up to
full thread engagement before seal welding.
4.7 Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are attached. Flanged
bolt holes shall straddle the normal centerlines unless different orientation is shown in the drawing.
Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the flange, shall
be done before welding it to the pipe.
4.8 Branch Connections
Branch connections shall be as indicated in the piping material specifications. For end preparation,
alignment, spacing, fit-up and welding of branch connections refer welding specifications. Templates
shall be used wherever required to ensure accurate cutting and proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using forged tees the
rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
4.9 Bending
Bending shall be as per ASME B3 1.3 except that corrugated or creased bends shall not be used.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 8 of 13
Cold bends for lines 1-1/2” and below, with a bend radius of 5 times the nominal diameter shall be used
as required in place of elbows wherever allowed by piping specifications. Bending of pipes 2” and above
may be required in some cases like that for headers around heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles, bulges, flat spots
and other serious defects. They shall be true to dimensions. The flattening of a bend, as measured by the
difference between the maximum and minimum diameters at any cross-section, shall not exceed 8% and
3% of the nominal outside diameter, for internal and external pressure respectively.
4.10 Forging and forming
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2” and below, shall be as
per ASME B 31.3.
4.11 Miter Bends and Fabricated Reducers
The specific application of welded miter bends and fabricated reducers shall be governed by the Piping
Material Specifications. Generally all 90 deg. miters shall be 4-piece 3-weld type and 45 deg. miters shall
be 3-piece 2-weld type unless otherwise specified. Reducers shall be fabricated as per directions of
Engineer-in-Charge. The radiographic requirements shall be as per Material Specifications for process
and utility systems and NDT Specification for steam piping under IBR, radiographic requirements of IBR
4.12 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut/trimmed/edge prepared
wherever required to meet fabrication and erection requirements, as per drawings and instructions of
Engineer-in-Charge. Nipples as required shall be prepared from straight length piping.
4.13 Galvanized Piping
Galvanized carbon steel piping shall be completely cold worked, so as not to damage galvanized
surfaces. This piping involves only threaded joints and additional external threading on pipes may be
required to be done as per requirement.
4.14 Jacketed Piping
The Jacketing shall be done in accordance with J P KENNY Specification or Licensors specification as
suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at shop by
Contractor. Position of jumpover and nozzles on the jacket pipes, fittings etc. shall be marked according
to pipe disposition and those shall be prefabricated to avoid damaging of inner pipe and obstruction of
jacket space. However, valves, flow glasses, in line instruments or even fittings shall be supplied as
jacketed.
4.15 Shop Fabrication / Prefabrication
The purpose of shop fabrication or pre-fabrication is to minimize work during erection to the extent
possible. Piping spool, after fabrication, shall be stacked with proper identification marks, so as facilitate
their withdrawal at any time during erection. During this period all flange (gasket contact faces) and
threads shall be adequately protected by coating with removable rust preventive. Care shall also be
taken to avoid any physical damage to flange faces and threads.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 9 of 13
4.16 Miscellaneous
4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler, supporting
elements like turn buckle’s, extension of spindles and interlocking arrangement of valves, operating
platforms as required by Engineer-in-Charge.
4.16.2 Spun Concrete lining
The work of inside spun concrete lining of pipes and specials of diameter 3 and above shall be done as
per material specifications and special conditions of contract.
4.16.3 Fabrication of pipes from plate
Pipes shall be fabricated at site as and when required as per the specifications and the actual Piping
Material Specification.
5.0 ERECTION
5.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and outside by
suitable means. The cleaning process shall include removal of all foreign matter such as scale, sand,
weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing with compressed air/or flushing
out with water. Special cleaning requirements for some services, if any shall be as specified in the piping
material specification or isometric or line list. S.S jacketed piping requiring pickling shall be pickled to
remove oxidation and discoloring due to welding.
5.2 Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without the consent of
Engineer-in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings shall be
strictly followed as these clearances may be required for the free expansion of piping / equipment. No
deviations from these clearances shall be permissible without the approval of Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall be brought to the
notice of Engineer-in-Charge and corrective action shall be taken as per his instructions.
5.3 Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as indicated in the
drawing. Confirmation in writing shall be obtained by the Contractor from the Engineer-in-Charge,
certifying that the gap between the pipes is as indicated in the drawing, before drawing the cold pull.
Stress relieving shall be performed before removing the gadgets for cold pulling.
5.4 Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the Contractor.
Corrective action shall be taken by the Contractor in consultation with Engineer- in-Charge wherever the
Contractor is not able to maintain the specified slope.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 10 of 13
5.5 Expansion Joints / Bellows
Installation of Expansion Joints/Bellows shall be as follows:
5.5.1 All Expansion joints / Bellows shall be installed in accordance with the specification and installation
drawings, supplied to the Contractor.
5.5.2
a. Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the case(s) and check
for any damage occurred during transit.
b. The Contractor shall bring to the notice of the Engineer-in- Charge any damage done to the bellows /
corrugations, hinges, tie-rods, flanges / weld ends etc.
c. Each Expansion Joint / Bellow shall be blown free of dust and foreign matter with compressed air or
cleaned with a piece of cloth.
5.5.3
a. For handling and installation of Expansion Joints, great care shall be taken while aligning. An
Expansion Joint shall never be slinged from bellows corrugations / external shrouds, tie / rods, angles.
b. An Expansion Joint / Bellow shall preferably be slinged from the end pipes / flanges or on the middle
pipe.
5.5.4
a. All Expansion Joints shall be delivered to the Contractor at “Installation length”, maintained by means
of shipping rods, angles welded to the flanges or weld ends or by wooden or metallic stops.
b. Expansion Joints stop blocks shall be carefully removed after hydrostatic testing. Angles welded to the
flanges or weld ends shall be trimmed by saw as per manufacturer’s instructions and the flanges or
weld ends shall be ground smooth.
5.5.5
a. The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned or shall have
specified lateral deflection as noted on the relevant drawings.
b. The pipe ends / flanges shall be spaced at a distance specified in the drawings.
5.5.6 The Expansion Joint shall be placed between the mating pipe ends/flanges and shall be tack welded/
bolted. The mating pipes shall again be checked for correct alignment.
5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged Expansion Joint, the
mating flanges shall be bolted.
5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes and Expansion
Joints are in correct alignment and that the pipes are well supported and guided.
5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain parallelism of
restraining rings or bellows convolutions.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 11 of 13
5.5.10 Precautions
a. For carrying out welding, earthing lead shall not be attached with the Expansion Joint.
b. The Expansion bellow shall be protected from arc weld spot and welding spatter.
c. Hydrostatic Testing of the system having Expansion Joint shall be performed with shipping lugs in
position. These lugs shall be removed after testing and certification is over.
5.6 Flange Connections
While fitting up mating flanges, care shall be exercised to properly align the pipes and to check the
flanges for trueness, so that faces of the flanges can be pulled together, without inducing any stresses in
the pipes and the equipment nozzles. Extra care shall be taken for flange connections to pumps,
turbines, compressors, cold boxes, air coolers etc. The flange connections to these equipments shall be
checked for misalignment, excessive gap etc. after the final alignment of the equipment is over. The joint
shall be made up after obtaining approval of Engineer-in-Charge.
Temporary protective covers shall be retained on all flange connections of pumps, turbines, compressors
and other similar equipments, until the piping is finally connected, so as to avoid any foreign material
from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between these flange faces is
uniformly compressed. To achieve this, the bolts shall be tightened in a proper sequence. All bolts shall
extend completely through their nuts but not more than 1/4”.
Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts uniformly after bringing
flange flush with gaskets with accurate pattern and lateral alignment.
5.7 Vents and Drains
High point vents and low point drains shall be provided as per the instructions of Engineer- in-Charge,
even if these are not shown in the drawings. The details of vents and drains shall be as per piping
material specifications / job standards.
5.8 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout drawings. In
case of any difficulty in doing this or if the spindle orientation / position is not shown in the drawings, the
Engineer-in-Charge shall be consulted and work done as per his instructions. Care shall be exercised to
ensure that globe valves, check valves, and other uni-directional valves are installed with the “Flow
direction arrow “on the valve body pointing in the correct direction. If the direction of the arrow is not
marked on such valves, this shall be done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking arrangements of valves (if called
for), shall be carried out as per drawings/ instructions of Engineer-in- Charge.
5.9 Instruments
Installation of in-line instruments such as restriction orifices, control valves, safety valves, relief valves,
rotameters, orifice flange assembly, venturimeters, flow meters etc. shall form a part of piping erection
work.
Fabrication and erection of piping upto first block valve / nozzle I flange for installation of offline
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 12 of 13
Instruments for measurement of level, pressure, temperature, flow etc. shall also form part of piping
construction work. The limits of piping and instrumentation work will be shown in drawings / standards
specifications. Orientations / locations of take-offs for temperature, pressure, flow, level connections etc.
shown in drawings shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above and the precautions
to be taken are covered in flushing, testing and inspection of piping. Care shall be exercised and
adequate precautions taken to avoid damage and entry of foreign matter into instruments during
transportation, installation, testing etc.
5.10 Line Mounted Equipments/ Items
Installation of line mounted items like filters, strainers, steam traps, air traps, desuperheaters, ejectors,
samples coolers, mixers, flame arrestors, sight glasses etc. including their supporting arrangements shall
form part of piping erection work.
5.11 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise specified in
piping classes) all bolts and nuts during storage, after erection and wherever flange connections are
broken and made-up for any purpose whatsoever. The grease and graphite powder shall be supplied by
the Contractor within the rates for piping work.
5.12 Pipe Supports
Pipe supports are designed for and located to effectively sustain the weight and thermal effects of the
piping system and to prevent its vibrations. Location and design of pipe supports will be shown in
drawings for lines 3” NB & above line below 3” NB Contractor shall locate and design pipe supports in
line with J P Kenny Standards and obtain approval of Engineer - in - Charge on drawings prepared by
Contractor, before erection. However, any extra supports desired by Engineer-in-Charge shall also be
installed.
No pipe shoe/cradle shall be offset unless specifically shown in the drawings.
Hanger rods shall be installed inclined in a direction opposite to the direction in which the pipe moves
during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and insulation is over.
Springs shall be checked for the range of movement and adjusted if necessary to obtain the correct
positioning in cold condition. These shall be subsequently adjusted to hot setting in operating condition.
The following points shall be checked after installation, with the Engineer-in-Charge and necessary
confirmation in writing obtained certifying that:
- All restraints have been installed correctly.
- Clearances have been maintained as per support drawings.
- Insulation does not restrict thermal expansion.
- All temporary tack welds provided during erection have been fully removed.
- All welded supports have been fully welded.
Document No. Rev

PIPING 11-0290-02-08-02-012 B
SHEET 13 of 13
GAIL GAS LIMITED

FOR WELDING OF STATION PIPING TOTAL SHEETS 21
DOCUMENT NO 11 0290 02 08 02 011

TABLE OF CONTENTS
1.0 GENERAL................................................................................................................. 3
2.0 WELDING PROCEDURES....................................................................................... 4

2.1 CONSUMABLES...........................................................................................4
2.2 WELDING PROCESS....................................................................................5
2.3 Joint Preparation .............................................................................................7
2.4 Preheating .......................................................................................................8
2.5 welding details……………………………………………… ………. 8
2.6 Welding Techniques……………………………………………………….10

2.7 Defects And Repairs .....................................................................................10
2.8 Post Weld Heat Treatment (PWHT) .............................................................10
2.9 WELDING PROCEDURE QUALIFICATION ...........................................11
2.10 Welder’s Qualification..................................................................................12
2.11 Destructive Testing .......................................................................................12
3.0 NON DESTRUCTIVE EXAMINATION.................................................................... 12
3.1 GENERAL....................................................................................................12
3.2 CODES AND STANDARDS.......................................................................13
3.3 ABBREVIATIONS ......................................................................................13
3.4 NDE COMPANY CERTIFICATION ..........................................................14
3.5 VISUAL INSPECTION................................................................................14
3.6 NON-DESTRUCTIVE TESTING................................................................16
3.7 MAGNETIC PARTICLE INSPECTION .....................................................16
3.8 DYE PENETRATION..................................................................................16
3.9 ULTRASONIC EXAMINATION ………………………………………...17
3.10 EXTENT OF INSPECTION AND TESTING……………………………..18
4.0 REPAIRS OF WELDS ............................................................................................ 19
5.0 INSPECTION .......................................................................................................... 20
6.0 DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR.............................. 21
Document No. Rev

FOR WELDING OF STATION PIPING 11-0290-02-08-02-011 B
SHEET 2 of 21
1.0 GENERAL
1.1 Scope
This specification shall be followed for the fabrication of all types to welding joints of
piping system within the battery limits of all pressure piping of station.
This specification shall apply to all suppliers, vendors, manufacturers, and fabricators
of welded pipes. The CONTRACTOR is responsible for all and shall ensure that all
components to be incorporated into the work meeting this specification.
No supplier, vendor, manufacturer or fabricator shall subcontract the welding

fabrication of any item without written approval from the OWNER and the OWNER will
not issue such an approval unless the proposed welding fabricator has received prior
OWNER approval for the type of welding to be carried out.
The welded pipe joints shall include the following and shall not relieve the contractor of
his responsibilities and guarantee.
a) All pipe joints, longitudinal butt welds, circumferential butt welds and socket welds.
b) Attachments of forging, flanges and other supports to pipes.
c) Welded manifold headers and other sub assemblies.
d) Welded branch connections with or without reinforcing pads.
e) Joints in welded / fabricated piping components.
f) The attachments of smaller connection for vents drain drips and other instrument
tapings.
1.2 Codes, Standards and Regulations
All welding performed under this Specification shall meet or exceed the requirements
specified by the latest revisions of the following applicable Codes and Regulations
a) Indian Provincial regulations governing the welding of piping systems, argumented

with the following:
1. AWS (American Welding Society).
a. A2.4 (Symbols for Welding and Non destructive Testing).
b. A3.0 (Standard Welding Terms and their Definitions).
c. A5.1 (Specification for Mild Steel Covered Arc Welding Electrodes).
d. A 5.17(Specification for Bare Carbon Steel Covered Electrodes).
e. A 5.18 (Specification for Carbon Steel Filler Metals for Gas Shielded Arc Welding).
f. A 5.20 (Specification for Mild Steel Electrodes for Flux Cored Arc Welding Electrodes).
2. Applicable Local Boilers and Pressure Vessels Act and Regulations.
3. ASME B 31.3 Chemical Plant and Petroleum Refinery and Process Piping.
4. ASME Sec. VIII Div. 1 - Pressure Vessels.
Document No. Rev

SHEET 3 of 21
5. ASME Sec. IX - Welding.
6. ASME/ANSI B31.8 - Gas Transmission and Distribution Systems.
7. ASME Sec V - Non-destructive examination.
8. API Std 1104 – Standard for Welding Pipelines and Related Facilities.
9. AWS D 1.1
All welding procedures used by fabricators and CONTRACTORS shall have been
established and qualified in accordance with the appropriate sections of one or more
of the codes and standards listed above, and approved by the OWNER.
Where a conflict occurs between these specifications and / or any of the above codes
or standards the more stringent shall apply.
2.0 WELDING PROCEDURES

