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Table of ContentsDocument Number Rev. Document Title Page

NumberA133-000-WA-MR-3211

B PIPES-ALLOY STEEL 2

6-44-0051 6 Technical notes for pipes. 166-78-0001 0 Specification for Quality Mgt. System Requirements from Bidders 266-78-0003 0 Specification for Documentation Requirement from Suppliers 35A133-000-16-43-ATR-3211

A ADDITIONAL TECHNICAL REQUIREMENTS 47

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ENGINEERS INDIA LIMITED

NEW DELHI

Project:

Client:

COKER BLOCK (LSTK 1)

CPCL

Requisition No. Rev

A133-000-WA-MR-3211 B

Page 1 of 4

MATERIAL REQUISITION (TOP SHEET)

ITEM: PIPES- ALLOY STEEL Issue Status 1. -> Entire Requisition Issued

2. -> Only Revised Pages are Issued

(Fill 1 or 2 from below in this bracket)

DOCUMENT NUMBER(Always quote this document number given below as reference)

A133 000 WA 3211MR 04/02/2015 16/43B

JOB NO. UNIT/AREA

COST CENTRE

DOCCODE

SR.NO. REV DATE ORIGINATINGDIVN./DEPT

VENDOR NAME VENDOR CODE

Material to be delivered at (job site) CPCL, CHENNAI within the delivery period specified in the "Request For Quotation"

(RFQ).

Notes :

This page is a record of all the Revisions of this Requisition.

The nature of the Revision is briefly stated in the "Details" column below, the Requisition in its entirety shall beconsidered for contractual purposes.

When a Requisition is revised, only the revised pages may be issued.

When revised pages only are issued, the revised pages shall form part of the original Requisition. The original requisition alongwith the revised pages shall be considered in its entirety for contractual purposes.

A

B

16/01/2015

04/02/2015

ISSUED FOR BIDS

REVISED & ISSUED FOR BIDS

[ ]

Vendors are required to quote strictly as per technical specifications / notes stipulated in the material requisition. Theoffers with deviations are likely to be summarily rejected.

1.

2.

3.

4.

5.

