Data Sheets, Approved Vendors
Data Sheets, Approved Vendors
Data Sheets, Approved Vendors
TENDER DOCUMENT
FOR
EPC CONTRACT
VOLUME - IB OF V
(PARTICULAR JOB SPECIFICATIONS)
MECON LIMITED
(A Govt. of India Undertaking)
SCOPE MINAR
th
15 Floor, North Tower
Laxmi Nagar District Centre
DELHI – 110 092
November,2006
TABLE OF CONTENT
FOR
VOLUME-IB OF V
(GENERAL – TECHNICAL)
Sl.No. Description
PART-D 1) Particular Job Specification (PJS) for Pipeline, Piping & Mechanical Works
TENDER DOCUMENT
FOR
EPC CONTRACT
(Volume-IA, IB, IC, II, III, IV & V)
MECON LIMITED
(A Govt. of India Undertaking)
SCOPE MINAR
th
15 Floor, North Tower
Laxmi Nagar District Centre
DELHI – 110 092
November,2006
D:\old data\Vijyant\GSPL\Tender\Const\master cover&content\Cover-Nov'06.doc
PADMALA – GODHARA GAS
PIPELINE PROJECT
Tender Document for EPC Contracts
Gujarat State Petronet Ltd. Tender Doc. No.: 05/51/23JT/GSPL/001(EPC) MECON LIMITED
Sl.No. Description
CONTENTS
Sl.No. Description
1.1 GENERAL
1.1.1 Special Condition of Contract shall be read in Conjunction with the General
Conditions of Contract, specification of work, Drawing and any other documents
forming part of this contract wherever the context so requires.
1.1.2 Notwithstanding the sub-division of the documents into these separate sections
and volumes every part of each shall be deemed to be supplementary to and
complementary of every other part and shall be read with and into the contract so
far as it may be practicable to do so.
1.1.4 The materials, design and workmanship shall satisfy the relevant INDIAN
STANDARDS, the TECHNICAL SPECIFICATIONS contained herein and CODES
referred to. Where the technical specification stipulate requirements in addition to
those contained in the standard codes and specifications, these additional
requirements shall also be satisfied.
1.1.5 Wherever it is mentioned in the specifications that the CONTRACTOR shall perform
certain work or provide certain facilities, it is understood that the CONTRACTOR
shall do so at his cost and the VALUE OF CONTRACT shall be deemed to have
included cost of such performance and provisions, so mentioned.
1.1.7 In the absence of any specifications covering any material, design of work(s) the
same shall be performed/ supplied/ executed in accordance with Standard
Engineering Practice as per the instructions/ directions of the Engineer-in-charge,
which will be binding on the Contractor.
1.2.1 M/s GSPL intend to lay a 12” x 37.5 km pipeline from Padamla tap-off near
Baroda on 24” OD Baroda – Ahmedabad – Kalol pipeline. The proposed pipeline
is approximately ~ 37.5 km long and 12” dia. and will transport ~ 1.5 MMSCMD
intermingled RLNG & Natural Gas from Padamla tap-off to Halol for distribution
to domestic, automobile, commercial & industrial consumers.
The proposed new pipeline shall be originated from Padamla tap-off at Baroda –
Ahmedabad – Kalol Pipeline and shall be terminated at Halol. The new pipeline
shall be of 12” OD and 37.5 km in length.
The route of the proposed pipeline has been decided by M/s GSPL, the salient
feature of the pipeline routes is described in the civil, mechanical document.
The entire pipeline network has been divided into the following section.
1.3.2 Spurline
1.3.4 Terminals
Based on the optimization studies carried out the following design parameters
have been considered for Mechanical Design of Pipeline System.
Corrosion Allowance : 0 mm
Material of Construction : Carbon Steel
Pipeline & its appurtenances shall be provided with carbon steel material suitable
for the intended service as indicated above.
a) Line Pipe
Line pipe shall confirm to API Specification 5L, PSL-2 Quality. The grade of line
pipe shall be API 5L Gr. X-65 / Gr. X-52 as indicated above. Pipe wall thickness
shall confirm to ASME B31.8 and shall also meet the requirement of OISD 141.
At river X-ing higher wall thickness shall be used.
All pipeline materials such as pipe, valves, flanges and fittings etc. shall be of
class 600#.
A) Mainline
B) Spurline-I
2.1 The work tendered in this bid package consists of detailed engineering,
engineering for procurement, supply, fabrication, installation, testing, pre-
commissioning and commissioning of the mainline, spur line, terminal facilities at
Despatch, SV cum Tap-off, Tap-off, Receiving Terminals including all associated
mechanical, civil, structural, electrical, telecommunication & Instrumentation works.
2.2 All works of the section & terminals included in the scope will be done
simultaneously from the date of issue of FOI. Bidder will organize equipment
and manpower accordingly to meet this requirement as per instruction of
Engineer-in-charge.
The detailed scope of work tendered for the project include detailed engineering,
engineering for procurement, supply, fabrication, testing and commissioning
alongwith all associated work pertaining to complete pipeline and terminal works.
The scope of work shall be generally being, but not limited to the following: -
3.1 Detailed Engineering
• Owner has got the detailed survey carried out for the entire pipeline route. The
plan and ground profile details to the extent available are being furnished to the
Bidder along with bid document. Contractor shall carry out any additional
topographic surveys required for local detours during execution of the project in
a similar manner without any extra cost to the Owner. However, laying and
construction of entire pipeline including detoured portion shall be within the
scope of contractor and governed by SOR of tender without any cost implication.
Contractor shall be deemed to have considered such eventualities while
formulating his bid. Pipeline route maps/ alignment sheets showing the pipeline
route are also enclosed with the bid package.
• Preliminary Alignment Sheets and plot plan and piping GAD drawings for scraper
launcher cum receiver stations, SV stations, tap-offs are included in the Bid
package. These drawings are indicative only and are furnished to enable Bidder to
estimate the quantum of work and to quote a firm price for the work..
• Collection of data at site and carrying out residual engineering for pipeline
system including terminals and crossings in accordance with design basis, codes
& standards and project specifications contained in this bid package.
Requirements of Indian standards and codes shall be complied with wherever
applicable.
• Carrying out Material Take Off for the entire pipeline system including those
materials supplied by Company if any and all piping at all terminals.
• The design shall take into consideration all stipulations, practices followed by
various authorities for all types of crossings and specifically all the factors that
are agreed upon between Company and state/local authorities as per
agreements reached as a part of permissions for various crossings. Contractor
shall provide all design data/drawings/calculations as required for statutory
clearances including obtaining necessary approvals.
• CONTRACTOR shall procure and supply all the materials other than OWNER
supplied materials if any, required for permanent installation of main pipeline and
terminals in sequence and at appropriate time. All equipment, materials,
components etc. shall be suitable for the intended service. Approved vendor list
has been indicated in the bid package for various items. For items, which are not
covered in the vendor list, CONTRACTOR shall obtain Owner’s prior approval for
the vendor. Equipment requiring specialized maintenance or operation shall be
avoided as far as possible. Equipment offered shall be field proven.
• Material take-off with complete description of size, rating, material, thickness and
specifications.
• CONTRACTOR shall provide for inspection of the items at vendor's works by the
OWNER/ Owner’s REPRESENTATIVE or by a reputed inspection agency and shall
submit inspection reports for Owner’s clearance.
• Stores management for contractor supply items as well as free issue materials if
any including receipt, warehousing, preserving the material in good condition, issue
of material to construction site, reconciling/ handing over surplus material to
OWNER of OWNER supplied items at Owner’s store.
• CONTRACTOR shall immediately report to the OWNER of all changes, which will
affect material quality, and recommend any necessary corrective actions to be
taken.
• Interact with authorities such as Sales Tax, Octroi, Excise, and Customs etc. as
necessary and arrange for transportation of the materials under his scope of supply
to site.
3.3 Construction
• All construction works shall be carried out as per "Issued for Construction"
drawings, procedures, specification and applicable codes and standards. Any
changes at site shall also need prior approval from the OWNER and revision of
drawings.
• The Owner shall provide to the Contractor free of cost the construction right-of-use
to lay the pipeline, systems as governed by the clauses defined elsewhere in the
tender document.
• The Contractor at his own cost and initiative shall obtain all other permissions,
permits and licenses necessary for the performance of the work. Insofar as any
such permission, permit or license required for the performance of the work by the
contractor can only be granted at the request or recommendation of the Owner,
the Owner shall at the request of the Contractor, provide recommendatory letters
to the contractor to obtain or procure the same. The contractor shall not, however
be entitled to any additional compensation over and above contracted rates of
services for any hardship or increased cost caused by any idleness, suspension or
disruption of work or any other account whatsoever as a result of the inability of
the contractor to obtain the permission(s), permit(s), license(s) aforesaid to match
with the progress of the work nor shall the same constitute a ground for extension
of time.
a) The approval from any authority required as per statutory rules and
regulations of Central/ State Government, PWD, and Irrigation Dep’t. etc.
shall be the contractor’s responsibility unless otherwise specified in the
tender document. The application on behalf of the Owner for submission to
relevant authorities alongwith copies of required certificates complete in all
respects shall be prepared and submitted by the Contractor well ahead of
time so that the actual construction/ commissioning of the work is not
delayed for want of the approval/ inspection by concerned authorities. The
Contractor shall arrange the inspection of the works by the authorities and
necessary coordination and liaison work in this respect shall be the
responsibility of the Contractor. However statutory fees paid, if the Owner
shall reimburse any, for all inspections and approvals by such authorities at
actuals to the Contractor on production of documentary evidence.
• The CONTRACTOR shall be responsible for claims if any arising out of damage/
obstruction to public utilities like lines of DOT etc. where the claims will cover the
restoration costs as well as loss of revenue due to down time.
• Contractor shall be carrying out engineering for major crossing and survey
specification.
• For all crossing, including above mentioned shall be crossed by heaviest wall
thickness carrier pipe among available pipes at site or as per approved drawings/
as decided by Engineer-in-charge.
• The Contractor shall start the execution work for entire length of mainline
simultaneously and shall deploy adequate manpower, machinery, tool & tackles
etc. accordingly.
• However, Owner may, at its sole option, assign priority of construction to either
any spread or any section in spread of total pipeline length or to any part/
segment of the work. Contractor shall comply with such priority of execution
and their deployment without any time and cost implication to the Owner.
• Owner has got the entire pipeline route surveyed and survey pillars have been
established along the pipeline centerline or the ROW centerline and along the
pipeline route. However, the pipeline route survey had been carried out sometime
back and when Contractor mobilize at site, some of the survey pillars may be
missing from ground. It shall be Contractor's responsibility to re-establish all
missing survey pillars based on the survey data furnished by the Owner. Such work
shall be done at no extra cost or time to Owner.
• Bidders are advised to make site visits to familiarize themselves with all the salient
features of subsoil, terrain and available infrastructure along the pipeline route.
Contractor shall be deemed to have considered all constraints and eventualities on
account of site conditions along pipeline route while formulating his bid. Contractor
shall not be eligible for any compensation in terms of cost and/ or time, on account
of site conditions along pipeline route varying to any extent from whatever
described in the Bid Package and the drawings furnished along with the Package.
• Materials and equipment required for all types of test such as radiography,
magnetic particle and dye penetrate examination.
• Provide, maintain and operate all temporary facilities required for the construction
related works and remove after completion of work.
• Hook up/ tie-in of pipeline and piping system with terminal facilities.
• All incidental and associated works and any other works not specifically listed
therein but are required to be carried out to complete entire work related to
pipelines and terminals.
all necessary intermediate storage area(s) required thereof till the pipes are
installed in permanent installation.
• Carrying out inspection of OWNER supplied materials if any at the time of receiving
and taking-over.
• Carrying out repairs of line pipe and pipe coating which will include repair of all
defects/ damages occurring during transportation and / or handling.
• For pipes where cutting out involves more than 25mm from pipe ends, ultrasonic
inspection shall be carried out at pipe ends as per relevant clause of line pipe
specification enclosed with the tender including supply of all equipments.
Contractor shall take prior approval from Company for the agency engaged for
carrying out ultrasonic inspection.
• The contractor shall notify the owner the probable date of commencement of work
at ROU site at least two (2) weeks in advance to enable the owner to arrange
handing over of the ROU/ site on the date requested. Should contractor fail in
such notification, the owner shall not be liable for any claim by contractor, of
whatsoever nature, for delay in the available of a ROU/ site.
• Welding of all tie-in joints including tie-in joints and bends on either side of major
river crossings/ with adjoining pipeline installed by others/ other facilities as
required, cutting of test header, rebevelling and tie-in with adjacent pipeline
segments.
• Field weld joint coating shall be by heat shrink sleeve/ other suitable material as
per specification enclosed with bid package compatible of pipe coating material.
• Carrying out corrosion coating of Long Radius (LR) bends if any. Coating shall be
carried out by heat shrink sleeve (Raychem or equivalent) / other suitable material
as per specification enclosed with bid package for field joint coating.
• Installation of casing pipes (by open cut/ jacking/ boring) assembly, including
supply of all materials viz. casing pipe, casing insulators and end seals, vents and
drains etc. complete, at cased crossings as per the drawings/ specifications
enclosed with bid package.
• Sand/ soft soil padding around pipe wherever required in areas where trenching
has been done in rock including supply of sand/ soft soil. The thickness of sand/
soft soil padding at the bottom of pipe shall be 300mm in rocky areas.
• Providing 300-micron high built abrasive resistant epoxy on the external surface
of all 6” CS conduits meant for OFC.
• Indian Railways shall approve the general arrangement drawings for railway
crossings and construction shall be carried out accordingly. The Contractor shall
make these drawings available at appropriate time during the execution of the
project. Pipeline at railway crossings shall be provided with a casing pipe. The
casing pipe shall be double of the nominal pipe sizes of carrier and shall be
installed by boring/ jacking. It should be noted that the extent of casing pipe
generally specified by Railways, is 15.0m beyond centerlines of the outermost
tracks on either side or 0.6 meter beyond the ROU limits of railways on either side,
whichever is more. All railway crossings shall be cased crossings. The railway
crossing shall comply with the requirements of API 1102 and Indian Railway
regulations. The crossing angle shall be as close to 90° as possible.
• Contractor shall firm the method of crossing of roads such as open cut/ boring up
in consultation with concerned authorities and Company. The Contractor shall also
take due care to identify and take due precautions so as not to disturb or damage
the utilities like cables, water lines and other structures.
• After laying the pipeline in a road crossing by open cut method, the Contractor
shall completely restore the road to its original condition.
• While laying the pipeline in road crossings by open cut method the Contractor
should ensure that the traffic is not stopped during the execution of work. This
may be done by cutting half of the road at a time so as to enable the traffic to pass
on the remaining half of the road. Alternatively, the Contractor can provide
diversion roads to maintain the flow of traffic.
• The Contractor shall provide proper caution boards during daytime and danger
lights during nighttime when the cutting operation of the road is going on.
• For cased crossings, the pipeline should be taken through the casing pipe which
should be at least 1.2 metres below the road top as specified or as per the
requirements of local authorities, whichever is higher.
• Contractor shall cross the road/ canal etc. by HDD at locations as directed by
Owner/ Consultant as per crossings survey drawing enclosed with tender. Before
start of HDD, the contractor shall ascertain by pre-construction survey all
underground obstacles namely electrical/ telecommunication cable, foreign
pipeline, water line, drain/ sewerage line and prepare crossing profile drawings
showing all elevations & levels. The contractor shall also ascertain, the type of soil
& their terrain whether rocky or normal by way of trial pit etc. before start of job.
The contractor shall submit procedure, profile drawing with complete design
calculations of HDD as per requirement of ASME B31.8/ OISD norms and safety
requirement that pipe is not under stress during and after crossing for Owner/
Consultant’s approval prior to start the execution of works.
• Contractor shall ensure all safety norms regarding distances from end point or from
bottom of crossing and also ensure that external coating of pipe is not damaged
during pulling & handling of pipe for crossing. For field joint coating in pipeline
string made for HDD, special type of heat shrink sleeve shall be used as per
specification enclosed with the tender. For line pipe coating repair, special type of
high shear strength repair patch material shall be used which characteristic shall be
same or equivalent as original wrap round heat shrink sleeve used in pipeline string
for HDD crossing.
• The contractor shall ensure that no any u/g existing utilities/ pipelines/ cable etc. is
damaged. It shall be responsibility of contractor to compensate any loss or damage
to other agency if damaged while crossing. Contractor shall arrange all statutory
permission from concerned authority before start of job. Contractor shall deploy
only GSPL’s/ MECON approved HDD Agency and approval of agency shall be
sought before deploying HDD agency.
• Where the pipeline route passes through forest/ plantation areas, Contractor shall
clear only the minimum width required for laying the pipeline as per Owner
approved procedure for pipeline construction. Number of trees/ plants to be felled
down shall be restricted to a minimum.
• Clean-up and restoration of ROW and other conveniences like road, rail, canals,
cultivable land etc. to original conditions as per specification and drawings to the
entire satisfaction of OWNER and/ or Authorities having jurisdiction over the same,
including disposal of surplus construction materials to a location identified by
CONTRACTOR approved by local authority without causing any disturbance to
environment, locals and to the entire satisfaction of OWNER.
• Carrying out Magnetic cleaning and Electronic Geometrical Pigging (EGP) for 12”
main line only including supply of all types of pigs, pig locating and tracking
device, spares, consumables, manpower etc. as per specification enclosed with
bid/ contract document.
• Carrying out repair of all defects found during Electronic Geometrical Pigging
(EGP) including locating, digging, cutting, welding, NDT etc.
• Tie-in with the pipeline at rail, road, river and other crossings including cutting
of test headers as required and tie-in with terminal piping & with existing
facilities as applicable.
• Idle time preservation of the pipeline (if required) for the specified period by
filling with nitrogen to a positive pressure of 0.5 bar (g) including supply of
nitrogen etc. as required.
• Counting the number and type of trees to be cut (before cutting) during pipeline
laying works in presence of DFO/ concerned authorities keeping record thereof
and handing over the cut trees as directed by concerned authorities/ Company.
concerned authorities and providing all safety appliances, gas detectors, fire
screens required during execution of the work as per the direction of
Company/Engineer-in-charge. Coordinating all activities with Company for
movement of men and material from and to existing and operating terminals
shall be the responsibility of the Contractor.
• All incidental and associated works and any other works not specifically listed
herein but are required to be carried out to complete entire work related to
pipelines and the associated facilities and making the entire pipeline system
ready for operation.
• The Contractor’s scope of work shall consist of supply, installation, testing and
pre-commissioning of terminal piping works along with other associated works
including (installation of skids if any) for the execution of composite works at the
terminals, tap-off, various consumer ends and SV Stations. Preliminary
equipment layout and GADs for the terminals/stations/TOP are included in the
tender. These drawings are indicative only and are furnished to enable the
Bidder to understand the nature of work involved. Contractor shall carry out
detailed engineering for the terminal works and final piping general arrangement
drawings (GAD’s (including stress analysis) good for construction based on
actual plot size/orientation provided by Company/consumer.
• Carrying out all works strictly in accordance with the drawings duly approved by
the Company and reference specifications/standards, P&IDs, documents, data
sheets etc. enclosed with this tender document and instructions of
Company/Engineer-in-Charge and other provisions of Contract document.
• Providing all equipments, manpower, machinery, consumables for fabrication,
installation, inspection, testing & pre-commissioning. Contractor shall also
provide all types of safety tools, tackles, devices and apparatus, equipment
complete as required, and facilities for inspection & interpretation of testing
results by Company/Company’s Representative personnel.
• Furnishing and mobilizing at site(s) all construction equipment, tools and tackles,
fully equipped and fully manned with other required support facilities etc.
needed for successful execution of the works.
• “Receiving and taking over” of all Company supplied free issue materials if any
from the designated place(s) of issue, transportation including loading,
• Obtaining all statutory clearances, doing required follow up, approvals and
permissions for the works within existing facilities, as required. Obtaining hot
work permits from Company/ concerned authorities having jurisdiction thereof to
work within existing and operating terminals including strictly complying with all
stipulations/ conditions/ recommendations of the concerned authorities and
providing all safety appliances, gas detectors, fire screens required during
execution of the work as per the direction of Company/Engineer-in-charge. Co-
ordinating all activities with Company for movement of men and material from
and to existing and operating terminals shall be the responsibility of the
Contractor.
• Supply, fabrication and erection of pipe/ equipment supports (for all sizes/
thickness) including shoes, pipes, cradles, turn buckles, T-posts for all types of
guides, anchors, all necessary equipment, consumables, labour etc. for
completing all works including supply of bolts, nuts, washers, U-clamps, wooden
blocks etc. as required for supporting.
• Hook-up of piping with equipments & vessels, with the existing facilities, with
the main pipeline and at the battery limit with the facilities installed by others by
welding or by flanged connection (as shown in IFC drawings) including cutting,
fit-up, welding, NDT, radiography, interface/co-ordination as required with other
Contractor(s)/Agencies.
• Painting of all equipments, structural steel elements for pipe supports, above
ground piping and all related miscellaneous items shall be provided suitable for
low temperature application as per company specification enclosed with the bid
document. Wherever touch up/repair of primer is required, high build epoxy zinc
phosphate primer shall be used.
• Protective coating of 500 micron thick two component high built epoxy duly
approved by Company for all underground piping, valves, fittings, etc. including
supply of all materials.
• Final clean up and restoration of site, facilities etc. as per the requirement of
Company/Engineer-in-Charge.
• Any other works not specifically listed herein but required for completion of the
works in all respects.
• Coated Line pipes and bare line pipe all valves of all sizes & ratings for mainline
and at terminals, actuators, launcher cum receivers (Bi-directional), insulating
joints, pig signalers, long radius bends (R=6D), flow tees etc., pipes for all sizes
and thickness fittings, flanges, O’lets (weldolets, sockolets, nippolets, threadolets
etc.), spectacle blinds, spacer & blinds required for permanent installation in the
system. Each valve item shall be inclusive of commissioning spares.
• All stud bolts, nuts, jack screws, all type of gaskets (metallic spiral wound / ring
type / non-metallic gaskets) in required quantities to be used for permanent
installation into the system for all sizes and ratings of flanges and flanged
valves, equipment etc.
• All consumable such as welding electrodes, oxygen, acetylene, inert gases, filler
wires, solder wires, brazing rods, flux etc. for welding/cutting and soldering
purposes. All equipments & consumables for Semi-Automatic welding and
radiography.
• All materials for all types of markers including paints conforming to Corrosive
environment as per spec, cement, sand, reinforcements, structural steel, etc.
• All materials, equipments, consumables including pigs required for magnetic
cleaning and EGP.
• LR bends fabricated from 12” line pipes required at terminals and wherever
required.
• All materials required for continuous concrete coating for providing negative
grading the Right-Of-Use pipeline and pipe laying/ installation and other works.
• All steel materials such as structural steels, reinforcement steels and steel for all
types of supports, foundations, ladders, platforms etc. including Bolts, nuts,
washers, U bolts, clamps, clips, gaskets, Shims, wedges and packing plates
(Machined wherever required) and materials required for fabrication of low
friction sliding bearing supports.
• All fencing, gate and steel materials such as structural steels, reinforcement
steels and steel for all types of supports, foundations, ladders, platforms, etc.
• All materials, manpower, spares, tools & tackles and consumables for carrying
out pre-commissioning activities and during commissioning (including bi-
directional and foam pigs, compressor, nitrogen required for achieving the
specified criteria for pipeline inertisation prior to declaring pipeline fit for
commissioning) necessary piping and instrumentation connection for measuring
flow rate, pressure, temperature etc., temporary facilities for blow down/
venting/ flaring along with necessary piping, valves & instrumentation as well as
consumables and manpower required during pre-commissioning and
commissioning.
• High built two component epoxy for corrosion protection of buried piping (pipes,
fittings, flanges, valves, etc.).
• Required quantities of Nitrogen for idle time preservation if pre-commissioning &
commissioning works, as required.
