Specifications & Sow

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)
SECTION-V SPECIFICATIONS & SCOPE OF WORK [SOW]
TENDER NO.
Page 1 of 32OF SPECIFICATIONS & SOW SUB: TRANSPORTATION, HYDRO TESTING, WRAPPING COATING & PRESERVATION OF INSURANCE LINE PIPE OF HVJ& DV PIPELINES AT GAIL, JHABUA.
SCOPE OF WORK & TECHNICAL SPECIFICATION

1.0 1.1 1.2 1.3 INTRODUCTION M/s GAIL (India) Limited is one of the major natural gas cross country pipeline operator in India & is operating more than 7500 kmof natural gas pipelines in India. These pipelines are feeding Natural Gas to various Petrochemical, Fertilizer, LPG & Power Plants located along the pipeline route. The pipeline is designed as per ASME B 31.8 &OISD 138 & 141 standards. Various guidelines under API, DIN, BS, Canadian Standards, NACE, NFPA, etc are also followed. GAIL (India) Limited, Jhabua maintains approximately 125.463 kilometers each of HVJ(36OD), DV-I(42OD) & DVII(48OD) pipelines from DevgarhBaria [Dahod district of Gujarat, (HBJChainage229.460km), IP-03 for HVJ&SV-08 for DVPL-I&II] to KasarBardi [Jhabua district of Madhya Pradesh, (HBJChainage 354.923), SV-13 for HVJ&SV-15 for DVPL-I & II] and its associated terminal facilities like IP/ RR &SV stations and also has a compression facility consisting of GTC trains of varying make & capacities along with other auxiliaries required for running the same. Maximum Allowable Working Pressure (MAOP) for these HVJ, DV-I & II pipelines under Jhabua jurisdiction is 92 Kg/Cm2g& pipe is operating as per the said operating condition. To cater to the emergency requirement GAIL (India) Ltd., Jhabua, intends a) To carry out the hydro testing ofcoated line pipes kept as insurance spares b) To take suitable remedial measures to prevent the line pipes from corrosion& ensuring proper preservation. The details of line pipes are given in technical detail section. OBJECTIVE The main objective of this tender is to carry out the following jobs:a. Shifting of 42 OD coated line pipes from GAIL (India) Limited, Vijaipur to GAIL (India) Limited, Jhabua, as per approved procedure. Road distance of GAIL, Vijaipur from GAIL, Jhabua is approximately 400 km (Four Hundred). GAIL, Vijaipur is having pin code of 473112 & is situated in district Guna in the state of Madhya Pradesh, India. b. Hydro testing of 36, 42 & 48 OD coated line pipes of varying wall thickness atrequired pressure as per approved procedure c. Holiday testing of coated line pipes to check the healthiness of the coating as per approved procedure d. Field repair of coating of line pipes having damaged coating as per approved procedure e. Inside painting of pipes as per approved procedure f. Stenciling/ painting of pipe details on its outer& inner surface as per approved procedure g. Stacking of pipes as per approved procedure h. Supply/ fabrication & installation of end caps for line pipes i. Proper documentation of hydro testing & other activities for future reference & records TECHNICAL DETAIL OF PIPELINE Detail of 42 OD coated line pipes to be shifted from GAIL, Vijaipur Sl. Coated Line Pipe Detail Wall Thickness Approximate Total Length No. of the Line pipe of Coated Line Pipe to be in mm Shifted in meter 1 3.2 42 OD API 5L GR X-70 20.6 324
1.4 1.5 1.6 2.0 2.1
3.0 3.1
Approximate Total No. of Coated Line Pipe to be Shifted 27
Detail of coated line pipes to be hydro tested Sl. Coated Line Pipe Detail Wall Thickness No. of the Line pipe in mm 1 2 3 42 OD API 5L GR X-70 48 OD API 5L GR X 70 36 OD API 5L GR X 60 20.6 23.8 22.22
Approximate Total Length of Coated Line Pipe to be Hydro tested in meter 72 72 72
Approximate Total No. of Coated Line Pipe to be Hydro tested 06 06 06
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3.3
Details of coated line pipes to be holiday tested&internallypainted Sl. Coated Line Pipe Detail Wall Thickness of Approximate Total Length of No. the Line pipe in mm Coated Line Pipe in meter 1 2 3 4 42 OD API 5L GR X-70 36 OD API 5L GR X 60 36 OD API 5L GR X 60 36 OD API 5L GR X 60 20.6 22.22 19.05 15.88 324 154 262 178
Approximate Total No. of Coated Line Pipe 27 14 25 16
3.4
Detail of line pipes for supply/fabrication and installation of end cap, stenciling/ painting of pipe details on its outer surface & inner surface & stacking. Sl. Coated Line Pipe Wall Thickness Approximate Total Approximate Total Approximate Total No. Detail of the Line pipe Length of Coated No. of Coated Line No. of End Cap in mm Line Pipe in meter Pipe required 1 2 3 4 5 6 7 42 OD API 5L GR X-70 48 OD API 5L GR X 70 48 OD API 5L GR X 80 48 OD API 5L GR X 70 36 OD API 5L GR X 60 36 OD API 5L GR X 60 36 OD API 5L GR X 60 20.6 23.8 17.5 15.9 22.22 19.05 15.88 324 133 112 44 154 262 178 27 11 09 04 14 25 16 54 22 18 08 28 50 32
4.0 4.1 4.1.1 4.1.2