MR Category :I

NK

NK

KB/UC

KB/UC

MI

MI

This is a system generated approved document and does not require signature

REV. DATE BY CHK. APPD. DETAILS

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B636

Typewriter

PMCCONTROL CODE: L15

B636

Typewriter

B636

Rectangle

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WA-MR-3211 B

Page 2 of 4

LIST OF ATTACHMENT

DOCUMENT TITLESR. NO DOCUMENT NO.REVISION

NO. DATE 1

2

3

4

5

6

TECHNICAL NOTES FOR PIPES

INDICATIVE ITP FOR SEAMLESS ANDWELDED PIPES

STANDARD SPECIFICATION FORPOSITIVE MATERIALIDENTIFICATION (PMI) ATVENDOR'S WORK

SPECIFICATION FOR QUALITYMANAGEMENT SYSTEM REQUIREMENTSFROM BIDDERS

SPECIFICATION FOR DOCUMENTATIONREQUIREMENTS FROM SUPPLIERS

ADDITIONAL TECHNICALRERQUIREMENTS

6-44-0051

A133-00-000-ITP-13A

44NC-4600-Q-0002-A4

6-78-0001

6-78-0003

A133-000-16-43-ATR-3211

6

0

0

0

A

25/09/2014

13/04/2010

04/06/2009

04/06/2009

16/01/2015

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WA-MR-3211 B

Page 3 of 4

MR ATTACHMENTSR.NO. DETAIL DESCRIPTION QTY. U. RATE TOT.VALUE CDD

PIPE, B-36.10, ASTM A 335 GR.P5, BE, SEAMLESS

PIPE, B-36.10, ASTM A 335 GR.P5, PE, SEAMLESS


PIPE, B-36.10, ASTM A 335 GR.P9, BE, SEAMLESS, IBR

PIPE, B-36.10, ASTM A 335 GR.P9, PE, SEAMLESS

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

PI25317Z00919ZZZZ

PI25317Z01318ZZZZ

PI25317Z01618ZZZZ

PI25317Z01819ZZZZ

PI25377Z00819ZZZZ

PI25417Z00919ZZZZ

PI25417Z00910ZZZZ

PI25417Z01118ZZZZ

PI25417Z01318ZZZZ

PI25417Z01519ZZZZ

PI25417Z01518ZZZZ

PI25417Z01619ZZZZ

PI25417Z01618ZZZZ

PI25417Z01680ZZZZ

PI25417Z01719ZZZZ

PI25417Z01718ZZZZ

PI25417Z01780ZZZZ

PI25417Z01818ZZZZ

PI25417Z01808ZZZZ

PI25417Z01882ZZZZ

PI25417Z01892ZZZZ

PI25417Z01995ZZZZ

PI25417Z01918ZZZZ

PI25417Z10510ZZZZ

PI25417Z10610ZZZZ

PI25417Z10810ZZZZ

PI25417Z10919ZZZZ

PI25417Z11119ZZZZ

PI25417Z11110ZZZZ

PI25477Z00510ZZZZ

2.0 INCH, XS

4.0 INCH, STD

8.0 INCH, STD

12.0 INCH, XS

1.5 INCH, XS

2.0 INCH, XS

2.0 INCH, S160

3.0 INCH, STD

4.0 INCH, STD

6.0 INCH, XS

6.0 INCH, STD

8.0 INCH, XS

8.0 INCH, STD

8.0 INCH, 14.3 MM THK

10.0 INCH, XS

10.0 INCH, STD

10.0 INCH, 14.3 MMTHK

12.0 INCH, STD

12.0 INCH, S120




14.0 INCH, STD

0.75 INCH, S160

1.0 INCH, S160

1.5 INCH, S160

2.0 INCH, XS

3.0 INCH, XS

3.0 INCH, S160

0.75 INCH, S160

16 METRES

5 METRES

11 METRES

3 METRES

6 METRES

51 METRES

3 METRES

14 METRES

8 METRES

6 METRES

106 METRES

20 METRES

15 METRES

12 METRES

14 METRES

13 METRES

6 METRES

15 METRES

6 METRES

22 METRES

6 METRES

6 METRES

35 METRES

6 METRES

28 METRES

38 METRES

10 METRES

6 METRES

6 METRES

295 METRES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

ITEMCODE

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WA-MR-3211 B

Page 4 of 4

MR ATTACHMENTSR.NO. DETAIL DESCRIPTION QTY. U. RATE TOT.VALUE CDD

PIPE, B-36.10, ASTM A 335 GR.P9, PE, SEAMLESS, IBR

PIPE, B-36.10, ASTM A 691 GR5CR CL.42, BE, E.FS.W





Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

PI25477Z10819ZZZZ

PI2C613Z02019ZZZZ

PI2C713Z02018ZZZZ

PI2C713Z02118ZZZZ

PI2C713Z022A2ZZZZ

PI2C713Z02218ZZZZ

PI2C713Z02204ZZZZ

PI2C713Z02418ZZZZ

PI2C713Z03019ZZZZ

PI25317Z01919ZZZZ

PI25417Z01319ZZZZ

PI25417Z01320ZZZZ

PI25417Z01508ZZZZ

PI25417Z01577ZZZZ

PI25417Z01609ZZZZ

PI25417Z01807ZZZZ

PI25417Z01819ZZZZ

PI25417Z01905ZZZZ

PI25417Z01992ZZZZ

PI25417Z01907ZZZZ

PI2C713Z02007ZZZZ

PI2C713Z02098ZZZZ

PI2C713Z02107ZZZZ

PI2C713Z02207ZZZZ

PI2C713Z02205ZZZZ

PI2C713Z03092ZZZZ

1.5 INCH, XS

16.0 INCH, XS

16.0 INCH, STD

18.0 INCH, STD


20.0 INCH, STD

20.0 INCH, S40

24.0 INCH, STD

36.0 INCH, XS

14.0 INCH, XS

4.0 INCH, XS

4.0 INCH, XXS

6.0 INCH, S120

6.0 INCH, 12.7 MM THK

8.0 INCH, S140

12.0 INCH, S100

12.0 INCH, XS

14.0 INCH, S60


14.0 INCH, S100

16.0 INCH, S100


18.0 INCH, S100

20.0 INCH, S100

20.0 INCH, S60


4 METRES

6 METRES

13 METRES

7 METRES

6 METRES

6 METRES

26 METRES

11 METRES

14 METRES

6 METRES

5 METRES

13 METRES

9 METRES

21 METRES

9 METRES

11 METRES

7 METRES

21 METRES

14 METRES

13 METRES

11 METRES

19 METRES

21 METRES

3 METRES

2 METRES

36 METRES

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

ITEMCODE

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SUMMARY SHEET OF CHANGES

Date:04.02.2015

Page 1 of 1

Note: This Document is to be read in conjunction with the documents attached with Material Requisition.

With reference to the MR for PIPES (ALLOY STEEL) -A133-000-WA-MR-3211, following are the changes:

Sl. No. Document Document no. Document Added (A)/ /Revised (R)

Affected Contents

1.

MATERIAL REQUISITION A133-000-WA-MR-3211 R A. Changes in MR attachment

1. Quantity changed for SR. No. 11, 14, 15, 38 & 39.

2. New items from SR. NO. 40 to 56 are added in the revised MR.

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APPENDIX - A

INDICATIVE INSPECTION & TEST PLAN** PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION

PROJECT

SHEET 1 OF 2

DOC. NO: A133-00-000-ITP-13A EQUIPMENT/ITEM DESCRIPTION : SEAMLESS/WELDED PIPES EQUIPMENT / ITEM TAG NO. : TEST & INSPECTION AS PER : (CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

VENDOR : P.O. NO. :

PR/PS NO. DRG. NO.