• Corrosion resistant straps required for strapping CS/ HDPE conduit with mainline
at crossings of water bodies and other crossings.
• All materials, equipment and personnel required for videography and all
associated works.
• Any other material not specifically listed herein, but required for successful
completion of the Work.
The rates quoted for the execution of the Work shall be inclusive of supply of
all materials mentioned above unless specifically covered otherwise under
Schedule of Rates.
There shall be no free issue supplies except metering skid at consumer end by
the Owner under this Contract.
All excess material related to Scope of Work of the Contractor shall revert to the
Contractor, except for spare provisions made as a part of the construction
programmed and supply of all materials and consumables for all the pipeline
systems in Mainline & Terminals.
All repairs of pipe shall be carried out as per specifications. All defective pipes
shall be replaced during the Defects Liability Period without any limit on the
quantum of the liability on the Contractor.
• The Contractor shall be responsible for taking over of the material and
subsequent handling, hauling, transportation to the actual work
site(s)/fabrication yard(s) and storage & safe keeping of the materials.
• The Contractor shall inspect all Company supplied free issue materials at the
time of taking over from the Company and defects noticed, if any, shall be
brought to the notice of Company/Company representative and jointly recorded.
Once the material has been taken over by the Contractor, all the responsibility
for safe keeping of the materials and repair of damage/ defects to pipe & pipe
coating shall rest with the Contractor.
• Rebuffing of dents in bevels less than 1 mm in depth shall be carried out by
Contractor ahead of welding in the field at no extra cost to Company.
• On completion of the works Contractor shall submit a “Material Appropriation
Statement” for all materials supplied by the Company as free issue materials.
• Every month the Contractor shall submit to the Company an account for the
material issued to the Contractor in the Performa prescribed by Engineer-in-
Charge.
• All materials shall be preserved against deterioration and corrosion due to poor
or improper storage while under the custody of the Contractor.
• All materials shall be duly protected by the Contractor at his own cost with the
appropriate preservatives like primer, lacquer, coating, grease etc. and shall be
covered with suitable material to prevent them from direct exposure to sun, rain,
wind and dust.
• Pipes shall be stacked according to the identification marks and stacks shall be
arranged on sleepers / sand bags at least 300 mm above ground.
• The Contractor shall check that valves, fittings, specials etc are not subjected to
corrosion from hydrostatic test water remaining in the piping. Any such condition
when detected should be brought to the notice of Engineer-in-Charge and
remedial measures taken as directed.
• All machined surface shall be properly greased and should be maintained and
protected from damages.
• Openings of equipment, machinery, valves etc. shall be kept blocked / covered
with blinds to prevent entry of foreign matter.
• As far as possible materials shall be transported to the site of erection only just
prior to the actual erection and shall not be left around indefinitely on ground
but kept on packing/sleepers etc. to maintain the minimum distance from the
ground as specified and/or as per directions of Engineer-in-Charge.
3.12 General
All consumables for welding such as oxygen, acetylene, inert gases and all types
of electrodes suitable for pipes of grades as specified in the specification, low
hydrogen electrodes, filler wire, solder wire, brazing rods, flux etc. for welding /
cutting and soldering purpose.
Equipment like hydrostatic pump etc., water and corrosion inhibitor for water
used for hydrostatic testing including all pipes, fittings and equipment, metallic
blinds, temporary gaskets as required for filling, pressurizing and dewatering in
connection with hydrostatic testing completion.
All pigs required for cleaning, gauging, filling, dewatering and swabbing of
pipeline.
All pipes, fittings and equipment metallic blinds temporary gaskets as required
for filling, pressuring and dewatering in connection with hydrostatic testing
completion.
Supply of nitrogen and other consumables, tools and tackles required for
venting, pre-drying, purging and filling of station piping.
Any other material not specifically listed herein, but required for the execution of
the work.
List of materials required to be supplied and quantities indicated are tentative.
These quantities can vary during execution to any extent and the same unit rate
shall be applicable for payment. Final quantities will be based on the drawing
issued to the contractor for construction. Quantities covered in SOR are for as
erected quantities. Bidder will procure additional materials as required to cover
cutting, scraps, wastages and damages during erection, testing and
commissioning. For these extra quantities no additional payment will be made.
3.13.1 Survey
• Company has got the detailed survey carried out for all the pipeline routes and
are enclosed with bid package. Apart from above, crossing details of rail, road
and water crossings are also available. All available survey drawings, report, soil
investigation, soil resistivity are enclosed with the bid. Contractor shall carry out
any additional topographic/ geotechnical surveys required during execution of
the project and for local detours during execution of the project without any
extra cost. However, the Contractor shall carry out hydrological and geo-
technical investigation of major rivers, as required.
• The surveyed pipeline alignment has been staked on ground. However the
pipeline route survey had been carried out sometime back and when the
Contractor mobilizes at site, some of these stakes may be missing. It shall be
the responsibility of the Contractor to re-establish the missing stakes from the
survey data made available by Company. Contractor shall maintain and preserve
survey monuments (staked on ground) such as bench marks and intersection
points, till construction is completed.
For all the details of pipeline routes for all the spur lines, terrain details &
crossings, refer respective pipeline detailed route survey report and survey
drawings enclosed with the bid package.
Based on above design parameters, pipeline wall thickness and grade have been
optimized and are indicated below :-
The number of crossings and features along the pipeline route described above
are approximate. A list of all crossings identified is attached in the survey
documents enclosed in the Bid Package for reference purpose. Contractor shall,
however, not be entitled for any compensation in terms of time and cost in case
of variation in the information provided or additional minor water crossings i.e.
canal/stream/ PWD/ Panchayat/ village roads/ municipal road crossings
encountered along the route.
Bidders are advised to make site visits along the pipeline routes prior to quoting
to familiarize themselves with all the salient features of terrain, availability of
ROU and infrastructure along the pipeline routes. Contractor shall be deemed to
have considered all constraints and eventualities on account of site conditions
along pipeline routes while formulating his bid. Contractor shall not be eligible
for any compensation in terms of cost and/or time, on account of site conditions
along pipeline routes varying to any extent from whatever is described in the bid
package and the survey drawings/data furnished along with the bid package.
Contractor using suitable material compatible with parent coating system and
meeting the requirements of coating system shall carry out any repairs to 3-
layer polyethylene coating. The coating repair material and procedure for
application shall be submitted to Company for approval prior to start of
construction.
• Defects exceeding the above and in number not exceeding 2 per pipe
and linear length not exceeding 500mm shall be repaired using heat
shrinkable sleeves/ cold applied tapes.
Long radius bends supplied by the Contractor shall be fabricated from contractor
supplied 12” bare line pipe. Bends shall be fabricated in accordance with
specification enclosed with the tender. Contractor shall firm up the exact
The Company shall obtain a general permission from most of the authorities
having jurisdiction over the area as necessary for construction of the pipeline.
However, for some of the permissions, if not available, Contractor shall do the
follow up with the concerned authorities to get the permissions to execute the
job in time. However, Company shall reimburse all statutory payments
required for such permissions at actual. Contractor shall also obtain the
necessary permits like work permit/ excavation permit/ trench opening permit
etc. for all works from the authorities having jurisdiction before the actual
execution of various phases of the works and all stipulations/ conditions/
recommendations of the said authorities shall be strictly complied with no extra
cost to Company. Contractor shall also obtain all necessary permissions from the
concerned authorities for installation of pipeline at railways, roads, water
crossings and at places where blasting is required. Company may, however,
assist Contractor in obtaining such permissions, wherever required, by issuing
recommendation letters etc. In case of damage to other utilities/infrastructure,
Contractor shall be responsible and the Contractor shall pay the required
compensation, as per the directions of concerned authorities. After completion of
work, Contractor shall obtain a certificate from the concerned authorities that
the job has been completed as per their requirement and the area/land has
been restored to their satisfaction.
• Intake and discharge of water required/used for line flushing and testing
should not cause unacceptable environmental disturbance. During
dewatering process, proper drainage arrangement shall be made to
discharge the hydro-test water to avoid flooding of the near by area.
Typical terminal piping layout drawing and pipeline survey drawings are included
in the bid package for the purpose of estimation of quantum and type of work
involved. This piping drawing and pipeline survey drawings are indicative only
and are furnished for Bidder’s information. Issued for Construction (IFC)
drawings for terminals shall be prepared by Contractor and shall be subject to
approval by Company. However, ‘IFC’ alignment sheets shall be prepared by the
contractor and submit for approval.
3.13.10 R.O.U.
For pipeline construction purposes, ROU of varying width shall be made available
depending upon site condition. In cross country areas the ROU of 15 m width)
shall normally be made available to Contractor to the extent feasible. Pipeline
shall be laid 10 m from one side of boundary of ROU (to be advised by Engineer-
in-Charge). In Forest areas, hilly terrain and congested areas such as built-up
areas etc., ROU of 10 m or less shall be available. The pipeline shall be laid at 2
m from the ROU edge in reserve forest areas. All these eventualities shall be
taken into account. It shall be Contractor’s responsibility to make arrangement
for any additional land required for fabrication, construction, storage and all
other work areas. Contractor shall carry out construction work with in the width
as made available to him. Where the pipeline route passes through
forest/plantation areas, contractor shall clear only the minimum width required
for laying the pipeline as per Company’s approved procedure for pipeline
construction. Felling of trees/plants shall be minimized. Damage to any
obstruction, temporary/permanent structure, boundary walls etc. within ROU
shall be repaired and restored and shall be to Contractor’s account.
The Contractor must ensure that during laying of the pipeline minimum damage
occurs to the land. The land has to be restored to original condition. All
construction activities shall be in accordance with the local Government
regulations and shall be performed by the competent and qualified persons for
providing adequate protection to the general public, livestock, wild life, forest,
power lines, buildings etc. in the vicinity of the pipeline.
In case contractor wishes to propose any detour from the acquired alignment
due to construct ability problems or otherwise, he may be permitted to do so
only after explicit approval from the Company. All immediate measures for
taking the land and compensations to land owner(s) shall be to Contractor’s
account. Company shall proceed with regular notifications etc. in due course. All
statutory fees shall be paid/ reimbursed by Company. However, such activity
shall not affect the construction schedule and overall completion period.
The pipeline shall be buried normally at a depth of 1.0 meter below natural
ground level except river/ rail/ road/ canal crossing..
3.14 Crossings
For all rail, road, canal, river & other water crossings, Contractor shall liaison
with relevant authorities and intimate them well in advance about the schedule
and methodology of crossing. It shall be obligatory on the part of the Contractor
to ensure that Authorized Representative of the authority under whose
jurisdiction the crossing falls should be made available at site by the Contractor
at the time of making crossing. After completion of works and complete
restoration of ROU, Contractor shall provide NOC from the relevant official
pertaining to complete restoration to their satisfaction and certification in respect
of no other damage caused to their property outside the earmarked ROU
The railway crossing shall comply with the requirements of API 1102 and Indian
Railways regulations. The crossing angle shall be as close to 90° as possible.
Cover of casing pipe for railway crossings shall be minimum 1.8 m. Casing shall
be suitably insulated from underground conduits carrying electrical wires. The
carrier pipe shall be electrically insulated from casing pipe and casing ends shall
be sealed using durable electrically non-conducting material. Contractor shall
obtain approval of crossing drawing from concerned authorities. Casing vent
pipe shall be at least 1.2 m away vertically from aerial electrical wires and shall
be suitable insulated from underground conduits carrying electrical wires on
railway land.
• The method of crossing of roads such as open cut / boring/ trench less
technology shall be firmed up by Contractor in consultation with
concerned authorities and Company. The Contractor shall also take due
care to identify and take due precautions so as not to disturb or damage
the utilities like cables, water lines and other structures.
• After laying the pipeline in a road crossing by open cut method, the
Contractor shall completely restore the road to its original condition.
• While laying the pipeline in road crossings by open cut method the
Contractor should ensure that the traffic is not stopped during the
execution of work. This may be done by cutting half of the road at a time
so as to enable the traffic to pass on the remaining half of the road.
Alternatively, the Contractor can provide diversion roads to maintain the
flow of traffic.
• The Contractor shall provide proper caution boards during day time and
danger lights during night time when the cutting operation of the road is
going on.
• For cased crossings, the pipeline should be taken through the casing
pipe. The top of casing should be at least1.2 metres below the road top
as specified, or as per the requirements of the local authorities,
whichever is higher.
Unless specified otherwise the top of pipeline for river crossings shall be
taken at least 1.5 metre below the scour depth or 2.5m below bed (1.5m
for rocky strata) whichever is more.
The detailed construction methodology and schedule. shall have to be
finalised by Contractor in consultation with concerned authorities having
jurisdiction over rivers. Company shall provide assistance by providing
introductory letters.
Pipeline at river crossings as detailed in para (d) below are intended to
be installed by open cut method, however Contractor may also propose
HDD or any other equivalent method in place of open cut based on flow
and soil conditions of individual rivers at the time of crossing. Company’s
prior approval shall be obtained for the crossing method other than open
cut. Contractor shall submit all design calculations, procedures &
drawings for Company’s approval in case of HDD option.
These river crossings shall be considered as a part of main line laying
works irrespective of method of crossing adopted by the Contractor.
Any additional land if required for string preparation for crossing of rivers
At all crossing locations (viz., rail, road, canal and minor water course crossings)
the optical fibre cable shall be installed inside a cable conduit to be installed by
the Contractor.
At all such crossings where the carrier pipe is installed by open-cut of the facility
crossed, HDPE conduit shall be installed along with the pipeline for installation of
the Optical Fiber Cable. At crossings of water bodies, where anti buoyancy
measures are provided for the carrier pipe, HDPE conduit will be strapped to the
mainline at 5m interval using high strength PE straps. For all river crossings by
HDD, CS conduit shall be strapped with carrier pipe for bundle pulling or a
separate drilling shall be performed for CS conduit. Required HDPE conduit shall
be installed inside CS conduit.
At all such crossings where the carrier pipe is installed by moiling/ jacking/boring
of carrier pipe directly and at all cased crossings, i.e., where carrier pipe is
installed inside casing pipe, 168 mm OD, 6.4 mm thk. API 5L Gr-B steel conduit
with HDPE inter duct shall be installed by jacking/boring separately. Each casing
end seal shall have a moulded opening suitable for HDPE conduit. The center to
centre distance between pipeline and CS cable conduit shall be 4.0 m based on
as installed dimensions.
The pipeline from tap-off point cum despatch terminal at Padamala to Halol (12” x
46 km) shall be hydrostatically tested to a minimum test pressure of 1.5 times the
design pressure of 95 bar such that the highest point of the test section shall be
subjected to the same but limited to 95% of SMYS of the pipe material.
The pipeline/ section(s) of pipeline shall never be left empty (filled with air) after
dewatering/ swabbing/drying.. Dewatering, swabbing and drying of pipeline after
hydro testing shall be taken up by Contractor only when Contractor is ready for
carrying out the drying operation immediately following pipeline swabbing. Till such
time Contractor is ready to start drying of pipeline, the pipeline/ section(s) of
pipeline after hydro testing shall be kept filled with inhibited water or the pipeline/
section(s) of pipeline shall not be dewatered. Preservation of pipeline using
inhibited water from the time of completion of hydro testing till Contractor is ready
for drying of pipeline, shall be carried out by Contractor as part of his scope of
work at no extra cost to Owner.
After the results of swabbing operation has been accepted by Owner, nitrogen
purging of line may be started for pre-commissioning activities as per specification.
Piping facilities between the insulating joint and hook up point/battery limit and
all above ground facilities installed by Contractor shall be hydrostatically tested
to a test pressure. in accordance with “Standard specification for Inspection,
Flushing and Testing of Piping System” enclosed with the Contract document. All
valves in the piping network being hydro tested shall be kept in the crack open
position. Holding time shall be six hours.
Contractor shall submit a detailed procedure for leak detection during hydro test.
Such method of detection shall consume minimum possible time to complete the
hydro test activity within contractual completion schedules. This procedure
needs approval of the Engineer-in-charge.
All works for locating and repair of major leak/burst occurred during hydrostatic
testing including necessary repairing/replacing/ cutting and removing out
defective pipe length as defined in the specification and shall not be payable as
per relevant items of schedule of rates.
Contractor shall carry out repairing / replacing of defective pipe length including
cutting and removing of defective pipes, pre testing of replacement pipe for 24
hours and welding into main line, NDT of the welds, coating of the weld joints,
clean up, re-testing of pipeline including providing all equipments, manpower &
consumables.
For all pipelines, the direction of construction shall be in the direction of flow i.e.
from Padamala towards Halol and from all tap-off points to consumer ends
unless specified otherwise. In case the Contractor proposes to carry out
construction in direction opposite to direction of flow, the Contractor may do so
at no extra time and cost to Company and subject to Company Approval.
Pipeline Contractor shall carry out magnetic cleaning and Caliper pigging (EGP),
of pipelines for 12” main line being installed by them as per requirements
stipulated elsewhere in the bid document.
Rectification of defects observed during pig run, shall be carried out by individual
Contractor including digging, cutting, replacement, repair, welding, NDT etc.
Contractor shall submit all proposed designs, drawings, installation and testing
procedures, work instructions with ITPs and inspection formats for review and
approval by Company as mentioned in scope of work. This shall be done seven
(7) days prior to the commencement of any phase of fabrication or installation.
The work shall begin only after Company’s approval has been obtained.
Calculations shall also be submitted for any other factors not listed in the bid
package but which are necessary to prove the validity for Contractor’s design or
proposed construction methods. Contractor shall furnish his document schedule
indicating clearly sequencing of documents. As part of residual engineering,
Contractor shall as a minimum, provide following deliverables for Company’s
review and approval.
• Piping stress analysis.
• Design and engineering of piping and equipment supports, RCC sleepers
for above ground piping, pipe racks, valve operating platforms, Detailed
list and schedule of submission of relevant documents drawings and
procedures.
• Methodology for crossings of rivers, canals, major roads, difficult terrain
(steep slope hilly terrain) etc. and detailed calculation & drawing as
applicable in case HDD/ any other method being adopted.
• Installation, hook-up, field testing and commissioning procedures/
specifications
• Golden joint-2 Nos for each station, tap-off, mainline and 2Nos per HDD.
• Pipeline Alignment Drawings for detoured areas.
• IFC Piping General Arrangement drawing for all terminals and
intermediate installations.
• Pipeline approach/ departure drawings.
• Operational & maintenance manual.
• Work instructions, ITPs and inspection formats paved areas etc.
• Equipment layout/ Overall plot plan.
5.1 The Contractor is deemed to have recognized any restrictive features and
constraints of the site(s), pipeline route and /or specific requirements of the
work and made due allowance for it in the work to be performed by him.
5.2 Company has provided the available information and survey data along pipeline
route and crossings. Company gives no guarantee or warranty as to the
accuracy or completeness of the information provided. It is the Contractor’s sole
responsibility to obtain sufficient information / data along pipeline route and
crossings to allow safe and sound design and installation of the proposed
pipeline.
5.4 Drawings and installation procedures, engineering for procurement & fabrication,
engineering for installation including drawings, QA/QC procedures, etc
performed by the Contractor for complete pipeline system shall be reviewed and
approved by Company. Contractor shall submit six sets of engineering
documents, drawings, and procedures as described under relevant clause for
Company’s review and approval. All works shall be executed based on approved
documents only.
5.5 Review and approval of Contractor’s work(s) by Company shall in no way relieve
the Contractor of his sole responsibility for safe and efficient design,
engineering, installation and subsequent operation of pipeline system.
5.8 Preparing and furnishing calculation books, pipe books, material/ purchase
requisitions, final purchase orders including specifications, Vendor's data books
(including Guarantees), fabrication and construction drawings, all survey reports,
inspection and testing reports, as-built records for all phases of work.
5.9 The Contractor is cautioned to exercise extreme care and take necessary
precautions to prevent damage to the existing pipeline(s), facilities, electrical
and other cables during execution of the entire works. Contractor shall carry out
Restoration/ reconstruction of all structures/ facilities affected during pipeline
construction.
5.10 Wherever Contractor comes across water lines/open channels/drains in the fields
used for cultivation, suitable arrangements similar to the existing type shall be
made by the Contractor for ensuring water supplies across the fields and
maintain the same till construction is completed in that stretch. Any claims
arising out of non-compliance to the above requirements, as granted by
competent authorities shall be to Contractor’s account.
5.11 Contractor shall carry out all testing and inspection of materials, equipment etc.
in independent testing institutions, laboratories, if so desired by Company.
5.13 Blasting if required, in all types of rocks for excavation shall be carried out in
controlled manner so as to protect the existing facilities, men, environment and
property etc from any damage, whatsoever. Blasting in all types of rock shall be
allowed subject to concerned central/state government and regulatory
authorities permitting the same.
5.14 Any other work not specifically listed but required for successful completion of
entire pipeline system.
6.1 Owner shall furnish piping and Instrumentation diagrams (P & I D), preliminary
plot plan for the construction of Terminal alongwith the tender. Contractor shall
submit the design & engineering drawings and construction drawings including
general arrangement drawings for piping, electrical, mechanical & instrumentation
systems and other related/ required systems, at appropriate times for Owner/ EIC
approval.
6.2 Contractor shall prepare isometric drawings & bill of materials and submit the same
for Owner/ Consultant’s approval/ record.
Contractor shall prepare drawing for utilities line as required as per SOR and
submit the same for Owner/ Consultant’s approval/ record.
6.3 No construction small or big shall be carried out without proper construction
drawings duly approved by Owner's Engineers or site office or Owner's
representative duly authorised to do so.
For Mainline route survey alignment sheets and crossing survey details shall be
furnished alongwith bid by Owner. However, detail-crossing drawings with
crossing methodology shall be submitted by Contractor for prior approval. Any
additional survey and data required to complete above should be done by
Contractor without any extra cost.
pipeline alignment sheet, all X-ing details, all CP drawings, pipe book etc. and for
Terminals P&ID, layout drg., piping GAD, Isometric, all electrical & instrumentation
drg., all civil drawings. For final submission only 4 sets of documents plus the
original transparencies shall be handed over by Contractor. Any construction done
by Contractor without duly approved drawings shall be wholly at his risk and cost.
Contractor shall also submit soft copy of pipe book in excel alongwith hard copy.
Soft copy of all as-built drawings shall be also submitted in AutoCAD. Video
graphy/ photograph of all major activities/ milestone achieved shall also be
arranged and submitted by the Contractor. For details of documentation to be
submitted for mainline and terminal refer enclosed specification for
documentation for pipeline construction Specification NO. MEC/S/05/62/09R
enclosed elsewhere with the tender.
6.5 Specifications
The work shall be carried out by CONTRACTOR strictly in accordance with the
following specifications enclosed in Volume-II of V this document :-
VOLUME-II OF V
Drawings
6.5 The following drawings are included in Volume-V of V of the bid package for BIDDER’s
reference purpose only; Bidders are advised to go through these drawings and also visit
the site before submitting their bids. The Contractor shall develop the drawings for all
crossings and detour of pipeline alignment.
VOLUME – V of V
1. MECHANICAL DRAWINGS
6.7.1 The drawings accompanying the Bid document are indicative of scope of work and
issued for tendering / bidding purpose only. These drawings indicate the general
scheme as well as the layout to enable the contractor to make an offer in line with
the requirements of the owner. Final construction shall be done as per approved
construction drawings issued by COMPANY.
The Contractor shall not recruit personnel of any category from among those who
are already employed by the other agencies working at the sites but shall make
maximum use of local labour available.
Owner shall not provide any land for residential accommodation of contractors staff
and labour.
a) Time Schedule
The Completion Time Schedule for the work (including mobilization period)
as per Appendix-I to Invitation for bid, PART-A of Tender in all respect,
from the date of issue of telex/telegram/letter/Fax of Intent.