2.1 CONSUMABLES
The CONTRACTOR shall provide at his own expenses, all the welding consumables
necessary for the execution of the job such as electrodes, filler wires, argon etc, and
these should bear the approval of the OWNER.
The welding electrodes and filler wires supplied by the contractor shall confirm to this
specification and standard codes and shall be of the make approved by the OWNER
and shall submit all test certificates to the Engineer in Charge for review and approval.
The contractor shall submit batch test certificates from the electrodes manufacturers,
giving details of physical and chemical tests carried out by them, for each batch of the
electrodes to be used.
Electrode qualification test records for each batch shall be carried by contractor and
test records submitted, for obtaining the approval of the ENGINEER INCHARGE.
The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth and
other foreign matter, which affect the quality of the welding.
All coated metal arc-welding electrodes shall comply with AWS specification A 5.5.
A5.1type unless approved otherwise by the OWNER.
All welding consumables. including fluxes shall be supplied in sealed containers and
stored in a dry location at a minimum temperature of 68°F/20˚C. and a maximum
relative humidity of 60%. Low-hydrogen electrodes, after removal from factory seal
containers, shall be stored at a minimum temperature of 150°F/66˚C and suitably
dried prior to use.
The welding filler metals shall have a chemical composition as near as possible to the
parent metals to be welded. The finished weld as deposited, or after post weld heat
treatment (PWHT) when required, shall be at least equal to the parent metal as to unit
strength, ductile, and other physical properties and in resistance to corrosion,
hydrogen attack, or other operating environment factors as required. Permission to
change filler metals to those other than the ones qualified in accordance with this
specification must be obtained in writing, from the OWNER.
Electrode and rod diameters shall conform to the parameters of the weld procedure.
The CONTRACTOR shall provide adequate drying ovens and take proper precautions
in the storage and handling of low-hydrogen electrodes.
Document No. Rev
SHEET 4 of 21
Electrodes and filler rods shall be protected from mechanical damage or deterioration.
All unidentified damaged or deteriorated electrodes or filler wires shall be removed
from the working area and rejected. Any low hydrogen type SMAW electrodes not
contained in heated quivers shall be removed from the site. Electrodes shall not be
exposed to wet or high humid conditions.
Care of welding consumables is the responsibility of the CONTRACTOR however, the

following are minimum requirements:
Low-hydrogen SMAW electrodes shall be kept in commercial electrode ovens after the
factory container has been opened. The electrode holding oven temperature shall be
maintained between 175°F (79°C) and 250°F (121°C). Any low-hydrogen SMAW
electrodes that have been exposed for more than 4 hours prior to restocking into the
holding oven or any SMAW low-hydrogen electrodes that have become wet or have
damaged coatings shall not be used rejected and removed from site.
Other (non-low-hydrogen) SMAW electrodes shall be kept in a dry and dust-free

enclosure after opening of the factory container. These non-low-hydrogen electrodes
shall be held at a temperature below 150°F (66°C).
Bare wire and bare filler rod (GTAW) shall be stored in a dry and free from dust,
grease etc.
2.2 WELDING PROCESS
Welding of various materials under this specification shall be carried out using one or
more welding process as given below with the approval of the ENGINEER IN
CHARGE.
- Shielded Metal Arc Welding Process (SMAW)
- Gas Tungsten Arc welding process (GTAW)
The CONTRACTOR shall have a separate welding procedure for each method of
welding be intends to employ.
Automatic and semiautomatic welding processes shall be employed only with the
express approval of the ENGINEER IN CHARGE. The welding procedure shall be
adopted and consumables used shall be specifically approved.
A procedure qualification record (PQR) shall be included for each WPS. The PQT
shall be witnessed by the OWNER/ OWNER’s Representative or shall be supported
with the lab report from the testing laboratory, if so previously agreed to by the
OWNER.
A combination of different welding process could be employed for a particular joint

only after duly qualifying the welding procedure to be adopted and obtaining the
approval of ENGINEER IN CHARGE.
All testing shall be performed and certified by OWNER approved testing laboratory,
agency or equivalent. The minimum acceptable written procedure shall detail
information on the following parameters.
1. The scope of work performed under the procedures.
2. The base metals and applicable specifications.
3. The welding process.
Document No. Rev

SHEET 5 of 21
4. Type, size, classification and composition of filler metals. (The specific brand name(s)
of the flux-wire shall become an essential variable of the procedure qualification)
5. Type of current and voltage range As per range
6. Width of electrode weave or oscillation
7. Joint preparation and cleaning procedures.
8. Tack welding procedures. Method of marking the location of tack welds to facilitate
post weld inspection shall also be included
9. Electrode polarity.
10. Applicable welding positions.
11. Preheat and inter pass temperatures. (Control method)
12. Welding travel speed.
13. Root preparation prior to welding from second side, (where applicable).
14. Removal methods for weld defects and stray arc strikes.
15. Inter pass-cleaning method.
16. Repair welding.
17. Post welding heat treatments (if required).
18. Shielding gas, and flow rates
19. Type of (GTAW) electrode, size and tip angle.
20. Welders qualified and deployed in production welds shall always bear an identity card
in the manner so approved by OWNER/OWNER’s representative.
The CONTRACTOR shall only employ welders who have a valid welding certificate for
the procedures being used.
The CONTRACTOR shall have all welders tested in accordance with the applicable
code or standard. Testing shall be at the Contractor's expense including test pieces.
Irrespective of pre qualification all welders proposed to be deployed in the work shall
be tested and qualified a fresh.
No welder shall be allowed to make any weld for which he is not qualified.
Welding with larger-size electrodes for specific applications may be allowed only if
each welder qualifies with the largest-size electrode to be used in production. This
option is strictly at the OWNER discretion. OWNER shall specify the details of the
welder qualification tests.
For carbon steel, filler wire combinations shall be chosen such that the deposited
hardness of the cap pass shall not exceed 240 BHN. For low-temperature materials
and other materials heat input shall be minimized and comply with the WIPS
parameters.
The CONTRACTOR may propose alternate process in addition to those listed. Any
proposed process shall require written OWNER approval and qualification prior to
implement CONTRACTOR and OWNER shall agree on tests, results, and other
Document No. Rev

SHEET 6 of 21
criteria before OWNER approval is granted.
All butt welds in pipe smaller than 60.3 mm O/D ("NPS 2" inch) Schedule 40 shall be
made by GTAW or shielded metal arc process, Root pass by gas metal arc is
acceptable for pipe larger than 60.3 mm O/D (NP (2'') inch).
All welds in pressure equipment must be qualified for Charpy V impact testing at (-)
20°C when the code requirements indicate that the parent material requires impact
testing.
When impact tests are required, tests shall be taken from the weld metal, fusion line,
2mm from fusion line, and 5mm from fusion line.
Permanently installed backing rings shall not be used,
All butt welds in pressure equipment shall have the same chemical and mechanical
properties as the parent metal.
All welding procedures must be qualified for Charpy V impact testing when the Code
requirements indicate that the parent material requires impact testing.
Extreme care shall be taken to ensure that electrode separation by classification is

maintained in the CONTRACTOR's inventory. All storage bins and ovens for welding
consumables shall be clearly labeled. In addition, all GTAW bare rod filler metals shall
be tagged with the AWS designation of the filler metal. Any welding consumables not
readily identifiable shall not be used.
All pressure containing welds shall be of a minimum of two passes with overlap of
starts and stops. This shall include socket welds and seal welds of threaded
connections.
Weld stops and starts shall he staggered so that adjacent weld passes do not contain
stops/starts within 25mm (1 "inch) of each other.
The electrodes shall be purchased from the list of approved manufacturer's and the
same shall be supplied with proper certificates and batch certificates.
The width of weave during production welding shall be within the acceptable limit of
the OWNER approved and qualified welding procedure, qualification certificates, and
production welding operating sheets. As a norm this will be limited to a maximum of 3
times the core diameter of SMAW electrodes, whichever is the lesser.
Each weld pass layer shall be completed in one full cycle/ circumference before
proceeding with the next. Blocking out or segmental welding is not permitted.
All tools and equipment used in the welding operations shall be in first class operating
condition and shall be of sufficient capacity to ensure welds of the specified quality are
achieved throughout the work. It shall be the right of the OWNER to request at any
times the re-calibration of gauges and meters. etc. to ensure compliance with welding
procedure-operating sheets/ WPS.
2.3 Joint Preparation
The surface of the pipe at the weld area shall be free from dust, grease, scale, paint,
grit or any other foreign material, which may adversely affect the final weld quality.
Bevels shall be 37½° and all field cuts shall be normal to the axis, of the pipe, Miter
welds are prohibited.
Document No. Rev

SHEET 7 of 21
All pipes shall be beveled for welding with an approved mechanical beveling machine.
Damage to bevels, which could possibly affect the quality of the weld, shall be
remedied prior to welding. If beyond repair the pipe shall be cut and the pipe end re
beveled. Lamination check by UT method shall be done prior to welding of gas cutting
end pipe.
Where welding pipe both to a flange or another pipe or component, there must be a
band of at least 25M mm (1" inch) wide around the internal / external joint weld
preparation that is ground to bright metal, and is free of all foreign matter,
To assure proper spacing and alignment in accordance with the applicable Code, an
approved lineup clamp shall be used.
All Weldments shall conform to the straightness and alignment specified herein.
Correction of improperly fitted parts shall be accomplished by disassembly and
refitting. Reworking by hammering or flame straightening shall not be permitted.
The ends of piping components to be joined shall be aligned as accurately as is

practicable within existing commercial tolerance on diameters, wall thickness, and out
of roundness. Maximum bore mismatch shall not exceed 1/16” inch (1.6 mm),
Alignment shall be preserved during welding.
When joints of unequal thickness are joined, the internal offset shall not exceed 1.6
mm (1/16"). If this value is exceeded, the excess thickness of the heavier end shall be
machined or ground back from the bevel on a one-to-four (1:4) taper.
Maximum bore mismatch shall not exceed 0.8mm (1/32 inch), Where ends are to be
Joined and the internal misalignment due to difference in wall thickness, etc. exceeds
1.6 min (1/16 inch), the wall extending internally shall be internally trimmed, Internal
machining shall be performed so that the inside diameters of the components
coincide.
When cutting pipe to length, it should be cut by mechanical means. if practical. Ends
that are to have flanges attached either in the shop or field must be cut true and
square.
2.4 Preheating
Preheat for pressure piping and furnace tubs shall be in accordance with ASME B31.3
and B31.8.
All pipe joints having a wall thickness greater than 9.5 mm (0.375") shall he preheated
to 100°C prior to welding when the ambient temperature is less than 10°C (500 F).
Preheating shall he carried out with an approved torch system or with electrical
induction coils which will provide uniform heating.
The preheating area shall be at least 200 mm (8") wide centered about the weld and
shall extend around the entire circumference of the pipe.
Preheat temperatures shall be checked with temperature sensitive crayons or by other

approved methods.
If a joint requires preheating, the same temperature requirements shall be maintained

for each succeeding pass,
2.5 WELDING DETAILS
2.5.1 All pressure welding shall be performed in accordance with approved and qualified
Document No. Rev

SHEET 8 of 21
welding procedures as required per code.
2.5.2 Each weld shall be uniform in width and size throughout its full length.
2.5.3 Each layer or welding shall be smooth and free of slag cracks, pinholes, undercuts
(Internal and external), porosity and excessive bead shall be completely fused to the
adjacent weld beads and base metal.
2.5.4 The cover pass shall be free of coarse ripples, irregular surface, non-uniform pattern,
high crown, deep ridges or valleys undercut, arc strikes, porosity, undercut, slag, or
shatter.
2.5.5 Butt welds shall be slightly convex, of uniform height, and have full penetration, unless
otherwise approved.
2.5.6 For piping, limitations on weld reinforcement shall apply to the internal surfaces as
well as to' the external.
2.5.7 Fillet welds shall be of a specified size with full throat and the legs of uniform length.
2.5.8 Arcs shall only be struck in the weld groove. A controlled arc must be maintained while
welding. Should an arc strike occur, it shall be removed by grinding and the area shall
be etched (10% Nital) to confirm heat affected area removal, and MT examined to
ensure absence of any surface cracking.
2.5.9 After each pass the layer of weld metal must be cleaned to remove all slag, scale dirt
etc. wire brushes, grinder, or chipping hammer shall be used as needed to prepare
proper surface for each succeeding weld pass.
2.5.10 Repair, chipping or grinding of welds shall be done in such a manner as not to gouge,
groove or reduce the base metal thickness.
2.5.11 No welding shall be done if the temperature of the base metal is below 50°F. Nor shall
there be any wedding done if there is moisture, grease, or any foreign material on the
joint to be welded.
2.5.12 A qualified welder shall make tack welds. Cracked lack welds shall be completely
ground out and NDE by MT/PT prior to re-weld.
2.5.13 The CONTRACTORS shall make no substitution of materials or modifications to

details without the prior written approval of the OWNER.
2.5.14 Welders and welding operators shall not be qualified on production welds.
2.5.15 The CONTRACTOR shall ensure that welders and welding operators are only
employed on those parts of the work for which they are qualified.
2.5.16 Each welder and welding operator shall possess an appropriate temperature-
measuring device. All supervisors shall possess a copy of the approved welding
procedures.
2.5.17 Alternatively, welding procedures may he clearly display at each welding location.
Welders shall be familiar with the requirements of the appropriate approved welding
procedures. Any welder found not complying with the approved welding procedures
during production welding shall be removed from the work and the non-conforming
weld(s) may be completely rejected, at the discretion of' the OWNER.
2.5.18 No welding should be undertaken without approved WPS.
2.5.19 The OWNER will not provide any WPS for the CONTRACTOR.
Document No. Rev

SHEET 9 of 21
2.6 Welding Techniques
2.6.1 General
a) All welding shall be performed in accordance with an approved and qualified welding
procedure.
2.6.2 Cleaning
a) All weld impurities shall be removed between passes. Cleaning may be done with
either hand or power tools.
b) All rough irregularities in the cover pass and weld spatter shall be removed.
2.6.8 Weld Identification
Each finished weld shall be clearly marked to identify the portion made by each welder.
2.7 Defects and Repairs
Welds containing defects not exceeding an aggregate of five (5) percent of the length
of the root bead may be removed by grinding, chipping or arc gouging and re-welded
in accordance with an approved procedure. Welds containing defects exceeding that
amount shall be cut out and replaced.
When defects are ground out the entire weld shall be preheated to a temperature of
150 °C (300 °F) prior to welding.
All repaired welds shall be radio graphed or by the same method of original defect
detention.
2.8 Post Weld Heat Treatment (PWHT)
2.8.1 CONTRACTOR is responsible for all PWHT requirements. Which shall be performed
as specified by the OWNER and in accordance with ANSI/ASME B31.3.
2.8.2 PWHT of pressure piping and furnace tubes shall be in accordance with ASME B31.3,
B31.8 and the specification for Post Weld - Heat Treating.
2.8.3 Controlled atmosphere furnaces are preferred for heat treatment. Procedures using
electric resistance, induction, or flame burner rings are acceptable for shop or field
heat treatment. OWNER prior to heat treatment must approve these procedures.
2.8.4 CONTRACTOR must notify the OWNER prior to starting PWHT operations.
2.8.5 CONTRACTOR shall furnish a PWHT record chart. The chart must be dated,
numbered and labeled with job identification. CONTRACTOR name, and person
Responsible for the PWHT. Heat-treated lane, welds and spool numbers shall be
identified on the chart.
2.8.6 The completed PM/HT record chart shall be submitted for OWNER approval following
completion of heat treatment.
2.8.7 Stress relieving of piping shall be performed as per ASME B31.3 ASME B31.8. as
applicable.
2.8.8 Stress relieving may he performed by electrical induction or by electric resistance

heating devices, or by furnace that has a large enough capacity to accommodate the
entire piece being heat-treated.
Document No. Rev