A C

T

I

V

I

T

Y

1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC

2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1

4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR / VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC

1 A A R X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS

2 A R X INSPECTION & TEST PROCEDURES INCLUDING NDT,PWHT, WELD REPAIR, HYDROSTATIC PROCEDURES,ETC.

3 R R X Rev.1

4 A X PACKING PROCEDURE Rev.1

5 W W X WPS/PQR QUALIFICATION / WELDER’S PERFORMANCE AND REPAIR PROCEDURE QUALIFICATION

6 R W X RAW MATERIAL INSPECTION IDENTIFICATION

7 R W X HEAT TREATMENT RECORDS / CHART

8 R *

W X NDT (RT, UT, PT, MT, EDDY CURRENT – AS APPLICABLE) EXAMINATION Rev.1

9 H W X STAMPING OF SAMPLES FOR ALL REQUIRED TESTS

10 H W X MECHANICAL TESTS (AS APPLICABLE)

− TENSILE TESTING

− BEND / REVERSE BEND

− FLATTENING TEST

− FLARING / FLANGING TEST

− IMPACT TEST

− HARDNESS CHECK

− IGC TEST / CORROSION TEST

11 R W X PRODUCT CHEMICAL CHECK ANALYSIS FROM INDEPENDENT LAB Rev.1

12 H W X HYDROSTATIC TEST (100% BY VENDOR AND AT RANDOM BY TPI AGENCY)

13 H W X OTHER EXAMINATION / TESTS, AS APPLICABLE

− MICRO, MACRO

− FERRITE CHECK IN WELD METAL

− ADDITIONAL TEST SPECIMEN FOR MECHANICAL TESTING

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APPENDIX - A

INDICATIVE INSPECTION & TEST PLAN** PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION

PROJECT

SHEET 2 OF 2

EQUIPMENT/ITEM DESCRIPTION : SEAMLESS/WELDED PIPES

EQUIPMENT / ITEM TAG NO. : TEST & INSPECTION AS PER : (CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

VENDOR : P.O. NO. :

PR/PS NO. DRG. NO.

A C

T

I

V

I

T

Y

1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC

2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1

4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR / VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC

14 R W X CHECK FOR GALVANISING, PICKLING & PASSIVATION, AS APPLICABLE Rev.1

15 H W X FINAL INSPECTION

− VISUAL EXAMINATION

− DIMENSION CHECK

− VERIFICATION OF MARKING

− COLOUR CODING

− ENDS PROTECTION

− REVIEW OF MANUFACTURER’S TEST CERTIFICATE

16 W W X PMI INSPECTION FOR AS / SS PIPES Rev.1

17 H X PACKING & LOADING OF ITEMS AS PER SHIPPING DRAWING

18 H H INSPECTION RELEASE CERTIFICATE

LEGENDS : H – HOLD, W – WITNESS, R - REVIEW, A - APPROVAL, I - INFORMATION, X – SUBMIT

PO – PURCHASE ORDER, PR – PURCHASE REQUISITION, PS – PURCHASE SPECIFICATION

** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF INSPECTION /REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED INSPECTION AND TEST PLAN INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF PO / PR TO BE GENERATED BY VENDOR AND SAME DULY APPROVED BY TPI A TO BE SUBMITTED TO OWNER/PMC FOR APPROVAL.

* TPI A TO CARRY OUT INSPECTION AT SUB-VENDORS’ WORKS. - OWNER/PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON

QAP / INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER CONDITION ISSUED BY CONTRACTOR.

Note : Following modification has been made from the original ITP attached with Bid Document.

1. In activity :scope of Inspection LSTK contractor has been deleted

2. Activity 3: Summary of all supplementary requirements as specified in the order/PS/PR deleted

3. Activity 4: Shipping drawings of completed equipments has been deleted

4. Activity 8: NDT as applicable has been modified as R for TPI

5. Activity 11 : Product Chemical check has been modified as R

6. Activity 14 : Check for Galvanizing has been modified as R for TPI.

7. Activities in respect of QAP / ITP and IRN /IC for categories will be as below: For PMC category A : QAP/ITP approval by EPC , TPIA & PMC. IRN/IC issued by TPIA and to be endorsed by PMC

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of 7

CHENNAI PETROLEUM CORPORATION LIMITED MANALI REFINERY, CHENNAI

RESID UPGRADATION PROJECT

LSTK-1 : COKER BLOCK : DELAYED COKER UNIT & LPG CFC TREATING UNITS

PART I

SECTION : 5

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION AT VENDOR’S WORKS

(PMI)

DOCUMENT NO : 44NC-4600-Q-0002-A4

0 13.04.2010 7 Issued for Feed APK PKB SBN

Rev No. Issue Date Pages Rev Description Prepared

By

Checked

By

Approved

By

of 49

Jacobs CPCL – CHENNAI INSPECTION, MONITORING PART-I 44NC - 4600 FOR LSTK CONTRACTOR SECTION-5 LSTK – 1 COKER BLOCK Doc.No.44NC-4600-Q-0002-A4 Rev.0 Page 2 of 7

TABLE OF CONTENTS

1.0 SCOPE 2.0 DEFINITIONS 3.0 PMI EXAMINATION 4.0 ACCEPTABLE METHODS FOR PMI 5.0 EXTENT OF PMI EXAMINATION 6.0 RECORDING AND DOCUMENTATION 7.0 MARKING 8.0 ATTACHMENTS

8.1 TYPICAL POSITIVE MATERIAL IDENTIFICATION REPORT FORM – ALLOY STEEL BULK MATERIAL

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1.0 SCOPE

1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be performed at vendor’s works on Metallic Alloy Materials procured either directly by Vendor or indirectly through their sub-vendors. Any deviations from this specification must be approved by Purchaser in the deviation / Waiver permit format. This specification shall also be read in conjunction with positive material identification at site.