The network will be reviewed and approved by Engineer- in-Charge and the
comments if any shall be incorporated in the network before issuing the
same for implementation. The network thus finalised shall form part of the
contract document and the same shall not be revised without the prior
permission from Engineer-in- Charge during the entire period of contract.
c) Functional Schedules
The Contractor shall present the programme and status at various review
meetings as required.
B) Weekly Reports
C) Daily Repots
8.5.1 CONTRACTOR shall make every effort to keep the OWNER adequately informed as
to the progress of the WORK throughout the CONTRACT period.
CONTRACTOR shall keep the OWNER informed well in advance of the construction
schedule so as to permit the OWNER to arrange for requisite inspection to be
carried out in such a manner as to minimize interference with progress of WORK.
It is imperative that close coordination be maintained with the OWNER during all
phases of WORK.
8.5.2 By the 10th (tenth) of each month, CONTRACTOR shall furnish the OWNER a
detailed report covering the progress as of the last day of the previous month.
These reports will indicate actual and scheduled percentage of completion of
construction as well as general comments of interest or the progress of various
phases of the WORK. The frequency of progress reporting by the CONTRACTOR
shall be weekly.
8.5.3 Once a week, CONTRACTOR shall submit a summary of the WORK accomplished
during the preceding week in form of percentage completion of the various phases
of the WORK, to the OWNER.
8.5.4 Progress reports shall be supplied by CONTRACTOR with documents such as chart,
networks, photographs, test certificate etc. Such progress reports shall be in the
form and size as may be required by the OWNER and shall be submitted in at least
3 (three) copies.
8.5.5 Contractor shall prepare daily progress report (DPR) in the desired format and
submit it to Engineer-in-charge alongwith schedule of next day to Engineer-in-
charge.
9.2 Procedures
CONTRACTOR shall have at all times during the performance of the WORK, a
Competent Superintendent on the premises. Any instruction given to such
superintendent shall be construed as having been given to the CONTRACTOR.
CONTRACTOR shall be solely responsible for making available for executing the
work, all requisite Construction Equipments, Special Aids, Cranes, Tools, Tackles
and testing equipments and appliances. Such construction equipments etc. shall
be subject to examination by owner and approval for the same being in first class
operating condition. Any discrepencies pointed out by OWNER shall be
immediately got rectified, repaired or the equipment replaced altogether, by
CONTRACTOR. OWNER shall not in any way be responsible for providing any such
equipment, machinery, tools and tackles.
The OWNER reserves the right to rearrange such deployment depending upon the
progress and priority of work in various sections.
Tie-end between main line and starting point of terminal is included in the scope of
contract, as and when main line section is available for Tie-ins.
10.0 DOCUMENTATION
The Contractor shall shoot, prepare and submit coloured photographs in 2 sets
to MECON site office along with monthly progress report covering all the
activities of pipeline constructions highlighting the progress or other areas of
10.4 Videotape
The Contractor shall be responsible for the Detailed Engineering of the Project.
The Contractor shall, within the scope of his work, prepare detailed working and
other plans, drawings and designs required for or in connection with the
performance of the work or selection, procurement of making of any supply, and
The Contractor shall within the scope of his work also carry out investigative and
design studies and prepare detailed design for the various materials and works
covered in the Contract Documents. Such detailed designs along with referred
codes, standards and practices, back-up calculations, and other details on basis
of which the designs have been prepared shall be subject to the Owner’ s
approval. Detailed working drawings and material specifications shall be
prepared and established on the basis of the approved design(s) and shall also
be subject to the Owner’ s approval.
Where the Contractor shall be required under the Contract to prepare or furnish
any plan(s), drawing(s), design(s) or specification(s) or other items for thing in
respect of the work or any particular work and/or supplies or any particular
supply, the Contractor shall within 30 (thirty) days (or such other period as the
Project Manager may prescribe in this behalf) on receipt of notification of
Acceptance of Bid or not less than 60 (sixty) days before the proposed date of
commencement of the relative work or supply, whichever shall be earlier, submit
to the Project Manager or other authority specified by the Owner in this behalf
for approval the relative plan(s) / drawing(s) / design(s) / specification(s) / or
item(s) or thing(s) concerned. The Owner / shall be entitled at any time to
suggest any amendment(s) or modification(s) in the plans/drawings and/or
specifications and the Contractor shall thereupon either convince the
Owner/Project Manager of the necessity in whole or part of such amendment or
modification or shall implement the same and shall cause the plan(s)/
drawing(s)/ design(s) / specification(s) or item(s) or thing(s) concerned to be
accordingly amended, provided that no such approval of or amendments /
modifications in the plans/ drawings/ designs/ specifications by or suggested by
the Owner / Project Manager shall any way absolve the Contractor of any of his
obligations, responsibilities or liabilities under the Contract, inclusive of an
relative to the utility and suitability of the Contractor(s) plans / drawings /
designs / specifications or items or things concerned in or for the relative
work(s) or supply and fulfillment of all specifications and performance and other
guarantees of the consequent works/supplies, any such approval or suggestion
by the Owner / Project Manager as aforesaid being intended only by way of
assistance to the Contractor and prima facie satisfaction of the Owner without
any attendant liability upon the Project Manager / Owner in this behalf and
without any estoppel against the Owner from assenting that notwithstanding
such approval, the plan, drawing, design, specification or other items or thin
approved and any resultant works or supply were faulty and/or not in
accordance with the contractual requirements.
The Contractor shall furnish seven (6) prints each of the drawings for approval
of the Project Manager.
The Contractor shall not permit any work to be done or any material to be
supplied or fabricated or manufactured at variance with drawings, designs,
specifications reviewed / approved by the Project Manager / Owner as the case
may be and / or as amended or modified. The reviewed/approved drawings may
be released to the Contractor for fabrication/installation progressively.
12.1 Before the WORK or any part thereof are begun, the Contractor’s agent and the
Engineer-in-Charge's representative shall together survey and take levels of the
SITE and decide all particulars on which the survey is to be made, and on which
measurements of the WORK are to be based. Such particulars shall be plotted by
the CONTRACTOR and after agreement the drawings shall be signed by the
Engineer-in-Charge.
12.2 The CONTRACTOR shall be entirely responsible for the horizontal and vertical
alignment, the level and correctness of every part of the WORK and shall rectify
any errors or imperfections therein. The CONTRACTOR at his own cost shall carry
out such rectifications, when the Engineer-in-Charge or his representative issues
instructions to this effect.
12.3 The Engineer-in-Charge shall furnish the relevant existing grid point with Bench
Mark on the land. It shall be Contractor’s responsibility to set out the necessary
control points in and to set out the alignment of the various works. The
CONTRACTOR shall have to employ efficient survey team for this purpose and the
accuracy of such setting out work shall be Contractor’s responsibility.
12.4 The CONTRACTOR shall give the Engineer-in-Charge not less than 24 (twenty four)
hours notice in writing of his intention to set out or give levels for any part of the
WORK so that arrangements may be made checking the same.
12.5 WORK shall be suspended for such times as necessary for checking lines and levels
on any part of the WORK.
12.6 The CONTRACTOR shall at his own expense provide all assistance, which the
Engineer-in-Charge may require for checking the setting out ot WORKS.
12.7 Before commencement of any activity, contractor's quality control set up duly
approved by company must be available at site.
13.1 The order in which the WORK shall be carried out shall be subject to the approval
of the Engineer-in-charge and shall be so as to suit the detailed method of
construction adopted by the CONTRACTOR, as well as the agreed joint
programme. The WORK shall be carried out in a manner so as to enable the other
contractors, if any, to work concurrently.
13.2.1 Drains, pipes, cables, overhead wires and similar services encountered in course of
the works shall be guarded from injury by the CONTRACTOR at his own cost, so
that they may continue in full and uninterrupted use to the satisfaction of the
Owners thereof, or otherwise occupy any part of the SITE in a manner likely to
hinder the operation of such services.
13.2.2 Should any damage be done by the CONTRACTOR to any mains, pipes, cables or
lines (whether above or below ground etc.), whether or not shown on the drawings
the CONTRACTOR must make good or bear the cost of making good the same
without delay to the satisfaction of the Engineer-in-Charge.
An Appendix-I of approved vendors for various major items is enclosed with this
tender specification. The bidder shall consider such names only as indicated in the
aforesaid list and clearly indicate in the bid the name(s) as selected against these
items. For any other item not covered in the list enclosed with this tender
document, prior approval shall be obtained by the contractor for its make/
supplier’s name.
The Contractor shall carry out the various tests as enumerated in the technical
specifications of this Bidding Document and technical documents that will be
furnished to him during the performance of the work at no extra cost to the
Owner.
All the tests either on the field or at outside laboratories concerning the
execution of the work and supply of materials by the Contractor shall be carried
out by Contractor at his own cost.
Compressed air for carrying out works shall be arranged by the Contractor at his
own cost.
For material supplied by Owner, Contractor shall carryout the tests, if required
by the Engineer-in-Charge, and the cost of such tests shall be reimbursed by the
Owner at actual to the Contractor on production of documentary evidence.
All results of inspection and tests will be recorded in the inspection reports,
proforma of which will be approved by the Engineer-in-Charge. These reports
shall form part of the completion documents. Any work not conforming to
execution drawings, specifications or codes shall be rejected and the Contractor
shall carryout the rectifications at his own cost.
For materials supplied by Owner, contractor shall carryout the tests, if required by
the Engineer-in- charge, and the cost of such tests shall be reimbursed by the
Owner at actual to the Contractor on production of documentary evidence.
Contractor shall inspect carefully all equipment before receiving them from Owner
for installation purposes. Any damage or defect noticed shall be brought to the
notice of Engineer-in- Charge immediately.
Inspection and acceptance of the work shall not relieve the Contractor from any of
his responsibilities under this Contract.
15.2.1 All inspection and tests on bought out items shall be made as per the
specifications forming part of this contract. Various stages of inspection and
testing shall be identified after receipt of Quality Assurance Programme from the
Contractor/ Manufacturer.
Owner/ MECON and copies shall be made available to owner/ MECON before
hand for undertaking inspection.
15.2.3 The contractor shall ensure full and free access to the inspection engineer of
Owner/ MECON at the Contractor’s or their sub-contractor’s premises at any
time during contract period to facilitate him to carry out inspection and testing
assignments.
15.2.4 The contractor/ sub-contractor shall provide all instruments, tools, necessary
testing and other inspection facilities to inspection engineer of Owner/ MECON
free of cost for carrying out inspection.
15.2.5 Where facilities for testing do not exist in the Contractor’s/ sub-contractor’s
laboratories, samples and test pieces shall be drawn by the Contractor/ Sub-
Contractor in presence of Inspection Engineer of a Owner/ MECON and duly
sealed by the later and sent for testing in Government approved Test House or
any other testing laboratories approved by the Inspection Engineer at the
Contractor’s cost.
15.3.1 Bidder shall be required to submit recent test certificates for the material being
used in works from the recognized laboratories. These certificates should
indicate all properties of the materials as required in relevant IS Standards or
International Standards.
15.3.2 Contractor shall also submit the test certificate with every batch of material
supplied which will be approved by Engineer-in-Charge. No secured advance will
be given for the materials not having test certificate. In case any test is to be
carried out, the same shall be got done in the approved laboratory at the cost of
contractor.
15.4.1 Contractor is required to employ Third party inspection agency (TPIA) for
inspection, witnessing tests and certification of works at Contractor’ s work
centers for procurement of line pipes, coating of line pipes, equipment
manufacturing, construction, etc. The owner shall approve the agency and it
shall not be same TPIA engaged by owner.
15.4.2 Owner reserves the right to employ his own TPIA as indicated in the subsequent
sections.
15.4.3 Owner will appoint an independent TPIA for construction of total pipeline.
15.4.4 Owner reserves the right to appoint agencies for quality surveyor lance during
the time of production and supply of major items.
15.4.5 GSPL reserves the rights of access for audit and inspection at Contractor, sub-
contractor / vendor’ s plants / work sites at any stage during the Project.
15.4.6 First day production and quality checks shall be carried out in presence of Owner
/ Owner’ s representatives.
15.4.7 EPC Contractor shall ensure that TPI inspectors have sufficient experience and
qualification to fulfill the inspection of specified items. EPC contractor shall
submit the CVs of proposed personnel before putting them on to the job. At
least not less than 3 (three) working days are to be given top GSPL for approval.
15.4.8 Inspection and test plans (ITP) are to be developed for all items of supply and
items of construction as per his QA/QC plan by Contractor and submit the same
to Owner for his review / approval within fifteen (15) days after award of work.
Owner will review the ITPs and approve the same for implementation in the
work.
All inspections and tests shall be made as required by the specifications forming
part of this contract. Contractor shall advise Owner/ Consultant in writing at least
10 days in advance of the date of final inspection/tests. Manufactures inspection
or testing certificates for equipment and materials supplied, may be considered for
acceptance at the discretion of Owner/ Consultant. All costs towards testing etc.
shall be borne by the contractor within their quoted rates. All inspection of various
items shall be carried out based on Quality Assurance Plan, which will be submitted
by the Contractor and duly approved by Owner/ Consultant.
DESIGN BASIS
Gujarat State Petronet Limited
MEC/23JT/05/21/M/002/0001 REVISION 4
CONTENTS
2.1 INTRODUCTION 8
2.2 SCOPE 8
2.7 TERMINALS 17
2.11 ELECTRICAL 19
2.13 SERVICES 20
MEC/23JT/05/21/M/002/0001 REVISION 4
1.1 M/s GSPL intend to lay a 12” NB x 37.23 km pipeline from Padamla tap-off near Baroda on
24” OD Baroda – Ahmedabad – Kalol pipeline. The proposed pipeline is approximately ~
37.23 km long and 12” NB and will transport ~ 1.5 MMSCMD intermingled RLNG & Natural
Gas from Padamla tap-off to Halol for distribution to domestic, automobile, commercial &
industrial consumers.
The tap-off shall be taken from existing SV at Padmala on Baroda – Ahmedabad – Kalol
Pipeline.
The proposed new pipeline shall be originated from Padamla tap-off at Baroda –
Ahmedabad – Kalol Pipeline and shall be terminated at Halol. The new pipeline shall be of
12.75” OD and 37.23 km in length.
Basic objective of the new pipeline is to cater for the need of industrial, commercial &
automobile consumers in that area.
MEC/23JT/05/21/M/002/0001 REVISION 4
The route of the proposed pipeline has been decided by M/s GSPL, the salient feature of
the pipeline routes is described in the civil, mechanical document. The entire pipeline
network has been divided into the following section.
1.2.2 Tap-Off
1.2.4 Terminals
• Tap-off : At Padamla
• Despatch Terminal : Sokhada
• Receipt Terminal : At Halol
• Tap-off Stations : At Sokhada ch. 1.00 km,
For GIDC, Manjusar at ch.11.42 km,
For GIDC Savili at ch. 23.87 km.
Tap-off shall be provided (Ch. 37.23 km), at
receiving terminal for GIDC, Kalol and for
Godhra.
Based on the optimization studies carried out the following design parameters have been
considered for Mechanical Design of Pipeline System.
MEC/23JT/05/21/M/002/0001 REVISION 4
Based on above design parameters, pipeline wall thickness and grade have been
optimised and are indicated below :-
Pipeline & its appurtenances shall be provided with carbon steel material suitable for the
intended service as indicated above.
a) Line Pipe
ERW, Line pipe shall confirm to API Specification 5L, PSL-2 Quality. The grade of line
pipe shall be API 5L Gr. X-65 as indicated above. Pipe wall thickness shall confirm to
ASME B31.8 and shall also meet the requirement of OISD 141. At river crossing higher
wall thickness shall be used.
All pipeline materials such as pipe, valves, flanges and fittings etc. shall be of class
600#.
All mainline valves/ station valves are full bore type and designed as per API 6D and API
6FA/ API 607 fire safe design requirements.
All mainline valves shall be double block & bleed type, double piston effect for low
temperature services. First isolation valve in mainline shall be butt welded type. All
mainline valves including launcher & receiver valves are gas operated and have body
material conforming to LF2.
MEC/23JT/05/21/M/002/0001 REVISION 4
All aboveground piping system shall be of low temperature seamless pipes of equivalent
grade to match 600# pressure and temperature rating. All fittings shall conform to ANSI
600# and low temperature application.
e) Ball Valves
All ball valves for terminals shall be full bore type. TMBV underground ball valve shall have
welded configuration and aboveground station valves can be a bolted configuration.
f) Flow Tees
All branch connection on the main line which are greater than 40% of mainline would be
provided with flow tees to allow smooth passage of pigs. Flow tees material would be
same as that of line pipe.
g) Insulating Joint
Sectionalizing Valve and station block valves shall be gas actuated. All Sectionalising
Valve shall have provision for remote operation (ROV). Sectionalising Valve shall be
buried and provided with stem extension. Mainline valve shall be full bore type ball
valves, to allow smooth passage of scrappers or pigs through them. All other valves
used in terminals shall also be full bore ball valves. These valves shall conform to API
6D.
i) Scrapper Traps
j) LR Bends
Cold field bends shall be in accordance with codes but in no case with a radius below 40
times diameters.
Induction bend shall only be used where ever space constraint is there. However at
stations it can be used.
MEC/23JT/05/21/M/002/0001 REVISION 4
k) Gas Chromatograph
l) SCADA
Foxboro make C-50 RTU shall be installed at despatch, SV’s & Receiving Station & Terminal
at the end of Spurlines. However M/s GSPL shall finalize all SCADA equipment shall be free
issue item to contractor & scheme.
m) Telecom System
OFC based telecom system shall be provided 24 fiber unarmored OFC shall be laid in self-
lubricated in φ 40mm / 50mm HDPE conduit. At crossing a spare φ 40mm / 50mm HDPE
conduit shall be laid in 6” casing pipeline. Telecom system shall comprise of minimum
STM-1 equipment at each station, SVs & tap-off points. Telecom equipment shall be free
issue item to contractor & scheme shall be finalized by M/s GSPL.
The selected corrosion coating shall be suitable for the temperature range specified in
the process design basis.
It is proposed to provide corrosion protection of the buried pipeline using 3-Layer Side
Extruded Polyethylene (PE) Coating for the pipeline. The minimum total thickness of
3LPE Coating shall be as given below :-
Field weld joints shall be coated with heat shrinkable sleeves or cold applied taps. In
addition to the corrosion coating, the entire buried portion of the pipeline system shall
be provided with cathodic protection system. No internal coating shall be provided.
Pipeline and associated facilities shall be constructed in accordance with ASME B31.8 and
other applicable standards. The pipeline shall be laid underground with minimum 1(one)
meter cover. Additional cover, wherever required, shall be provided in accordance with
OISD 141.
Welding shall be carried out as per API 1104. All welds shall be 100% radiographed.
After the installation is completed, the entire pipeline shall be hydrostatically tested. The
hydrostatic test pressure at any test section shall 1.25 – 1.4 times the design pressure
for respective class location. The maximum hydrostatic test pressure at any location in
MEC/23JT/05/21/M/002/0001 REVISION 4
the pipeline during testing shall be not exceed the pressure required to produce hoop
stress equal to 95% SMYS of pipe material. The test duration shall be 24 hours for
pipeline. Despatch/ Receipt Terminals as well as other intermediate facilities shall also
be tested at 1.4 times the design pressure. The test duration shall be 6 hours.
In case of soft soil, conventional trenching and backfilling can be considered for laying of
pipeline.
In case of sub surface encountered being weathered rock, a minimum of 150mm thick
layer of soft back-fill material shall be provided all around the pipeline prior to back-
filling the trench with excavated material. Where blasting can not be carried out due to
close proximity of existing facilities, mechanical equipment for rock excavation can be
used. Conventional trenching and back-filling using trenching machine has been
considered for laying of the pipeline in the soft soil areas other than described
above.
The type of corrosion coating selected (PE) for the pipeline has adequate mechanical
properties to withstand the hard surface features. A typical cover of one (1) meter over
the top of pipeline is considered.
MEC/23JT/05/21/M/002/0001 REVISION 4
Pipeline Crossings
a) Rail
Boring method shall cross railway lines. Approval of designs and construction
methodology shall be obtained from concerned railway authorities. Pipeline at
railway crossing shall be provided with casing pipe. The carrier pipe shall be
installed inside casing pipe. The casing pipe shall be three nominal sizes larger than
carrier pipe. The minimum clear cover at the crossing above top of pipeline shall be
1.7mm. The crossing angle shall be as close to 90° as possible. The railway
crossing shall comply with the requirement of API 1102 and Indian Railway
authorities.
Casing insulator and seals shall be provided to isolate carrier and casing pipes.
Road crossing shall comply with the requirement of API 1102 and requirements
of the concerned road authorities. Pipeline at National Highways and State
Highways Crossing (wherever required) shall be provided with the casing pipe.
Metalled roads other than the national highways and state highways shall be
crossed by open cut method. However at locations where it is not possible to
cross the road by open cut method boring/ jacking method shall be used. No
casing pipe shall be considered at such locations. All the cart tracks crossings
shall be carried out by open cut method. The road crossing shall be provided
with minimum cover of 1.2mm measured from top of the carrier pipe.
c) River Crossing
All rivers crossing are proposed to be crossed by conventional open cut method
except for the rivers specifically proposed to be crossed by HDD Method.
Pipeline shall be installed approx. 1.5m (for rocky) / 2.5m (for normal soil) below
the lowest bed level. Lowest bed level shall be calculated after giving due
consideration to scour depth of such water crossings. The line pipe shall be
concrete coated, if required to sufficient negative buoyancy.
At all major crossing two nos. of HDPE conduits shall be laid in steel casing pipe
to take care of future requirement.
MEC/23JT/05/21/M/002/0001 REVISION 4
2.1 INTRODUCTION
M/s GSPL proposes to lay 12” NB and 37.23 km long pipeline from Padamla Tap-off for
supplying 1.50 MMSCMD Natural Gas to industrial consumers in Halol and nearby areas.
2.2 SCOPE
Components Mol%
C1 : 89.68
C2 : 6.34
C3 : 2.49
i-C4 : 0.48
n-C4 : 0.59
i-C5 : 0.040
n-C5 : 0.040
C6+ : 0.0
N2 : 0.34
CO2 : 0
Gas Quality : Dry Gas
Specific Gravity : 0.62
MW : 18.17
3
Calorific Value, MJ/Sm Gross :41.65
C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc
OIL & GAS SBU DESIGN BASIS FOR 12” NB x
37.23 KM PIPELINE FROM
PADMALA TO HALOL
GUJARAT STATE PETRONET LIMITED MECON LTD., DELHI
MEC/23JT/05/21/M/002/0001 REVISION 4
3
Calorific Value, MJ/Sm Net : 37.86
2.4 STATIONS B/L CONDITIONS
2
Gas Pressure, kg/cm g (at Tap-off) : 50 bar
Aboveground Temperature, °C : 5°C (Minimum)
Aboveground Temperature, °C : 50°C (Maximum)
Sub Soil Temperature, °C : 20°C (Minimum) – GSPL to Confirm
Sub Soil Temperature, °C : 25°C (Maximum) – GSPL to Confirm
Mainline
MEC/23JT/05/21/M/002/0001 REVISION 4
Pressure : 50 bar(g)
Temperature, °C : 5 to 50°C
Gas Flow, MMSCMD : 1.5
To protect pipeline from external corrosion three layers of polyethylene coating will be
provided, the minimum thickness of coating shall be 3.2mm. This include 180 micron
thickness of epoxy, adhesive thickness of 200 micron.
Design basis for cathodic protection system has been attached as Appendix I
For effective maintenance of pipeline, pig launching & receiving facilities will be provided
at the ends of pipeline that is at Sokhada despatch terminal & Halol Receiving Terminal.
Provision shall be kept for intelligent pigging.
MEC/23JT/05/21/M/002/0001 REVISION 4
All branch connection on the main line which are greater than 40% of mainline would be
provided with flow tees to allow smooth passage of pigs. Flow tees material would be
same as that of line pipe.