SHEET 10 of 21
2.8.9 The stress relieving temperature to be attained shall be 1100°F/593˚C minimum.
1150°F/621˚C maximum. The soak period of this temperature shall be one hour per
25.0 mm (1 inch) of pipe wall thickness and in no case shall the soak period be less
than one hour.
2.8.10 Rate of heating and cooling shall be in accordance with the requirements for thermal
stress relief presented in Section VIII of the ASME Boiler and Pressure Vessel Code.
In any event, the rate of heating above 600°F/315˚C may not be more than
400°F/205˚C per hour, nor the rate of cooling more than 500°F/260˚C per hour when
above 600°F/315˚C.
2.8.11 For field stress relieving, a continuous temperature record Log shall be furnished of
the program from heating, soaking and cooling to 600°F. A minimum of two
thermocouples shall be installed at each weld so that continuous readings can be
assured in the event of thermocouple failure.
2.8.12 Local heat treatment of welds shall consist of heating ID pipe length completely
around the circumference of the pipe welds or pipes as required to eliminate thermally
induced stresses. A continuous record of time and temperature shall be maintained for
at least two points on each weld during the course of heat treatment with methods
other than exothermic kits.
2.8.13 During heat treatment, the ends of the pipe shall be temporarily plugged to minimize
air-cooling. Sufficient insulation shall be applied to maintain the required heat
treatment temperature. The full thickness of 75mm (3"-inch) insulation shall be
continued for a minimum distance of 610 mm (2 feet) on each side of the heating
elements, and shall be in place until the weld has cooled to below 100°F/37˚C.
2.8.14 When local heat treatment is used, care shall be exercised with restrained piping so
that no upsetting will be caused by thermal expansion.
2.8.15 A minimum 10% of all locally (field) heat-treated welds shall require Brinell hardness
testing.
2.8.16 Unless otherwise indicated by OWNER, Brinell hardness limits apply to welds after
PWHT. The hardness of the weld shall be determined by the average value of three
tests (of 3 indentations) taken per 120 degrees quadrant around the weld.
2.8.17 The test areas of the weld shall be ground or filled to provide a suitable surface for
testing. If a Tele brineller is used to measure the hardness the bar shall be as close as
practical to the anticipated weld hardness. If a poor indention is obtained on an
individual test, a retest shall be made on an adjacent area.
2.8.18 Hardness tests other than Brinell may be used if the values obtained can be equated
to the Brinell hardness numbers, and the proposed equipment and procedures have
received prior OWNER approval.
2.8.19 Flange facing and threaded connections must be adequately protected against
oxidation during stress relieving and must be cleaned and freed of defects after stress
relieving.
2.8.20 No heating or welding may be applied to any piping or weld joint after stress relieving
is complete.
2.8.21 All stress relieving equipment and execution shall be supplied at Contractor’s
expense.
2.9 WELDING PROCEDURE QUALIFICATION
Welding procedure qualification shall be in accordance with the relevant requirement
Document No. Rev

SHEET 11 of 21
of ASME Sec. IX latest edition or other applicable codes and the job requirements.
The Contractor shall submit the welding procedure specification in format as per PQR.
Format immediately after the receipt of the order. Owner’s representative will review,
check and approve the welding procedure submitted and shall release the procedure
for qualification test. The complete set of test result as per ASME sec. IX shall be
submitted to the OWNER/ OWNER’s representative for approval immediately after
completing the procedure qualification test and at least 2 weeks before the
commencement of actual work. Standard test specified in the code shall be carried out
in all cases. In addition to these test the following test shall be carried out.
1) Macro/ Micro Examination.
2) Hardness test.
3) Dye Penetrate examination.
4) Charpy V-notch Impact test at Weld and HAZ at 0 °C
These tests shall be carried out on specimens depending upon the type of base
material, operating conditions and requirements laid down in the detailed drawing and
specification. It shall be the responsibility of the Contractor to carry out all the tests
required to the satisfaction of the OWNER/ OWNER’s representative.
2.10 Welder’s Qualification
Welders shall be qualified in accordance with the ASME sec. IX or other applicable
codes. It shall be the responsibility of the Contractor to carry out qualification tests of
welders.
No welder shall be permitted to work without the possession of identity card.
If a welder is found to perform a type of welding or in a position for which he is not

qualified, he shall be debarred from doing any further work. All welds performed by an
unqualified welder shall be cut and redone by a qualified welder at the expenses of the
contractor.
2.11 Destructive Testing
OWNER has the authority to order the cutting of up to 0.1% of the total numbers of
welds completed for subjecting to destructive test at no extra cost to OWNER. The
destructive testing of joints shall be as per ASME- Sec IX welding procedure
qualification.
In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. The sampling and the re-execution of welds shall be carried out by
the contractor at his own expenses. If the results are unsatisfactory, welding
operations shall be suspended and may not be restarted until the causes have been
identified and the contractors have adopted measures which guarantee acceptable
results.
If it is necessary in OWNER opinion the procedure shall be re-qualified. The weld joint
represented by unsatisfactory welds shall stand rejected unless investigation proves
otherwise.
3.0 NON DESTRUCTIVE EXAMINATION

3.1 GENERAL
a) This specification shall govern the basic requirements for Non Destructive
Document No. Rev
SHEET 12 of 21
Examination (NDE) as it applies to the fabrication, testing and inspection of all
Pressure Piping, and Transmission Piping.
b) No supplier, vendor, manufacturer or fabricator shall subcontract the non destructive

examination of any such equipment without written approval from the OWNER, and
the OWNER will not issue such an approval unless the proposed NDE SUB-
CONTRACTOR has received prior OWNER approval for the type of NDE work
proposed.
3.2 CODES AND STANDARDS
a) Work performed under this section shall confirm to the latest edition of following codes
and standards:
i) ASME B31.3 Process Piping.
ii) ASME. Section V - Non destructive Examination.
iii) ANSI/ASIA. B31.8 Gas Transmission and Distribution System.
iv) ASNT/PCN/CGSB Standards for certification of Non Destructive testing Personnel.
b) Work shall also be carried out in compliance with all general specification dealing with
welding and fabrication of various equipment.
3.2.1 CONFLICT
Where a conflict occurs between this Specification and any of the above Codes or
Standards the more stringent shall apply. The contractor shall inform the OWNER in
writing and receive written certification form the OWNER. The contractor shall have
readily available for use at the request of the OWNER latest editions of all codes,
specification and standards necessary for execution of the work at work site.
3.3 ABBREVIATIONS
ASME American Society of Mechanical Engineers
ANST American Society for Non-Destructive Testing
ASTM American Society for Testing and Materials
AWS American Welding Society
DPI Dye Penetrant Inspection
HS&E Health Safety and Environment
MPI Magnetic Particle Inspection
NDT Non-Destructive Testing
PCN Personnel Certification in Non-Destructive Testing
PWHT Post Weld Heat Treatment
UT Ultrasonic Testing
Document No. Rev

SHEET 13 of 21
3.4 NDE COMPANY CERTIFICATION
All Non Destructive Examination (NDE) CONTRACTORs contracted by the OWNER

or working for fabricators or CONTRACTORs carrying out work on the OWNER behalf
shall have in place an up-to-date Quality Control Manual and Code of Practice which
shall cover the following:
i) All aspects of NDE of which the CONTRACTOR SUB-CONTRACTOR is qualified.
ii) Current resumes of all presently employed personnel including their certifications
(PCN, ASNT, CGSB or equivalent).
iii) All proposed specific NDE procedure,
A registered copy of QC manual shall be made available to OWNER and shall be

reviewed and approved by the OWNER quality assurance personnel prior to services
being used. Updates to the Manual shall be forwarded to the registered holder as they
become available.
The OWNER will review and approve element's i), ii) & iii) above: prior to start on any
said company work. Any approval given by the OWNER does not relieve the
CONTRACTOR of his obligations under governing, codes, rules and specifications.
All equipment shall be certified and current, to recognized calibration standard and in
first class working condition.
Full compliance with all governmental and local regulatory requirements of HS&E,
which shall be fully complied with.
3.5 VISUAL INSPECTION
a) Visual examination shall be carried out before, during and after fabrication in
accordance with ASME Sec. V article 9 and ASME B31.3.
b) Cracks, (regardless of size and location) and under cutting or any evidence of poor
workmanship, materials, etc., if not repairable shall be cause for rejection.
c) Welds shall be visually inspected wherever accessible in accordance with the

following requirements:
Document No. Rev

SHEET 14 of 21
1. Internal misalignment 1.5 MM or Less
2. Cracks or lack of fusion None permitted.
3. Incomplete penetration (for Depth shall not exceed the lesser of 0.8 MM or
other than 100% 0.2 times thickness of thinner component joined
Radiography butt-weld) by butt-weld.
The total length of such imperfections shall not

exceed 38 MM in any 150 MM of weld length.
4. Surface porosity and Not permitted
exposed slag inclusions
(4.7mm.Nom Wall
thickness and less)
5. Concave root surface For single sided welded joints concavity of the
(SLICK UP) root surface shall not reduce the total thickness of
joint including reinforcement to less than the
thickness of the thinner of the components being
joined.
6. Weld ripples irregularities 2.5 MM or Less
7. Lack of uniformity in bead 2.5 MM or Less
width
8. Lack of uniformity of leg 2.5 MM or Less
length
9. Unevenness of bead 2.0 MM or Less
10. Weld undercutting 0.8 MM or 'A thickness of thinner components
joined by butt weld, whichever is less. (shall be
smooth finished)
11. Overlap 1.5 MM or Less
12. Bead deflection 2.5 MM or Less
13. External weld reinforcement and internal weld protrusion (when backing rings
are not used) shall be fused with and shall merge smoothly into the component
surfaces. The height of the lesser projection of external weld reinforcement or
internal weld protrusion from the adjacent base material surface shall not
exceed the following limits
Wall thickness of thinner Weld reinforcement or internal weld protrusion
component joined by butt (MM) Max
weld (MM)
6.4 and under 1.6
Over 6.4 – 12.7 3.2
Over 12.7 – 25.4 4.0
Over 25.4 4.8
14. Throat thickness of fillet welds:
Nominal thickness of the thinner component x 0.7 or more.

15. FLATTENING
Flattening of a bend, as measured by difference between the nominal outside

diameter and minimum or maximum diameter at any cross section shall not
exceed 5% of the nominal outside diameter of pipe.
16. REDUCTION OF WALL THICKNESS
Reduction of wall thickness of a bend, as measured by difference between the

nominal thickness and minimum thickness shall not exceed 10% of the nominal
wall thickness of pipe.
Welds having any imperfections which exceed the limitations specified in

various clauses shall be repaired by welding, grinding or overlaying etc.
Document No. Rev

SHEET 15 of 21
However number of times of repair welding for the same weld shall be as follows:
MATERIAL NO. OF TIMES OF REPAIR WELDING

1.0 CS UPTO 300# 3 OR LESS
2.0 CS ABOVE 300# 2 OR LESS
3.6 NON-DESTRUCTIVE TESTING
3.6.1 GENERAL
a) All NDT shall be performed in accordance with ASME B31.3 /ASME 8.31.8/ ASME
code Section V except as modified by this specification.
b) Category of piping are defined by categories I, II, III as shown in Table 1.
The minimum requirement for extent of NDT inspection shall be as stated in Table 2.
c) The CONTRACTOR shall prepare NDT procedure covering all aspects of the
work. The NDT procedure shall be submitted to OWNER for review and approval.
Approval of the NDT procedure shall be required before any NDT can be performed.
d) The CONTRACTOR shall prepare and maintain documentation to track percentage of

welds tested and the weld repair rate. The proposed documentation shall be made
available for review and approval.
e) Unless otherwise specified, 10% of welds in each pipe class rating shall be inspected
by NDT. Welds selected for examination shall include, as a minimum, 10% of each
welder, welding operator and welding procedure such that welding quality can be
established.
f) All non-pressure tie-in welds and all field welds, regardless of pipe class shall be
examined by 100% visual, radiography and MPI, DPI.
g) CONTRACTOR shall not deviate from any requirement of this specification

without written approval to do so from OWNER.
h) No exemption permitted in regards to full HS&E compliance.
3.6.2 RADIOGRAPHIC EXAMINATION
3.6.2.1 General
a) The quality of radiographs shall meet or exceed all requirements of the appropriate
b) International standards and applicable general specifications.
c) X - Ray is the preferred radiographic method. Use of Gamma ray for examination is
not permitted.
d) Particular attention shall be paid to using radiographic ultra fine grain film suitable for
the application, maintaining correct radiographic geometry during exposure, obtaining
correct density also required by the appropriate standard and the correct placement
and exposure of image quality indicators (IQI's or penetrameters).
e) ASTM wire type IQI's are preferred. The OWNER may permit the use of ASTM hole
type IQI's on a pre-approved basis, provided the NDT CONTRACTOR can
Document No. Rev
SHEET 16 of 21
demonstrate satisfactory results.
f) Radiographic technique shall produce maximum contrast and good definition of IQI
wires and shall obtain minimum radiographic density of 10 in the weld image.
Fluorescent intensifying screens shall not be used.
f) Max radiographic density shall be 4.0 in all areas of the weld and parent metal.
g) The inability to view the appropriate wire or hole on any radiograph shall be cause for
automatic rejection of that radiograph which shall be re-radiographed at no expense to
the OWNER.
3.6.2.2 Operator Certification
a) Radiographers supplied by the CONTRACTOR shall be certified to ASNT Level II,

AWS QC] and as per AWS B1.10 (guide for non-destructive inspection of welds).
b) An operator qualified to ASNT Level I may assist the Level II operator but all film and
sentencing interpretation shall be carried out by a Level ll or higher operator who shall
sign off all report sheets.
c) Visual welding inspection shall be conducted only by a qualified welding inspector,

who shall have a minimum AWS (QC. I) CWI or CSWIP 3.1 certification.
d) The OWNER shall review and approve all QA/QC personnel prior to deployment on
the project.
3.7 MAGNETIC PARTICLE INSPECTION (WPI)
a) MPT shall be carried out in accordance with the requirements of ASME. Section V.
Article 7, & Section VIII DIV 1, Appendix 6. and as modified by this specification.
b) AC electromagnetic yokes shall be used. A background of white contrast paint shall be

used in conjunction with a black magnetic ink (wet particle). The technique shall be
carried out in the continuous mode and two examinations shall be carried out at right
angles to cover for both transverse and longitudinal defects. There shall be sufficient
overlap to allow 100% coverage.
c) All unacceptable or spurious indications found by this method shall be investigated

and removed by grinding followed by thickness check.
3.8 DYE PENETRATE INSPECTION (DPI)
a) DPI shall be carried out accordance with the requirements of ASME BPV, Section V,
Article 6, & ASME Section VIII DIV 1, Appendix 8, and as modified by this
specification.
b) Unless requested otherwise, DPI shall be carried out using the solvent removable
method.
c) If necessary welds may be lightly dressed to facilitate DPI testing or to assist in the
interpretation of any indications.
d) All unacceptable or spurious indications found by this method shall be investigated

and removed by grinding followed by thickness check.
3.9 ULTRASONIC WELD EXAMINATION (UT)
Document No. Rev

SHEET 17 of 21
3.9.1 Ultrasonic Operators
a) Ultrasonic operators supplied by the NDE CONTRACTOR shall be certified to a

General Standards Board (ASNT/PCN) approved by the OWNER.
3.10 EXTENT OF INSPECTION AND TES'T'ING
3.10.1
a) Piping systems which are designed and constructed in accordance with ASME
Standard B3 I.3, Chemical Plant and Petroleum Refinery Piping, shall be radiographed
as per Table II.
b) Piping systems which are designed and constructed in accordance with ASME B31.8
standard for gas pipeline systems shall have all welds radiographically inspected for
100%,
3.10.2 Hardness testing shall be carried out of welds on vessels and piping in sour or
corrosive service and 10% of local PWHT weld as per ASTM Specification E 10, ANSI
1331.3.
3.10.3 Ultrasonic Testing
a) UT testing shall be carried out as per ASME B31.3 and ASME Sec. V article 5.
b) All category 'D' welds which are not being radio graphed and all other welds
configuration, which does not permit to be radio graphed, shall be ultrasonic tested.
c) All tie-in welds where pressure testing are not possible.
TABLE-I
EXAMINATION CATEGORIES
CATEGORY I HIGHER DUTY PIPING

• Severe cyclic conditions as indicated in the respective
isometric drawings, all service.
• Carbon Steel material, ASME rating 600# all services
• All ASME classes for lethal substances.(Category `M'
fluid service)
CATEGORY II NORMAL FLUID SERVICE
ASME rating 150 & 300# not covered by Categories I & III
CATEGORY III CATEGORY 1) FLUID SERVICE
ASME rating 150 for all systems in Category `1' Fluid services
such as:
• Service air
• Instrument air
• Open Drains
Document No. Rev