1.2 This Specification covers the procedures and methodology to be adopted to assure that the chemical composition of alloy material is consistent with the material specification as specified in purchase documents using alloy analyser at the time of final inspection before despatch.

1.3 The scope of this specification shall include but not limited to Positive Material identification (PMI) to be performed on Alloy Piping Materials listed below :

However all grades of piping materials including stainless steel are subjected to PMI verification / test after receipt at site.

− Alloy Steel Pipes − Alloy Steel Flanges & Forgings − Alloy Steel Fittings − Alloy Steel Fasteners − Alloy Cast & Forged Steel Valves − Alloy Steel Instrumentation items (Control Valve, Safety Valves etc.) − Equipment, Pipe & Fittings Welds. − Gaskets (Ring Type Joints)

Following items shall be excluded from scope of PMI examination

− Gasket other than Ring Type Joints − Valve internal Components

2.0 DEFINITIONS

2.1 Vendor : Any supplier or manufacturers on whom an order is placed for supply of referred piping items. This definition shall also include any sub-vendor or manufacturers on whom a sub-order is placed by the vendor.

2.2 Inspection Lot : A group of items offered for Inspection covered under same size,

heat and heat treatment lot.

2.3 Alloy Material : Any metallic material (including welding filler materials) that contains alloying elements such as chromium, nickel, molybdenum, vanadium, etc which are intentionally added to enhance mechanical or physical properties and/or corrosion resistance.

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3.0 PMI EXAMINATION

3.1 The Vendor shall submit a procedure of PMI to comply with the requirements of this Specification. Approval of PMI procedure shall be obtained from Purchaser prior to commencing manufacturer / inspection of product.

3.2 PMI examination of alloy materials is independent of any certification, markings of

colour coding that may exist and is aimed at verifying that the alloy used are as per specified grades.

3.3 The Vendor shall identify all incoming alloy materials and maintain full traceability of

all alloy materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting to ensure maintenance of identification on off-cuts.

3.4 The Vendor shall ensure that all materials are segregated and stored in separately

identified locations to prevent the mix-up of materials of different alloy specifications or alloy material with carbon steel. Non-ferro-magnetic materials shall be segregated at all times from ferro – magnetic materials.

3.5 PMI examination is subject to surveillance inspection by Vendor / Third Party

Inspection Agency / Purchaser as specified in Quality Assurance Plan.

4.0 ACCEPTABLE METHODS FOR PMI

4.1 The Method used for PMI examination shall provide a quantitative determination of the alloying elements like Cr, Mo, Ni, V in Alloy Steel items. For Non-Ferrous alloys quantitative determination of appropriate alloying elements shall be verified.

4.2 Instruments or methods used for PMI examination shall be of those that will provide

quantitative, recordable, elemental composition results for positive identification of alloying elements present.

4.3 The acceptable instrument for alloy analyser shall be either “Portable X-ray

fluorescence” or “Optical Emission Spectro Analyser” type capable of verifying the percentage of alloy elements within specified range.

4.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current

methods are not acceptable for PMI examination.

4.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the specified range.

4.6 Each analyser must be calibrated according to the manufacturer’s specification at the

beginning and end of each shift. Instrument must be checked against known standard for each alloy type to be inspected during the shift.

4.7 Certified samples with full traceability of “known” alloy materials shall be available for

use as a random spot check on the instrument calibration.

4.8 The surface to be examined shall be prepared by light grinding or abrasive paper and solvent cleaner. Evidence of arc burn resulting from examination shall be removed by light grinding or abrasive paper.

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4.9 Alloy steel type joint gaskets shall only be inspected by using portable X-ray fluorescence instrument.

4.10 Testing shall be done as per the procedures outlined by the manufactures of alloy

analyser being used. Modification of these procedures if any, must be approved by Purchaser.

4.11 The persons performing PMI shall demonstrate their capabilities to the satisfaction of

Owner/PMC/Third Party Inspection Engineer. If the vendor has qualified operator in his rolls, he may perform the examination. Otherwise PMI examination shall be sub contracted to an independent testing agency.

4.12 Whenever materials, items and welds are identified as not meeting requirements by

the visiting engineer a rejection note shall be issued. The above shall be marked with a red “R” pending resolution.

5.0 EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various alloy items.

A. Flanges, Fittings, Valves, RTJ Gaskets

: 100%

B. Pipes : 100% (for pipes procured from traders).

10% random samples (minimum 2 Nos.) drawn from each size/Heat/Lot (for pipes procured directly from mills).

C. Tubes for heat transfer service : 100% (for tubes procured from traders).

Spot checking by sampling 1% of the tubes or 25 nos. whichever is less (for tubes procured directly from mills.

D Fasteners

:

Lot Size Sample Size

Upto 100 2% (Min 2)

101 to 500 1% (Min 3)

501 and above 0.5% (min 5) 6.0 RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in the PMI Report Form as enclosed with this specification.