2.6.1 Instrumentation & control system will be provided for safe reliable and efficient control of
natural gas transportation in pipeline. For this purpose, microprocessor based electronic
instruments having 4-20 mA DC current signal as input/output have been envisaged. The
basic function of the instrumentation system shall be to monitor and control of natural gas
parameters viz , pressure , temperature, flow, % of LEL, Actuated Valve’s status , pig
signaling , gas analysis, etc as indicated in the P&ID diagram. Instrumentation for
measurement of control will be combination of both local and remote operation from the
control room.
One control panel shall be provided in Despatch Terminal at Sokhada. Control panel shall be
used for mentoring of inlet pressure, temperature, pig signaling, LEL detection system and
actuated valve’s, status indication & control. Fire gas alarm system shall be provided.
Provision shall be kept to hook-up all parameters with SCADA through RTU.
However the SCADA System including RTU shall be finalized by M/S GSPL and shall be
executed by other contractors.
One control panel shall be provided in SV-I for pressure, temperature indication, actuated
valve’s status indication & control. Provision shall be kept to hook-up all parameters with
SCADA through RTU.
Control panel shall be provided in gas distribution cum receipt terminal. Control panel shall
be used for indication of inlet/ outlet pressure, temperature, differential pressure indication
across cartridge filter, pig signaling, LEL detection, actuated valve’s status indication, outlet
flow, status indication of Pressure Control Valve, Slam Shut Valve, and inputs from Flow
Computers. Provision shall be kept to hook-up all parameters including TR Unit on-line data
MEC/23JT/05/21/M/002/0001 REVISION 4
with SCADA through RTU. However the SCADA System including RTU shall be finalized by
M/S GSPL and shall be executed by other contractors.
Fire & Gas Alarm System and CO2 Flooding System shall also be provided in all control
rooms.
2.6.2 The design shall employ the latest technology of proven capabilities. The selection of
equipment shall be such as to offer flexibility for future modification and expansion
without affecting the system reliability.
2.6.3 All instruments shall be capable of operating for the specified turndown conditions. All
instruments unless otherwise specified, shall be electronic type. However, final control
element shall be pneumatically operated.
2.6.4 The type of instrument as specified in the Instrument Data Sheet shall be invariably
selected unless the vendor has valid technical reasons for proposing a change. Any
deviation on the type of instrument from the data sheet shall be specifically highlighted
with technical reason and approval sought from MECON/GSPL. Contractor to note that
the ultimate responsibility to select the particular instrument to suit process conditions
shall be Contractor’s responsibility.
2.6.5 All safety shutdown and interlocks shall be carried out using electromagnetic relays.
2.6.6 All field instruments, junction boxes and cable glands shall be certified for use in
hazardous area as per area classification mentioned elsewhere in the tender document.
The Instrumentation shall be certified intrinsically safe in general, as per IEC-79.
However, field switches, solenoid valves shall be certified flameproof for use in classified
area as applicable (IS-2148/ IEC-79). Moreover, all field instruments junction boxes,
cable glands shall be weather proof to NEMA-4 / IP 55 as per IS:2147 / IEC-529 and
explosion proof/ flame proof to NEMA-7 or equivalent IS Standard.
2.6.7 The philosophy of power supplies for Instrumentation purposes are as follows :-
i) 230 VAC, 50 Hz , UPS for Min incoming power supply to control panel.
ii) 24 VDC (Dual redundant) for panel mounted instrument, field transmitters,
solenoid valve LEL gas detectors and interlock based relay systems.
iii) 230 VAC , 50 HZ , non-UPS for panel lighting, electrical heat tracing.
2.6.8 Isolated 230V AC @50 Hz, 24V DC and its distribution within the battery limits including
UPS and battery backup shall be Contractor’s responsibility. AC distribution board and DC
distribution board shall be provided in control room with suitable isolator for each feeder.
2.6.9 All open and close loops shall have an individual MCB in the panel for isolating the field
instruments for maintenance (i.e. for field switches, transmitters, SOV, Control Valve
etc.)
MEC/23JT/05/21/M/002/0001 REVISION 4
2.6.10 The design and installation of instruments shall be generally in accordance with ISA /
API recommended practices and other applicable standards like ASI, IBR etc. Material
specifications and practices shall, in general, conform to appropriate ASTM or equivalent
standards. All standards, code of practice shall be of the latest edition.
2.6.11 All instruments and equipments shall be suitable for use in hot, humid and tropical
industrial climate in which corrosive gases and/ or chemicals may be present. As a
minimum, all instruments and enclosures in field shall be dust proof, weather proof to
NEMA 4 (IP 55) and secure against the ingress of fumes, damages, insects and vermin.
All external surfaces shall be suitably treated to provide anti corrosion protection against
plant atmosphere.
2.6.13 Ranges for instruments shall be selected, in general, such that in normal process
operation the indication on the indicator or chart is between 40% to 60% of span for
linear scale and 60% to 80% of span for square root scale.
2.6.14 The complete instrument system shall be designed for safe operation, by using normally
contacts which open on fault conditions.
2.6.15 The design of the alarm annunciation system shall be such that the transient alarms of
less than 330 milli seconds duration shall be automatically discounted.
2.6.16 All lamps on control panels shall be provided with lamp test facility
2.6.17 All process switches shall be provided with DPDT (two nos.) switches with contact rating,
as a minimum of 110V, 0.5 A DC or 230 V 5.0 Amp (Inductive) AC as applicable. For all
field switches (except limit switches), differential of switch shall be less than 40% of
difference between set value & normal operating value.
2.6.18 Control valve sizing formula shall, in general, be as per ISA 75.01. Control valves shall be
sized for the available pressure drop at normal flow and in addition shall permit upto
150% of normal flow or 110% of the maximum flow, whichever is higher. Vendor shall
submit the sizing calculations for all control valves.
2.6.19 All transmitters shall be of SMART type provided with in-built output meter/ output
gauge at the transmitter end.
2.6.20 All solenoid valves shall be of three way “universal “ type and continuous rated type.
MEC/23JT/05/21/M/002/0001 REVISION 4
2.7 TERMINALS
A 12” NB tap-off available at Padamla shall be used to supply gas. The despatch
terminal at Sokhada will have following facilities.
2.7.2.1 A sectionalising valve will be provided at a distance of 23.87 km from dispatch terminal for
shut down of the pipeline. SV-1 gas over-oil valves shall be made remoteopera table from
SCADA Control Room. However SCADA & RTU shall not be in EPC contractor scope.
2.7.3 Terminal
After despatch terminal gas flow through the pipeline will be distributed through Gas
Distribution/ Receipt Terminal at Halol. The following facilities have been envisaged at
Receiving Terminal.
1. Scrapper Receiver cum Launcher with pig signaler (16” x 12” NB) – 1 No.
2. Control Panel
3. Control Room Building
4. LEL Detection System
5. F&G Alarm
MEC/23JT/05/21/M/002/0001 REVISION 4
The purpose of SCADA System is to ensure effective and reliable control, management &
supervision of the pipeline from centralized location using remote terminal units located
along the pipeline at suitable locations.
Central SCADA control centre will be interlocked through Optical Fiber Cable (OFC) link with
Remote Terminal Units (RTUs) located along the pipeline. The following pipeline facilities
have been considered for telemetry operation.
i) Despatch terminal
ii) Sectionalising Valve Station SV-1
iii) Gas Distribution Terminal at Halol .
iv) Pipeline and skid mounted terminal for industrial consumer at Manjusar, Savili and
Receiving Terminal at Halol. However Metering Skid shall be free use item to
EPC contractor.
RTU’s have been envisaged in the future for SCADA system covering the requirements of
above mentioned points. The RTU shall be integrated with SCADA Master Stations by M/s
GSPL. The RTU’s will be used for scanning and telemetering of pipeline parameters such as
flow , temperature , pressure, valve status, scraper pig signaling ,density, CP parameters etc
to update the main computer database for monitoring the entire pipeline operation. The
SCADA system will also be used for remote operation and monitoring of sectionalized valve.
However, the future SCADA system including RTU shall be finalized by M/s GSPL and
executed by other contractor.
IR based detection system having adequate nos. of fixed gas detectors at various critical
locations in the Receiving Terminal shall be provided for continuous monitoring of
hydrocarbon level in the air in the proximity of filtration, pressure reduction & metering unit,
piping etc. the basis of location for the same shall be based on wind direction, gas
component density and coverage of gas detections in Receiving Terminal & same shall be
integrated with SCADA, RTU through serial communication.
The panel (completely wired) for housing the monitor/ controller for gas detectors with
relays, hooters/ annunciators indicating the location shall be provided in the control room.
The single channel monitor to be used with two channels as spare. The gas detection
system shall give high gas alarm on 20% low explosion level (LEL) and very high gas alarm
of 40% LEL detection in the gas detectors. One no. of calibration kit complete with
calibration gas cylinders for gas detector calibration shall be provided. in each
station/terminal.
MEC/23JT/05/21/M/002/0001 REVISION 4
Suitable fire and gas detection system for control room and field area are to be provided,
with receiver instruments in control room with separate alarm.
The supply shall include fire detectors, monitor/ controllers, and enunciators in fire panel to
be placed in the control room (CR).
The fire and gas detector layout shall cover the entire plant area system following NFPA-72
standard. Develop the detailed layout and same will be finalized during detailed
engineering.
The location & type of fire and gas detection system to be provided in different areas is as
follows:-
Manual call point/ break glass Exit doors of the building in Receiving Terminal.
All the connections for fire/ gas/ smoke detection system will lead for annunciation to the
fire panel to be placed in the control room. The receiver instrument will be placed in the
control room.
To facilitate proper operational and management control of the pipeline, a reliable and
dedicated Telecommunication System is proposed to be setup in future connecting the
various attended and unattended stations along the pipelines. At present only Optical fiber
cable shall be laid in HDPE Duct along with the pipeline
The future Communication System proposed will provide for remote operation of SV-I along
the pipeline along with communication amongst other attended stations. The system will
also provide for voice communication from unmanned stations to the attended stations and
also remote monitoring of the cathodic protection. STM-1 equipment shall be installed at
each station/ tap-off points in future. However, the future Telecommunication System
including STM equipments shall be finalized by M/s GSPL and executed by other Contractor.
2.11 ELECTRICAL
MEC/23JT/05/21/M/002/0001 REVISION 4
i) Dispatch Terminal
ii) SV Station & Tap-off-III
iii) Receiving Terminal
• Bore well shall be provided in each station (such as Dispatch, SV, Tap-off and
Receipt Terminal).
• Boundary wall with gate shall be provided in Dispatch, SV & Receipt Terminal while
in tap-off only fencing with gates are to be provided.
• Civil work such as pavement, pipes support & equipment foundation in Dispatch, SV,
tap-off and receipt terminal.
Detail design basis for Civil/Structural has been attached as Appendix III
2.13 SERVICES
2.13.1 Air conditioners (Split and Window) will be provided in control room shift-in-charge room
and SCADA & Telecom room in Dispatch, Receiving Terminal and in control SV and tap-off
Stations control room.
* Power supply for critical services such as Instrument/ Telecom/ SCADA &
Control Panel and total for non-critical services shall be furnished by MECON
during detail engineering.
It has been considered that fire fighting facilities such as static fire fighting equipment such
as DCP type fire extinguisher at station will be provided to cover the pipeline facilities at the
despatch station SV, tap-off and Receiving Terminal.
MEC/23JT/05/21/M/002/0001 REVISION 4
2.14.1 The total route length shall be decided based on survey drawings.
2.14.2 No instrumentation, plant air shall be available. However, instruments shall be gas operated
only.
2.14.3 An existing plot of 105m x 70m is provided as indicated by GSPL at Dispatch Terminal at
Sokhada.
MEC/23JT/05/21/M/002/0001 REVISION 4
ASME B31.8 :
Gas Transmission and Distribution Piping System
ASME B16.25 :
Gas Transmission and Distribution Piping System
ASME B16.9 :
Factory – Made Wrought Iron Steel Butt-Welding Fittings
ASME B31.3 Process Piping :
ASME B31.4 :
Pipeline Transportation System for Liquid Hydrocarbons and
others
ASME B16.5 : Pipe Flanges and Flanged Fittings
ASME B16.9 : Factory Made Wrought Steel Butt Welding Fittings
ASME B16.10 : Face to Face and End to End – Dimensions of Valves
ASME B16.11 : Forged Fittings, Socket-Welding and Threaded
ASME B16.20 : Metallic Gaskets for Pipe Flanges – Ring Joint, Spiral Wound
and Jacketed.
ASME B16.21 : Non-Metallic Flat Gaskets for Pipe Flanges
ASME B16.25 : Butt Welding Ends
ASME B16.28 : Wrought Steel Butt Welding Short Radius Elbows
ASME B16.34 : Valves – Flanged, Threaded & Welding Ends
ASME B16.36 : Orifice Flanges
ASME B16.47 Series “A” : Large Diameter Steel Flanges NPS 26 through NPS 60
ASME B18.2.1 : Square and Hex. Bolts and Screws
ASME B18.2.2 : Square and Hex. Nuts
ASME B31.3 : Process Piping
ASME B36.10M : Welded and Seamless Wrought Steel Pipe
ASME Boiler & Pressure : Section-IX – Qualification standard for welding and Brazing
Vessel Code procedures, welders, brazes, and welding and brazing
operators
ASME Boiler & Pressure : Part C – Specifications for Welding Rods, Electrodes, and
Vessel Code-II Filter Metals
ASME Boiler & Pressure : Section-II Materials Part A – Ferrous Materials Specifications
Vessel Code
MEC/23JT/05/21/M/002/0001 REVISION 4
API Std 607 : Fire Test for Soft Seated Quarter Turn Valves
API RP 500 : Recommended practice for classification of locations of
Electrical installations at Petroleum Facilities classified as Class
I, Div. 1 and 2.
Spec 6FA : Specification for Fire Test for Valves
STD 590 : Steel Line Blanks
STD 594 : Check Valves, Wafer, Wafer Lug and Double Flanged Type
STD 598 : Valve Inspection and Testing
STD 600 : Steel Gate Valves Flanged or Butt Welding Ends, Bolted and
Pressure Seal Bonnets
STD 602 : Compact Steel Gate Valves – Flanged, Threaded, Welding and
Extended Body Ends.
STD 607 : Fire Test for Soft-Seated Quarter-Turn Valves
MEC/23JT/05/21/M/002/0001 REVISION 4
st
SEL 072 – 1 Edition : Ultrasonically tested heavy plate
DIN 20670 : Polyethylene coatings for steel pipes and fittings
DIN 2413 Part-II : Design of steel bends used in pressure pipelines
ISO/TR 5168 : Measurement of fluid flow-Evaluation of uncertainties
OISD-GDN-115 :
Guidelines on Fire Fighting, Equipment and appliances in
Petroleum Industry
Fire Protection Manual : Fire Engines, Trailer Pumps and Hydrant Systems
- TAC
OISD-Standard-141 : Design and construction requirements for cross country
hydrocarbon pipelines
OISD-Standard-118 : Layouts for oil and gas installations
ASTM A82 : Standard Specification for Steel Wire, Plain, for Concrete
Reinforcement
ASTM A185 : Standard Specification for Steel Welded Wire Fabric, Plain, for
Concrete Reinforcement
ASTM E92 : Standard Test Method for Vickers Hardness Testing of Metallic
Materials
ASTM E94 : Standard Practice for Radiographic Testing
ASTM E165 : Standard Practice for Liquid Penetrant Inspection Method
ASTM E709 : Standard Guide for Magnetic Particle Examinations
SR.
INSTRUMENT DATA SHEET NO. REV
NO.
1 Pressure Gauge MEC/23JT/05/E5/DS-PG 1
2 Pressure Transmitter MEC/23JT/05/E5/DS-PT 1
8 Indicator MEC/23JT/05/E5/DS-IND 1
1) LR BEND MFR. :
TABLE-I
Sl. Details of P/L material Bend End Type Qty. Angle Strainght Pipe length reqd. to
No. NB Thk. Material Radius (Nos.) Length fabricate the bend
mm (R) after m/ bend Total
curvature @ length
(mm) ' (m) @
TABLE-II
12 x Thk.
Note:
1) Test Bend shall be of 90°
2) Quantity & angles of LR Bends shall be finalized during detailed engineering activities
3) A check shall be performed on each bend by passing gauging pig consisting of two discs having a diameter equal to 95% of the nominal
internal diameter of the pipe, connected rigidly together at a distance equal to 300mm. Details of the gauging pig, including its dimensions
shall be approved by Purchaser.
DESIGN DATA
3. RATING : 600#
6. SERVICE : R-LNG
13. CHARPY TEST : REQUIRED AT (-) 200C, CV (Avg.) - 35 J/cm2 / CV (Min.) - 28 J/cm 2
17 MATERIALS SPECIFICATION
(EQUIVALENT OR SUPERIOR)
A) TEE : MSS-SP-75 WPHY-65
B) END PIECES : ASTM A 694 F-65
C) INTERNAL SLEEVE : API 5L Gr. B
DESIGN DATA
3. RATING : 600#
6. SERVICE : R-LNG
8. SIZE NB (INCHES) : 12 X 12 X 8
13. CHARPY TEST : REQUIRED AT (-) 200C, CV (Avg.) - 35 J/cm2 / CV (Min.) - 28 J/cm 2
3. RATING : 600#
3. RATING : 600#
3. RATING : 600#
NOTE: THE THICKNESS OF PIPE/ PUP SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING
REV. NO. DATE ZONE DESCRIPTIONS BY APPRD
REVISIONS REFERENCES DRG. NO.
SECTION OIL & GAS CLIENT : GUJARAT STATE PETRONET LIMITED
NAME DATE CHKD DATE MECON LIMITED
DSGN PROJECT : PADAMLA - HALAOL NATURAL GAS
DRWN PIPELINE PROJECT OF GSPL IN GUJARAT
SCALE : NTS REV
APPROVED AK.JOHRI DATA SHEET FOR DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-009-03 0
INSULATING JOINTS ( 8" DIA., 600# SIZE )
3. RATING : 600#
NOTE: THE THICKNESS OF PIPE/ PUP SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING
REV. NO. DATE ZONE DESCRIPTIONS BY APPRD
REVISIONS REFERENCES DRG. NO.
SECTION OIL & GAS CLIENT : GUJARAT STATE PETRONET LIMITED
NAME DATE CHKD DATE MECON LIMITED
DSGN TR TRAY PROJECT : PADAMLA - HALAOL NATURAL GAS
DRWN PIPELINE PROJECT OF GSPL IN GUJARAT
SCALE : NTS REV
APPROVED A.K.JOHRI DATA SHEET FOR DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-009-04 0
INSULATING JOINTS ( 4" DIA., 600# SIZE )
2.0 Valve Size (NB), mm (inch) :(20)3/4", (25)1'', (40)11/2'' ANSI Rating :600# Design Standard : BS:5351
3.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C :-20 to +60°C
11.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
Actuator Data Sheet No.: N.A.
12.0 Fire Resistant Design Requirement : Type-Test as per Standard API 607/ BS:6755 (Part-II)
2.0 Valve Size (NB), mm (inch) : 50(2"),100(4'') ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
2.0 Valve Size (NB), mm (inch) : 300(12'') ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
2.0 Valve Size (NB), mm (inch) : 50(2"), 100(4'') ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20°C to +60°C
8.0 Corrosion Allowance : 1.5 mm Service : Natural Gas (Composition as per Annex-I to T.S.)
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
Notes:
1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2
2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards.
3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle.
4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied.
5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having
average value of 35J and minimum value shall be 28J.
* Ball & stem shall be ENP coated for minimum thickness of 25 microns.
REV. NO. DATE ZONE DESCRIPTIONS BY APPRD
1 30.12.06 REVISIONS: As per GSPL BB GS REFERENCES DRG. NO.
SECTION PROCESS & PIPING CLIENT : GSPL
2.0 Valve Size (NB), mm (inch) : 300(12'') ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20°C to +60°C
8.0 Corrosion Allowance : 1.5 mm Service : Natural Gas (Composition as per Annex-I to T.S.)
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
Notes:
1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2
2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards.
3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle.
4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied.
5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having
average value of 35J and minimum value shall be 28J.
* Ball & stem shall be ENP coated for minimum thickness of 25 microns.
REV. NO. DATE ZONE DESCRIPTIONS BY APPRD
1 30.12.06 REVISIONS: As per discussions with GSPL BB GS REFERENCES DRG. NO.
SECTION PROCESS & PIPING CLIENT : GSPL
2.0 Valve Size (NB), mm (inch) : 300(12'') ,200(8") ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: MEC/TS/05/26/002
Data Sheet No.: MEC/DS/05/26/23JT/002/01
13.0 Fire Resistant Design Requirement : API 6FA (Gas over Oil)
2.0 Valve Size (NB), mm (inch) : 300(12'') ,200(8") ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: MEC/TS/05/26/002
Data Sheet No.: MEC/DS/05/26/23JT/002/01
13.0 Fire Resistant Design Requirement : API 6FA (Gas over Oil)
2.0 Valve Size (NB), mm (inch) : 100(4''), 200(8'') ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
2.0 Valve Size (NB), mm (inch) :300(12") ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
2.0 Valve Size (NB), mm (inch) :300(12") ANSI Rating : 600# Design Standard : API 6D
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C : -20 to +60°C
12.0 Gas Powered Actuator Requirement : Yes No Actuator Specification No.: N.A.
2.0 Valve Size (NB), mm (inch) : 300(12") ANSI Rating : 600# Design Standard : API 6D/ BS:1868/
4.0 Connecting Pipeline Design Pressure, kg/cm2(g) : 96.87 Design Temperature, °C :-20 to +60
6.2. End Connections : Flanged both ends Flanged (as per ASME B16.5)
: Butt Weld both ends
Flanged one end, butt weld other end
1. Valve Manufacturer :
2
11 Test Pressure with Air : 7.0 kg/cm (g)
12 Schedule of Quantity :
Valve Size, NB Quantity
(Nos.)
2" As per SOR
4'' As per SOR
Notes:
1. Valve shall be designed for intristically fire safe.
2. Testing shall be asper BS:6755 (Part-I)
3. Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided for .
Wherever bidder agrees with MECON's data sheet, bidder shall clearly indicate "agreed".
4 Charpy V- notch test for body, bonnet, stem, disc, body seat rings & studs/nuts will be conducted at -20°C on five samples having
average value of 35J and minimum value shall be 28J.
* Minimum thickness of ENP coating shall be 25 microns
Painting Specifications:
1 Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909.
2 Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each
coat shall be within 80 to 120 micron.)
1. Valve Manufacturer :
12 Schedule of Quantity :
Valve Size, NB Quantity
(Nos.)
2'' As per SOR
4'' As per SOR
12'' As per SOR
Notes:
1. Valve shall be designed for intristically fire safe.
2. Testing shall be asper BS:6755 (Part-I)
3. Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided for .
Wherever bidder agrees with MECON's data sheet, bidder shall clearly indicate "agreed".
4 Charpy V- notch test for body, bonnet, stem, disc, body seat rings & studs/ nuts will be conducted at -20°C on five samples having
average value of 35J and minimum value shall be 28J.
* Minimum thickness of ENP coating shall be 25 microns.
Painting Specifications:
1 Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909.
2 Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each
coat shall be within 80 to 120 micron.)
Quantity (No.) 3
DESIGN CONDITIONS
Maximumk Allowable Operating Pressure, kg/cm2(g) 96.87
Temperature, °C (-) 20 to (+) 60
Design Code ASME B31.8
Corrosion Allowance (MM) 1.5
ANSI Rating (#) 600 #
Design Factor 0.5
Service RLNG
End Connection BE
Installation Aboveground
Electrical Area Classification IEC - Zone-1, Gas Group-IIA & IIB, Temp. Class-T3
Internals SS-316
1. Valve Manufacturer :
2
12 Test Pressure with Air : 7.0 kg/cm (g)
13 Schedule of Quantity :
Valve Size, NB
2''
4''
12''
Notes:
1. Valve shall be designed for intristically fire safe.
2. Testing shall be asper BS:6755 (Part-I)
3. Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided for .