SHEET 18 of 21
TABLE – II
EXTENT OF TESTING AND INSPECTION
METHOD EXAMINATION EXAMINATION EXAMINATION

CATEGORY I CATEGORY II CATEGORY III
Visual 100% 100% 100%
MPI (or DPI for 100% 100% examination 100% examination of 1 in
non- examination of all of 1 in 10 branch 10 branch and attachment
ferromagnetic branch and and attachment welds
materials) (Note attachment welds welds
2)
RT (butt weld) 100% 100% examination 100% examination of I in
(Note 1) examination of all of 1 in 10 welds 10 welds
welds (Nose 5)
UT (Branch 100% 0 0
weld) (Note 5) examination of
all welds
Hydro test (or Yes Yes Service Test
pneumatic test) (Note 3)
Minimum 1 hour 1 hour 1 hour
Duration
Records Yes Yes Yes
Notes:
I) Ultrasonic testing, in lieu of radiography, is acceptable only where radiography is not
practicable e.g. branch connections.
2) UPI or DPI of branch welds to be performed prior to and lifter attachment of
compensating plate if applicable.
3) Open drains vents or other open ended line shall be leak tested only.
4) For piping within skid packages, the CONTRACTOR shall use this table as a guide
only and prepared NDE plan for review and approval by OWNER as required in the
respective package specification.
5) Vat required where wall thickness of scanning surfaces are less than 10mm and
where branch size is less than NPS 4". Non-ferrite materials shall not be examined
with UT methods.
6) RT shall be 20% of welds for all class 300# series.
4.0 REPAIRS OF WELDS

4.1 With the prior permission of ENGINEER IN CHARGE welds that do not comply with
the standards of acceptability shall be repaired or the joint cut out and re-welded.
A separate welding procedure specification sheet shall be formulated and qualified by

CONTRACTOR for repair welds simulating the proposed repair to be carried out.
Separate procedures are required to be qualified for (a) through thickness repair (b)
external repair and (c) internal repair. Welders shall be qualified in advance for
repairs. The root pass, for repairs opening the root, shall be replaced by the vertical
uphill technique. The procedure shall be proven by satisfactory procedure tests to API
1104 including the special requirements of the specification, and shall also be
subjected to metallographic examination, hardness surveys and Charpy test to
determine the effects of repair welding on the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root defects
shall be ground thoroughly and welded with a minimum of two passes. However, while
grinding for repairs, care shall be taken to ensure that no grinding marks are made on
the pipe surface anywhere.
The repair shall be subjected, as a minimum requirement, to the same testing and
inspection requirements as the original weld. Re-radiography of the repaired area shall
Document No. Rev
SHEET 19 of 21
be carried out. In addition, a minimum of 6” weld length on the either side of the
repaired area, shall be re-radiographed. A 100% ultrasonic test shall be done at the
repaired area externally. Any repaired area that is wide, irregular or rough shall be
rejected and a full cut out shall be done.
Repairs are limited to a maximum of 30% of the weld length. Welds containing cracks
shall be cut out and rebeveled to make a joint. COMPANY shall authorize all repairs.
4.2 Weld Rejected by Accumulation of Defects
Where a weld is rejected by accumulation of defect clause, as defined by API 1104

and this specification, repairs within these limitations are permitted. Defects in the
filling and capping passes shall be repaired preferentially.
5.0 INSPECTION
5.1 The CONTRACTOR shall extend all facilities, assistance and co-operate fully with the
OWNER in all aspects of inspection and NDE and shall give adequate notice of any
required fabrication inspection stages, together with sufficient time for thorough
inspection by the OWNER. OWNER shall have the right to establish hold points at any
point in the fabrication sequence.
5.2 Although is the Contractor’s primary responsibility to perform weld examination,

OWNER shall have the right to observe the examination of all welds by nondestructive
means. The inspection may be at any time before, during and after fabrication. The
CONTRACTOR shall conduct daily NDE percentage of welds to assess weld quality.
Up-to-date examinations are required to identify and prevent the reoccurrence of weld
defects on subsequent welds. Records and evidence of all weld examinations shall be
available at all times for OWNER to review and approve.
5.3 OWNER may use any method of inspection necessary to establish quality control and
ensure adherence to welding procedures. OWNER shall have the right to accept or
reject any weld not meeting the requirements of this specification.
5.4 OWNER reserves the right to perform inspection at shop / field where fabrication and
erection of piping is in progress for (but not limited) for the following objective:
a) To check conformance to relevant stands and suitability of various welding

equipments and welding performance.
b) To witness the welding procedure qualification.
c) To witness the welder performance qualification.
d) To witness the Electrode qualification Test.
5.5 Contractor shall intimate sufficiently in advance the commencement of qualification

test, welding works and acceptance tests to enable the owner/ owner’s representative
to be present to supervise them.
5.5 Any discrepancies between the approved WPS and the production welds noted by
OWNER, any or all of the work made under these conditions is subject to rejection.
Document No. Rev

SHEET 20 of 21
6.0 DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR
a) Electrode and welding consumables qualification records for the welding consumables
tested and approved for the work.
b) Batch test certificate, for the electrodes used, obtained from the Electrode
Manufacturers.
c) Proposed heat treatment chart procedure.
d) Heat treatment chart.
e) Weld joint tensile, hardness test, Impact test result.
f) Welding procedure specification immediately after receipt of order.
g) Welding procedure qualification records.
h) Welder performance qualification records immediately after conducting welder
qualification tests.
i) Radiography procedure and the NDT procedure.
Document No. Rev

SHEET 21 of 21
GAIL GAS LIMITED
CLIENT JOB NO. -

TECHNICAL NOTES FOR BUTT WELDED,
SOCKET WELDED AND SCREWED FITTINGS
TOTAL SHEETS 5
DOCUMENT NO 11 0290 02 08 02 008

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS
1.0 GENERAL
1.1 Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment and marking
shall conform to the applicable latest codes/standards/specifications as specified in the material requisition
(MR). Any deviation shall be highlighted on a separate sheet by the vendor in the quotation itself.
1.2 Test reports shall be supplied for all mandatory tests as per the material specifications Test reports shall
also be furnished for any supplementary tests as specified in the MR, Clauses 1.7.8, 1.9, 1.10 & 1.11.
Material test certificates (physical properties, chemical composition & heat treatment report) shall also be
furnished for fittings supplied.
1.3 All fittings shall be seamless in construction unless otherwise specified. If fittings are specified as welded,
the same shall conform to Clause 1.7. Seamless fittings can be supplied in place of welded fitting but with
maximum negative tolerance of 0.3mm (max.) on wall thickness. Welded fittings shall not be acceptable in
place of seamless fittings.
1.4 Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings shall be in
accordance with ASME B36.10 and ASME B36.19 as applicable.
1.5 For reducing butt weld fittings having different wall thicknesses at each end, the greater wall thickness of
the fitting shall be employed and inside bore at each end shall be matched with the specified inside
diameter.
1.6 Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as follows:

Upto 22 mm Figure 2 Type A
Carbon Steel (Except Low Temp. Carbon Steel)
Upto 10 mm Figure 4
Alloy Steel, > 10 mm &
Figure 5 Type A
Stainless Steel & Low Temp. Carbon Steel Upto 25 mm
1.7 Welded Fittings:
1.7.1 All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. Welds shall be
ground smooth at least 25 mm from the ends.
1.7.2 For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be manufactured
with the addition of filler metal.
1.7.3 Welded tees shall not be of fabricated (stub-in) type.
1.7.4 All welded fittings shall be normalised & 100% radiographed by X-ray on all welds made by fitting
manufacturers & also on the parent materials.
1.7.5 Welded pipes employed for manufacture of fittings shall be made by automatic welding only.
1.7.6 All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative tolerance of 0.3
mm.
1.7.7 Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after weld repairs.
Document No. Rev

TECHNICAL NOTES FOR
BUTT WELDED, SOCKET WELDED 11-0290-02-08-02-008 B
AND SCREWED FITTINGS
SHEET 2 of 5
1.7.8 Irrespective of the material code requirement, all welded fittings indicated in the MR as “Cryo”& “LT” shall
meet impact test requirements of ASME B31 .3. The impact test temperature shall be -196°C & -45°C for
stainless steel & carbon steel respectively unless specifically mentioned otherwise in the MR.
1.8 Stainless Steel Fittings:
1.8.1 All stainless steel fittings shall be supplied in solution heat treated condition.
1.8.2 Solution annealing for stainless steel fittings shall be carried out again after weld repairs.
1.8.3 For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as per the
following:
- ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”.
Or
- ASTM A 262 Practice “E” with acceptance criteria of “no cracks as observed from 20X magnification” &
“microscopic structure to be observed from 250X magnification
1.8.4 When specifically asked for in MR for high temperature application of some grades of austenitic stainless
steel (eg. SS309, 310,316,316H etc.) ASTM A 262 Practice “C” with acceptance criteria of “15 mils/year”
shall have to be conducted.
1.8.5 For the IGC test as described in Clauses 1.8.3 & 1.8.4, two sets of samples shall be drawn from each
solution treatment lot, one set corresponding to the highest carbon content and other set to the highest
fitting thickness. When testing is conducted as per ASTM A 262 Practice “E”, photograph of microscopic
structure shall he submitted for record.
1.9 Fittings under “NACE” category shall meet the requirements of MR-01-75.
1.10 Thickness/schedule lower or higher than specified shall not be accepted.
1.11 The gasket contact surfaces of stub ends shall be flat with face finish as specified below:
• Serrated Finish Serrations with 250 to 500µ in AARH

• Smooth Finish: Serrations with 125 to 250 µ in AARH
1.12 Seamless stub ends shall not have any welds on the body.
1.13 Galvanised fittings shall be coated with zinc by hot dip process conforming to IS 4736/ ASTM A 153.
1.14 Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B 1.20.1 upto 1.5” NB & IS
554 from 2” to 6” NB.
1.15 Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in accordance
with ASME B16. 11 to the extent covered in the specification except for unions which shall be in
accordance with MSS-SP-83.
1.16 Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME, MSS-SP & J P
Kenny Standards shall be as per manufacturer’s std. Contours of these fittings shall meet the
requirements of ASME B3 1.3. Manufacturer shall submit drawings / catalogues of these items along with
the offer.
1.17 Length of all long half couplings shall be 100 mm unless otherwise specified.
1.18 All seamless pipes employed for manufacturing of fittings shall be required to have undergone hydrotest to
ASTM A 530. Welded pipes employed for manufacture of fittings shall be tested as given below:
Document No. Rev

TECHNICAL NOTES FOR
SHEET 3 of 5
Welded Pipe Employed For Manufacture Of Welded Fittings. Test Criteria
ASTM A671 Gr. C65,70 (Cl.32) P = 2ST/D

ASTM A672 Gr. C60,65,70 (C1.12, 22) S = 90% of SMYS.
ASTM A671 Gr. CF60,65,70,66 (CL32) T = Nom. Wall Thickness
ASTM A691 Gr. 1/2Cr, 1Cr, l¼ Cr, 2¼ Cr, 5Cr, 9Cr (Cl.42) D = O.D. of Pipe.
P = 2ST/D
API5L
S = 85% of SMYS.
ASTM A358 TP 304, 304L, 304H,318, 318L, 318H,321,347
T = Nom. Wall Thickness
(Cl.1, 3, 4)
D = O.D. of Pipe.
ASTM B725 ASTM B725

ASTM B517 ASTM B517
ASTM B514 ASTM B514
1.19 The bevel ends of all butt weld fittings shall undergo 100% MP/DP test.
1.20 Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable in forging materials
(upto 1½”) and wrought fitting materials (above 11/2”) also in the corresponding material grades.
1.21 Abbreviations for ends of swages and nipples shall be as follows:

PBE : Plain Both Ends
TBE : Threaded Both Ends
2.0 IBR REQUIREMENTS
2.1 IBR Documentation Required:
2.1.1 Fittings under the purview of “IBR” (Indian Boiler Regulations) shall be accompanied with original IBR
certificate in Form Ill-C duly approved and countersigned by IBR authority / local authority empowered by
Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector
where the supplier is located is the minimum requirement for acceptance.
2.1.2 For materials 1¼Cr - ½Mo (ASTM A 234Gr.WP11 & ASTM A234 Gr.WP11W) & 2¼Cr - 1Mo (ASTM A
234 Gr.WP22 & ASTM A234 Gr. WP22W),where fittings are manufactured from pipe, Form Ill-C
approved by IBR shall include the tabulation of Et, Sc, & Sr values for the entire temperature range given
below. Et, Sc, & Sr values shall be such that throughout the temperature range
Et /1.5 ≥ SA
Sr /1.5 ≥ SA
Sc ≥ SA
SA : Allowable stress at the working metal temperature.
Et : Yield point (0.2% proof stress at the working metal temperature)
Sc : The average stress to produce elongation of 1 % (creep) in 100000 hrs at the working metal
temperature.
Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature and in
no case more than 1.33 times the lowest stress to produce rupture at this temperture.
Document No. Rev

TECHNICAL NOTES FOR
SHEET 4 of 5
SA (psi)
Temp(°F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
Material
A 234
Gr.WP11 /
21700 20900 20500 20100 19700 19200 18700 13700 9300 6300 4200 2800
A234
Gr.WPI1W
A 234
Gr.WP22 /
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A234
Gr.WP22W
Note : SA values given above are from ASME B31.3-1996. Values shall be as per the latest edition prevailing.
2.2 For carbon steel fittings described “IBR” chemical composition shall conform to the following:
Carbon (max) : 0.25%
Others (S, P, Mn) : As prescribed in IBR regulations
The above composition is not valid for non-IBR fittings.
3.0 MARKING AND DISPATCH
3.1 Each fitting shall be legibly and conspicuously stamped in accordance with the requirements of
applicable standards along with special condition like “IBR”, “Cryo”, “NACE” etc.
3.2 Steel die marking with round bottom punch may be permitted on body of butt weld CS & lower alloy steel
fittings, but for SS & higher alloy steel fittings, the same should be marked by electro-etching only.
3.3 Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead or Copper
which causes corrosive attack on heating.
3.4 Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.
3.5 Fittings shall be protected from rust, corrosion and mechanical damage during transportation, shipment
and storage.
3.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a petroleum
solvent and the same shall not be harmful to welding.
3.7 Fittings under “IBR”, “Cryo”, “NACE” shall be painted in red, light purple and canary yellow stripes
respectively for easy identification. Width of the stripe shall be 25 mm.
3.8 Each end of fitting shall be protected with a wood, metal or plastic cover.
3.9 Each size of fitting shall be supplied in separate packaging marked with the purchase order number, item
code number, material specification, size and schedule I thickness / rating.
Document No. Rev

TECHNICAL NOTES FOR
SHEET 5 of 5
GAIL GAS Limited
DEWAS
TECHNICAL SPECIFICATION CLIENT JOB NO.

FOR
MONOLITHIC INSULATING JOINTS TOTAL SHEETS 9
DOCUMENT NO 11 0290 01 09 02 002

TABLE OF CONTENTS
Sl.No. DESCRIPTION PAGE NO.
1.0 SCOPE 3
2.0 REFERENCE DOCUMENTS 4
3.0 MATERIALS 5
4.0 DESIGN & CONSTRUCTION REQUIREMENTS 5
5.0 INSPECTION & TESTING 6
6.0 TEST CERTIFICATES 7
7.0 PAINTING, MARKING & SHIPMENT 8
8.0 SPARES AND ACCESSORIES 8
9.0 DOCUMENTATION 8
Document No. Rev

FOR 11-0290-01-09-02-002 B
MONOLITHIC INSULATING JOINTS SHEET 2 of 9
1.0 SCOPE
This specification covers the basic requirements for design manufacture, testing and supply of
carbon steel insulating joints to be installed in onshore cross country pipeline systems used for
transporting non-sour hydrocarbon gases including LPG.
This specification does not cover the Insulating joints for sour hydrocarbons (liquid/gas) service as
defined in NACE standard MR-01-75.
1.1 Abbreviations
The following definitions shall apply:
• ASME : American Society of Mechanical Engineers.