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7.0 MARKING

7.1 All alloy materials tested by PMI shall be identified using either of the following methods by indicating “AV”

a) Electro – etching b) A low stress stamp marking c) Hologram Sticker d) Vibro – etching e) Colour Coding

Location of markings will be near to vendor’s monogram, material specification, heat number / cast number, welders stamp, etc as applicable.

8.0 ATTACHMENTS

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PMI REPORT FORM – ALLOY BULK MATERIAL

ATTACHMENT 8.1

TYPICAL POSITIVE MATERIAL IDENTIFICATION REPORT : ALLOY STEEL BULK MATERIALS Page ….of ….

Project : Client : Job No. :

PMI Report No. : Vendor / Sub-Vendor :

Purchase Order No. : Testing Agency :

Purchase Requisition No. PMI Location :

Bulk Item Type (as per Requisition)

Material Specification / Grade :

Number of items in Lot :

Requisition Item No. Description : Alloy Content Weight Percent Remarks Accept/Reject

Cr. Mo Ni V

Instrument Type / ID

Source Age Source dt.

Last Service Date :

PMI Examination by :

Approved by Vendor Witnessed by

Company

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ENGINEERS

TECHNICAL NOTES FOR 5fg-ar I~-3dg INDIA LIMITED PIPES

IA GoN of Indo Undeflakng)

STANDARD SPECIFICATION No.

6-44-0051 Rev. 6 Page 1 of 10

lebri ch i•JA

TECHNICAL NOTES FOR PIPES

6 25.09.14 REVISED AND ISSUED AS STANDARD SPECIFICATION SH' K ATD(‘'\:' SC

5 31.12.13 REVISED AND ISSUED AS STANDARD SPECIFICATION UK SH AK RN SC

4 04.07.08 REVISED AND ISSUED AS STANDARD SPECIFICATION RN SC DM VC

3 15.03.00 REVISED AND ISSUED AS STANDARD SPECIFICATION RN BRB NS AS

2 04.04.94 HYDROTEST & I.G.C. TEST CLAUSES REVISED

AKG BPV GRR AS

Rev. No

Date Purpose Prepared

by Checked

by

Standards Committee Convenor

Standards Bureau

Chairman

Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

of 49

ENGINEERS TECHNICAL NOTES FOR INDIA LIMITED

PIPES IA Govt ot Intha Undertalfing)


6-44-0051 Rev. 6 Page 2 of 10

rivvottt.1.5trool,

Abbreviations:

ANSI American National Standards Institute API American Petroleum Institute ASME American Society of Mechanical Engineers ASTM American Society for Testing & Materials BHN Brinell Hardness Number BIS Bureau of Indian Standards E.FS.W Electric Fusion Weld E.R.W Electric Resistance Weld HAZ Heat Affected Zone HIC Hydrogen Induced Cracking IBR Indian Boiler Regulations IGC Inter Granular Corrosion IS Indian Standard LT Low Temperature MR Material Requisition NACE MR National Association of Corrosion Engineers : Material Requirement NB Nominal Bore NPT Nominal Pipe Thread PMI Positive Material Identification PR Purchase Requisition SMYS Specified Minimum Yield Strength SS Stainless Steel

Piping Standards Committee

Convenor : Mr. R. Nanda

Members : Mr. M. Ismaeel Mr. Amrendra Kumar Mr. G. Balaji Mr. K.J. Harinarayanan (HMTD) Mr. P P Lahiri / Mr. S. Ghoshal (SMMS) Mr. S. Mukherjee (Construction) Mr. K.V.K. Naidu (Projects)

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved

of 49

$;fgW 2154- 1+fV7R rwnrt ,151,70541,

ENGINEERS TECHNICAL NOTES FOR INDIA LIMITED IA Govl of lodia Undeftalong)


6-44-0051 Rev. 6 Page 3 of 10

PIPES

CONTENTS

1.0 GENERAL 4

2.0 IBR PIPES 6

3.0 ACCEPTABLE DEVIATIONS 7

4.0 HYDROSTATIC TEST 7

5.0 MARKING AND DESPATCH 10

6.0 REFERENCES 10


Copyright EIL —All rights reserved

of 49

ENGINEERS TECHNICAL NOTES FOR 2f5le'g INDIA LIMITED PIPES

IA Govl ol lnaia Undertakog)


6-44-0051 Rev. 6 Page 4 of 10

1.0 GENERAL

1.1

A11 pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydrostatic test and other testing and marking requirements shall conform to the latest codes and standards specified in the material requisition (MR). Supplier shall strictly comply with MR/PR stipulations and no deviations shall be permitted. Post Order Concession/Deviation Permit 5-0000-0180-F1 as mentioned in Cl. 5.18 of Specification for Quality Management System Requirements from Bidders (6-78-0001) is not applicable.

1.2 Testing

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

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

1.2.3 PMI shall be performed as per the scope and procedures as defined in the spec for PMI at Supplier's Works (6-81-0001).

1.2.4 Refer to specification nos. 6-81-0002 and 6-81-0003 for Inspection & Test plans for welded pipes and seamless pipes respectively.

1.3 Manufacturing Processes

1.3.1 Steel made by acid Bessemer process shall not be acceptable.

1.3.2 A11 longitudinally welded pipes should employ only automatic welding.

1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters respectively.