DETAILED SCOPE OF WORK General Transporting, loading & unloading the pipes from GAIL pipe yard to work location (for hydro testing, holiday testing, coating repair, inside painting etc.) & vice-versa. The line pipes for are PE coated and all possible care must betaken to avoid coating damage during the work. While handing over the pipeline to contractor for different jobs, a joint inspection by GAILs representative & contractor shall be done to check the condition of coating. In case of damage of coating occurred during transportation, handling, stacking, other working etc. by the contractor then same shall be repaired as per direction of EIC without any extra cost to GAIL including supply of all materials. Shifting activities of 42 OD coated line pipes from GAIL, Vijaipur, as mentioned at para 3.1 above shall be consisting but not limited to thefollowing:The line pipes required to be shifted from GAIL, Vijaipur are PE coated and all possible care must betaken to to see that pipes along with coating shall not get damaged at the time of handling, storage & transportation.While handing over the line pipe to contractor for hydro testing, a joint inspection by GAILs representative & contractor shall be done to check the condition of coating. In case of damage of coating occurred during transportation, handling, stacking etc by the contractor then sameshall be repaired as per direction of EIC without any extra cost to GAIL including supply of all materials. All mobile cranes shall have adequately long slings to prevent buckling of pipes and must have hooks with Teflon padding. Coated pipes shall be handled using suitable means & in a manner to avoid damage to coating pipe walls & beveled ends. At the time of transportation pipes shall be stacked in maximum 2(two) layers
4.2 4.2.1
4.2.2 4.2.3 4.2.4
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4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11
4.2.12 4.2.13 4.2.14 4.2.15 4.2.16 4.2.17 4.2.18
Pipes shall be transported by trailers having requisite load bearing capacity and must have proper & valid legal documents. Trucks/ Trailers shall prior to loading be cleaned of debris or any other substance that might damage the pipe. Coated pipes shall be handled by rolling of the pipes on the level beads and padded racks. Cranes of proper capacity and having valid test certificates (issued by any competent authority) shall be used for lifting, loading & unloading of coated pipes. In any case Fork Lifts should not be used for handling of coated pipes. Notarized copy of valid fitness certificate & load test certificate issued by competent authority w.r.t crane & slings (metallic, nonmetallic) deployed for the job shall be submitted to EIC prior to start of the job. Direct contact with steel or hemp slings or with any material whose shape or nature may deteriorate the pipe shall be strictly prohibited. Trucks/ trailers used to transport coated pipes shall have an uninterrupted flat bed of approximately 12 meters length and 2.4 meters width equipped with side stanchions of about 0.9m height. Pipes shall be protected against truck bed by means of at least five nonmetallic cross beams. Nonmetallic separation shall be provided to avoid any damage to coating by side stanchions. Wooden slipper shall be made from good quality SHISHAM wood. After loading suitable nonmetallic slings shall be used to tie the load securely to the truck. During transport, the tension of these slings shall be regularly checked. The pipe ends shall be protected from contact with other metallic materials. Persons engaged in handling, storage & transportation shall follow safety norms. Contractor or his authorized representative (carrying proper photo authentication and duly forwarded by EIC) shall receive the pipes from store in charge of GAIL, Vijaipur& shall sign on the store issue voucher (SIV). Necessary transit insurance shall be arranged by GAIL. Pictorial representation of stacking arrangement of 42 OD coated pipes on trailer for transportation & coated pipe transportation arrangement of 42 pipe on trailer has been placed at annexure I & II respectively. All arrangement w.r.t manpower, machinery, materials required for receiving the pipes at GAIL, Vijaipur, loading in trailers, transportation to GAIL, Jhabua, in transit paper formalities & statutory clearances(if any), unloading at GAIL, Jhabua, stacking etc. shall be the responsibility of the contractor. Hydro testing of 36, 42 & 48 OD coated line pipes of varying wall thickness at required pressure as per approved procedure as mentioned at para 3.2 above shall be consisting but not limited to the following:Transporting, loading & unloading the pipes from GAIL pipe yard to hydro testing location & vice-versa.Pipes shall be transported from pipe yard to hydro testing location&after hydro testing same shall be transported to pipe yard as per instruction of EIC& will be stacked on wooden slipper. The line pipes for hydro testing are PE coated and all possible care must betaken to avoid coating damage during the work. While handing over the pipeline to contractor for hydro testing, a joint inspection by GAILs representative & contractor shall be done to check the condition of coating. In case of