• ASNT : American Society for Non-destructive Testing.
• ASTM : American Society for Testing and Materials.
• ISO : International Standards Organization.
• NDE : Non-destructive Examination.
• MSS : Manufacturers Standardization Society.
• NPS : Nominal Pipe Size.
• UNS : Unified Numbering System.
1.2 Definitions
Purchaser : The Company which makes purchase order.
Manufacturer : Manufacturer who receives the purchase order.
Shall : This verbal form indicates requirements strictly to be

followed in order to confirm to the standards and form
in which no deviation is permitted.
Should : This verbal form indicates that among several possibilities

one is particularly suitable without mentioning or
excluding others or that a certain course of action is
preferred but not necessarily required.
May : This verbal form indicates a course of action permissible

within the limits of this standard.
Can : This verbal form used for statements of possibility &

capability , whether material, physical or casual.
1.3 Compliance
Compliance by the MANUFACTURER with this specification shall not relieve him of his
responsibilities to supply Monolithic insulating joints suited to meet the specified requirements
and/or local codes governing health and safety.
The MANUFACTURER shall notify the CONSULTANT in writing, of any proposed deviation from
this Specification. The Consultant’s decision in respect of concession requests will be final.
The CONTRATOR shall continually verify the quality and fitness for purpose of the
Monolithic insulating joint, and shall propose appropriate actions/measures if any aspects of
manufacture are found to be unsatisfactory.
Document No. Rev

FOR 11-0290-01-09-02-002 B
1.4 Quality Conformance
The MANUFACTURER shall demonstrate to the satisfaction of the OWNER / CONSULTANT

that his activities within the scope of this document are in accordance with the relevant section of
BS EN ISO 9001. The MANUFACTURER shall submit to the CONSULTANT for review and
approval, a Quality Plan and procedural specifications prior to commencement of work. The
Quality Plan shall define all sub manufacturers’ involvement in the work. The review in this
Specification shall only indicate a general requirement and shall not relieve the
MANUFACTURER of his obligations to comply with the requirements of the Contract.
1.5 Safety
Safety is paramount. All work shall be performed in accordance with the safety requirements
listed in the contract documentation.
2.1 Reference has been made in this specification to the latest edition of, the following Codes,
Standards and Specifications.
API 1104 : Specification for welding pipelines and related facilities.
ASME B 31.3 : Process piping.
ASME B 31.4 : Liquid transportation systems for hydrocarbons, LPG, Anhydrous

Ammonia and Alcohols
ASME B 31.8 : Gas Transmission and Distribution piping systems.
ASME Section VIII : Boiler & pressure Vessel Code.

ASME Section IX
ASTM A 370 : Standard Test Methods and Definitions for Mechanical Testing
of steel Products.
ASTM B 733 : Auto catalytic Nickel Phosphorous coating on metals.
ANSI B 16.25 : Butt Welding Ends
EN 1024 : Metallic Materials-Types of inspection documents.
MSS-SP-25 : Standard marking systems for valves, Fittings, Flanges and

union.
MSS-SP-53 : Quality standard for steel casting and forging for valves,
flanges, fittings and other piping components –Magnetic particle
Examination method.
MSS-SP-75 : Specification for High Test Wrought welding fittings.
NACE RP 286 : The electrical isolation of catholically protected pipelines.
ISO 13623 : Petroleum & Natural Gas industry –Pipeline transportation

system.
Document No. Rev

FOR 11-0290-01-09-02-002 B
ISO 14313 : Petroleum & Natural Gas Industry, Pipeline transportation
system –pipeline valves.
SSPC-VIS-I : Steel structures painting council-Visual standard
2.2 In case of conflict between the requirements of this specification and any code, Standard or
Specification referred to in this Specification, the requirements of this specification shall govern.
3.0 MATERIALS
3.1 Material for the pressure containing parts of the insulating joints shall be as indicated in the
Monolithic insulating joint data sheets. Material for pups shall be equivalent or superior to the
material of connecting pipeline, which is indicated in the data sheets. Pup piece material shall be
such as to limit the thickness of pup piece to be welded with pipeline. Other part shall be as per
Manufacturer's standard suitable for the service condition indicated in Insulating Joint Data Sheets
and shall be subject to approval by purchaser / Purchaser’s representative.
All process wetted parts, metallic and non-metallic shall be suitable for the commissioning fluids and
service specified by the company. Manufacturer shall confirm that all wetted parts are suitable for
treated water/sea water environment, which may be used during field testing.
3.2 Insulating joints which are subjected to field welding by purchaser shall have carbon equivalent (CE)
not exceeding 0.43 based on check analysis for each heat of steel calculated according to the
following formula:
CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15
3.3 Charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected
zone of all pressure containing parts such as body, welding ends in accordance with the impact test
provisions of ASTM A 370 at a temperature of 0 °C. The charpy impact test specimens shall be
taken in the direction of principal grain flow and notched perpendicular to the original surface of the
plate of forging. Average impact energy value of three full sized specimens shall be 35 joules.
Minimum impact energy value of individual specimen shall be 27 joules. No specimen shall exhibit
less than 80% shear area.
When Low Temperature carbon steel (LTCS) materials are specified in data sheet or offered by
manufacturer, the charpy V-notch test requirements of applicable material standard shall be
complied with.
3.4 Carbon steel used for the manufacture shall be fully killed.
3.5 Hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum
hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10,
unless specified otherwise.
3.6 Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286.
4.0 DESIGN & CONSTRUCTION REQUIREMENTS
4.1 Mechanical
4.1.1 Insulating joints shall be of integral type fabricated by welding and with suitable pups on either side.
A corrosion allowance as indicated in data sheet shall be considered in design. Bolted and threaded
joints are not acceptable.
Document No. Rev

FOR 11-0290-01-09-02-002 B
4.1.2 All materials used for the manufacture of the insulating joint shall be in accordance with clause 4.0 of
this Specification.
41.3 Insulating joints shall be designed using the design principles of ASME Section-VIII Div. 1.
4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to 1 millibar.
4.1.5 The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld
design shall be such as resulting in a weld joint factor of 1.0.
4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding
ends having unequal thickness with respect to connecting pipe, shall be as per ASME B31.4/ B31.8
as applicable.
4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed
for a distance of at least 50mm from each end to facilitate welding.
4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal bore shall be
same as that of connecting pipe including its tolerances.
4.1.9 The insulating joint shall be formed by sandwiching and locking in positions the insulating material in
a bell and spigot type of joint. The joint shall be assembled in such a way that its various
components are firmly locked in position and the completed joint is capable of withstanding stresses
due to designed operating conditions and field hydrostatic testing.
4.1.10 Insulating joints shall be suitable for aboveground installations as indicated in the data sheets.
4.1.11 All welds shall be made by welders and welding procedures qualified in accordance with the
provisions ASME section IX. The procedure qualification shall include impact test and hardness test
and shall meet the requirements of clause 3.3 & 3.5 of this specification.
4.1.12 Repair welding on parent metal is not allowed. Purchaser’s representative for each repair shall carry
out repair of welds only after specific approval. Welders shall carry out the repair welding and
welding procedures duly qualified as per ASME section IX and records for each repair shall be
maintained.
4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm from the nominal internal
diameter.
4.1.14 Out of roundness measured at the root face of the welding ends shall not be more than 0.5% of the
specified inside diameter.
4.2 Electrical
4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts.
4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either side of the insulating joint
for connecting 10 mm2 and 50 mm2 cables for measurement/ shorting purposes. Cleats shall be
attached to the insulating joint by welding.
5.0 INESPECTION & TESTING
5.1 The manufacture shall perform all inspection and tests as per the requirements of this specification
and the relevant codes, prior to shipment at his works. Inspection & tests shall be performed to
ascertain the requirements of this specification & not limited to the following:
5.1.1 All insulating joints shall be visually inspected.

Document No. Rev
FOR 11-0290-01-09-02-002 B
5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings.
5.1.3 Chemical composition and mechanical properties including hardness shall be checked as per
relevant material standards and this specification, for each heat of steel used.
5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below:
a) 100% radiography shall be carried out on all butt & repair welds of pressure containing parts.
Acceptance limits shall be as per API 1104.
Welds, which in purchaser's Representative opinion cannot be inspected by radiographic

methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall
be as per ASME Section VIII Appendix-12 and Appendix-6 respectively.
b) All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a
distance of 50mm from the ends. Any lamination larger than 6.35 mm shall not be acceptable.
c) All forgings shall be wet magnetic particle inspected on 100% of forged surfaces. Method and
acceptance shall comply MSS-SP-53.
d) All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle inspection and ≥
6mm shall be examined 100% by UT. Acceptance criteria for MPI & UT shall be as per ASME
Sec.VIII Appendix-6 & Appendix-12 respectively.
5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data sheet. The test
duration shall be of 15 minutes.
5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for 10 minutes.
The tightness shall be checked by immersion or with a frothing agent. No leakage shall be
acceptable.
5.1.7 Dielectric Test
a) Insulation resistance of each insulating joint shall be at least 50 mega-ohms when checked
with1000 V DC.
b) Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for
one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic
test shall be equal. Testing time voltage and leakage shall be recorded and certified. No
repair shall be permitted to the insulating joints failed in the above mentioned tests.
5.2 Purchaser reserves the right to perform stage wise inspection and witness test as indicated in Para
5.1 at Manufacturer's works prior to shipment. Manufacturer shall give reasonable notice of time and
shall provide without charge reasonable access and facilities required for inspection to the
purchaser's Representative.
Owner’s approved Third Party Inspection Agency (TPIA) shall be deputed by the
MANUFACTURER for inspection at manufacturer premises to witness / review material Tests
certification as per EN-10204 type 3.2C certification at manufacturer’s cost.
Inspection and tests performed/witnessed by the Purchaser's Representative shall in no way relieve
the Manufacturer's obligation to perform the required inspection and test.
6.1 Manufacturer shall submit following certificates to Purchaser's Representative.
Document No. Rev

FOR 11-0290-01-09-02-002 B
a) Test certificates relevant to the chemical analysis and mechanical properties including
hardness of the materials used for construction of insulating joint as per this specification
and relevant standards.
b) Test reports on non-destructive testing.
c) Test certificates for hydrostatic and air tests.
d) Test certificate for electrical resistance test.
e) Test report for dielectric strength test.
7.1 Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting
to SP-6 in accordance with "steel structures painting council - Visual standard SSPC-VIS-l.".
External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar
epoxy resin with a minimum dry film thickness of 300 microns.
Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for
approval.
7.2 Insulating joints shall be marked with indelible paint with the following data:-
a. Manufacturer's name
b. Suitable for- inch nominal diameter pipeline
c. End thickness in mm
d. Material
e. Design Pressure/ Hydrostatic Test Pressure
f. ANSI Class Rating
g. Tag No.
h. Year of Manufacture
i. PO No.
7.3 Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel
protectors shall be provided to weld ends.
7.4 Only those insulating joints, which have been inspected and certified by Purchaser, shall be shipped.
Not Applicable
9.0 DOCUMENTATION
9.1 All documents shall be in English Language.
Document No. Rev

FOR 11-0290-01-09-02-002 B
9.2 At the time of bidding, Bidder shall submit the following documents:-
a) General arrangement drawing along with cross sectional view, overall dimensions and
details of insulating materials recommended.
b) Reference lists of previous supplies of insulating joint of similar specification.
c) Clause wise list of deviation from this specification, if any.
9.3 Within two weeks of placement of order, the Manufacturer shall submit four copies of but not limited
to the following drawings, documents and specifications for approval.
a) Fabrication drawings and relevant calculations for pressure containing parts.
b) Welding procedure and method of manufacture for all phases of manufacture.
c) Quality Assurance Plan (QAP)
Once the approval has been given by purchaser any changes in design, material and method of
manufacture shall be notified to the Purchaser whose approval in writing of all changes shall be
obtained before the insulating joint are manufactured.
9.4 Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies
of the approved drawings, documents and specifications as listed in 9.3 of this specification.
9.5 Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test
certificates as listed in Clause 6.0 of this specification.
Document No. Rev

FOR 11-0290-01-09-02-002 B
GAIL GAS LIMITED
DATA SHEET CLIENT JOB NO. -
FOR MONOLITHIC INSULATING JOINT TOTAL SHEETS 02

DOCUMENT NO 11 0290 01 09 03 002

PROCESS DATA:
PIPE CLASS 3A1 RATING: 300 #
FLUID R.L. NATURAL GAS FLUID SYMBOL RLNG
DESIGN CONDITIONS:
PRESSURE 49 Barg
TEMPERATURE 0 to 60 C
OPERATING CONDITIONS:
PRESSURE Barg
TEMPERATURE C
CORROSION ALLOWANCE: 0.5 MM
CONSTRUCTION DATA:
ASME VIII, DIV. 1 APP.2, ASME IX AND
DESIGN AND CONSTRUCTION CODE : ANSI B31.8
ALLOWABLE STRESS VALUE : 50 % SMYS (Design factor : 0.4)
CONSTRUCTION MATERIAL
BODY MSS SP-75, WPHY Gr. 52/ ASTM A 694
Gr. F 52.
:
AS PER PIPE MATERIAL
PIPE PUPS : SPECIFICATION
INSULATION : AS PER MANUFACTURER’S STANDARD
INSULATING JOINTS : Carbon steel, fully killed, fine grain (*)
SEALING GASKETS : (*)
SPACING RING : (*)
FILLING MATERIAL : (*)
EXTERNAL COATING Epoxy Resin (*)
INTERNAL LINING Epoxy Resin (*)
TESTING INSPECTION AND CERTIFICATES:
HYDROTEST : 1.5 X Design pressure
5 000 VAC, 50 Hz Holding time at least one minute > 50M ohm
ELECTRICAL TEST : (1000VDC)
DIMENSIONAL STANDARD ANSI B 16.5
END CONNECTION : BUTT WELDED ENDS AS PER ANSI B 16.25
Machined True round
MARKING : Manufacture name

:
Note:
(*) To be selected by Vendor in his bid and submitted for approval.
1. For the welding end, the out of roundness shall be 5 mm and tolerance on internal diameter at pipe ends
shall be Same as diameter tolerance for the pipe ends indicated in API 5L Table 8
Document No. Rev

DATA SHEET
FOR 11-0290-01-09-03-002 B
MONOLITHIC INSULATING JOINT SHEET 2 of 2
PROJECT: CITY GAS DISTRIBUTION PROJECT
QAP NO: 11-0290-01-09-10-002
CONSULTANT: WGI ITEM DESCRIPTION/ QUANTITY: MIJ
QUALITY ASSURANCE PLAN PAGE NO: 1 of 2
SR. COMPONENTS & TYPE OF QUANTAM OF REFERENCE ACCEPTANCE FORMAT OF INSPECTION
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD P W R

1 RAW MATERIAL
Physical &
1.1 Pipe 1 sample per lot ASTM A 370 ASTM A 370 Test certificate 4 1,2
chemical properties
Physical &
1.2 Forged Rings 1 sample per lot ASTM A 370 ASTM A 694 F52 Test certificate 4 1,2
chemical properties
Epoxy Laminated Glass Physical & Company

1.3 1 sample per lot ASTM D 709 Test certificate 3 1,2
Fabric Base Electrical Properties Standard
2 NDT
Dye Penetration
Forged Ring welded with
2.1 Test & 100% API1104 API 1104 Test certificate 2,3 1,2
pipe(w1 & w2)
Radiography Test
Dye Penetration
100% Test certificate 2 1,2
Test API1104 API 1104
2.2 Final Weld (W 3)
M.P.I 100% ASME Sec VIII Test certificate 3 1,2 1,2
ASME Sec V Div.01
NOTE: 1. Qualified welders & procedure will be used as per ASME Sec. IX for all welds.
2. In case Mill certificates are not available test certificates from approved laboratory shall be furnished.
3.TPI to issue 3.2 certificate as per EN1 10204 format.
P - Performing Test 1 - Client/Third Party

R - Review of Test Report 2 - Vendor
W - Witnessing Report 3 - Sub Vendor
4 - Outside Laboratory
PROJECT: CITY GAS DISTRIBUTION PROJECT
QAP NO: 11-0290-01-08-10-002
CONSULTANT: WGI ITEM DESCRIPTION/ QUANTITY: MIJ
QUALITY ASSURANCE PLAN PAGE NO: 2 of 2
SR. COMPONENTS & CONDITION TYPE/METHOD QUANTAM OF ACCEPTANCE FORMAT OF INSPECTION
P
W R
NO. OPERATIONS OF CHECK CHECK NORMS RECORD
3 FINAL INESPECTION
3.1 Dimensional Report Normal Measurement 100% Appd.Drg. Report 2 1 1,2
3.2 Hydro Test 74 Bar for 15 Min. Testing 100% Appd.Drg. Test Certificate 2 1 1,2
3.3 Pneumatic Test 5 Bar for 10 min Testing 100% Appd.Drg. Test Certificate 2 1 1,2
Insulation Electrical
3.4 1000 V DC for 1 min Testing 100% Min. 25 MΩ Test Certificate 2 1 1,2
Resistance
3.5 Di-Electric Strength 5000V AC for 1 min. Testing 100% No breakdown Test Certificate 2 1 1,2
3.6 COATING Inespection Inner & Outer Testing Random Report 3 1,2 1,2
P - Performing Test 1 - Client/Third Party

R - Review of Test Report 2 - Vendor
W - Witnessing Report 3 - Sub Vendor
4 - Outside Laboratory
GAIL GAS LIMITED
CLIENT JOB NO.