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

b. Unless otherwise mentioned in the respective material code, E.FS.W pipes < 36" shall not have more than one longitudinal seam joint and E.FS.W pipes 36" shall not have more than two longitudinal seam joints.

1.6 Pipe with screwed ends shall have NPT external taper pipe threads conforming to ASME/ANSI B1.20.1 up to 1.5" NB & IS 554 for 2" to 6" NB.

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0

of 49

wlrrT t,vcrtV ItISOIstt)

ENGINEERS TECHNICAL NOTES FOR INDIA LIMITED PIPES IA Govt ol Intlia Gott000k,o9)


6-44-0051 Rev. 6 Page 5 of 10

1.7 Pipe with beveled ends shall be in accordance with ASME B16.25. Weld contours shall be as follows:

Material Wall Thickness Weld Contour

Carbon Steel (Except Low Temp. Carbon Steel)

Up to 22 mm Figure 2 Type A

> 22 mm Figure 3 Type A

Alloy Steel, Stainless Steel & Low Temp. Carbon Steel

Up to 10 mm Figure 4

> 10 mm & Up to 25 mm Figure 5 Type A

> 25 mm Figure 6 Type A

1.8 Galvanized pipes shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM A 153.

1.9 All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilizing heat treatment shall be carried out subsequent to the normal solution annealing. Soaking time & holding temp. for stabilizing heat treatment shall be 4 hrs & 900°C respectively.

1.10 I.G.C. Test for Stainless Steels

1.10.1 For all austenitic stainless steel pipes inter-granular corrosion test shall have to be conducted as per following:

ASTM A262 Practice "B" with acceptance criteria of "60 mils/year (max.)". OR

ASTM A262 Practice E with acceptance criteria of no cracks at 20X magnification and microstructure to be observed at 250X magnification shall ensure the absence of any cracks/ fissures. When testing is conducted as per practice 'E' photograph of microstructure shall be submitted for record.

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

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

All welded pipes indicated as `CRY0' & `LT' in MR shall be impact tested per requirement & acceptance criteria of ASME B31.3. The impact test temperature shall be -196°C & -45°C for stainless steel and carbon steel respectively unless specifically mentioned otherwise in MR.

1.12 NACE/HIC Requirements

1.12.1 Pipes under "NACE" category and those designated as "HIC1" shall meet the requirements given in NACE MR-0103 unless mentioned otherwise.

1.12.2 Pipes made from plates and designated as "HIC1" shall meet the HIC requirements of EIL specification 6-79-0013 unless mentioned otherwise.


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`511 ENGINEEFZS TECHNICAL NOTES FOR 5fga 02-eg INDIA LIMITED

Ift Govt of UnciertaNingf PIPES


6-44-0051 Rev. 6 Page 6 of 10

1.11UR ertcnt ,TR,1-4.1)

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

1.14 For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be 20%.

1.15 All 1Cr-V2Mo and 11/4Cr-1/4Mo seamless pipes shall be normalised and tempered.

1.16 For all welded alloy steel pipes with mandatory requirement of heat treatment and radiography, radiography shall be performed after heat treatment.

1.17 For Hydrogen service pipes following special requirements shall also be met:

1.17.1 All carbon steel pipes having wall thickness 9.53 mm (0.375") and above shall be normalised. Cold drawn pipes shall be normalised after the final cold draw pass for all thicknesses.

1.17.2 All alloy steel (Cr-Mo) pipes shall be normalised and tempered. The normalising and tempering shall be a separate heating operation and not a part of the hot forming operation. The maximum room temperature tensile strength shall be 100,000 psig.

1.17.3 For carbon steel Pipes, hardness of weld and HAZ shall be 200 BHN (max.). For alloy steel Pipes, hardness of weld and HAZ shall be 225 BHN (max.).

1.17.4 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A Ferrite No.(FN) not less than 3% and not more than 10% is required to avoid sigma phase embrittlement during heat treatment. FN shall be determined by Ferritescope prior to post weld heat treatment.

1.17.5 For all Carbon steel and Alloy steel pipes with wall thickness over 20mm, Charpy-V Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-1 for weld metal and base metal from the thickest item per heat of material and per heat treating batch. Impact test specimen shall be in complete heat treated condition and accordance with ASTM A370. Impact energies at 0°Celsius shall average greater than 27J (20 ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).

1.18 For dual grades of SS where specified, chemical composition and mechanical properties of both grades specified shall be ensured.