damage of coating occurred during transportation, handling, stacking etc by the contractor then same shall be repaired as per direction of EIC without any extra cost to GAIL including supply of all materials. Wooden slipper having width & thickness: 12 and length: as per requirement of pipes, shall be provided by contractor and suitable profile/curvature shall be cut in the wooden slipper to stack the line pipes. Wooden slipper shall be made from good quality SHISHAM wood. All the welding works including edge preparation etc. required for hydro testing of pipes shall be done by contractor & all the consumables including welding machine, generator,hydro testing pumps, water, manpower etc. shall be arrange by the contractor. Utilities like water, electricity etc. may be provided by GAIL on request of contractor on chargeable basis as per terms & conditions of GAIL which shall be completely binding on contractor. Hydro testing may be done either by welding of hydro test header in each pipe or series of pipes may be welded together for hydro testing. However, due to space constrain it will not be possible to carry out hydro testing of more than 50(fifty) meter of length in a single section. Hydro testing shall be done near pipe yard only & space available shall be used for hydro testing. While utilizing the space for hydro testing care must be taken for approach to pipe yard & free movement of vehicles &fire tender. Hydro testing shall be done around at 128.8 Kg/cm2gpressure & hold time shall be minimum four (04) hours in accordance to specification detailed elsewhere in the tender document. Pressure recording from electronic data recorder shall be done & graph plotted from data recorder shall be submitted along with hydro testing report. Cleaning, grading of area, removal of all unwanted vegetation & rubbish where hydro testing is to be done shall be done by the contractor.The contractor shall barricade the layout of proposed area and necessary warning sign boards are to be displayed and shall have to take necessary action for safety.
4.3 4.3.1 4.3.2
4.3.3 4.3.4
4.3.5
4.3.6
4.3.7
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4.3.8 4.3.9 4.3.10 4.3.11 4.3.12 4.3.13 4.3.14 4.3.15 4.3.16 4.3.17
4.3.18 4.3.19 4.3.20 4.3.21 4.3.22 4.3.23 4.3.24 4.3.25 4.3.26 4.3.27
4.3.28 4.3.29 4.3.30 4.3.31
After hydro testing each pipe shall be cut &beveled. Ultrasonic thickness testing of heat affected zone shall be done to check lamination. The beveling shall be done as per instruction of EIC. To facilitate the hydro test in small sections, stacking and line up for welding including arrangement of supports, cleaning of internal surface of line pipe for dirt, dust, mud & other foreign material, repairing of bevels (if required), welding of line pipes shall be done by contractor. Beveling/edge preparation of line pipe shall be as per API1104. Fabrication of end caps/dish-end from CS plate, stiffening end cover and welding the line pipes shall be as per API1104.CS plate of required thickness will be arranged by contractor. Fabrication and arrangement of test header shall be in the scope of contractor. Header should have the provision for connection of pressure gauge, temperature gauge, air vent and drain etc. Making arrangement for hydro test of line pipes including fabrication and welding of test header. The entire fabrication job will be performed as per API 1104, approved procedure and as per direction of EIC. All welding shall be done by welders qualified in accordance with ASME section IX. Contractor shall submit welder qualification record for the running welder being deployed for the job. The welder qualification shall be suitable for the D1A or higher ratingwith proper validity of such qualification. The whole procedure of hydro testing will be witnessed and certified by EIC or his authorized representative. Dewatering and disposal of water at appropriate place, drying the pipes by air blowing including arrangement of air compressor and generator, cutting of welded joints after hydro testing, re-beveling, pipe end ultrasonic test, repairing of coating damages, holiday checking shall be in the scope of contractor. All tools, tackles, equipment, instruments (valves, pressure gauges, recorders etc.) and requisite manpower, power and water supply etc. required to complete the above job in totality will be arranged by contractor as per the requirement and directions of EIC. Utilities like water, electricity etc. may be provided by GAIL on request of contractor on chargeable basis as per terms & conditions of GAIL which shall be completely binding on contractor. Test header fabricated by contractor for hydro testing of coated line pipes shall be subjected to hydro test at a pressure of 128.8 Kg/cm2g prior to putting it into service. Ends of the pipes shall be covered by suitable end seal and payment for supply & installation of end cap shall be done as per relevant SOR. Writing of all necessary information on hydro tested pipes by paints as per