TECHNICAL SPECIFICATION FOR PAINTING
TOTAL SHEETS 27
DOCUMENT NO 11 0290 02 09 02 005

TABLE OF CONTENT
1.0 GENERAL................................................................................................................................. 3
2.0 CODES & STANDARDS .......................................................................................................... 3
3.0 CONDITIONS OF DELIVERY................................................................................................... 4
4.0 COMPOSITION OF THE PAINT PRODUCTS USED .............................................................. 4
5.0 IDENTIFICATION...................................................................................................................... 5
6.0 SURFACE PREPARATION STANDARDS .............................................................................. 6
7.0 PREPARATION OF THE SURFACES ..................................................................................... 6
8.0 METALLISATION ................................................................................................................... 10
9.0 CARRYING OUT THE PAINTWORK ..................................................................................... 10
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 2 of 27
1.0 GENERAL
1.1 These technical specifications shall be applicable for the work covered by the contract, and without
prejudice to the provisions of various codes of practice, standard specifications etc. It is understood that
contractor shall carry out the work in all respects with the best quality of materials and workmanship and
in accordance with the best engineering practice and instructions of Engineer-In-Charge.
Wherever it is stated in the specification that a specific material is to be supplied or a specific work is to
be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any
deviation from this standard without written deviation permit from appropriate authority will result in
rejection of job.
1.2 SCOPE
1.2.1 Scope of work covered in the specification shall include, without being limited to the following.
1.2.2 This specification defines the requirements for surface preparation, selection and application of primers
and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures,
external & internal protection of storage tanks for all services, MS Chimney without Refractory lining and
Flare lines etc. The items listed in the heading of tables of paint systems is indicative only, however, the
contractor is fully responsible for carrying out all the necessary painting, coating and lining on external
and internal surfaces as per the tender requirement.
1.2.3 Extent of Work
1.2.3.1 The following surfaces and materials shall require shop, pre-erection and field painting:
a. All uninsulated C.S. & A.S. equipment like columns, vessels, drums, storage tanks(both external &
internal surfaces), heat exchangers, pumps, compressors, electrical panels and motors etc.
b. All uninsulated carbon and low alloy piping, fittings and valves (including painting of identification
marks), furnace ducts and stacks.
c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc.
e. Flare lines, external surfaces of MS chimney with or without refractory lining and internal surfaces of
MS chimney without refractory lining.
f. Identification colour bands on all piping as required including insulated aluminium clad, galvanised,
SS and nonferrous piping.
g. Identification lettering/numbering on all painted surfaces of equipment/piping insulated aluminium

clad, galvanized, SS and non-ferrous piping.
h. Marking / identification signs on painted surfaces of equipment/piping including hazardous service.
i. Supply of all primers, paints and all other materials required for painting (other than Owner supplied
materials)
j. Over insulation surface of equipments and pipes wherever required.
k. Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
l. Painting of pre-erection/fabrication and Shop primer.
m. Repair work of damaged pre-erection/fabrication and shop primer and weld joints in the field/site
before and after erection as required.
Document No. Rev
FOR PAINTING 11-0290-02-09-02-005 B
SHEET 3 of 27
n. All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP plant.
1.2.3.2 The following surfaces and materials shall not require painting in general. However, if there is any
specific requirement by the owner, the same shall be painted as per the relevant specifications:
a. Uninsulated austenitic stainless steel.

b. Plastic and/or plastic coated materials
c. Non-ferrous materials like aluminum.
1.2.4 Documents
1.2.4.1 The contractor shall perform the work in accordance with the following documents issued to him for
execution of work.
a. Bill of quantities for piping, equipment, machinery and structures etc.

b. Piping Line List.
e. Painting specifications including special civil defence requirements.
1.2.5 Unless otherwise instructed, final painting on pre-erection/ shop primed pipes and equipments shall be
painted in the field, only after the mechanical completion, testing on systems are completed as well as
after completion of steam purging wherever required.
1.2.6 Changes and deviations required for any specific job due to clients requirement or otherwise shall be
referred to J P Kenny for deviation permit.
2.0 CODES & STANDARDS
Without prejudice to the specifications of the contract, the following codes and standards shall be
followed for the work covered by this contract.
IS: 5 Colors for ready mixed paints and enamels.
IS: 101 Methods of test for ready mixed paints and enamels,
IS: 161 Heat resistant paints.
IS: 2074 Specifications for ready mixed paint, red oxide zinc chrome priming.
IS: 2339 Aluminum paint for general purposes in dual container.
IS: 2379 Color code for identification of pipelines.
IS: 2932 Specification for enamel, synthetic, exterior (a) undercoating. (b) Finishing.
3.0 CONDITIONS OF DELIVERY
Packaging
Every recipient will be fitted with a hermetically-sealed lid with an opening that is sufficiently large to
allow the contents to be stirred: the outside and inside are protected against oxidation, and, the lid,
are marked with a strip of color identical to the contents.
4.0 COMPOSITION OF THE PAINT PRODUCTS USED
a) Quality
The composition and quality of the products may not differ from batch to batch. A batch is all of
the products of a specified manufacture. If the analyses of products bring to light that the
Document No. Rev
FOR PAINTING 11-0290-02-09-02-005 B
SHEET 4 of 27
composition does not conform to the specifications of the paint manufacturer, the OWNER may
refuse to use this batch of products. The paint products must comply with the following
conditions
• They must have the viscosity necessary for the described use and the established
condition: use of the brush - paint roller (spray gun only for special cases and in the
workshop)
b) Quality control - Sampling
While the works are in progress on the construction site, the OWNER may carry out sampling on
the paint being used for the purpose of checking conformity. The paint products must be made
available free of charge to the laboratory or the approved supervisory body in sufficient
quantities so that all the tests can be carried out on the same batch.
If analyses reveal a non-conformity in the composition of the products used (tolerance of + 3 %

of the dosage of every component), the OWNER may refuse application of the product under
consideration, halt the work and have the nonconforming product already applied removed.
Before proceeding the work, a product that does conform will be required. The only Purpose of
the analysis is to reveal any nonconformity of the composition of the products. Their purpose is
therefore not to assess the quality of the different components. The analyses concerned are not
acceptance tests of the products supplied and in no way affect the obligations of the contractor
specified in the contract towards the OWNER.
5.0 IDENTIFICATION
Every recipient will bear the following information:
• Name of the manufacturer
• Date and number of manufacture
• Name of the product type
• Batch no
• Net weight of the produced or the contents of the recipient
• Date of the expiry.
At the time of delivery, this packaging must bear labels in conformity with the legal stipulations in force.
Leaving the site after work
After completion of a job a general clean-up shall be carried out by the Contractor to remove all debris,
materials or irregularities that his work has brought to the site so that it is left tidy:
The restoration work includes among other things:
• the removal of abrasives.
• the removal of the different protective coverings.
• the Contractor will make the required repairs to any damage after refitting the supports.
• the removal of paint and cleaning of the stains on the floor.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 5 of 27
6.0 SURFACE PREPARATION STANDARDS
Following standards shall be followed for surface preparations:
1 Swedish Standard Institution- SIS-05 5900-1967
2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP)
3 British Standards Institution (Surface Finish of Blast-cleaned for Painting) BS-4232.
4 National Association of Corrosion Engineers. U.S.A. (NACE).
5. IS-1477-1971 (Part-1) - Code of Practice for Painting of Ferrous metals in Buildings. (Part 1,
Pre-treatment)
a) The contractor shall arrange, at his own cost to keep a set of latest edition of above
standards and codes at site.
b). The paint manufacturer's instruction shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
• Proper storage to avoid exposure as well as extremes of temperature.

• Surface preparation prior to painting.
• Mixing and thinning.
• Application of paints and the recommended limit on time intervals between
coats.
c) Any painting work (including surface preparation) on piping or equipment shall be

commenced only after the system tests have been completed and clearance for taking
up painting work is given by the OWNER, who may, however, at his discretion authorize
in writing, the taking up of surface preparation or painting work in any specific location,
even prior to completion of system test.
7.0 PREPARATION OF THE SURFACES
7.1 General Specifications
The cases that occur in practice on building sites, with regard to painted surfaces, can be broken down
as follows:
• Material of which the oxide content disappears by natural oxidation.

• Material that has already been covered with a layer of paint in the workshop.
• Material that is covered with old paint layers that show different degrees of weathering.
Good preparation oldie surface is the best guarantee for good anti-corrosion protection.
Paintwork may never begin until the surface to be treated is dry and is independent of the base coat and
cleared of dirt, dust, rust, scale, grease, salt attack, cement powder, cement mud-scale, sand, oil, etc.
Based on the environmental conditions of coastal and saline nature, the Painting specification for station
pipes defines the complete requirements like:
• Surface preparation standards like NACE etc.

• Sand blasting process
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 6 of 27
• Color Codes for piping
• Paint materials types and their DFT measurement.
• Selection and application of paints on external surfaces.
The pipeline passes through the coastal and marine environment, the Table-4 of this specification to be
followed for the painting works.
The method of preparation of the surface will be implemented in accordance with the preparation
methods described below:
• Cleaning (bright blast-cleaning);

• Mechanical cleaning;
• Manual derusting.
The Contractor should have the required material at his disposal to clean the surfaces to be coated
thoroughly in accordance with the preparation methods regardless of the form or the condition of such
surfaces. The cleaning devices that might be damaged during the surface preparation shall be screened
off by the Contractor.
7.2 Sandblasting
Before beginning cleaning by blasting, the person carrying out the work will take the following measures:
• Clear the steel surface of oil and/or grease;

• Ensure that each flange collar (section where the sealing is applied) is properly screened off
against the blasting and the subsequent works;
• Check that no blasting grains can act into the pipes during this process. Any openings not
sealed off must be screened off;
• Where there are valves, regulators and other devices, the manufacturer's identification plate will
be dismantled so that all surfaces can be treated. The plate will then be put back again.
• Screen off all non-metal structures such as rubber where there is a filter;
• With valves, operators and other devices, care should be taken to ensure that no metal filings or
paint get into the apparatus:
• The OWNER reserves the right to carry out part or all of these works himself.
To prevent rust forming quickly as the result of humidity on the blasted surface, cleaning by blasting may
only be carried out when the temperature of the steel surface is at least 3°C higher than the dew-point of
the ambient air.
Blasting may not be carried out if the relative degree of humidity exceeds 80%. The choice of the type of
blasting medium used depends on local circumstances such as the possible presence of gas and the
material to be blasted.
The abrasive to be used must conform to the local low i.e. it may contain no carbon and less than 1%
free silicon dioxide. The Sa 3 will always be requested and must at least reach Sa 2½ during the initial
stage of the paintwork. For blasting followed by metallisation, the surface preparation degree to be
achieved is always Sa 3. The degree of cleanliness to be obtained will be inspected in accordance with
the Swedish standard SVENSK STANDARD ISO 8501-1-1988 SS 05.5900.
• Sa 3: surface blasted down to the bare metal; when the surface is inspected with a magnifying
glass, scale, rust and foreign bodies must be completely removed and it should be possible to
raise a metallic -shine on the treated surface.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 7 of 27
• Sa 2 1/2: blasted very carefully. Scale, rust and foreign bodies must be removed in such a way
that anything left behind will only be visible as nuances (shading) or strips.
The blast-cleaning will be carried out by means of compressed air free of water and oil.
After the blasting and before painting, the surface should be completely cleaned of blasting material and
so forth with a soft brush, a dry cloth or dry compressed air.
7.3 Mechanical cleaning
If sandblasting is not permitted or if the metal structures are not easily accessible for blasting or blasting
for one reason or another is technically unfeasible, mechanical derusting can be used instead. With
mechanical cleaning by means of chipping, rotating steel brushes and sanding discs, a degree of
cleanliness St. 3 should be reached.
St 3 : removal of the old paint layers of which the adhesion leaves something to be desired and/or of
which the paint layer no longer fulfils the requirements.
If parts are present that are so corroded that St 3 is difficult to achieve, this should be notified to the
OWNER representative prior to the start of the works.
N.B:
St. 3 : means removal of every old paint layer. Retouching means local polishing with St. 3 or Sa 3
followed by application of the desired painting system.
After mechanical cleaning, the surface should be made dust-flee with a cloth or a so brush, washed with
an organic solvent and thoroughly dried off with a dry cloth (e.g. with 1.1.1. Trichoroethane such as
Solvethane, Chloroethene).
7.4 Manual Derusting
Manual derusting with the aid of scrapers. steel brushes, sandpaper etc. shall only be permitted in
exceptional cases for local repairs. Any deviation there from must be requested from the OWNER/
OWNER 's Representative.
With manual derusting, a surface preparation degree St 3 must be obtained. The length of the handles
of the equipment used may not exceed 50 cm.
7.5 Preparation of a surface covered with a layer of paint in the workshop.
This layer is in general applied by the manufacturer, for example, on valves, regulators etc. Layers of
this kind will be checked for their proper adhesion in accordance with ASTM D 3359, method A
(Standard Test Method for measuring adhesion by tape test). The adhesion should be at least .
If the paint layer shows less adhesion or is incompatible with the rest of the system it should be
completely removed. If the paint layer is not removed, the Contractor accepts it in the state in which the
coating is found and the guarantee remains in force. The adhesion does not have to be examined if
system 63 has already been applied in the workshop on behalf of the OWNER.
The Contractor, who must provide for the protection on the construction site, must therefore obtain the
information regarding the treatment of the surface and the quality of the paint that was used and must,
moreover, examine the adhesion of the layer on the construction site, the percentage of damage and
weathering as well as the value of the preparation of the surface in the workshop together with the
thickness thereof that must be supplemented if necessary.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 8 of 27
a) Galvanized surface
Galvanized surfaces, both old and new will be carefully roughened up. Every foreign body
(concrete splatters, chalk marks, grease and oil stains, etc.) will be removed. Thereafter, rub the
surfaces with abundant water and, if necessary, with cleaning products.
To this end, nylon brushes will be used for every kind of dirt as well as for removing zinc salt
residue. Thereafter, the surfaces will be treated in accordance with system 21. Where the zinc
layer is lacking, it will be derusted manually to a degree of cleanliness St 3, after which a primer
coat will be applied in accordance with system 22.
b) Metallised surfaces treated with an impregnation layer
• degrease with the desired degreasing product:

• clean under high pressure or with a product prescribed by the paint supplier.
If the paint layer adheres well and is applied on a clean base, the painting system described may be
continued. If the percentage of damage and weathering does not exceed 5 % m. retouching may be
considered. These partial repairs will be carried out.
If on the other hand, the percentage of damage does exceed 5 %/m or if the layer applied in the
workshop comes loose the Contractor must draw the attention of the OWNER to this and carry out the
complete application system.
7.6 Preparation of surfaces covered with earlier paint layers that show different degrees of weathering.
If the surfaces do not show deep weathering limited to the spread of rust by small pitted areas or non-
penetrative rust in spots, it will very often be sufficient to clean the surfaces with abrasives or with an
abrasive disc, then to rub them down with steel wool, remove the dust and wash off. If thick rust
appears, in spots, scale rust and active rust canker, this should be removed with needle hammers or
stripped away directly by blasting, removing the dust and washing oft.
7.7 Preparation of concrete or cement plaster surfaces
Remove unsound paint layers and loose components with scrapers, blades or rotating steel brushes.
Thoroughly clean the entire surface with water containing ammonia. Thoroughly remove moss, algae
and fungal growths. Where these growths have been removed, treat the area with a fungicide in
accordance with the instructions for use.
Once the entire area is completely dry, brush off the dead residue of moss, algae and fungus with a hard
brush. In the case of reinforcement steel that has been laid bare, remove as rust, dust and grease as
possible and treat with a printer coat. When painting concrete surfaces, they must first be checked for
cracks. Cracks larger than 0.3 mm must be repaired with an appropriate system in accordance with the
type and extent of the repairs (e.g. injection with epoxy mortar). Repair damage such as cracks and
bursts to concrete parts with a two-component mortar or preferably with micro-mortars. Finally check the
alkalinity of the surface with the aid of litmus paper and neutralize it if necessary.
7.8 Use of solvents
It is sometimes necessary to use solvents when the surfaces to be painted are streaked with grease or
oil. In this case a suitable organic solvent should be applied. The operation should be carried out with
the aid of clean brushes or rags and clean solvent.
All the legal specifications in connection with solvents etc. must be adhered to. The OWNER/OWNER's
Representative will be informed in advance of any toxicity or flammability. All measures must be taken to
prevent any risk of fire and to nick out any possibility of poisoning (ventilation). The Contractor will
provide drip collectors to keep the environment free of pollution.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 9 of 27
7.9 Condition of the metal after stripping
The Contractor must call in a representative of the OWNER/OWNER's representative or of the Approved
supervisory Body responsible for checking the condition of the metal during stripping and informing the
OWNER/OWNER's representative immediately of any damage that he might have noticed.
• Deep corrosion of the plates - rivets - bolts