2.0 IBR PIPES

2.1 IBR Documentation

2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form III-A duly approved and countersigned by IBR authority/local authority empowered by the Central Boiler Board of India(Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance) or Form III-D [for well known pipe manufacturers as per IBR] signed by Manufacturer's authorized representative. Well known pipe manufacturers, as recognized by IBR, shall submit a duly attested copy of Form XVI-G along with Form

2.1.2 For materials 11/4Cr - V2Mo (ASTM A335 Gr.P11 / A691 Gr.11/4Cr), 21/4Cr - 1Mo (ASTM A335 Gr.P22 / A691 Gr.21/4Cr) & 9Cr -1Mo-V (A335 Gr.P91/A691 Gr.91), Form III-A approved by IBR shall include the tabulation of Et, Sc & Sr values for the entire temperature range given below. Et, Sc & Sr values shall be such that throughout the temperature range


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$R-ar 22-eg 1.177, rrmrr an s~›

ENGINEERS TECHNICAL NOTES FOR INDIA LIMITED IA Govt ot India Undertalfingt


6-44-0051 Rev. 6 Page 7 of 10

PIPES

E,/ 1.5

Sr / 1.5

Sc

where ,

SA Allowable stress at the working metal temperature. Yield point (0.2% proof stress at the working metal temperature)

S, The average stress to produce elongation of 1%(creep) in 100000 hrs at the working metal temperature.

Sr The average stress to produce rupture in 100000 hrs at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperature.

SA (psi)

Temp(°F) Material

500 600 650 700 750 800 850 900 950 1000 1050 1100

A335 Gr.P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800

A691 Gr.11/4Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800

A335 Gr.P22 / A691 Gr.21/4Cr

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

A335 Gr.P91/ A691 Gr.91

28100 27700 27300 26700 25900 24900 23700 22300 20700 18000 14000 10300

Note : SA values shall be as per the latest edition prevai ing.

2.2 For carbon steel pipes under IBR the chemical composition shall conform to the following:

Carbon (max)

0.25% Others (S, P, Mn) As prescribed in IBR.

The chemical composition as indicated in this clause is not applicable for pipes other than IBR services.

3.0 ACCEPTABLE DEVIATIONS

3.1 Pipes to IS 3589 Gr.410 are acceptable in place of IS 3589 Gr.330.

3.2 Pipes of Grades SS317 of corresponding material are acceptable in place of Grades SS316 or SS316(2.5 Mo min.).

3.3 Pipes of Grades SS317L of corresponding material are acceptable in place of Grades SS316L or SS316L(2.5Mo min.).

3.4 Seamless pipes are acceptable in place of welded pipes except in the case of welded SS321/SS321H pipes with nominal thickness greater than 9.53mm.

4.0 HYDROSTATIC TEST

4.1 A11 pipes shall be hydrostatically tested.

SA


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~_le7 e5•

ENGINEERS TECHNICAL NOTES FOR INDIA LIMITED

PIPES IA Govt of Incha Undertalting)


6-44-0051 Rev. 6 Page 8 of 10

4.2 The mill test pressure shall be as follows:

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

a) Carbon Steel

Material Std. Test Pressure Std.

ASTM A106 Gr.B ASTM A530

API 5L Gr.B, Seamless API 5L

API 5L, E.R.W. API 5L

API 5L, Spiral API 5L

ASTM A333 Gr.3 & 6, Seamless ASTM A530

ASTM A333 Gr.3 & 6, E.R.W. ASTM A530

b) Seamless Alloy Steel


ASTM A335 Gr.P1, P12, P11, P22, P5, P9 ASTM A530

ASTM A268 TP 405, TP410 ASTM A530

c) Seamless Stainless Steel


ASTM A312 Gr.TP 304, 304L, 316L, 316H, 321, 347

304H, 316, ASTM A999

d) Seamless Nickel Alloy


ASTM B161 UNS No. 2200 ASTM B161




e) Welded Nickel Alloy


ASTM B725 UNS No. 2200,4400 ASTM B725




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41 ENGINEERS TECHNICAL NOTES FOR 01 -eg INDIA LIMITED PIPES

IA Govt of Indo UnclertaNngt


6-44-0051 Rev. 6 Page 9 of 10

4.2.2 Electric Fusion Welded

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


API 5L Gr.B P = 2ST/D ASTM A671 Gr.CC65, 70 (C1.32) S = 90% of SMYS ASTM A672 Gr.C60, 65, 70 (CI.12,22) Except for API 5L Gr.B ASTM A671 Gr.CF60, 65, 66, 70 (C1.32) S = 85% of SMYS ASTM A691 Gr.V2Cr, 1Cr, 11/4Cr, 21/4Cr, For API 5L Gr.B SCr, 9Cr (C1.42) T = Nominal Wall Thickness

D = O.D of Pipe

b) Stainless Steel E.FS.W (2" to 6")

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

Material Gr.1 :ASTM A312 TP 304 / 304H / 316 / 316H / 321 / 347 welded. Material Gr.2 :ASTM A312 TP 304L / 316L welded.

Size Pipe Schedule : 10S Pipe Schedule : 40S Pipe Schedule : 80S

Material Gr. 1

Material Gr.2

Material Gr.1

Material Gr.2

Material Gr.1

Material Gr.2

2" 100 80 155 130 230 190

3" 80 60 155 130 230 190

4" 80 50 155 130 230 190

6" 65 35 90 75 155 130

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


ASTM A358 TP 304L, 304, 304H, 316L, 316, 316H, 321, 347 (Classes 1, 3 & 4)

P = 2ST/D S = 85% of SMYS T = Nominal Wall Thickness D = O.D of Pipe

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

P = 2ST/D S = 72% of SMYS T = Nominal Wall Thickness D = 0.D of Pipe

4.2.3 Carbon Steel Pipes to BIS Standards


IS 1239 IS 1239

IS 3589 IS 3589

4.3 Hydrostatic pressure testing shall be performed using iron free water, which is clean and free of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 50 ppm.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

of 49

STANDARD SPECIFICATION No. ENGINEERS TECHNICAL NOTES FOR

OrcRes INDIA LIMITED 1.1,P+,,M11 J457,01/ IA GoN ol India UnclettaMing)

PIPES 6-44-0051 Rev. 6 Page 10 of 10

5.0 MARKING AND DESPATCH

5.1 All pipes shall be marked in accordance with the applicable codes, standards and specifications. In addition the purchase order number, the item code & special conditions like "IBR", "CRY0", "NACE", "H2" etc. shall also be marked.