Wherever bidder agrees with MECON's data sheet, bidder shall clearly indicate "agreed".
4 Charpy V- notch test for body, bonnet, stem, disc, body seat rings & studs/ nuts will be conducted at -20°C on five samples having
average value of 35J and minimum value shall be 28J.
* Minimum thickness of ENP coating shall be 25 microns.
Painting Specifications:
1 Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909.
2 Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each
coat shall be within 80 to 120 micron.)
This document and the design it covers are the property of MECON and issued for the specific project mentioned therein. This is not to be copies or used for
other projects unless expressly permitted by MECON.
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
PRESSURE GAUGES
Gas-Nm3/hr Steam- kg/hr Pressure-Bar Temperature- °C Level/Length-mm
Units:- Flow : Liquid-m3/hr
1 Type Direct 17 Type ---
2 Mounting Local 18 Wetted parts material ---
3 Dial size 150 mm Element ---
ColourWhite(Non rusting plastic Lower body ---
with black engraving)
4 Case material Cast aluminium 19 Non wetted parts ---
5 Bezel ring Screwed 20 Process connection ---
6 Window material Shatter proof glass Size ---
7 Enclosure IP 55 / NEMA 4 Rating ---
8 Pressure element Bourdon tube 21 Facing &Finish ---
9 Element material SS 316 22 Capillary material ---
10 Socket material SS 316 23 Capillary length ---
11 Accuracy ± 1% FSD 24 Flushing & Filling ---
12 Zero adjustment Micrometer pointer 25 Over range protection 130% of range
(Internal)
26 Blow out protection Required
13 Connections ½” NPT (M) 27 Options
Conn. Location Bottom a) Snubber
14 Movement SS 304 b) Syphon
15 Diaphragm seal --- c) Gauge saver
16 d) Liquid filled casing
e) Solid front
Pressure Design Temp.
Tag No. Range Operatin Design Fluid Service Options
g
42-PI-0103 * 42 – 50 95 60 N.GAS Natural Gas
42-PI-0104 * 42 – 50 95 60 N.GAS Natural Gas
42-PI-0104A * 42 – 50 95 60 N.GAS Natural Gas C,
42-PI-0601 * 42 – 50 95 60 N.GAS Natural Gas
42-PI-0602 * 42 – 50 95 60 N.GAS Natural Gas
NOTES:
1 08.03.07
Data Sht No.:MEC/23JT/05/E5/DS-PG
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
PRESSURE TRANSMITTERS
Units:- Flow : Liquid-m /hr Gas-Nm3/hr Steam- kg/hr Pressure-Kg/cm2g Temperature- °C Level/Length-mm
3
NOTES:
1) Offered instruments shall be suitable for corrosive constituents CO2 – 1.5%
2) ‘*’ – Information to be furnished by Contractor/ Vendor.
1 08.03.07
Data Sht No.: MEC/23JT/05/E5/DS-PT
REV. DATE BY CHKD APPD
PROJECT: PADAMLA-GODHARA (HALOL)
NATURAL GAS PIPELINE (PGPL)
MECON LTD. DELHI
CLIENT : GUJARAT STATE Data Sht. No. :
PETRONET LIMITED(GSPL) MEC / 23JT/ 05 /E5/DS-TT
TEMPERATURE TRANSMITTERS
UNITS :Flow : Liquid --> M3/Hr, Gas --> Nm3/Hr, Steam --> Kg/Hr, Pressure --> Kg/Cm2G, Temp --> °C, Level/Length > mm
DRIVING CAABILITY 24 V DC
4-20 mA 19 OPTIONS
8 OUTPUT
a) Output Meter
1 08.03.07
Data Sht. No. : MEC / 23JT/ 05 /E5/DS-TT
REV DATE BY CHKD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
NOTES:
‘*’: Information to be supplied by Contractor.
1) Offered Instruments shall be suitable for corrosive constituents CO2 – 1.5 %.
1 08.03.07
Data Sht No: MEC/23JT/05/E5/DS-RTD
REV. DATE BY CHKD APPD
PROJECT : PADMALA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)
MECON LTD. DELHI
CLIENT : GUJARAT STATE
Data Sht No : MEC / 23JT/ 05 /E5/DS-DPS
PETRONET LIMITED(GSPL)
3 3
UNITS : Flow --> Liquid M /Hr Gas --> M /Hr Steam --> Kg/Hr Pressure --> Kg/Cm2G Temp --> °C Level / Length -->MM
1 TYPE BLIND/PRESSURE/DIRECT
2 MOUNTING YOKE
SIZE RATING
NOTES:
1 130% OF RANGE OF MAX. PROCESS WHICHEVER IS GREATER
2 SET POINT SHOULD BE ADJUTABLE THROUGHT THE RANGE.
3 (*) BY VENDOR
1 08.03.07
Data Sht. No. : MEC / 23JT/ 05 /E5/ DS-DPS
REV DATE BY CHKD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
e. Gas Detection Panel housing the monitors, alarm annunciator, switches and relays,
etc. for carrying out necessary monitoring and shutdown functions.
5. Both open path and point gas detectors shall be provided for each station Open
path gas detectors of Infrared Absorption type shall be suitable for specified hazardous area
and shall be installed in the most adequate location . Point gas detectors shall be provided in
metering/filtration/letdown skids.
6. The low and high gas concentrations and a failure/default state shall be detected and
signalized by the Control Unit.
7. Analog signals ( i.e. LEL indication ) and High Alarm from each gas detectors shall be
required at SCADA. For that necessary provision shall be made available at Gas Detection
Panel.
8. Hooter / Flasher for LEL High Alarms shall be provided in Local Gas Detection Panel and
also in outdoor remote position.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 1 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
TYPE : Infrared Absorption type (Both Open Path and Point type)
OPERATING VOLTAGE : 24 V DC
MOUNTING
ACCESSORIES : Vendor to indicate.
NOTE 1: Splash guard & weatherproof cap for protection against dust and rain shall be provided.
NOTE 2: The junction box shall be weatherproof to IP 55 and certified to Explosion proof.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 2 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 3 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
One Portable Purge Calibrators consisting of a Volume Bottle containing a known gas/air mixture,
a Pressure Regulator with gauge, a Flexible Hose and Adaptor Cap (to fit the sensor head) shall be
supplied at each station to enable calibration of the sensors in the field without dismantling them.
Sufficient quantity of calibration gas shall be supplied to enable calibration of all sensing heads
atleast for six months. Calibration gas cylinder/bottle shall have validity of 1 year.
2 Nos. hand-held , Portable Gas Detector shall be supplied. These gas detectors / analysers shall be
capable of measuring methane from 0% to 100% by volume, 0% to 100% LEL and 0% to 100%
by volume oxygen as well.
Portable Gas Detectors shall be supplied complete with its controller, audio visual alarm and shall
be suitable (preferably intrinsically safe) for use in hazardous area specified. Such units shall be
certified by BASEEFA, CENRLEC, FM, PTB, CMRI etc. These units shall be supplied with
rechargeable batteries and 240V, 50 Hz ac battery,. Sufficient number of battery charger/nimber of
points per charge shall be provided based on quantity of such portable units. These units shall be
supplied complete with all accessories like carrying case, maintenance kit, calibration kit etc.
i. Monitors / Conrollers.
ii. Alarm Annunciator.
iii. Relays / Logic Cards for shutdown / protection system.
iv. Push buttons / Switches as required ( including Lamp Test Push Buttons).
v. Any other items which are not listed above but essential to make the system
operational and meet the requirements as specified.
The panel shall be provided with 5% installed spares ( minimum one number) for items like
monitors/ controllers, relays / logic cards etc. Alarm Annunciator shall have installed 20% spare
points. Panel shall have spare space (10%) for future expansion.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 4 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
Panel Construction
3. Ventilation : Required with louvers backed by wirefly screen & fan. Fan
Failure alarm required
4. Doors : Rear Double removable hinged doors with flush pull type
handles & with locking arrangement.
5. Door width : Shall suit the width of panel. The Panel width is indicative
only. The sizes shall be sufficient to accommodate the
required hardware specified in MR. However the depth and
height shall be 800 & 1800 respectively.
6. Cable Entry : Bottom, Cable Glands shall be double compression type for
external armoured cables. All unused entries shall be
plugged.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 5 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
2. Front Plate : 3.2 mm thick CRCA steel/5.0 mm thick HRCA steel, Welded
to frame
4. Door panel : 1.6-mm thick CRCA steel. Double side hinged, concealed
hinges and flush pull chrome-plated handles.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 6 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
Wiring
1. Type : General purpose, Intrinsically safe
2. Wiring details
3. Signal Wiring
3.1 External to Cabinet : 1.0 mm² twin twisted individual shielded overall s
shielded with overall drain PVC insulated armoured
3.2 Inside the cabinet : Multi stranded min. 0.5mm² copper conductor
PVC insulated twin twisted and shielded.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 7 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
2. Lamps
Type : LED Type
Voltage : 24 VDC
Make / Model No. : By Vendor
Quantity : As reqd.
3. Push Buttons
Type : Spring return
Contacts : 2 No. + 2 NC
Contact rating : 2A 24V DC
Make : ESBEE / SIEMENS/ TEKNIC
Color : As per standard
Quantity : As reqd.
4. Selector switch
Type : As per functional switches( 3 Position,
4 Pole)
Specification : Silver alloy gold plated contacts
To military specification with
SS shaft dust covers with water
Proof covering and contact shall
Be made before break type
Rating : 10A 230V 50Hz / 2A 24V DC
Make : KAYCEE/ SIEMENS/TEKNIC
Quantity : As reqd.
5. Relays
Type : Plug in relays
Contact Type : Potential free contact
Contact No. : 3 NO. + 3 NC
Rating : 24V DC, 5.0 A
Make / Model No. : OEN/ OMRON
Quantity : As reqd.
6. Space Heater
Rating : 60 W, 230 V AC with Thermostat.
Make : KEC
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 8 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
Alarm Annunciator
Alarm annunciator shall be provided at top of panel to display group alarms, shutdown alarms etc.
Alarm annunciator shall be solid state electronic type provided with single input type logic module
and solid state audio alarm unit. It shall be provided with first out type sequence (ISA F3A) with
function test, acknowledge and reset push buttons. Each window shall be of 75 mm X 50 mm size
and provided with two lamps. Lamps shall be removable from panel front.
DESPATCH TERMINAL
QUANTITY
2 Nos. Open Path type & 2 Nos. Point type.
Calibration Kit : 1 set.
SV TERMINAL
QUANTITY
2 Nos. Open Path type & 2 Nos. Point type.
Calibration Kit : 1 set.
RECEIVING TERMINAL
QUANTITY
6 Nos. Open Path type & 6 Nos. Point type.
Calibration Kit : 1 set.
SPARE QUANTITY
2 Nos. Open Path type & 2 Nos. Point type.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-LEL
REV. DATE BY CHKD APPD
Page 9 of 9
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
SPECIFICATIONS
FOR
CONTROL PANEL & ACCESSORIES
GENERAL
Site of Installation
2. Owner : GSPL
5. Floor : Concrete.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-CP
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
3. Ventilation : Required with louvers backed by wirefly screen & fan. Fan
Failure alarm required
4. Doors : Rear Double removable hinged doors with flush pull type
handles & with locking arrangement.
5. Door width : Each max. of 600mm and shall suit width of the panel. Panel
width is indicative only. The sizes shall be sufficient to
accommodate the required hardware specified in MR.
However the depth and height shall be 800 & 2100
respectively.
6. Cable Entry : Bottom, Cable Glands shall be double compression type for
external armoured cables. All unused entries shall be plugged.
9. Name Plates : Front of Panel Instrument name plates shall be black laminated
plastic with white core. Nameplate shall be provided on the
rear of the panel also.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-CP
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
2. Front Plate : 3.2 mm thick CRCA steel/5.0 mm thick HRCA steel, Welded
to frame
4. Door panel : 1.6-mm thick CRCA steel. Double side hinged. Concealed
Hinges and Flush pull chrome-plated handles.
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-CP
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
WIRING
1. Type : General purpose, Intrinsically safe
2. Wiring details
3. Signal Wiring
3.1 External to Cabinet : 1.0 mm² twin twisted individual shielded overall s
shielded with overall drain PVC insulated armoured
3.2 Inside the cabinet : Multi stranded min. 0.5mm² copper conductor
PVC insulated twin twisted and shielded.
2. Output : 24 VDC
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-CP
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
2. Lamps
Type : LED Type
Voltage : 24 VDC
Make / Model No. : By Vendor
Quantity : As reqd.
3. Push Buttons
Type : Spring return
Contacts : 2 No. + 2 NC
Contact rating : 2A 24V DC
Make : ESBEE / SIEMENS/ TEKNIC
Color : As per standard
Quantity : As reqd.
4. Selector switch
Type : As per functional switches( 3 Position,
4 Pole)
Specification : Silver alloy gold plated contacts
To military specification with
SS shaft dust covers with water
Proof covering and contact shall
Be made before break type
Rating : 10A 230V 50Hz / 2A 24V DC
Make : KAYCEE/ SIEMENS/TEKNIC
Quantity : As reqd.
5. Relays
Type : Plug in relays
Contact Type : Potential free contact
Contact No. : 3 NO. + 3 NC
Rating : 24V DC, 5.0 A
Make / Model No. : OEN/ OMRON
Quantity : As reqd.
6. Space Heater
Rating : 60 W, 230 V AC with Thermostat.
Make : KEC
1 08.03.07
Data Sht No. : MEC/23JT/05/E5/DS-CP
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
INDICATOR
SL .NO DESCRIPTION TECHNICAL REQUIREMENTS TO BE CONFIRMED BY VENDOR
1.0 Type Microprocessor based
Dual Channel Indicating
2.0 Mounting Flush Panel
3.0 Enclosure General Purpose
4.0 To be used in intrinsically With Extl. Zener Barrier/Isolator
safe system
5.0 Power for transmitters 24V DC (From Bulk Power Supply/SDC)
6.0 Inputs 4-20mA DC (2 wire)
7.0 Outputs 4-20mA DC
8.0 Capacity No. of Analog inputs
Other inputs *
Other outputs – Retransmission *
Max. No. of Alarms settings
9.0 Facia Details B.ar graph display with 4 digit 7 segment
LCD/LED digital display of PV.
9.1 Indications Continuos
Bargraph
Digital
Required for Process variable
10.0 Scan time 500 msec. Max
11.0 A/D converter Resolution 1500 steps min.
12.0 D/A converter Resolution 1500 steps min.
13.0 Load driving capability 750 ohms
14.0 Configuration From Indicator
15.0 On line diagnostic messages Required
16.0 Memory type If retentive:-
Erasive
Erasing by
If volatile:-
Battery backup for min. 72 hrs.
Battery type chargeable
Continuous.
Battery type chargeable
Configuration protection time (In case of power
failure)
Battery drain indication required.
17.0 Indicator functions
Arithmatic functions Addition / Subtraction
Multiplication
Division
Square Root
Bias
Summation (Integration)
Linearisation Sq. Root Extraction
Flow computation
(Press and Temp. compensation)
18.0 Power supply 24 V DC
19.0 Accuracy +/- 0.5%
20.0 Repeatability + / - 0.5 %
21.0 Qty. & Tag No. As per the P& ID and attached sheet.
22.0 Make & Model *
• - By contractor / vendor
1 08.03.2007
Data Sht.No.: MEC/23JT/05/E5/DS-IND
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
1 08.03.2007
Data Sht.No.: MEC/23JT/05/E5/DS-IND
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
5. ACCURACY ± 0.1%
6. POWER SUPPLY 24 V DC
8. OUTPUT LOAD DRIVING CAPACITY 750 Ohms MINIMUM FOR EACH OUTPUT
ZENER BARRIERS
5. SUPPLY VOLTAGE 24 V DC
6. FUSE RATING *
7. END TO END RESISTANCE *
8. POLARITY *
9. MOUNTING DIN RAIL (BACK OF THE PANEL)
1 08.03.07
Data Sht No. - MEC/23JT/05/E5/DS-ZB-01
REV. DATE BY CHKD APPD
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
ZENER BARRIERS
6. FUSE RATING *
1 08.03.07
Data Sht No. - MEC/23JT/05/E5/DS-ZB-02 REV DATE BY CHKD APPD
.
MECON LIMITED PROJECT: PADAMLA-GODHARA (HALOL)
DELHI NATURAL GAS PIPELINE (PGPL)
ZENER BARRIERS
2. APPLICATION INSTRUMENT TYPE & (i) Limit switches (SPDT snap action Micro type) –
QUANTITY
(ii) R/L status of AV-valves -
(iii) Push buttons for AV-Valves –
(iv) Pig Signaller –
(v) Spares –
5. SUPPLY VOLTAGE 24 V DC
6. FUSE RATING *
7. END TO END RESISTANCE *
8. POLARITY *
1 08.03.07
Data Sht No. - MEC/23JT/05/E5/DS-ZB-03 REV DATE BY CHKD APPD
.
PROJECT: PADAMLA-GODHARA (HALOL)
MECON LTD. DELHI
NATURAL GAS PIPELINE (PGPL)
CLIENT : GUJARAT STATE Data Sht. No.:
PETRONET LIMITED(GSPL) MEC/23JT/05/E5/DS-ANN
ALARM ANNUNCIATOR
GENERAL DISPLAY
1 TYPE Audio & Visual 12 Type Back Lighted Bull's Eye
Intrinsically
4 15 Window Size As per P& Id.
Safe
Area
5 Safe 16 Inscription Lines / Window
Classification
Character / Line
6 Cabinet Style Side Swing Door
OPTIONS
7 Volatage 24V DC, Pot. Free 17 Hooter Explosion Proof Gen Purpose ( X )
Intrinsically Safe Weather Proof
Integral Separate
POWER SUPPLY UNIT Pneumatic Solid State
8 Location With Logic / Separate Industrial Tone adj( X )
Volume Adj ( X )
9 Enclosure General Purpose Solenoid Valve for Hooter
Test ( X ) Acknowledge ( X )
LOGIC UNIT
Reset ( X ) Integral / Remote
11 Logic Integral ( X )
Remote 19 No. of Hooters One
Notes
1 . No. of Windows to be Decided by Vendor From P&ID and Control Panel Specifications. 10% Spare window shall be provided fully
wired upto Terminal Block in CP.
3. Vendor to Submit the List of Alarms in the Filled in the data Sheet for Review / Approval.
1 08.03.07
Data Sht. No.:MEC/23JT/05/E5/DS-ANN
REV DATE BY CHKD
APPENDIX-III
1. SCRAPPER TRAP
2. BALL VALVES
4. REDUCER
5. GLOBE VALVES
6. CHECK VALVES
7. ASSORTED PIPE
8. FLOW TEE
9. INSULATING JOINT
PO NO :
CLIENT TECH SPEC NO. : Manufacturing specification : API 5L 43RD Edition, 2004 & MECON Spec. No.: MEC/TS/D5/21/012D Rev-0
QAP NO : 05/28/23JT/M-001
SIZE
OD (MM) WALL THICK.(MM) SPECIFICATION GR
323.9 6.4 API 5L X-65 (PSL-2)
323.9 7.1 API 5L X-65 (PSL-2)
323.9 8.7 API 5L X-65 (PSL-2)
219.1 7.1 API 5L X-65 (PSL-2)
Approved By
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Page 2 of 11
QUALITY
ASSURANCE PLAN
Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
ii) Carbon Eqivalent (CE) Customer Tech. Spec. and 1 sample / heat CEL (PCM) < 0.2 Mill Test Certificate R R
CE(IIW) _< 4.0
API 5L Cl. 6.1.3 (Boron content shall be considered even it is
less than 0.001%)
iii)Tensile Test ASTM A 370 / API 5L Table- 1 sample / heat As per attached 'Annexure B' & Client Mill Test Certificate R R
3B/Cust Tech spec 6.2.1 Specification
iv) Grain Size ASTM A - 370 1 sample / heat ASTM 7 or final as per ASTM E-112 Mill Test Certificate R R
2 Mill Control i) Chem. Analysis Customer Tech. Spec.Cl 1 Sample/Heat As per attached 'Annexure A' Chemical Test Report W R
ii)Mill Control Tensile Test ASTM A 370 / API 5L Table- 1 Samples/Heat As per attached 'Annexure B' Mechanical Test Report W 10%W
3B/Cust Tech spec 6.2.1
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Page 3 of 11
QUALITY
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
iii) Flattening Test API 5L Cl 6.2.2 & 6.2.2 of 4 SAMPLES /COIL, 2 I) Flatten to 1/2 of original OD without weld Rolling Report W W
cust tech spec SAMPLE EACH FROM opening.
START AND LAST PIPE II) Continue flattening to 1/3 of Specified OD
OF COIL. THE without cracks other than in weld.
SAMPLES SHALL BE iii) Continue flattening until opposite walls of
FLATTENED AT 0 AND pipe meet. No evidence of lamination on
90 DEG. IN CASE OF material during the test.
WELD STOP, 1 SAMPLE
FROM EACH CROP END
SHALL BE TESTED AT
90 DEG
iv) Reverse Bend Test Customer Tech. Spec. One Sample Per coil A specimen which fractures completely Rolling Report W W
6.2.7 prior to the specified engagement of
mandral and specimen, or which reveals
cracks or ruptures in the weld or HAZ
longer than 4 mm shall be rejected.
Cracks less than 6 mm long at the
edges of the specimen shall not be
cause for rejection.
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Page 4 of 11
QUALITY
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
v) Hydrostatic Test Customer Tech. Spec.9.4 Each pipe( Calibration of No leakage for 15 sec. Holding Time Hydro Test Report and W W
pressure guage weekly) (Pressure calculation based on 95% SMYS). Graph
P=2St*0.95/D, where
S=SMYS Hydro
Pressure as per attached 'Annexure C'
vi) Cyclic Hydro Test Customer Tech. Spec. 9.4 1 Pipe every 500 pipes Testing shall be done as per approved Cyclic Test Report W W
including one PQT test procedures. There should not be any
pipe leakage or bulging of the pipes or flaring up
of the pipe ends.
vii) Burst Test Customer Tech. Spec. 9.4 one pipe for entire As per approved procedure Burst Test Report W W
at 130% of SMYS campaign (lowest Pressure as per attached 'Annexure C'
thickness)
viii) Product Analysis (Spectro) Customer Tech. Spec.Cl 2 Sample per Heat per lot As per attached 'Annexure A' Chemical Test Report W R
6.1.1 of 50 pipes. One at the
beginning of heat and one
at the end of heat.
ix) Tensile Test (Transverse Body ASTM A 370 / API 5L Table- 1/50 pipes/ heat As per attached 'Annexure B' Mechanical Test Report W W
& Transverse Weld) 3B/Cust Tech spec 6.2.1
x) Metallographic Examination
a) Microscopic/macro Analysis Customer Tech. Spec. 1/50 pipes/ heat No untempered martensite remains & Metellographic W W
6.2.6 uniformly distributed ferritic structure shall be Examination Report
established and fusion line shall be clearly
visible. Grain size shall be finer than 7.
Approved By
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Page 5 of 11
QUALITY
ASSURANCE PLAN
Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
b) Vicker Hardness Test-HV 10 Customer Tech. Spec. 1/50 pipes/ heat Maximum Hardness 250 HV 10 Max. The Metellographic W W
6.2.6 maximum difference in hardness between Examination Report
the base metal and any reading taken on
weld or HAZ shall be less than 80 HV 10
xi) Fracture Toughness Test( API 5L SR5 & Cust Tech One set per lot of 100 Absorbed energy at -20, 25 & 0 Impact Test Report W W
Charpy V-notch Impact Test-)- at 0 -Spec 6.2.5 pipes per Heat. Each set deg.Centigrade (for full size specimen ) as
20 and - 25 degree C for first day shall consisting of 3 per Appendix d' attached. and percentage
production from body, FL, FL+2 specimen with notch in shear area for base metal- min 75 %. And
and FL+ 4mm base material, . For 8" x Heat Average 85 % Minimum.