• Faulty welding
• Fittings that appear to be dangerous because of their age.
7.10 Removing coating from surface pipelines
The Contractor must have the equipment necessary for the removal of asphalt from the pipe without
damaging the latter (scratching, impact, etc,). The Contractor undertakes to carry out the work in
accordance with an approved procedure.
8.0 METALLISATION
8.1 Applying the metallisation
Metallisation must be carried out in accordance with ISO 2063,
Metallisation is carried out as rapidly as possible after blasting in order to limit corrosion of the pipes
(max. 3 hours later). With metallisation, a surface preparation degree Sa 3 is compulsory. The
roughness of the blasted surfaces should be from 25 to 50µ R Max.
• The metallising is always carried out on dry parts in good weather conditions (maximum relative
humidity 80 %);
• For metallisation, a wire composed of 85 % zinc and 15 % aluminum with a minimum

guaranteed degree of purity of 99.5 % is used (subject to other specifications). The application
thereof is always carried out in accordance with the conditions of the manufacturer and may at
all times be submitted to the OWNER’s representative.
• The sealant should be applied maximum 3 hours alter metallisation.
• The sealant must be thinned and applied as per the present specifications. A visual inspection
whereby the sealant completely covers the metallisation will suffice here.
• When evaluating the metallisation, a negative deviation from the minimum coating thickness, to
80 µ for 20% of the measurements will be permitted.
9.0 CARRYING OUT THE PAINTWORK
9.1 Conditions for carrying out paintwork
Painting may not be carried out in unsuitable conditions.
All preparatory work and painting may only he carried out in dry weather and at a minimum temperature
of 10C, except for special eases requested by the OWNER's Representative.
Unless otherwise stipulated in the specifications of the paint supplier, application of the paint is forbidden
if it is forecast that the temperature will fall to below 0C before the paint is dry. The temperature of-the
surface to be painted must be at least 3°C higher than the dew point of the ambient air. Application of
the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or
condensation sets in.
The work must be stopped:
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 10 of 27
• If the temperature of the surface to be painted is higher than that described by the supplier.
• In rain, snow, mist or fog or when the relative humidity is higher than 80 %.
Coats that have not yet dried and have been exposed to frost, mist, snow or rain and might thereby be
damaged must be removed after drying and the surfaces must be repainted at the expense of the
Contractor.
Working in direct sunlight or in hot weather must be avoided,
The first coat of paint must be applied maximum 3 hours after the preparation of the surface of the
relative humidity of the air is between 50% and 80%. This time span may be increased to 6 hours if the
relative humidity is less than 50%. In all cases, the preparation of the surface must exhibit degree Sa 3
and at the very least the appearance of degree Sa 2 ½ at the time of painting.
The coats of paint may only be applied on carefully cleaned surfaces that must be dry and free of grease
and dust.
9.2 Special conditions
Painting may be carried out when the Contractor can be sure that the instructions of the paint supplier
have been scrupulously followed with regard to the parameters in the following (non-exhaustive) list:
• Ambient temperature.
• Surface temperature.
• Relative humidity.
• Dew point.
• Drying times.
The Contractor must in this respect be able to produce the instructions for the paint on the site. The
OWNER/CONSULTANT will guarantee 100% supervision in this regard during the execution of the
work.
In addition, the paintwork may only be carried out to a minimum ambient temperature of 5°C and/or to a
maximum relative degree of humidity of 85 %. Application of the paint is also not permitted if there is a
danger that the coat of paint will not be dry before dew or condensation sets in.
9.3 Paint Materials
Manufacturers shall furnish the characteristics of all paints indicating the suitability for the required
service conditions. Primer and finish coats shall be of class-I quality and shall conform to the following:
a) Primer (P-1)
Red oxide Zinc Chromate Primer
Type and Composition Single pack, Modified phenolic alkyd medium pigmented with
red oxide and zinc chromate.
Volume solids 30 - 35%
DFT 25 microns/coat (min)
Covering capacity 12-13 M²/Lit/coat
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 11 of 27
b) Primer (P-2)
High build chlorinated rubber zinc phosphate primer
Type and Composition Single pack, Chlorinated rubber medium Plasticised with
unsaponifiable plasticiser pigmented with zinc phosphate
Volume solids 35- 40%
DFT 50 MICRONS/COAT (MIT)
Covering capacity 7-8 M²/Lit/Coat
c) Primer (P-3)
High build zinc phosphate primer
Type and Composition Single Pack, Synthetic medium, pigmented with zinc
phosphate.
Volume solids 40-45%
DFT 35-50 microns/coat
Covering capacity 10-12 M²/Lit/coat
Heat resistance Upto 100º C (dry)
d) Primer (P-4)
Etch Primer / Wash Primer
Type and Composition Two pack Poly vinyl butyral resin medium cured with
phosphoric acid solution pigmented with zinc tetroxy
chromate.
Volume solids 7-8%
Covering capacity 7-8 M²/lit/coat
e) Primer (P-5)
Epoxy Zinc Chromate Primer
Type and Composition Two pack, Polyamide cured epoxy resin medium pigmented
with zinc chromate.
Volume solids 40%(min)
Covering capacity 11-12 M2/lit/Coat
f) Primer (P-6)
Epoxy Zinc Phosphate Primer

Document No. Rev
FOR PAINTING 11-0290-02-09-02-005 B
SHEET 12 of 27
Type and Composition Two pack, Polyamide cured Epoxy resin medium pigmented
with zinc phosphate.
Volume solids 40% 35 microns / coat (min)
g) Primer (P-7)
Epoxy high build M10 Paint (Intermediate Coat)
Type and composition Two pack Poly Polyamide cured epoxy resin medium
pigmented with micaceous iron oxide. Volume solids 7- 8%
Volume Solids 50%
Covering capacity 5.0 M²/lit/coat
h) Primer (P-8)
Epoxy Red Oxide zinc phosphate primer
Type and Composition Two pack. Polyamine cured epoxy resin pigmented with Red
oxide and Zinc phosphate.
Volume solids 42%
Covering capacity 13-14 M/lit/coat
i) Primer (P-9)
Epoxy based tie coat (suitable for conventional alkyd based coating prior to application of acrylic
polyurethane epoxy finishing coat)
Type and Composition Two pack, Polyamide cured epoxy resin medium
suitably pigmented.
Covering capacity 10-12 M²/Lit/Coat
j) Finish Coats (F-1)
Synthetic Enamel
Type and Composition Single pack, Alkyd medium pigmented with superior
quality water and weather resistant pigments
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 13 of 27
Covering capacity 16-18 M/²lit/Coat
k) Finish coat (F-2)
Acrylic Polyurethane paint
Type and Composition Two pack, Acrylic resin and iso-cyanate hardener
suitably pigmented.
Volume Solids 40% (min)
DFT 30-40 microns / coat
Covering Capacity 10-12 M²/lit/ coat
l) Finish Coat (F-3)
Chlorinated Rubber Paint
Type and Composition Single pack, Plasticised chlorinated rubber medium with
chemical & weather resistant pigments.
Volume solids 30%
Covering capacity 1 0.0 M² / lit /coat
m) Finish Coat (F-4)
High build chlorinated rubber M10 paint.
Type and Composition Single pack Chlorinated rubber based high build pigmented with
micaceous iron oxide.
Covering capacity 6.0-7.0 M² / lit / coat
n) Finish coat (F-5)
Chemical Resistant Phenolic based Enamel
Type and Composition Single pack phenolic medium suitably pigmented.
DFT 25 microns/ coat
Covering capacity 15.0 M² /lit/ coat
o) Finish Coat (F-6)
Epoxy High Building Coating
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 14 of 27
Type and Composition Two pack. Polyamide cured epoxy resin medium suitably
pigmented.
p) Finish Coat (F-7)
High build Coal Tar Epoxy
Type and Composition Two pack, Polyamine cured epoxy resin blended with Coal Tar.
Volume solids 65% (min)
q) Finish Coat (F-8)
Self-priming epoxy high build coating (complete rust control coating)
Type and Composition Two packs. Polyamide-amine cured epoxy resin suitably
pigmented. Capable of adhering to manually prepared surface
and old coatings.
Covering capacity 4-5 M² / lit / coat
r) Finish Coat (F-9)
Inorganic Zinc Silicate coating
Type and Composition Two pack , Self cured Ethyl silicate solvent based Inorganic Zinc
coating.
Volume solids 60% (min)
Covering capacity 8-9 M² / lit / coat
s) Finish coat (F-10)
High build Black
Type and Composition Single pack. Reinforced bituminous composition phenol based
resin.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 15 of 27
Covering capacity 5.50-6.0 M ²/ lit / coat
t) Finish Coat (F-11)
Heat Resistant Aluminium Paint Suitable up to 250°C.
Type and Composition Duel container (paste & medium). Heat resistant spec varnish
medium combined with aluminium flakes.
Covering capacity 10-12 M² / lit/ coat
u) Finish Coat (F-12)
Heat Resistant Silicon Paint suitable up to 400º C.
Type and Composition Single pack Silicone resin based with aluminium flakes.
v) Finish Coat (F-13)
Synthetic Rubber Based Aluminium Paint Suitable up to 150C.
Type and Composition Single Pack, Synthetic medium rubber medium combined with
leafing Aluminium,
DFT 25 microns/coat
Covering capacity 9.5 M² /lit/ coat
Notes
1 Covering capacity and DFT depends on method of application Covering capacity specified above
is theoretical. Allowing the losses during application, min specified DFT should be maintained.
2. All paints shall be applied in accordance with manufacturer's instructions for surface preparation,
intervals, curing and application. The surface preparation quality and workmanship should be
ensured.
3. Selected chlorinated rubber paint should have resistance to corrosive atmosphere and suitable
for marine environment,
4 All primers and finish coats should be cold cured and air-drying unless otherwise specified.
5. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
6. In case of use of epoxy tie coat, manufacturer should demonstrate satisfactory test for inter coat
adhesion. In case of limited availability of epoxy tie coat (P-9) alternate system may be used
taking into the service requirement of the system.
Document No. Rev
FOR PAINTING 11-0290-02-09-02-005 B
SHEET 16 of 27
7. In case of F-6, F-9, F-1 1 & F-1 2 Finish Coats, No Primer are required.
MANUFACTURERS
The paints shall conform to the specifications given above and Class-I quality in their products range of
any of the-following manufacturers:
i) Asian Paints (India) Ltd,

ii) Bombay Paints
iii) Berger Paints India ltd.
iv) Gaodlass Nerolac Paints Ltd.
v) Jenson & Nicholson
vi) Shalimar Paints
STORAGE
All paints and painting material shall be stored only in rooms to be provided by contractor and approved
by OWNER/ OWNER 's Representative for the purpose. AlI necessary precautions shall be taken to
prevent fire. The storage building shall preferably be separate from adjacent, building.
A signboard bearing the words given below shall be clearly displayed outside:
PAINT STORAGE No NAKED LIGHT highly -inflammable
COLOR CODE FOR PIPING:
i) For identification of pipelines, the color code as per Table -1 shall be used.
ii) The color code scheme is intended for identification of the individual group of the pipeline. The
system of color coding consists of a ground color and color bands superimposed on it.
iii) Colors (Ground) as given in Table-2 shall be applied throughout the entire length of uninsulated
pipes, on the metal cladding & on surfaces. Ground color coating of minimum 2m length or of
adequate length not to he mistaken as color band shall be applied at places requiring color
bands. Color bands shall be applied as per approved procedure.
V) Line coating shall meet DIN 30670 standard for external coating and API 5L RP – 2 for internal
coating.
VI) The thickness for the epoxy should be 180 microns, adhesive 200 microns and balance should
be PE
VII) The minimum coating thickness on weld seam shall be 3.2 mm and minimum coating thickness
on body should be 3.2.
VIII) Minimum thickness for liquid epoxy for internal coating should be 100 ± 20 microns.
Max design temperature for coating should be considered +80 ºC
COLOR CODE:
A) Ball Valve (Above Ground) : Off White

B) Globe Valve (Above Ground) : Oxford Blue-RAL 5005, IS-519941005
C) Check Valve(Above Ground) : Oxford Blue-RAL 5005, IS-519941005
D) Launcher / Receiver : Yellow Golden
E) Jib Crane / Trolley : Yellow Golden
F) All underground valves shall have epoxy base coating after surface finish of SA 2:5
G) Valves and above ground pipes need to be properly blasted to achieve surface finish of Sa 2:5 before
the application of paints.
IDENTIFICATION SIGN
i) Colors of arrows shall be black or white and in contrast to the color on which they are
superimposed.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 17 of 27
ii) Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as
approved by OWNER.
iii) Size of arrow shall be either of the following:
a) Color Bands
Minimum width of color band shall be as per approved procedure.
b) Whenever it is required by the OWNER to indicate that a pipeline carries a hazardous material,
a hazard marking of diagonal stripes of black and golden, yellow as per IS:2379 shall be painted
on the ground color.
IDENTIFICATION OF EQUIPMENT
All equipment shall be stenciled in black or white on each vessels, column, equipment, painting as per
approved procedure.
INSPECTION AND TESTING
1. All painting materials including primers and thinners brought to site by

contractor for application shall be procured directly from manufactures as per
specifications and shall be accompanied by manufacturer's test certificates Paint formulations
without certificates are not acceptable.
2. The painting work shall be subject to inspection by OWNER/ OWNER's Representative at all
times. In particular, following stage wise inspection will be performed and contractor shall offer
the work for inspection and approval at every stage before proceeding with the next stage.
In addition to above. record should include type of shop primer already applied on equipment e.g. Red
oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect noticed during the various stages of inspection shall be rectified by the contractor to the
entire satisfaction of OWNER/ OWNER's Representative before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work. Contractor shall be responsible for
making good any defects found during final inspection/guarantee period/defect liability period as defined
in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application
of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra
cost to OWNER.
PRIMER APPLICATION
i. The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of
sand blasting. Holiday detectors and pinhole detector and protector whenever required for
checking in case of immerse conditions.
ii. At the discretion of OWNER/ OWNER's Representative, contractor has to provide the paint
manufacturers expert technical service at site as and when required. For this service, there
should not be any extra cost to the OWNER.
iii. Final Inspection shall include measurement of paint dry film thickness, check of finish and
workmanship. The thickness should be measured at as many points/ locations as decided by
OWNER/ OWNER's Representative and shall be within +10% of the dry film thickness.
iv. The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The OWNER shall have the right to test wet samples of paint
Document No. Rev
FOR PAINTING 11-0290-02-09-02-005 B
SHEET 18 of 27
at random for quality of same. Batch test reports of the manufacturer's for each batch of paints
supplied shall be made available by the contractor.
PAINT SYSTEMS
The paint system should vary, with type of environment envisaged in and around the plants. The types
of environment as given below are considered for selection of paint system. The paint system is also
given for specific requirements.
a) Normal Industrial Environment, Table 2.

b) Corrosive industrial Environment, Table3
c) Coastal & Marine Environment, Table 4
Notes 1. Primers and finish coats for any particular paint systems shall be from same
manufacturer in order to ensure compatibility.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 19 of 27
Table – 1
Colour Coding Scheme for Pipes and Equipment
SI. No. Content Ground Color First Color Second Color