5.2 Pipes under "IBR","CRY0", "NACE" & "H2" shall be painted with one circumferential stripe of colour red, light purple brown, canary yellow & white respectively for easy identification. Width of stripe shall be 12mm for pipe sizes lens than 3" and 25mm for pipes 3" and above.

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

5.4 Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

5.5 Pipes shall be protected from rust & corrosion.

5.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a petroleum solvent and the same shall not be harmful to welding.

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

Plain end

Plastic cap Bevel end

Wood, Metal or plastic cover Threaded end

Metal or plastic threaded cap

5.8 Pipes may be provided with plastic push-fit type end caps/ steel caps without belt wire.

5.9 Steel end protectors to be used on galvanized pipes shall be galvanized. Plastic caps can also be used as end protectors for galvanised pipe ends.

6.0 REFERENCES

6.1 6-81-0001: Specification for Positive Material Identification (PMI) at Supplier's Works.

6.2 6-81-0002: Inspection & test plan for welded pipes.

6.3 6-81-0003: Inspection & test plan for seamless pipes.

6.4 6-79-0013: Material requirements for carbon steel components used in sour service for petroleum refinery environments


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ADDITIONAL TECHNICAL REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3211 Rev. A

Page 1 of 2

A 16.01.14 ISSUED FOR BIDS NK KB/UC MI

Rev. No Date Purpose Prepared

by Checked by Approved by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved


(FOR PIPES)

of 49


DOCUMENT No.

A133-000-16-43-ATR-3211 Rev. A

Page 2 of 3



(FOR PIPES)

1. Bidder to note that no correspondence whatsoever shall be entered into or entertained after the bid submission.

2. Bidder shall furnish quotations only for those items, for which he can supply

strictly as per MR specifications and for which he is approved by EIL/Owner.

3. No technical details of any nature shall be included in the offer. If the offer contains any technical deviation or clarification or stipulates any technical specifications (even if in line with the MR requirements), the offer shall be summarily rejected.

4. The submission of prices by the Bidder shall be construed to mean that he has

confirmed compliance with all technical specifications of the corresponding item(s).

5. Bidders shall ensure compliance to all the attachments listed in the “list of

attachment sheet” of the MR, A133-000-WA-MR-3211.

6. Negative tolerance on quantity is not acceptable and positive tolerance on quantity shall be restricted to single random length only. In case the MR quantity is within single random length, the supplied quantity shall be maximum single random length only.

7. For pipes under NACE category Hardness shall be below BH No. 200 for CS

material and Carbon equivalent (CE) shall be limited to 0.43.

8. For Items Specified with requirements of “LUM1”, shall meet the requirements

of “NACE” specified in MR-0103 and Sulphur content in the material is to be

restricted to 0.01% (max). Hardness shall be below BH No. 200 for CS

material. Carbon equivalent (CE) shall be limited to 0.43.

9. Items specified with requirements of “UOP1” shall meet both the requirements

of „NACE” specified in MR-0103 and Indian Boiler Regulations. Sulphur

Content in the material is to be restricted to 0.01% (max). Hardness shall be

below BH No. 200 for CS material. Carbon equivalent (CE) shall be limited to

0.43.

10. Items specified with requirements of “HIBR” shall meet both the requirements

of Hydrogen service (as per clause 1.17 of Technical Notes for Pipes) and

Indian Boiler Regulations (Clause 2.0 of Technical Notes for Pipes).

11. Refer Clause 5.1 of Technical notes for pipes (6-44-0051), in addition to the services mentioned in this clause, the pipes under “LUM1” & “HIC1” shall be painted in sky blue stripes & light orange stripes respectively. Pipes under “UOP1” shall be painted in dual stripes of Red and Sky blue. Pipes under “HIBR” service shall be painted in dual stripes of Red and Sea Green.

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DOCUMENT No.

A133-000-16-43-ATR-3211 Rev. A

Page 3 of 3


12. Clause 5.5 of Technical notes for pipes (6-44-0051), shall be read as below: “Pipes shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage.”

13. The attachment no. 6.1, 6.2 and 6.3 specified in Clause 6.0 of Technical notes for pipes (6-44-0051) to be ignored and replaces as following:

6-81-0001 to be replaced by 44NC-4600-Q-0002-A4 ( Standard Specification For Positive Material Identification At Vendor‟s Works-PMI)

6-81-0002 and 6-81-0003 to be replaced by A133-00-000-ITP-13A (Indicative ITP for seamless and welded pipes).

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