7.1, 3 specimen with
notch in base material,
pieces with notch in fusion
line, 3 pieces with notch in
fusion line+2 mm, Fusion
Line +4 mm.
b) Ends UT (Manual) do Each pipe, pipe weld at Ref Std. -1/4" Dia FBH for lamination & 1.6 -do- W W
ends (100 mm from both mm drilled hole for weld
ends) , sprayed portion in Acceptance Limit-100% of reference std.
auto UT , & 25 mm
circumferentially by TR
probe for lamination
Approved By
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Page 6 of 11
QUALITY
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
c) Pipe Body UT (Not mandatory if do 100 % Body each pipe Ref Standerd 35 x 8 x t/2 Flat Bottom Notch. Ultrasonic Test Report-Pipe W W
UT of skelp edge and body is Acceptance as per BS 5996 Body
done)
d) Magnetic Particle Inspection do Bevel Face & 100 mm No lamination and cracks. The Residual Magnetic Particle W 10%W
circumferential width from Megnetism shall not exceed 20 Gauss Inspection Report
the end measured by Gauss Meter.
e) Radiography ( X Ray) do 0.5% of length Reference Standered: ASTM Hole Type/ ISO X Ray Inspection Report W 100% Film review
Wire Type IQI. Acceptance Criteria:
Cracks, Lack of panetration , LOF and
imperfection greater in size and /or
distribution shown in table 21 & 22 of API 5L
shall be considered defect.. Such defect
shall be dispossed of AS per API 5L Cl 9.9
f) Manual UT of Pipe weld (100 % do One pipe in 200 pipes Ref Std. -1.6 mm drilled hole for weld Manual Ultrasonic Test W W
Weld seam) Acceptance Limit-100% of reference std. Report
xiv) Dimensions
a) Outer Dia. (mm) API 5L & Customer Tech. Once per four hr. Body: +/-2.4 mm Inspection Report W 10%W
Spec. 7.2 production in a shift End : -0.40 mm, +1.60 mm
-0.80 mm, +2.40 mm
b) Thickness(mm) Customer Tech. Spec.Cl Each Pipe Nominal Thickness -0.0%, +10.0% do W W
7.3 and annex. of spec.
d) Length Customer Tech. Spec. 7.5 Each Pipe 11.5-12.5 M with a average of 12 M do W 10%W
minimum. Sample pipe length 10.5 M is also
acceptable
e)Weight Table 10 of API 5L Each Pipe (+10%, -3.5%) of Standerd Weight do W 10%W
f) Out of roundness Cl 7.2 of cust tech spec Each Pipe -0.79 mm, +2 mm do W W
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Page 7 of 11
QUALITY
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
a)Dents API-5L Cl.7.8.1 & cust Each Pipe The depth of dent shall not be more than do W 10%W
Tech spec 7.8.1 3mm or grinding / jacking work shall not be
allowed on pipe to remove the dent. Dents on
weld and HAZ are not acceptable.
b) Off set of plate edges API-5L Cl.7.8.2 Each pipe Radial offset of plate edges plus flash trim do W 10%W
shall not be greater than 1.5 mm
c) Height of Flash API-5L Each Pipe The height of flash at weld seam shall be - do W 10%W
0, +1.0 mm.and Outside flash shall be
trimmed to flush condition.
d)Trimmed Inside Flash API-5L Cl.7.8.7 3 Times per operating The Depth of groove after the resulting of do W 10%W
shift internal flash shall be 0.40 mm max ,
e) Hard Spot API 5L Cl 7.8.8 Each Pipe Hardness Max 345 HV10 at hard spot. Min. do W 10%W
Dimension in any direction shall not be more
then 50.8 mm if it exceed then section of
pipe containing the hard spot shall be cut-off
as cylinder.
e) Cracks, Sweats and Leaks API 5L Cl 7.8.9 Each Pipe All cracks, sweats and leaks shall be Inspection Report W 10%W
considered defects.
f) Lamination API 5L Cl 7.8.10 Each Pipe No lamination > 6.4 mm at the bevel face, do W 10%W
Geater than 19.0 mm at the body of the pipe
and area not greater than 7742 mm2.
g) Arc Burn Cust Tech Spec. Cl 7.8.11 Each Pipe Arc burns are shall be buffed with wire brush do W 10%W
or sanding disc and etched with 5% nital
solution, however , not more than 3 arc burns
per pipe is permitted, However UT shall be
performed to check for harmful defects at arc
area.
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Page 8 of 11
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
h) Other Defects Cust Tech Spec. Cl 7.8.14 Each Pipe Any Imperfection depth >5 % of Wall do W 10%W
thickness shall be considered unacceptable
xvi) End Bevelling Cust Tech Spec. Cl 7.9.3 Each Pipe I) Bevel angel 32.5 deg. , (+2deg. ,-2 deg) do W 10%W
xvii) Marking API 5L Spec. Cl. 10 & Each pipe Marking shall be as per API 5l. Marking shall - W R
Customer Tech. Spec.10 be in English. It shall include Manufacturer’s
name, API monogram, Manufacturing date,
Nominal Diameter, Wall Thickness, Grade,
Hydrostatic test pressure, Pipe Number,
Heat Number, Length ASL No etc. Marking
shall be done by paint stencil on outside
surface. Additionally pipe no & Length shall
be marked on ID surface at one end by
Permanant marker.
xviii) Coating and End Protection As per PO Each Pipe Both ends of pipe shall be protected by - W -
plastic/Metallic end protectors. The pipe
shall be delivered bare.
xix) Pipe Loading API RP 5L1 The finished pipes shall be loaded on a - W -
trailor. The pipe shall be placed on wooden
blocks.
xx) Test Reports and Certifications API 5L Each Pipe - Mechanical, NDT, Hydro W R
Test Reports as per API
5L SR 15 and Raw
material TC
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Page 9 of 11
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
4 First Day Production Cust Spec. Annex.-II (New) Two pipe each from 3 As above W W
Tests Different Heats
I) Chemical Composition
a) Heat Analysis One per Heat
b) product Analysis Two per Heat
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Page 10 of 11
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Gujarat State Petronet Ltd. MECON Ltd.
QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
ANNEXURE A
Chemical Requirements
Element Maximum %
C 0.15
Mn 1.60
Si 0.45
S 0.01
P 0.02
Nb 0.05
V 0.05
Ti 0.10
Al 0.07
Cu 0.35
Ni 0.20
Mo 0.08
Cr 0.20
N 0.012
B 0.0005
V+Nb+Ti 0.15
Cu+Ni 0.4
AL/N 2 (Min)
CE 0.40
CE(Pcm) 0.20
Minimum for Si is not applicable for Aluminium Killed Steel
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Page 11 of 11
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QAP NO. : 05/28/23JT/M-001 SIZE :- SIZE: AS PER COVER PAGE
CLIENT:- GUJARAT STATE PETRONET LIMITED SPEC. AS PER COVER PAGE
ANNEXURE 'B'
Approved By
Prepared By Reviewed and Approved by
Page 1 of 1
* Notes : The frequency given above is applicable only if the heat lot is established alongwith original MTC. Otherwise all above test shall be done for each pipe.
2 Raw Material 1 Manufacturing process of steel Critical Varification with M.T.C. Each Heat Appl. Material As per tender Material Test R R MTC Register
Specification / STD document / Material Certificate and MI Tractability to be
Specification / STD Register checked.
2 Chemical Composition Spectro Analysis Each Heat
3 Forgins 1 Reduction Ratio Critical Measurement Minimum 1 per size Standard Manufacturing Std. Procedure Forging process P R
Procedure record / internal
Register
2 Temperature During Forging Optical Pyrometer As per Std. AMSE
B16.5
3 Forging Dimensions Measurement
4 Heat Treatment (as Heat Treatment Cycle Major Verification of Heat Each Heat / HT Lot As per Tender Doc. / As per Tender Doc. / T.P.M. Sheet, Heat P/W R Test Specimen to
applicable) Treatment Cycle Material Specification / Material Specification / Treatment Graph Mark after Verification
STD STD to Heat Treatment.
5 Mechanical Testing 1 Tensile Test (TS, YS, RA%, Major Tensile Testing One / HT / Lot / Group As per Tender Doc. / Std. Procedure Mechanical Test H W
(as applicable) EL%) Material Specification / Report & T.C.
STD
2 Hardness IMPACT Testing As per Material As per Material
Specification ASTM Specification ASTM
A350 LF2 A350 LF2
3 IMPACT (-20 °C)
6 NDT 1 DP Major DP Testing 100% ASTM E-165 As per article 9.2 of Mechanical Test W W
appendix 9 of ASME Report & T.C.
Spec. VIII, Div. 2
2 UT Ultrasonic Flaw ASTM E-388 AM 203.2 of ASME
Detector Spec. VIII, Div. 2
3 MPI MPI Testing ASTM A-275 As per article 9.1 of
appendix 9 of ASME
Spec. VIII, Div. 2
7 Final Inspection Visual & Dimensions Major Visual / Measurement 100% As per Tender Doc. / As per Tender Doc. / Dimension Report P/W W
Material Specification / Material Specification / Format
STD STD
8 Making, Colour Making, Colour Coding, Rust Major Visual 100% As per Tender Doc. / As per Tender Doc. / Packing List & Ruboff P/W R
Coding, Rust Prevension & Packing Material Specification / Material Specification / 1 item per size
Prevension & STD STD
Packing
9 Certification TPI Inspection Release Note & Major Verification of PO 100% As per Tender Doc. / As per Tender Doc. / Release Note & TC P P
TC Spec. & QAP Material Specification / Material Specification /
STD STD
10 Shipping Verification of surface coating / Major - - As per Tender Doc. / As per Tender Doc. / Shipping documents P -
type of packing Material Specification / Material Specification /
STD STD
LEGENDS : W : WITNESS, M : MONITOR, R : REVIEW, P - PERFORM, TPIA : INSPECTION AGENCY, SPEC.: TECHNICAL SPECIFICATION
2 Raw Material 1 Manufacturing process of steel Critical Varification with M.T.C. Eact Heat Appl. Material As per tender Material Test R R MTC Register
Specification / STD document / Material Certificate and MI Tractability to be
Specification / STD Register checked.
2 Chemical Composition Spectro Analysis Eact Heat
3 Forgins 1 Reduction Ratio Critical Measurement Minimum 1 per size Standard Manufacturing Std. Procedure Forging process P R
Procedure record / internal
Register
2 Temperature During Forging Optical Pyrometer As per Std. AMSE
B16.5
3 Forging Dimensions Measurement 100%
4 Heat Treatment (as Heat Treatment Cycle Major Verification of Heat Each Heat / HT Lot As per Tender Doc. / As per Tender Doc. / T.P.M. Sheet, Heat P/W R Test Specimen to
applicable) Treatment Cycle ASTM A694 F 65 or ASTM A694 F 65 or Treatment Graph Mark after Verification
A860 WPHY 65 A860 WPHY 65 to Heat Treatment.
5 Mechanical Testing 1 Tensile Test (TS, YS, RA%, Major Tensile Testing One / HT / Lot / Group As per Tender Doc. / As per Tender Doc. / Mechanical Test H W
(as applicable) EL%) Material Specification / Material Specification / Report & T.C.
STD STD
2 Hardness IMPACT Testing As per Material As per Material
Specification ASTM Specification ASTM
A350 LF2 A350 LF2
3 IMPACT (-20 °C)
6 NDT 1 DP Major DP Testing 100% ASTM E-165 As per article 9.2 of Mechanical Test W W
appendix 9 of ASME Report & T.C.
Spec. VIII, Div. 2
2 UT Ultrasonic Flow ASTM E-388 AM 203.2 of ASME
Detector Spec. VIII, Div. 2
3 MPI MPI Testing ASTM A-275 As per article 9.1 of
appendix 9 of ASME
Spec. VIII, Div. 2
7 Final Inspection Visual & Dimensions Major Visual / Measurement 100% As per Tender Doc. / ASME B16.5 / ASME Dimension Report P/W W
Material Specification / B16.47 A Format
STD
8 Making, Colour Making, Colour Coding, Rust Major Visual 100% As per Tender Doc. / As per Tender Doc. / Packing List & Ruboff P/W R
Coding, Rust Prevension & Packing Material Specification / Material Specification / 1 item per size
Prevension & STD STD
Packing
9 Certification TPI Inspection Release Note & Major Verification of PO 100% As per Tender Doc. / As per Tender Doc. / Release Note & TC P P
TC Spec. & QAP Material Specification / Material Specification /
STD STD
10 Shipping Verification of surface coating / Major - - As per Tender Doc. / As per Tender Doc. / Shipping documents P -
type of packing Material Specification / Material Specification /
STD STD
LEGENDS : W : WITNESS, M : MONITOR, R : REVIEW, RW : RANDOM WITNESS, TPIA : INSPECTION AGENCY, SPEC.: TECHNICAL SPECIFICATION
4 Heat Treatment As per Tender Doc. / As per Tender Doc. / Material Spec. P R
Material Spec.
5 Visual Test As per Tender Doc. / As per Tender Doc. / Material Spec. P 10% W
Material Spec. 100% R
6 Mechanical Test As per ASTM A370 / As per ASTM A370 / Tender Doc. P 10% W
Tender Doc. 100% R
7 Impact Test (at -20 °C) As per Tender Doc. As per Tender Doc. P 10% W
100% R
8 NDT Test As per Tender Doc. / As per Tender Doc. / Material Spec. P 10% W
Material Spec. 100% R
LEGENDS : R : REVIEW, W : WITNESS, H - HOLD, P : PERFORM, TPIA : INSPECTION AGENCY, SPEC.: TECHNICAL SPECIFICATION
Notes :
1 The above Testing and acceptance criteria are minimum requirements, however, equipment shall ensure and that the product also
comply to the additional requirements as per Technical Specifications and data sheets.
2 The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA.
3 Supplier shall submit calibration certificates of all Instruments / Equipments to be usd for Inspection and Testing to TPIA with relevant procedures and updates
standards for TPIA review / approval.
4 TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA alongwith with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / drawings etc. submitted by supplier.
6 Contractor shall in coordination with Supplier / Sub vendor shall issued detailed Production and Inspection schedule including the dates and the locations to
facilite Owner / Owner's representative and TPIA to organise Inspection.
4 Low temperature certificate charpy test ASTM A-370 2 Certificate with impact test P 100% W
35 J/cm (A) / 28
at -20°C J/cm2(S)
5 HT Each heat treatment batch ASTM A-370 API / ASTM Certificate P 100% W
Notes :
1 The above Testing and acceptance criteria are minimum requirements, however, equipment shall ensure and that the product also
comply to the additional requirements as per Technical Specifications and data sheets.
2 The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative.
3 Supplier shall submit calibration certificates of all Instruments / Equipments to be usd for Inspection and Testing to TPIA with relevant procedures and updates
standards for TPIA review / approval.
4 TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA alongwith with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / drawings etc. submitted by supplier.
6 Supplier shall in coordination with sub vendor shall issued detailed production and Inspection schedule including the dates and the locations to
facilite Owner / Owner's representative and TPIA to organise Inspection.
7 Certification requirements shall comply with European Standard EN 10204 (latest edition).
LEGENDS : P - PERFORM, R - REVIEW, W - WITNESS, H - HOLD TPIA - THIRD PARTY INSPECTION AGENCY
Notes ;-
1 The Above Testing and acceptable criteria are minimum requirement, however, equipment supplier shall ensure and that the product also comply to the additional requirements as per Technical specifications and data sheets.
2 The supplier shall submit their own details QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA.
3 Supplier shall submit Calibration certificates of all Instruments/Equipments to be used for Inspection and Testing to TPIA with relavent procedures and update standards for TPIA review / Approval.
4 TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA along with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / Drawings etc. submitted by supplier.
6 Contractor shall in coordination with Supplier / Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilities Owner/Owner's representative and TPIA to organise Inspection.
1.3 STEM PHY. TEST PER HEAT AS PER APR DRG. / TENDER DOC. AS PER APR DRG. / TENDER DOC. LAB T.C. P W
IMPACT TEST
PER HEAT AS PER TENDER 35 / 28 JOULE INSPECTION REPORT P W
(-20oC)
CHEM. TEST PER HEAT AS PER DATA SHEET 35 / 28 JOULE SUPPLIER TEST CERTIFICATE R R
PHY. TEST PER HEAT AS PER DATA SHEET AS PER DATA SHEET SUPPLIER TEST CERTIFICATE P W
1.4 PUP PIECE VISUAL 100% AS PER DATA SHEET CERTIFICATE W W
IMPACT TEST
PER LOT ASTM A 370 / GTS / PTS 35 / 28 JOULE SUPPLIER T.C. P W
(-20oC)
2 INTERMEDIATE AUDIT
TRANSFER OF HEAT NO. 100% PROCESS CARD 100% W R/W
R R
2.1 BODY & SIDE PIECE W-1
DIMENSIONS 100% APPVD. DRG APPVD. DRG INSPECTION REPORT
w sample per
size per lot
2.2 BALL & SEAT RING TRANSFER OF HEAT NO. 100% APPVD. DRG APPVD. DRG INSPECTION REPORT W R/W
2.3 STEM DIMENSIONS 100% APPVD. DRG APPVD. DRG INSPECTION REPORT W R/W
RADIOGRAPHY 100% ASME / ANSI B 16.34 / API 6D ASME / ANSI B 16.34 / API 6D INSPECTION REPORT W R/W
2.4 PUP PIECE WELDING
VISUAL 100% ASME / ANSI B 16.34 ASME / ANSI B 16.34 INSPECTION REPORT W R/W
3 BROUGHT ITEM
3.1 CHEMICAL PER LOT A 320 GR. L7 & 194 GR. 7 A 320 GR. L7 & A 194 GR. 7 SUPPLIER T.C. R R
3.2 PHYSICAL PER LOT A 320 GR. L7 & 194 GR. 7 A 320 GR. L7 & A 194 GR. 7 SUPPLIER T.C. P W
3.3 FASTERNS DIMENSIONS 10% P W
IMPACT TEST
3.4 PER LOT ASTM A 370 / A 194 GR 7 AS PER TENDER DOC. SUPPLIER T.C. P W
(-20oC)
3.5 HEAT TREATMENT 100% ASTM A 370 AS PER CODE HEAT TREATMENT REPORT P W
Notes ;-
1 The Above Testing and acceptable criteria are minimum requirement, however, equipment supplier shall ensure and that the product also comply to the additional requirements as per Technical specifications and data sheets.
2 The supplier shall submit their own details QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA.
3 Supplier shall submit Calibration certificates of all Instruments/Equipments to be used for Inspection and Testing to TPIA with relavent procedures and update standards for TPIA review / Approval.
4 TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA along with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / Drawings etc. submitted by supplier.
6 Contractor shall in coordination with Supplier / Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilities Owner/Owner's representative and TPIA to organise Inspection.
Note :
1 The above testing and acceptance criteria are minimum requirements, however, equ supplier shall ensure and that the product also comply to the additional requirements as per technical specifications and data sheets.
2 Supplier shall submit their own detailed QAP prepared on the basis of the above for approval of owner/owner's representative.
3 Supplier shall submit Caliberatio certificates of all instruments/equipments to be used for inspection and testing to TPIA with relevant procedures and updated standards for TPIA review/approval.
4 TPIA will have right to inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA along with Owner/Owner's Representative shall review/ approve all the documents related to QAP/Quality Manuals/Drawings etc. submitted by supplier.
6 TPIA shall also review the Test certificates submitted by the Actuator manufacturer.
7 Contractor shall in coordination with Supplier/Sub Vendor shall issue detailed Production and Inspection Schedule indicating the dates and the locations to Facilitate Owner/Owner's Representative and TPIA
to organise Inspection.
7 Bare pipe receipt at mill, handling & Each pipe As per TS No. PACKING LIST & TS No. MEC/S/05/62/014 & approved procedure VISUAL H M
storage etc. MEC/S/05/62/014 Test report
8 PROCEDURE QUALIFICATION TESTS:- BEFORE START OF REGULAR PRODUCTION 5 PIPES TO BE COATED (4 PIPES FULLY COATED WITH 3LPE AND ONE PIPE COATED PARTLY WITH EPOXY & PARTLY WITH EPOXY & ADHESIVE).
8.1 Bare pipe stacking & handling in Each pipe PE sheet over sand row Teflon STOCK REGISTER TS No. MEC/S/05/62/014 & approved procedure VISUAL H M
yard/plant padded hooks
8.2 Bare pipes receiving surface defect, Bevel Each pipe No defects, damages, Data sheet TS No. MEC/S/05/62/014 Visual solvent H W
damage, Grease/ oil on surface oil/grease on pipe surface etc. cleaning for pipes
with oil grease
8.3 repair of Bare pipes defects pipes removed for defects As per API 5L & pipe Approved procedure Bevel cutting m/c, H W
Specification Jacks etc.
8.4 Pre heating All pipes 65 - 850C Data sheet Cl. no. 8.4 of TS & approved procedure LPG Burner, contact H R/W
thermometer
8.5.1 Ambientemp., Relative humidity, Dew Each pipe RH should be less than 85% Data sheet TS No.MEC/S/05/62/014 and approved procedure. thermo hygrometer, H R/W
point & Elapsed time (IF RH> 85% no shot blasting). Dew point apparatus
8.5.2 phosphoric Acid treatment Each pipe pH = 1-2, Pipe temp prior to Data sheet Cl. No. 8..6.2 of TS approved procedure PH paper, contact H R/W
phosphoric acid treatment = 45- thermometer
750C or as manuf.
Recommendation.
8.5.3 DM water wash Each pipe pH = 6.0-7.0, pipe surface Data sheet TS No. MEC/S/05/62/014 PH paper H R/W
should be dried
8.5.4 Cleaniness Each pipe SA 2½ Data sheet Cl no.8.7 of TS and approved procedure ISO - 8501-1 H R/W
8.5.5 Degree cf dust Each pipe Rating 2 or Class 2 Data sheet Cl no.8.7 of TS and approved procedure ISO - 8502-3 H R/W
8.5.6 Surface roughness Each pipe 50 - 70 µm (Rz) Data sheet Cl no.8.7 of TS and approved procedure Surface Profile H R/W
gauge, Hand held
30X magnifying
glass
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QAP NO :05/21/JT/3LPE Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPE COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
8.5.7 Bare pipe temp. Every pipe 0
180-230 C or as per manuf. Test report TS No. MEC/S/05/62/014 & approved procedure contact thermometer H R/W
Recommendation
8.5.8 Bare pipe temp. after Epoxy application by Every pipe by online pyrometer 190-230 0C or as per - TS No. MEC/S/05/62/014 IR Optical pyrometer H R/W
IR thermometer recording manufacturer recommendation
9 TEST ON COATED PIPES PARTLY WITH EPOXY AND PARTLY WITH EPOXY & ADHESIVE LAYERS
9.1 Epoxy layer thickness One pipe at 3,6,9,12 positions 180µm min. Test report Sl. No. 3 of amendment-1 to TS & as per approved Coating thk. gauge H W
procedure
9.2 Adhesive Layer thk. One pipe at 3,6,9,12 positions 200µm min. Test report Sl. No. 3 of amendment-1 to TS & as per approved Coating thk. gauge H W
procedure
9.3 Degree of cure One pipe(one sample) ∆Tg = +3, -20C Test report Cl. no. 7.5.1.(a) of TS DSC Machine H W
% cure = 95% min.
9.4 Adhesion test (St. Andrews cross Method) One pipe Rating -1-3 Test report Cl. no. 7.5.1.(e) of TS Utility knife H W
10.2 Bond strength test at ends & middle Three pipe @ 20+50C = 8 Kg/Cm Test report Cl. no. 7.5.2.(a) of TS & approved procedure Peel test M/C by H W
0
@65+5 C = 5 KG/Cm dynamometer (type-
2)
10.3 Degree of cure One pipe (One sample) ∆Tg = 3, -20C Test report Cl. no. 7.5.2.(e) of TS & approved procedure DSC Machine H W
% cure = 95% min.