Band Band
1 COMPRESSED AIR
a) Plant Air Sky Blue Silver Grey -
b) Instrument Air Sky Blue French Blue -
2 GASES
a) Charge Gas Canary Yellow Signal Red Smoke Grey

b) Regeneration Gas Canary Yellow White Dark Violet
c) Residue Gas Canary Yellow White French Blue
d) LPG Canary Yellow Brilliant Green White
e) Acetylene Canary Yellow Dark violet -
3 ALL EQUIPMENT
a) Such as vessels. columns, Light Grey

exchangers, etc. containing non-
hazardous fluids.
b) All equipment containing hazardous Canary Yellow
fluids
c) Pipe carrying hazardous fluids Bar is to be
replaced by
Hazardous
Marking as per
IS: 2379 Clause
7.1C
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 20 of 27
Table 2
Normal Industrial Environment (Above Ground)
Sl. Description Temp. Surface Primer Finish Coat Total Remarks

No. Range Preparation DFT
1.0 External surface of equipment's and piping.
1.1 -Do- -10 to 20 SSPC-SP-3 One coat One coat F-4 175 Primer and
P-2 65 microns/ Finish coat
50 coat (min) can be
microns / Two coats F- applied at
coat 3, 30 ambient
(min) Microns/coat temp.
(min)
1.2 -Do- 21 to 60 SSPC-SP-6 Two Two coats of 90 -
coats P- F-1, 20
1, 25 microns/coat
microns/ (min)
coat
(min.)
1.3 -Do- 61 to 80 SSPC-SP-6 Two Two coats of 150 -
coats P- F-13, 25
3, 50 microns/coat
microns/ (min)
coat
(min)
1.4 -Do- 81 to 250 SSPC-SP-6 Covered Three coats 60 Paint
in Finish of F-11, 20 application
coat microns/ coat at ambient
(min) temp. curing
at elevated
temp. during
start-up.
1.5 -Do- 251 to 400 SSPC-SP-10 Covered Three coats 60 -do-
in Finish of F-12, 20
coat. microns/ coat
(min)
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 21 of 27
Table- 3
Corrosive Industrial Environment (Above Ground)
SI. Description Temp. Surface Primer Finish Coat Total Remarks

No. Range preparation DFT
1.0 External surface of un-insulated and other equipment
I.1 - do - -10 to SSPC-SP-3 Two coat Two coat F- 160 Primer and paint
20 P-2, 50 3, 30 application at
microns) microns / ambient temp.
coat (min.) coat (min.)
1.2 - do - 21 to SSPC-SP- Two coats Two coats 270 Paint application
80 10 P-5, 35 F- 6, 100 at ambient temp.
microns / microns
coat (min.) coat (min.)
I.3 - do - 81 to SSPC-SP-3 Covered Three coats 60 Paint
400 in finish F- 12, 20 application.
coat Microns / at ambient temp,
coat (min.) and curing at
250'C for 4
hours,
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 22 of 27
Table – 4
Coastal and Marine Environment (Above Ground)
SI. Description Temp. Surface Primer Finish Coat Total Remarks

No. Range Preparation DFT
1.0 External surface of equipment’s and piping.
1.1 -do- -10 to SSPC-SP-3 Two coats Two coats F- 160 Primer and
60 P-2, 50 3, 30 Finish
micron/ Microns/coat coat
coat (min) (min.) application
at Ambient
temp.
1.2 do - 61 to SSPC-SP- Two coats Two coats of 270 -do-
80 10 P-5. 35 F-6, 100
Microns. Microns/Coat
coat (min.)
(Min.)
1.3 - do - 81 to SSPC-SP-I0 One coat - 85 Paint
400 F-9, 83 application
Microns/ at Ambient
Coat(Min.) temp.
Primer is
acting
as primer
cum finish
coat.
1.4 - do - i) Upto SSPC-SP- One coat One coat of 95 Paint
80 10 F-9, 6.5 F-2. 30 application
microns / Microns/coat at ambient
coat (Min) (min.) temp.
ii) 8l to SSPC-SP- -do- -do- 85 Paint

400 10 application
at ambient
temp.
Primer is
acting
as primer
cum
finish coat.
1.9.4 Precautions to be taken
Neither the environment of the site nor the marking labels of devices may be covered with paint and they
must be kept free of paint splashes. To this end, it is advisable to use removable masking tape.
Paint splashes, leaks, etc. on any adjacent installations such as measuring apparatus, valves, pipes.
sources of light, insulation, heat insulators, walls, concrete, etc, must immediately be wiped up and the
damage repaired before the paint is dry.
Otherwise, the OWNER will be obliged to have the cleaning carried out at the expense of the Contractor.
The paint recipient will only be opened at the time of use (unless otherwise specified by the
manufacturer).
The product will be mixed in the recipient with the aid of suitable tools and thus homogenized.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 23 of 27
1.9.5 Method of application
Normally, three methods of application will be used on the construction site for the paint products. i.e.
with a brush, with a roller or with a spray gun.
• The brush method makes it possible to obtain good penetration of the paint over irregularities in the
metal.
• Only this method will be used for application of the base coats, for retouching and for protrusions,
welded areas, riveted joints or bolted joints:
• The roller method may be used on large flat surfaces for the intermediate and topcoats.
• The spray gun method must be used in accordance with the instructions of the manufacturer and carried
out by qualified personnel.
The Contractor must guarantee that all safety measures have been taken for such work. The spray gun
method may only he used on site for places that arc difficult to reach with the brush. In this case, a
request must be made to the OWNER/ OWNER's Representative for a deviation.
All paintwork will be carried out with good brushes or rollers that are suitable for the type of paint being
used and for the form of the material to be painted and fitted with short handles. The maximum length of
the brush and roller handles will be 50 cm; longer handles may only be used for places that are
absolutely inaccessible. The maximum width of a brush will be 13 cm.
1.9.6 Application of the coating
Application of the paint will be carried out in accordance with best practice in order to obtain a
homogeneous and continuous layer. The OWNER or the Approved Supervisory body demands that
painting of a layer will only be started after acceptance by them of the surface preparation or of the
previous layer of paint.
The layers of paint must have a uniform thickness. They must he spread in such a way that all concave
parts are dried out and that the surface is completely covered and has a glossy appearance without
leaving brush marks and without exhibiting bubbles, foam, wrinkles, drips, craters, skins or gums that
arise from weathered paint,
Each layer must have the color stipulated in the tables of the present specifications, which clearly differs
from the previous layer, taking account of the Color of the top layer, all of which for the purpose of being
able to identify the number of coats and their order of sequence. If the color of the coats is not
mentioned in the tables the color difference in consecutive coats must, if possible, he at least 100 RAL.
The color of the top layer is given in the table.
The coating power should be such that the underlying layer is not visible. Only 1 layer per day may be
applied, unless otherwise specified by the OWNER or the Approved Supervisory Body.
The drying times prescribed by the paint manufacturer must be strictly observed in relation to the
environmental conditions before proceeding with the application of the next layer.
The dry coating thickness indicated in the description of the paint systems are minimum thickness. In
this connection, the Contractor is obliged to contact the paint manufacturer and conform to his
guidelines. The Contractor must respect the thickness specified by the supplier.
1.9.7 Transporting treated items
In the case of works being carried out in a workshop, the metal structures will be surrounded by
ventilated contraction film that prevents damage during transportation. This film may only be applied
after complete polymerization of the paint.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 24 of 27
1.10 GROUND-LEVEL TRANSITION POINT
1.11 Polyester protection system
The Contractor will provide system 02 over the entire length of the pipes above ground and below
ground and up to a height of 20 cm and a depth of 40 cm. perpendicular to the ground level mark. In
each case, he must ensure that the jointing below the asphalt is in good condition and assures' faultless
adhesion. He will apply the following products over the entire surface area, prepared in accordance with
is Sa 3:
1) The primer of system 01.
2) Reinforced polyester ± 20 cm above the ground level marker and ± 5 cm on the asphalt cleaned
beforehand (application of reinforced polyester is carried out in accordance with the work
method prescribed by the manufacturer). Moreover, in the case of PE, in contrast to asphalt, he
will apply a polygon primer to PE immediately before applying the reinforced polyester.
3) He will then apply the other coats of system 01a to the surface section and thus cover the
reinforced polyester with about 5 cm.
4) For new constructions, the polygon primer will be applied to PE and then subsequently
processed as described under point 2.
1.11.1 USE OF SCAFFOLDING
Mounting, maintenance and dismantling of scaffolding for carrying out adaptation and/or paintwork to
surface gas pipes or gas transport installations in use;
• The Contractor will specify the cost of scaffolding in the price list.
• The supplementary rental price for delays attributable to the Contractor will be charged to him:
• In his price quotation the Contractor should present the OWNER with diagrams of the scaffolding
that he intends to install for carrying out the works of the OWNER.
1.12 QUALITY CONTROLS AND GUARANTEE
1.12.1 The Contractor is responsible for checking the weather conditions to ascertain whether the paintwork
can be carried out within the technical specifications.
The Contractor should have the required calibrated monitoring apparatus for this purpose on site (with
calibration certificates). The personnel who will have to use this apparatus should have the training for
this purpose.
The OWNER or his representative and possibly the approved supervisory body indicated by the
OWNER will maintain supervision during the works and inspect the works with random checks. A daily
report will be drawn up in relation to the department that maintains supervision of these works.
The supplementary inspection and the supervision by the OWNER or the approved supervisory body do
not diminish in any way the liability of the Contractor. The proper execution of the work and the materials
used may be checked at any time.
1.12.2 Reference Surfaces
At the start of the works. the OWNER or the approved supervisory body will indicate a few surfaces that
the Contractor will prepare and cover in accordance with the recognized method of operation under the
inspection and to the satisfaction of all parties ; the OWNER or his representative, the approved
supervisory body. the contractor and possibly the paint manufacturer. These reference surfaces will
serve as a point of comparison for the good adhesion of the paint on the installations as a whole. The
Document No. Rev
FOR PAINTING 11-0290-02-09-02-005 B
SHEET 25 of 27
parties will together work out a system for the identification of these surfaces in order to be able to
monitor the conditions of the coatings over time. If the paintwork on a section of the installations is in a
worse condition than the reference surfaces, the Contractor may be obliged to treat these parts again.
1.12.3 Measures to be taken in the event of a dispute
If on delivery of the works no agreement can be reached between the Contractor and the OWNER
regarding the conformity of the works to the requirements of these specifications, an Approved
Supervisory Body will he Called in. The Approved Supervisory Body will then carry out inspections' on
site whereby the following assessment criteria wilt be used:
• The Swedish standards ISO 8501-1 1988 SS 05.5900 concerning the degree of cleanliness of
the areas derusted by blasting, by machine or by hand.
• The wet film thickness of the paint will be measured in accordance with ISO 2808 or ASTM DI
212;
• The dry layer thickness of the film will be measured electronically, will complete statistical
information. in accordance will, ISO 2808 or ASTM D 1186.
• The thickness of each layer will he measured in accordance with ISO 2808. ASTM 4138 or DIN
50986.
• Adhesion tests will be carried out in accordance with ISO 2409. ASTM 3359 or DIN 53151.
• Traction tests will he carried out in conformity with ISO 4624 or ASTM D 4541.
• The rugosity will be measured electronically in accordance with DIN 4768;
• The non-porosity will be measured with a test tension depending on the type of coating, the
layer thickness and after consultation with the Paint manufacturer.
• Any defects in the paint film may be inspected visually by means of a magnifying glass or
microscope. If necessary a photographic report may be drawn up in accordance with ASTM
Standard D 4121-82,
The final judgement of the Approved Supervisory Body is irrevocable and binding for the Contractor and
the OWNER. In the event of non-conformity of the works with the criteria of these specifications, all costs
arising from the inspection by the Approved Supervisory Body shall be borne by the Contractor.
1.12.4 Guarantee
a) General Principles
The Contractor declares that he is aware of:
The maximum operating temperature of the surfaces to be covered.
• The maximum permitted degree of humidity of the bearing surface.
• The properties of the environment to which the surfaces to be covered are: subject.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 26 of 27
b) Summary of the Guarantee.
The contractor fully guarantees the following without reservation:
• The observance of all stipulations of the specifications for paintwork regarding, among other
things:
o The preparation of the surfaces.

o The thickness of each layer.
o The total thickness of the covering.
• The uniformity of the materials used.
• The repair of all defects before delivery of the works.
The Contractor will carry out the requested repair work as promptly as possible.
Document No. Rev

FOR PAINTING 11-0290-02-09-02-005 B
SHEET 27 of 27

GAIL Gas City Project Piping Specification

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GAIL Gas City Project Piping Specification

Uploaded by

Copyright:

Available Formats

GAIL GAS LIMITED

CITY GAS DISTRIBUTION PROJECT

CLIENT JOB NO. -

DOCUMENT NO 11 0290 02 08 02 001

B 10/08/09 ISSUED FOR APPROVAL GV DDS PKS

A 07/08/09 ISSUED FOR IDC GV DDS PKS

REV DATE DESCRIPTION PREP CHK APPR

CONTENT PAGE No.

CODES AND STANDARDS 3

PIPING CLASS DESCRIPTION 6

PIPING CLASS 1A1 7

PIPING CLASS 3A1 11

PIPING CLASS 6A1 15

Document No. Rev

Shall : This verbal form indicates requirements strictly to be followed in order

3.0 CODES AND STANDARDS

ASME B 16.5 Steel Pipe Flanges and Flanged Fittings

ASME B 16.9 Factory made Wrought Steel Buttwelding Fittings

ASME B 16.11 Forged Steel Fittings, Socket Welding and Threaded

ASME B 16.20 Metallic Gaskets for Pipe Flanges.

ASME B 16.21 Non-Metallic Flat Gasket for Pipe Flanges

ASME B 16.47 Large Diameter Steel Flanges (26” throu 60”)

ASME B 31.3 Process Piping

ASME B 31.8 Gas Transmissions and Distribution Piping System

ASME B 36.10 Welded and Seamless Wrought Steel Pipe

ASME B 46.1 Surface Texture

API 5L Line Pipe

API 6D Pipeline Valves

API 590 Steel Line Blank

Document No. Rev

API 602 Compact Steel Gate Valves

MSS SP 44 Steel Pipe line Flanges

MSS SP 75 Specification for High Test Wrought Butt Welding Fittings

MSS SP 97 Integrally Reinforced Forged Branch Outlet Fitting – Socket Welding,

ASTM A 105 Forging, Carbon Steel for Piping Components

ASTM A 333 Low temperature service seamless pipe.

4.1 Flange Facing

RTJ - Ring Type Joint

Document No. Rev

4.4 Wall Thickness

SCH - Schedule in accordance with ANSI B 36.10 or B 36.19

4.5 Valve Description

4.6 Pipes Description

Document No. Rev

PRESSURE (18.75 bar g) CORROSION ALL. 0.5 mm

ITEM SHORT SIZE DESCRIPTION RATING DIMENSION MATERIAL REMARKS

CODE FROM- AND/OR STANDARD

PIPELINE PL 2"-4" BE 6.4 mm API 5L API 5L Gr. X42

6"-14" BE 6.4 mm API 5L API 5L Gr. X42

2" BE, SEAMLESS S80 ANSI B36-10 ASTM A 106 Gr.B

ELBOWS 90 LR E 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105

2" - 14" BW, 1.5D M ANSI B16.9 ASTM A 234 Gr WPB

ELBOWS 45 LR E45 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105

2" - 14" BW, 1.5D M ANSI B16.9 ASTM A 234 Gr WPB

TEES EQUAL T 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105

2" - 14" BW M ANSI B16.9 ASTM A 234 Gr WPB

TEES RED TR 0.50" - 1.50" SW 6000# ANSI B16.11 ASTM A105

2" - 14" BW MXM ANSI B16.9 ASTM A 234 Gr WPB

SOCKOLET S 0.50" - 1.50" SW 6000# MSS-SP 97 ASTM A105

WELDOLETS W 2" - 14" BW - ANSI B16-25 M X XXS MSS-SP 97 ASTM A105

CAPS C 0.50" - 1.50" SCRF 6000# ANSI B16.11 ASTM A105

2" - 14" BW ANSI B16-9 ASTM A 234 Gr WPB