10.4 Impact strength Three pipe 7 Joules/mm Test report Cl. no. 7.5.2.(b) of TS & approved procedure Impact tester H W
10.5 Indentation test Twp sample for both temp. from 0.2 max. at 23+ 20C Test report Cl. no. 7.5.2.(c) of TS & approved procedure Controlled temp, H W
4 pipes 0.3 max. at 70+ 20C bath, Dial Gauge,
weight
10.6 Elongation at failure Three PE coated pipes only (5 300% min. Test report Cl. no. 7.5.2 (d) of TS & approved procedure Tensile M/C H W
samles from each pipe)
10.7 Cathodic Disbondment test Two samples for 30 days at 60 0 ECR = 15 mm max. (for 30 Test report ASTM G-42 & sl. No. 01 of amendment-1 of TS No. CD, test assembly H W
+ 30C, one sample for 48 hrs. at days) - at 60 0C+ 30C MEC/S/05/62/014
0
600 + 30C 7 mm max. (for 48 hrs. at 60 C
+ 30C
10.8 Holiday test at 25 kv All pipes Max. + 30C One holiday Test report Cl. no. 7.5.2(f) of TS & approved procedure Holiday detector H W
surface area < 0.01 sq.mtrs.
(repair as per approved
Procedure)
10.9 Over all Coating Thickness All pipes 3.2mm on Body (S-v) Test report Cl. No. 7.5.2.(g) of TS & Sl. No. 03 of Coating thk. gauge H W
ammendment-1 to TS no. MEC/S/05/62/014
10.10 Air entrapment at 30X magnification All pipes Polyethylene and adhesive Test report Cl. no. 7.5.2.(h) of TS No. MEC/S/05/62/014 30X magnification H W
layers shall have not more hand-held
than 10% of the observed microscope
area.
10.11 Visual inspection All pipes No defect (Blisters, pinholes Test report TS no. MEC/S/05/62/014 Visual H W
scratches, wrinklee etc.)
10.12 Cut back length All pipes 110 mm, (+)20, (-) 0 mm Test report Sl. No. 04 of ammendment-1 to steel Scale H W
TS no. MEC/S/05/62/014
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QAP NO :05/21/JT/3LPE Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPE COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
B REGULAR PRODUCTION
BARE PIPES AT INLET
1 Bare pipe stacking & handling in Each pipe PE sheet over sand row Teflon STOCK REGISTER TS no. MEC/S/05/62/014 & approved procedure VISUAL H M
yard/plant padded hooks
2 Bare pipes receiving surface defect, Bevel Each pipe No defects, damages, Data sheet TS no. MEC/S/05/62/014 & approved procedure Visual solvent H M
damage, Grease/ oil on surface oil/grease on pipe surface etc. cleaning for pipes
with oil
3 repair of Bare pipes defects pipes removed for defects As per API 5L & pipe - API 5L & pipe specification Bevel cutting m/c, H W
Specification Jacks etc.
4 recording of pipe parameters and tick off Each pipe Clear visibility OF STENCIL Test report Mill packing list Visual & white paint H M
against mill packing list. MARKING
5 Pre heating All pipes 0
65 - 85 C Data sheet Cl. no. 8.4 of TS & approved procedure LPG Burner, contact H R/W
thermometer
2 phosphoric Acid treatment Each pipe pH = 1-2, Pipe temp prior to Data sheet Cl. no. 8.6 of TS & approved procedure PH paper, contact H R/W
phosphoric acid treatment = 45- thermometer
0
75 C or as per manuf.
Recommendation.
3 DM water wash Each pipe pH = 6.0-7.0, pipe surface Data sheet TS no. MEC/S/05/62/014 PH paper H R/W
should be dried
4 Cleaniness Each pipe SA 2½ Data sheet Cl. no. 8.7 of TS no. MEC/S/05/62/014 & approved ISO - 8501-1
procedure H R/W
5 Degree of dust Each pipe Rating 2 or Class 2 Data sheet Cl. no. 8.7 of TS no. MEC/S/05/62/014 & approved ISO - 8502-3
procedure H R/W
6 Surface roughness Each pipe & one in 50 pipes by 50 - 70 µm (Rz) Data sheet Cl. no. 8.7 of TS & approved procedure Surface Profile
press-o-film gauge, Hand held
30X H R/W
D. COATING APPLICATION
1 Bare pipe temp. Every pipe 180 - 230 0C or as per powder Data sheet TS No. MEC/S/05/62/014 & approved procedure contact thermometer
manufacturer recom. H R/W
2 Bare pipe temp. after Epoxy application by Every pipe by online pyrometer. 190-230 0C or as per powder - TS No. MEC/S/05/62/014 & approved procedure IR Optical phrometer
IR thermometer Recording every one hour. manufacturer recommendation
H R/W
3 Adhesive film temperature. Every hour. 200 - 240 0C or as per Test report TS no. MEC/S/05/62/014 Optical
manufacturer recom. pyrometer/digital
thermometer H R/W
4 PE film temperature. Every hour. 220-270 0C or as per Test report TS no. MEC/S/05/62/014 Optical
manufacturer's pyrometer/digital
recommendation. thermometer H R/W
5 Recording of batch no.'s of Epoxy, Every hour. As per standard data Test report Manufacturer's test certificate visual
Adhesive Polyethylene H M
E. ON LINE INSPECTION & TESTING
1 Epoxy layer thickness Every shift at 3,6,9,12 positions Epoxy thk. - 0.18mm min. Test report Cl. no. 10.3 of TS & approved procedure Coating thk. Gauge. R/W
Adhs. Thk. - 0.20mm min. H
2 Holiday test at 25 kv All pipes Max. one holiday surface area Test report Cl. no. 10.4 of TS & approved procedure Holiday detector R/W
< 0.01 sq. mtrs.
(repair as per approved
procedure) H
3 Over all Coating Thickness All pipes 3.2mm on Body (S-v) Test report Sl. no. 03 of ammendment-1 to TS no. Coating thickness W
MEC/S/05/62/014 gauge H
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE Padmala - Godhra Pipeline of GSPL Page 3 of 5
QAP NO :05/21/JT/3LPE Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPE COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
F. OFF LINE TESTS
1 Impact test. (30 Impacts) at 30mm Two pipes per shift. 7J/mm Impact energy (No Cl. no. 10.5 of TS & approved procedure Impact test
intervals. holiday shall be observed at instrument
25KV at impact area.) Test report H W
2 Resistance to peel test at cut back ends. One in 50 pipes. Peel strength at 20 + 50C - Cl. no. 10.6 & amendment-1 to TS no. Peel test Machine,
8.0Kg/cm min. MEC/S/05/62/014 chisel etc.
Peel strength at 60 + 50C -
5Kg/cm min. Test report H W
3 Resistance to indentation test (Two Two pipes per shift. At 23+20C = 0.2mm Test report Cl. no. 10.7 of TS & as per approved procedure Indentation bath
samples for each temp.) At 70+20C=0.3mm heater, dial gauge,
thermostate H W
4 Air entrapment at 30X magnification One sample per shift Cl. no. 10.8 of TS. 30X magnification
Polyethylene and adhesive hand-held
layers shall have no more than microscope
10% of the observed area. Test report H W
5 Degree of cure Once per shift ∆Tg = 3, -20C Cl. no. 10.9 of TS DSC M/C
% cure = 95% min. Test report H W
6 Adhesion test (St. Andrews cross Method) Once per shift Test report Cl. no. 10.10 of TS Utility knife H W
7 Cathodic Disbondment test Every batch no. of epoxy Max. Disbondment radius 7 Test report Cl. no. 10.11 of TS & approved procedure Test vessel D.C. H W
powder. mm (At 650C + 30C for 48 votage supplier
hours. electrodes etc.
G. FINAL INSPECTION
1 Cut back length at ends. Each pipes 110 mm, (+)20, (-) 0 mm Test report Cl. no. 9.2.11 & sl. no. 04 of amendment-1 to TS Measuring tape, W M
no. MEC/S/05/62/014 scale etc. and visual
2 Marking on caoted pipes external color Each pipes Proper information on coated As per TS No. Spray gun, stencil paper etc. H M
band surface (ME side) I.e. as MEC/S/05/62/014
follows. (1 mtr. From end
PROJECT ……PIPE DIA…
WALL THK….
PIPE NO… LENGTH…HEAT
NO……..
COATING No….COLOUR
BAND, ANY OTHER
INFORMATION CONSIDERED
RELEVANT BY COMPANY
2 Storage Each pipes Proper stacking on sand rows STOCK REGISTER TS no. MEC/S/05/62/014 --do-- H R/W
covered with PE sheets with
stack separator.
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE Padmala - Godhra Pipeline of GSPL Page 4 of 5
QAP NO :05/21/JT/3LPE Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPE COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
J. CALIBRATION OF EQUIPMENT
1 Digital thermometer Every month. Add or subtract the observed Test report Ref. Thermometers, H R/W
value w.r.t. reference water/ oil bath etc.
measurement.
2 Thickness gauge. Every month. ----di--- Test report ref. Thickness foils, H R/W
steel
3 Roughness gauge Every month. ----di--- Test report Standard roughness H R/W
4 Holiday detector Every month. By spark gap method Test report Spark gap assmbly/ H W
Calibrated meter
5 Hygrometer Once in four month By spark gap method Test report
6 D meter Every time before use By standard thickness block Test report H W
Raw Material Combination to be used During Production as per ANNEXURE - 1 of TS no. MEC/S/05/62/014
LEGEND : W = WITNESS; H = HOLD; M = MONITORING; R = REVIEW OF DOCUMENTS; R/M = RANDOM CHECK; A = APPROVED; TPIA = THIRD PARTY INSPECTION AGENCY
Notes:-
1 The above Testing and acceptance criteria are minimum requriements, however, equipment supplier shall ensure and that the product also comly to the additional requirements as per Technical Specifications and data sheets.
2 The supplier shall submit their own detailed QAP prepared on the basis of the aboe for approval of Owner/Owner's representative and TPIA.
3 Supplier shall submit Calibration certificates of all instruments/Equipments to be used for inspection and Testing to TPIA with relevent procedures and updated standards for TPIA review/Approval.
4 TPIA will have Right to inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/drawigs etc. submitted by suppler.
6 Contractor shall in coordination with Supplier/Sib vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitaate Owner/Owner's representative and TPIA to organise inspection.
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE Padmala - Godhra Pipeline of GSPL Page 5 of 5
QAP NO : 05/21/JT/3LPP Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPP COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
A. PRIOR TO REGULAR PRODUCTION
1 Quality control test plan Before production - - TS/ Approved Procedure - H R
2 repair procedure - - - TS/ Approved Procedure - H R
3 Handling, Storage & transportation of bare - - - TS/ Approved Procedure - H R
and coated pipes procedure
4 Raw material acceptance review of test Each Batch certificate Raw material manufacturer's Raw Material TS no. MEC/S/05/21/014B VISUAL R R
cetificates for Epoxy, Adhesive, Poly test certificates. manufacturer's test INSPECTION FOR
propy,ene & repair product. certificates. MARKING
5 Test of raw material Each batch As per manufacturer Test report Cl. No. 4 of TS MEC/S/05/21/014B - H W
(Epoxy, adhesive & Poly propylene & recommednation & TS NO.
repair product) MEC/5/05/62/014B
6 Storage All Materials Manufacturer Recommendation STOCK REGISTER TS/ Approved Procedure - H M
7 Bare pipe receipt at mill, handling & Each pipe As per TS PACKING LIST & Test TS/ Approved Procedure VISUAL H M
storage etc. report
8 PROCEDURE QUALIFICATION TESTS:- BEFORE START OF REGULAR PRODUCTION 5 PIPES TO BE COATED (4 PIPES FULLY COATED WITH 3LPE AND HDPE, ONE PIPE COATED PARTLY WITH EPOXY & PARTLY WITH EPOXY &
ADHESIVE).
8.1 Bare pipe stacking & handling in Each pipe As per Cl. No.10 of TS TS/ Approved Procedure VISUAL H M
yard/plant
8.2 Bare pipes receiving Each pipe No defects, damages, oil/grease Data sheet TS/ Approved Procedure Visual solvent H W
surface defect, Bevel damage, Grease/ oil on pipe surface etc. cleaning for pipes
on surface with oil grease
8.3 repair of Bare pipes defects pipes removed for defects As per API 5L & pipe API 5L/ Pipe Specficiation Bevel cutting m/c, H W
Specification Jacks etc.
8.4 Pre heating All pipes 65 - 850C Data sheet TS/ Approved Procedure LPG Burner, contact H R/W
thermometer
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP Padmala - Godhra Pipeline of GSPL Page 1 of 5
QAP NO : 05/21/JT/3LPP Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPP COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
8.5.7 Bare pipe temp. Every pipe 0
185 - 210 C for liquid epoxy coat Test report TS/ Approved Procedure contact thermometer H R/W
0
130-200 C for powder epoxy
coat or as per manuf.
Recommendation
8.5.8 Bare pipe temp. after Epoxy application by Every pipe by online 190-2300C or as per - TS/ Approved Procedure IR Optical phrometer H M
IR thermometer pyrometer recording powdermanufacturer
recommendation
9 TEST ON COATED PIPES PARTLY WITH EPOXY AND PARTLY WITH EPOXY & ADHESIVE LAYERS
9.1 Epoxy layer thickness One pipe at 3,6,9,12 0.18 mm min. Test report TS/ approved procedure Coating thk. gauge H W
positions
9.2 Adhesive Layer thk. One pipe at 3,6,9,12 0.20 mm min. Test report TS/ approved procedure Coating thk. gauge H W
positions
9.3 Degree of cure One pipe(one sample) △ Tg = +3, -2 C
0 Test report TS/ Approved Procedure DSC Machine H W
% cure = 95% min.
9.4 Adhesion test Two locations Rating -1-3 Test report TS/ Approved Procedure Utility knife H W
9.5 Electrical Porosity at 25 KV One pipe No defects Test report TS/ Approved Procedure DC Holiday detector H W
9.6 2.50 Flexibility test One pipe ( 3 Specimens) No Cracking Test report TS/ Approved Procedure Hydraulic, press/ H W
binding manfa. Etc.
9.7 Cross section & Interface porosity test One pipe ( 3 Specimens) Rating - 1-4 Test report TS/ Approved Procedure Microscope knife H W
etc.
10 TEST ON COATED PIPES WITH ALL THREE LAYERS
10.1 U.V. Aging Each pipe Larger than 390% Test report ASTM D 638/ NF A - 49-74 - R R
10.2 Overall Thickness Each pipe 3.2 mm Test report TS/ Approved Procedure Magnatic/ H W
electromagnatic type
over lap measuring
instrument
10.3 Cut back Each pipe 110 mm , + 20 mm Test report TS/ Approved Procedure Steel tape H W
10.4 Electrical Porosity at 25 KV Each pipe no defects Test report TS/ Approved Procedure DC holiday H W
10.5 Impact Test Three pipe > 15 Nm / mm Test report TS/ Approved Procedure Pile Hammer H W
10.6 Rockwell Hardness Each pipe > 60 Test report TS/ Approved Procedure H W
10.7 Resistance to peeling Each pipe 0 Test report TS/ Approved Procedure r Dynometer H W
> 500 N/ 50 mm 50+5 C
0
> 400 N/50 mm 90+5 C
10.8 Indentation All pipes 0 Test report TS/ Approved Procedure H W
< 0.1 mm at 25 C
0
<0.3 mm at 100 C
10.9 Bendability Each pipe No holiday, no crack, no surface Test report TS/ Approved Procedure Bending Machine H W
defect
10.10 Cathodic disbonding Three samples < 15 mm after 60 days Test report TS/ ASTM G8 H W
< 7 mm after 48 hrs.
10.11 Coating Specific Resistivity Each pipe 8 2 Test report TS/ NFA 49-711 As Per TS H W
> 10 ohm x m
10.12 Elongation at Break Two pipes CL. No.5.3.4 (d) of TS Test report Cl . No.7.5.2 (d) of TS As per TS H W
10.13 Air entrapment Each pipe 10% thickness Test report Cl. No. 7.5.2 (h) of TS 30x microscopr H W
10.14 Digree of cure One pipe △Tg = +3, -2% cure - 95% min. Test report Cl. No. 7.5.2 (i) of TS DSC Machine H W
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP Padmala - Godhra Pipeline of GSPL Page 2 of 5
QAP NO : 05/21/JT/3LPP Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPP COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
B REGULAR PRODUCTION
BARE PIPES AT INLET
1 Bare pipe stacking & handling in Each pipe - TS/ Approved Procedure VISUAL H M
yard/plant
2 Bare pipes receiving surface defect, Bevel Each pipe No defects, damages, oil/grease Data sheet TS/ Approved Procedure Visual solvent H M
damage, Grease/ oil on surface on pipe surface etc. cleaning for pipes
with oil
3 Repair of Bare pipes defects pipes removed for defects As per API 5L & pipe - TS/ Approved Procedure Bevel cutting m/c, H W
Specification Jacks etc.
4 Recording of pipe parameters and tick off Each pipe Clear visibility OF STENCIL Test report Mill packing list Visual & white paint H M
against mill packing list. MARKING
5 Pre heating All pipes 65 - 850C Data sheet TS/ Approved Procedure LPG Burner, contact H W
thermometer
2 Phosphoric Acid treatment Each pipe pH = 1-2, Pipe temp prior to Data sheet TS/ Approved Procedure PH paper, contact H R/W
phosphoric acid treatment = 45- thermometer
0
75 C or as manuf.
Recommendation.
3 DM water wash Each pipe pH = 6.0-7.0, pipe surface Data sheet TS/ Approved Procedure PH paper H R/W
should be dried
4 Cleaniness Each pipe SA 2½ Data sheet TS/ Approved Procedure ISO - 8501-1 H R/W
5 Degree of dust Each pipe Rating 2 or Class 2 Data sheet TS/ Approved Procedure ISO - 8502-3 H R/W
6 Surface roughness 4 per shift on each of the first 50 - 70 µm (Rz) Data sheet TS/ Approved Procedure Surface Profile
25 pipes gauge, Hand held
30X H R/W
D. COATING APPLICATION
1 Bare pipe temp. before epoxy application Every pipe 0 Test report contact thermometer
210 - 220 C or as per powder
manufacturer recom. TS/ As per Approved Procedure H R/W
2 Bare pipe temp. after Epoxy application by Every pipe by online 185-2100C or as per powder - IR Optical phrometer
IR thermometer pyrometer. Recording every manufacturer recommendation
one hour. TS/ Approved Procedure H R/W
3 Adhesive film temperature. Every hour. 0 Test report Optical
180 - 230 C or as per
manufacturer recom. pyrometer/digital
TS/ Approved Procedure thermometer H R/W
4 PE film temperature. Every hour. 0 Test report Optical
240-260 C or as per
manufacturer's pyrometer/digital
recommendation. TS/ Approved Procedure thermometer H R/W
5 Recording of batch no.'s of Epoxy, Every batch As per standard data Test report visual
adhesive & polyethylene Manufacturer's test ceritificate H R/W
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP Padmala - Godhra Pipeline of GSPL Page 3 of 5
QAP NO : 05/21/JT/3LPP Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPP COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
E. ON LINE INSPECTION & TESTING
1 Epoxy & adhesive thickness Every shift at 3,6,9,12 Epoxy thk. - 0.18mm min. Test report Coating thk. Gauge.
positions Adhs. Thk. - 0.20mm min. TS/ Approved Procedure H W
2 Holiday test at 25 kv All pipes Max. one holiday surface area < Test report Holiday detector
0.01 sq. mtrs.
TS/ Approved Procedure H W
3 Over all Coating Thickness All pipes 3.2mm on Body Test report Coating thickness
TS/ Approved Procedure gauge H W
4 Cut back All pipes 110 mm, + 20 mm Test report TS/ Approved Procedure Steel Scale H W
F. OFF LINE TESTS
1.0 Epoxy layer thickness One pipe at 3,6,9,12 Coatng thk. gauge
positions 0.18 mm min. Test report TS/ As per approved procedure H W
2.0 Adhesive Layer thk. One pipe at 3,6,9,12 Coatng thk. gauge
positions 0.20 mm min. Test report TS/ As per approved procedure H W
△Tg = +3, - 2 C
0
3.0 Degree of cure One pipes (one sample) DSC Machine
% cure = 95% min. Test report TS/ Approved Procedure H W
4.0 Adhesion test 3 pipes Rating - 1-3 Test report TS/ Approved Procedure Utility knife H W
5.0 Impact Strength 1 pershift 15 Nm/ mm thick. Test report TS/ Approved Procedure - H W
6.0 Rockwell Hardness 1 pershift > 60 Test report TS/ Approved Procedure - H W
0
7.0 Strength 1 pershift 500 N/ 50mm, 50+ 5 C Test report TS/ Approved Procedure - H W
0
400 N/ 50mm, 90+ 5 C
8.0 Rockwall Hardness 1 pipe per shift, one test per > 60 Test report TS/ Approved Procedure H W
50 pipes
9.0 Resistance to peeling 1 test per shiftbut 5 test > 750 N/ 50 mm Test report TS/ Approved Procedure H W
minimum
10.0 Indentation 1 test per shiftbut 5 test < 0.1 mm at 250C Test report TS/ Approved Procedure H W
minimum 0
< 0.3 mm at 100 C
G. FINAL INSPECTION
1 Cut back length at ends. Each pipes 110 mm, + 20 mm Test report TS/ Approved Procedure Measuring tape, H W
scale etc. and visual
2 Marking on caoted pipes external color Each pipes Proper information on coated STOCK REGISTER TS/ Approved Procedure H W
band surface (ME side) I.e. as follows.
(1 mtr. From end
PROJECT ……PIPE DIA…
WALL THK….
PIPE NO… LENGTH…HEAT
NO……..
COATING No….COLOUR
BAND, ANY OTHER
INFORMATION CONSIDERED
RELEVANT BY COMPANY
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP Padmala - Godhra Pipeline of GSPL Page 4 of 5
QAP NO : 05/21/JT/3LPP Coating Rev.
Date :
QUALITY ASSURANCE PLAN Prepared by : Checked by
3 LPP COATING OF LINEPIPE Approved by :
MECON LIMITED
Sl. No. ACTIVITY TEST FREQUENCY ACCEPTANCE CRITERIA DOCUMENTAION REFERENCE DOCUMENT INSTRUMENTS INSPECTION REMARKS
MANUF. TPIA
H. HANDLING & STORAGE
1 Repair of Coating followed by holiday All coating repair All repairs as per approved Test report TS Heating torch. H R/W
detection at 25 KV procedure Chisel, scale etc.
2 Peel test on repari area One in 25 pipes As per manufacturer's Test report TS Spring balance H R/W
recommendation
I. RECOMMENDATION
1 Handling Each pipes No damages on coated pipes. STOCK REGISTER TS Crane with teflon H R/W
Support bed, min. 2 nos. support padded hooks,
on trailor & securing by three trailor with rubber
wire rope covered with nylon padded beds etc.
rubber tubing
2 Storage Each pipes Proper stacking on sand rows STOCK REGISTER TS --do-- H R/W
covered with PE sheets with
stack separator.
J. CALIBRATION OF EQUIPMENT
1 Digital thermometer Every month. Add or subtract the observed Test report Calibration procedure Ref. Thermometers, H R/W
value w.r.t. reference water/ oil bath etc.
measurement.
2 Thickness gauge. Every month. ----di--- Test report Calibration procedure Ref. Thickness foils, H R/W
steel
3 Roughness gauge Every month. ----di--- Test report Calibration procedure Standard roughness H R/W
4 Holiday detector Every month. By spark gap method Test report Calibration procedure Spark gap assmbly/ W
Calibrated meter H
5 Hygrometer Once in four month By spark gap method Test report Calibration procedure W
6 D meter Every time before use By standard thickness block Test report Calibration procedure H W
Raw Material Combination to be used During Production as per ANNEXURE - 1 As per TS No. MEC/S/05/21/014B
LEGEND : W = WITNESS; H = HOLD; M = MONITORING; R = REVIEW OF DOCUMENTS; R/M = RANDOM CHECK; A = APPROVED; TPIA = THIRD PARTY INSPECTION
Notes:-
1 The above Testing and acceptance criteria are minimum requriements, however, equipment supplier shall ensure and that the product also com;y to the additional requirements as per Technical Specifications and data sheets.
2 The supplier shall submit their own detailed QAP prepared on the basis of the aboe for approval of Owner/Owner's representative and TPIA.
3 Supplier shall submit Calibration certificates of all instruments/Equipments to be used for inspection and Testing to TPIA with relevent procedures and updated standards for TPIA review/Approval.
4 TPIA will have Right to inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/drawigs etc. submitted by suppler.
6 Contractor shall in coordination with Supplier/Sib vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitaate Owner/Owner's representative and TPIA to organise inspection.
T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP Padmala - Godhra Pipeline of GSPL Page 5 of 5
APPENDIX-IV
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
10 Bongnae-Dong 1, Joong-Gu,
14 Seah Steel Corporation
Seoul South Korea
386, Veer Savarkar Marg, (022) 4307023, (022) 430 7365, 430
21 3LPE Pipe Coating PSL Holdings Ltd
Prabhadevi, Mumbai- 400 025 4309058 5335
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
32 Trub chomutov
Seamless Pipe
33 Manfacturer TENARIS
34 Valcvony
Vallurorec Maneshman
35
Tubes Barzil
Virgo Engineers Virgo Engineers,J/517, MIDC
36 020-2747 4481 020-2747 0772 Upto 24" class 600
Ltd,Pune Bhosari,Pune – 411 026
Oswal Industries Limited
404, Sakar-III
37 Oswal Industries Ltd 079-30947636 079-27540839 Up to 12" class 600
Opp. Old High Court
Ahmedabad – 390 014
Plot no. R-241, TTC Industrial Area
Steel Strong Valves (P) Up to 12" class 600 of
38 MIDC,Rabale, New Bombay-400
Ltd. split body type
701
Flow Chem Industries
10, Navdurga Indl. Estate
39 Flow Chem Industries Opp. Forge Blower 79-220 4773 79-220 1401 Up to 12" class 600
Naroda Road
Ahmedabad – 25
B.D.K. Engineering (I) Ltd.
40 Micro Finish Valves Gokul road Up to 12" class 600
Hubli 580 030
BALL VALVES
4, Karmabhumi Industrial Estate,
Hawa Valves (India)
41 Opp. Ajit Mill Police chowky, Up to 8" class 600
Pvt. Ltd
Rakhial Road, Ahemdabad
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Große Straße 14
Up to 30" class 600
86 INTERFORGE 27356 Rotenburg +49 4261 4081 +49 4261 3090
fittings and Flow Tee
GERMANY
Mark S. Clarkelaan 13 a
Haven No. M 512 Up to 30" class 600
87 KÜRVERS Piping +31 168 33 43 44 +31 168 33 43 49
4761 RK Zevenbergen fittings and Flow Tee
THE NETHERLANDS
Premier estate
Leys Road
Up to 30" class 600
88 MEREK Engineering Brockmoor Brierley Hill +44 121 544 9938 +44 121 544 9132
fittings and Flow Tee
DY5 3UT West Midlands
UNITED KINGDOM
Unit 3 Rowan Court
Crystal Drive
Up to 30" class 600
89 PETROFIT Smethwick 0121 544 9938 0121 544 9132
fittings and Flow Tee
B66 1RB West Midlands
UNITED KINGDOM
Ten Bergstraat 4
PHOCEENNE Up to 30" class 600
90 2830 WIllebroek +32 3 860 73 70 +32 3 860 73 71
(Groupe Genoyer) fittings and Flow Tee
BELGIUM
Schaarbeeklei 189
VAN LEEUWEN Up to 30" class 600
91 1800 Vilvoorde +32 2 255 40 00 +32 2 253 20 92
BUIZEN fittings and Flow Tee
BELGIUM
M.S.FITTINGS MFG.CO.(P)LTD.
MS Fittings Mfg. Co. 033- 2362902,
92 H.O. 17-WESTERN STREET, 033-2252103 Upto 24 " class 600
Pvt. Ltd, Kolkatta 2362903
KOLKATA-13
Pipe Fittings (Elbows, Ferro Tubes & Forging Industries C-
Tee, Reducers) Ferrous Alloy Forging
93 1/129, GIDC Estate, Vaghodia, 02668-62479 upto 12"
(P) Ltd.
Baroda-391760
496/1, GIDC Industrial Estate,
94 Pipe Fit Engineers Makarpura, Baorda-390010 0265-2636 547/545 0265-2636 546 upto 24" size, 600#
pipefit@pipefit.net
315/317, Navratan 69, P D Mello +91 22 342 3382-83,
95 Teekay Tube Road Near Carnac +91 22 343 7716, (022) 349162 Up to 24" class 600
Bridge,MUMBAI - 400 009 3445477, 3446975
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Nottinghamshire S82 PY
119 GD ENGINEERING +441909482323 +441909477902
ENGLAND
Quick Opening
Closures and Pig INTERNATIONAL Walkerville Industrial Estate
121 Signallers PIPELINE PRODUCTS Catterick Garrison North Yorkshire +441748834577 +441748834121
LTD. DL9 4RR,ENGLAND
RMA MASCHINEN-
UND
Oststrasse, 17 77694
122 ARMATURENBAU +4978518680 +49785186813
KEHL/RHEIN , GERMANY
KEHL FAULHABER &
TRUTTENBACH KG
Indian Register of
124
Shipping
Bax counsel 303, Madhava, Bandra Kurla
022-
125 Inspection Bureau Complex, Bandra (E), Mumbai- 022-26591526
26591526,26590236
Pvt. Ltd. 400051
The Leela Galleria ,5th
126 Bureau Veritas Floor,Andheri-Kurla Road,Andheri 022-6956300 022-6956309
(East),Mumbai-400059
304-305, Anna
127 Germanischer Lloyd Salai,Teyanampet,Chennai - 044-24320335 044-24328186
600018
Velosi Certification Services (I) Pvt.
Ltd.,
Velosi Certification
128 212,ShivKrupa Commercial Centre, 022-5376770 022-5426777
Services, Mumbai Off Gokhale Road,Navpada
Thane (W) 400 602
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
M/s CANARA
140 ELECTRIC
Transformer Rectifier CONTROLS MUMBAI
Unit [TRU] AC Input DC
Output, & CPPSM M/s CIMCON
SOFTWARE
141
SERVICES
INC.,AHMEDABAD
M/s TITANOR
142
COMPONENTS,GOA
M/s ELTECH,
143
NETHERLANDS
MMO ANODES
M/s ORANZIO DE
144
NORA,USA
M/s CORPRO
145 TECHNOLOGIES,
SINGAPORE
M/s SHAKTI
147 ENTERPRISES
AHMEDABAD
M/s ELECTRO-
149 PROTECTION
SERVICES
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
M/s
153 ELECTROCHEMICAL
DEVICES USA
SURGE DIVERTORS
M/s CONTROL
158
TECHNOLOGY
M/s DAIRYLAND
159 ELECTRICAL
INDUSTRIES
M/s INTERNATIONAL
160 CORROSION CONTROL
Inc.
M/s INTERNATIONAL
162 CORROSION CONTROL
Inc.
M/s DAIRYLAND
165 ELECTRICAL
INDUSTRIES
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
171 M/s. R M A
INSULATION MONO
174 M/s. PHOCENNE
BLOCKS
M/s. PPELINE
175 ENGINEERING &
SUPPLY CO.
M/s.INTERNATION
178 CORROSION CONTROL
Inc.
P.O.Box 15 01 20 * D-51344
180 Denso GmbH +49 214 2602-0 +49 214 2602-318
Cold Applied Tapes Leverkusen, Germany
181 Raychem
Multi Thread Fasteners.,
Multi Thread Fasteners, 0265-2647310
182 885/B GIDC Makarpura, 0265-2642821
Baroda
Baroda – 390010
Stud Bolts with Nut
183 Darukhanwala Mumbai
Precision Engineeris ,
184 Baroda
Baorda
709/710, Tolstoy House, Tolstoy
185 Raychem RPG Limited
Marg, New Delhi - 110 001
Heat Shrinkable Sleeves Canussa (Bhotika Bhotika Brothers, 59,
R.N.Arcade,1st Floor, Lokhandwala
186 Brothers- Indian 022-6331458/9 022-6362253
Complex, Andheri West ,Mumbai-
Represntative)
400053
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
233 INCAB
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Baliga Lighting
234
Equipments Pvt. Ltd.
Sudhir Switch Gears
235
Pvt. Ltd.
Flame Proof Control
236 Flameproof Lighting Gears Pvt. Ltd.
Fixtures, FLP, Flame Proof Equipment
237
J.Box/FLP Switch Pvt. Ltd.
Socket
Flameproof &
Flex pro Electricals Pvt.
238 Explosion Proof
Ltd, Navsari
Electrical Equipment
239 CEAG
Relays OMRON
250 OEN
Fuji Electric Company
251
Limited
B-14/1, G.I.D.C. Electronics Zone,
079-232 21636 /
252 Hi-REL Controls Ltd. Sector - 25, GANDHINAGAR - 382
22531
U.P.S. 044, GUJARAT
Emmerson Network
253
Power Management
254 Gutor Electronics Ltd.
255 Emerson
256 Yokogawa Blue Star
257 Pressure Transmitter Tata Honey Well Ltd
Invensys India/emerson
258
Process
259 H. Guru
Pressure & Temperature
260 A.N. Instrument
Gauge
261 Wika
262 Switzer
263 Delta
264 SOR
Pressure Switch
265 United Electric
266 ITT-Barton
267 CCS
268 ICA
269 Rittal
Instrumentation Panel
270 Pyrotech Controls
271 Enclotek
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
Patson Transformers
272
Pvt. Ltd. , Ahmedabad
Transformer
Voltamp Transformers
273
Pvt. Ltd., Ahmedabad
309 P&F
310 SITOP
24 V DC Power Supply
311 PHEONIX
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
314 Masibus
Power Indicator
24/3,Pantra palya, Mysore Road 080-
315 Yokogawa 080-26742855
Bangalore-560039 India 26742551/26744015
317 P&F
318 Concord
Indication Lamp
319 L&T
320 Control Switch Gear
321 Electromac
322 Commet
Cable Glands
323 Baliga
Sr. Item Name of the vendor Address Phone No Fax No Qualified for Size
2) Contractor shall submit the details of each of the party before placement of order.
3) For any item, if the vendor names are not available, it is the reponsiblity of the contractor to submit the credentials of at least
three parties for GSPL approval
AMENDMENT TO PIPELINE
STANDARD AND SPECIFICATION
AMENDMENT TO PIPELINE STANDARD AND TECHNICAL SPECIFICATIONS
SCOPE
CONTENTS
Following to be noted :
Root – E6010
Filler & Hot Pass – E7010
a) Refer Page No.: 4 of 17, Clause No. 5.1 shall be read as “The duration
of hydrostatic test shall be minimum of 24 hrs. after stabilization and
the test pressure shall be 1.5 x Design pressure (95 bar) and as
indicated in Clause 5.2”.
c) Refer Page No.: 4 of 17, Clause No. 5.2, shall be read as “The
maximum base pressure shall not be higher than one resulting in a
hoop stress corresponding to 95% of SMYS of pipe material based on
the minimum wall thickness in the test section & minimum test
pressure shall not be lower than the one resulting in a hoop stress
corresponding to 85% of SMYS of pipe material based on the
minimum wall thickness in the test section”.
d) Refer Page No.: Page No. 4 of 17, Clause No. 6.0 equipment and
instrumentation. Fill pump capacity shall be such that pig travel speed
is approx. 2 km/hr.
e) Refer Page No.: 9 of 17, Clause No. 7.8, The line “In order the above
ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.
1.06)” shall be replaced by the line “In order the above ratio is
acceptable, it shall not differ from 1 by more than 2% (i.e. 1.02)”.
f) Refer Page No.: 9 of 17, Clause No. 7.8, “V1/Vp exceeds 1.06” shall be
replaced by “V1/Vp exceeds 1.02”.
g) Refer Page No.: 9 of 17, Clause No. 7.9, Replace Para 1 by following :
“After the section has been pressurized and the air volume test has
given acceptable results the test pressure shall be held for 24 hours
for strength test at specified test pressure maintained by periodically
make-up and bleed off after stabilization. After temperature and
pressure has stabilized, the injection pump shall be disconnected and
all connections at the test heads shall be checked for leakage. The
pressure recorders shall then be started with the charts in a real time
orientation for continuous recording throughout the test”.
h) Refer Page No.: 11 of 17, Clause No. 9.1, shall be read as:
“Contractor shall de-pressurise the line at the rate of 5 kg/cm2 per
minute upto 2 kg/cm2 and shall dewater the tested line as per the
following requirement after test acceptance.
The dewatering shall be carried out by using four cup pigs and foam
pigs driven by compressed air. The detailed dewatering procedure
shall be developed by the contractor in such as a way as to provide
adequate control to pigs during dewatering. Pigs and equipment
required for dewatering the line shall be furnished by contractor and
shall be approved in advance by the company. Four cup pigs shall first
be passed through the line to displace the water. Foam pigs shall then
be passed in order to complete the line dewatering. Contractor shall
use a number of foam pigs, each in different colors / numbered for
this purpose. The line shall be considered dewatered when a
negligible amount of water is flushed out by the last foam pig and
approval is given by the company.
i) Gamma ray shall be used for Terminal Pipe welding provided slow film
like D4 film is used.
ii) Acceptability Criteria shall be only as per API-1104
(1) Clause no. 4.4.1, Para no. 6, the last line shall be read as “Test period
shall be maintained for minimum 6 (six) hours”.
(2) Refer page no. 9 of 9 clause no. 4.5, para 3 shall be read as “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 and leakage test at design
pressure i.e. 95 bar by N2 to be carried out by the contractor for
complete loop/ circuit including equipments (except rotary
equipments).
a) Refer page no. 2 of 8, clause no. 2.0 para no. 3, shall be read as “The
contractor shall be responsible for demonstrating the successful
D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc Page 4 of 10
completion of all the activities i.e. flushing of terminal piping,
dewatering, swabbing, drying inertisation and commissioning of the
pipeline. All necessary work to perform the job successfully including
necessary modifications required shall be the responsibility of the
contractor”.
4.3.3 DRYING
4.3.3.2 General
The dew point at the inlet and outlet ends; each individual
consumer points and sectionalising valve stations shall be
D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc Page 5 of 10
monitored to ensure that the required dew point is achieved
throughout the pipeline system.
4.3.4.1 General
The air drying operation shall remove the residual water in the
pipeline left behind after swabbing by means of absorption of the
water into super dry air blown through the pipeline.
The inlet air shall be oil free dry and have dew point below the
required dew point in the pipeline.
When the pipeline is dried using super dry air, contractor shall dry
the pipeline to a dew point of (-) 20 0C, at atmospheric pressure.
a) Refer Page No. 5 of 9, Clause No. 8, The new para added “Prior
calibration with dent pipe to be done at site in presence of owner /
consultant.
i) For dents = 5% of O. D.
ii) Ovality = 5% of I. D.
iii) Location Accuracy = Actual + 3.0 m
= Circumferential : + 12°
iv) Final report shall be submitted within 30 days
For Rail Road crossing: 1.8 m from base of rail to top of pipe
Line Pipe shall be manufactured by ERW Process only and the steel coils to be
procured from following steel suppliers.
In case bidder propose steel manufacturer other than above for supply of HR
Coils to be used in manufacturing of quoted line pipes, bidder should submit
documentary evidence confirming supplier past track record of at least tonnage
equivalent to present bid quantity confirming to API 5L Gr. X 65 and above grade
steel. GSPL reserve the right to accept /reject the proposed steel supplier if they
don’t have past experience.
Charpy V-notch impact test in accordance with SR5 ( Appendix - F) shall also be
performed at (-)20 degree C for regular production and at (-)25 degree C. for First
Day Production.
Impact testing to be done at – 20, -25 degree and 0 degree at Base Metal,
Fusion line, Fusion line+2mm and Fusion line + 4 mm and acceptance
criteria for standard size sample as per ASTM A 370 is as follows
The tolerances on specified wall thickness shall be (+) 10% and (-) 0% on pipe body
as well as on weld.
The length of pipe upto 10.5 m shall also be acceptable for sampling pipes.
The test pressure of pipe shall be such that hoop stress (fibre stress) generated is at
least 95% of SMYS and test pressure shall be determined in accordance with
Appendix–K of API-5L.
Cyclic Hydro Test has to be carried out 1 in every 500 pipes including 1 pipe in the “
First Day Production Test” as detailed below :
• The pipe to be pressurized upto 50% of the Hydro test pressure and hold
pressure for one hour.
• Drop the pressure to static head plus one bar.
• Pressurise again to 75% of the Hydro test pressure and hold the pressure for
one hour.
• Drop the pressure to static head plus one bar.
• Pressurise again to 100% of the Hydro test pressure and hold the pressure
for 6 hours and recorder shall be used to monitor the TIME V/S PRESSURE
throughout the Test duration of 24 hours.
For UT and MPI , one qualified inspector of Level-III shall be available at pipe mill
for overall supervision of UT and MPI.
Either coiled strip area shall be 100% ultrasonically tested or pipe body shall be
100% ultrasonically tested for lamination detection.
Spot random radiographic examination of weld seam to the extent of 0.5% shall be
carried out at pipe mill for the ordered quantity.
The primary reference sensitivity level shall be adjusted on the following reference
reflectors for UT inspection:
Lamination Detection - FBH 1.6 mm
Defect Detection Welds - Notch N5
APPENDIX – F
SR 6 : Drop Weight Tear Testing ( DWTT ) On Welded Pipe
DWTT shall be carried out in accordance with the requirement of SR 6.2 through SR
6.8 Two transverse specimens shall be taken from one length of pipe from each lot
of 100 pipes per heat.
D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc Page 9 of 10
The test shall be conducted at(-)20 degree C.
At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or
more for the specified test temperature.
APPENDIX
TABLE OF CONTENTS
1. INTRODUCTION
2. SCOPE
4. ELECTRICAL
5. FIELD INSTRUMENTS
1. INTRODUCTION
Owner has decided that the Independent Third Party Inspection Agency (TPIA) shall
witness, review and certify all quality related activities pertaining to Supply of Materials
and Construction. The TPIA shall ensure that all quality related requirements during
manufacturing/construction are followed as per Owner/Owner’s representative
specifications and approved Documents. The extent of TPIA involvement as indicated in
tender shall be binding on the contractor and no activity shall be accepted if not
approved/certified by TPIA.
This chapter also indicates general quality control requirements for various activities
pertaining to Gas Pipeline Projects.
2. SCOPE
TPIA, as appointed and paid by the Owner, shall be involved in all inspection and
testing related activities for Mechanical, Electrical, Civil and Instrumentation system.
The extent of TPIA involvement is indicated in the various Quality Control Sheets
attached with the tender document and also shall be as per final approved QA/QC
procedures or as per codes and standards, wherever applicable. For items/construction
activities for which, Quality Control Tables are not attached, contractor shall require to
submit the Quality Control Sheets and Quality manual and shall obtain Approval of
Owners/Owner’s representative. Prior to start of any activity pertaining to supply of
material or carrying out construction at site. Owner/Owner’s representative shall get the
documents reviewed by the TPIA.
As indicated in various QC tables, TPIA shall witness minimum 10% of the activities
pertaining to manufacture on each day or as indicated in final approved documents.
TPIA representative deputed at Construction site will apart from the construction
activities, shall also be involved in certification of all supply material received at site.
Contractor shall not be allowed to use such material in construction activities, which is
not certified by the TPIA.
Contractor shall have to carryout all necessary inspections and testing which are
indicated in Approved documents and shall have to provide all necessary latest Tools &
Tackles, measuring Instruments and facilities, which are required by the TPIA/
Owner/Owner’s representative and all necessary assistance to carry out
Inspection/Testing at Contractor’s cost.
Contractor on award of the Contract/LOI shall submit the detail procurement and
construction schedules within fifteen (15) days to Owner/Owner’s representative for
their approval. The detail item wise Construction/Manufacturing schedule indicating
dates and location of manufacturer works shall be submitted by the Contractor within
seven (7) days from the date of issue of their internal Indent /Purchase order to sub
vendor.
Contractor shall inform in writing seven (7) days in advance to inform the
Owner/Owner’s representative for Inspection Notice/Call. All coordination among
Owner/Owner’s representative/TPIA and Contractor’s/ Vendor’s works shall be the
responsibility of Contractor. In case the Contractor fails to honor its inspection
calls/notice, contractor has to reimburse all costs incurred by the Owner/Owner
representative toward TPIA at actual.
3.1. Mechanical
The Minimum requirements are indicated in the Quality Control Tables attached and as
detailed above.
3.2. Civil
In addition to as indicated above, all procured items required for civil works should
satisfy the following conditions:
• It should be of reputed make having proven record of being successfully used in similar
works earlier and as per approval by Owner’s Representative.
• All materials shall be of standard quality and shall be procured from renowned sources /
manufacturers approved by Owner/ Owner’s representative.
• All tests of the materials as specified by the relevant BIS codes should be carried out by
the contractor in an approved laboratory and the test reports should be duly
authenticated by the laboratory and should be submitted to TPIA for his approval. If so
desired by Owner/ Owner’s representative, tests shall be conducted in his presence or
in presence of his authorized nominee.
• Quality and acceptance of materials not covered under general technical specifications
shall be governed by relevant BIS codes. In case BIS codes are not available for
particular material other codes i.e. BS/DIN/ API/ASTM shall be considered.
• The Contractor shall submit manufacturer’s test reports on quality and suitability of any
material procured from them and their recommendations on storages/ application/
workmanship etc. for the intended use. Submission of manufacturer’s test reports does
not restrict Owner/ Owner’s representative from asking fresh test results from an
approved laboratory of the actual materials supplied even from an approved
manufacturer.
4. ELECTRICAL
• Contractor shall furnish the QAP for Panels, DG Sets, Cables, UPS for Owner’s review.
• QA Plan will commence at the instigation of the requisition and follow through to
equipment acceptance thus ensuring total conformity to the specifications.
• Routine tests shall be carried out on the panels, DG sets, Cables, UPS, Flame proof
equipment and other items as per I.S.S.
• Owner/Owner’s Representative will witness the routine tests on Panels, DG sets, UPS at
the manufacturer works prior to dispatch, to prove compliance with specifications.
• Owner/Owner’s Representative shall carry out the inspection of the erection and witness
the testing & commissioning of the equipment at site and approve the test certificates.
5. FIELD INSTRUMENTS
• Contractor shall furnish the quality assurance procedure for field instruments and cables
for review of Owner/ Owner’s representative.
• QAP will commence at the instigation of the requisition and follows through to
equipment acceptance. Thus ensuring total conformity to the specifications.
Note:
1. Bidder is required to mobilize the above minimum equipments in good working condition and suitable to lay this
12” diameter pipeline. Bidder is required to augment the above list with additional numbers of equipments as per
actual requirement and instruction of Engineer-In-Charge without any additional financial implication to client.
2. Bidder shall replace any defective / damaged equipments promptly to complete the work without any time & cost
implication to the client / owner.
3. After completion of certain activities, in case equipments are not required the same can be demobilized with prior
approval of Engineer-In-Charge.
4. Any other equipment required for completion of pipeline laying and associated works but not specifically
mentioned above here, shall be deployed by Contractor without any additional cost.