direction of EIC The work shall be treated as complete after completing the work in all respects as per specifications, conditions and as directed by EIC. It is contractors responsibility to clean and restore the site to the original conditions to the specification of EIC or his authorized representative. Rate quoted should be inclusive of all the above factors as well as other factors required for completing the job in all respect & same is not mentioned in the tender document. No separate payment shall be made on this regards. The average length of each pipe is 12 Mtrs. The pipe length should not be reduced more than 100mm before and after the job. The bevel angle shall be 37.5 degree with straight face of 1.5mm. The pipe scrap shall be returned back to GAIL Cranes of proper capacity and having valid test certificates (issued by any competent authority) shall be used for lifting, loading & unloading of coated pipes. In any case Fork Lifts should not be used for handling of coated pipes Notarized copy of valid fitness certificate & load test certificate issued by competent authority w.r.t crane & slings (metallic, nonmetallic) deployed for the job shall be submitted to EIC prior to start of the job All the instruments like pressure gauges, dead weight testers etc. which are to be used for hydro test are to be calibrated from NABL/ Govt. accredited testing lab. The calibration certificates are to be submitted to GAIL before the commencement of the hydro test.The reference for calibration shall be accessible as per ISO. Before commencement of work, contractor shall submit a hydro test procedure for the above said line pipe for the approval of EIC.However,ageneral hydro test procedure is enclosed with this tender document which is covering minimum requirements of supply, works and operations to be performed by CONTRACTOR for hydrostatic testing of line pipes.This hydro test procedure specificationsshall be read in conjunction with the conditions of all specifications and documents included in the CONTRACTbetween GAIL and CONTRACTOR. Identity cards should be issued to all the persons deployed by the contractor for carrying out the job. A list of all the persons deployed shall be given to EIC prior to commencement of work. The contractor will submit the field management organogram for the persons to be deployed to carry out the tendered work along with Techno-commercial Bid in enclosed proforma with this document. All arrangement necessary for carrying out this job shall be the contractors responsibility. However, GAIL will extend all possible help in this regard but the same shall not relieve the contractor of his responsibilities. If because of exigency of work, contractor is required to carry out the work round the clock, making all necessary
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4.3.32 4.3.33 4.3.34 4.4 4.4.1 4.4.2
arrangements like relieving his personnel, arranging food etc. for his employees shall be the contractors responsibility without any liabilities to GAIL. The jobs mentioned under Scope of Work shall be carried out as per work procedure, documentation, recommendations of the manufacturers procedure and as per the guidelines/directions of EIC or his authorized representative given from time to time to contractor. All the items supplied by the contractor are to be manufactured and tested as per relevant IS codes.Standard procedure for hydro testing of line pipes as per API/ASME/ANSI. Contractor shall submit the welding procedure and arrange the qualified welder or welder qualification test in accordance with API 1104 at his own expense. Holiday testing of coated line pipes to check the healthiness of the coating as per approved procedure as mentioned at para 3.3 above shall be consisting but not limited to the following:Transporting, loading & unloading the pipes from GAIL pipe yard to testing location & vice-versa.Pipes shall be transported from pipe yard to testing location&after holiday testing same shall be transported to pipe yard as per instruction of EIC& will be stacked on wooden slipper. The line pipes for hydro testing are PE coated and all possible care must betaken to avoid coating damage during the work. While handing over the pipeline to contractor for holiday testing, a joint inspection by GAILs representative & contractor shall be done to check the condition of coating. In case of damage of coating occurred during transportation, handling, stacking etc by the contractor then same shall be repaired as per direction of EIC without any extra cost to GAIL including supply of all materials. Wooden slipper having width & thickness: 12 and length: as per requirement of pipes, shall be provided by contractor and suitable profile/curvature shall be cut in the wooden slipper to stack the line pipes.Wooden slipper shall be made from good quality SHISHAM wood Each coated pipe length shall be checked over 100% of coated surface by means of a holiday detector of a type approved by owner for detecting holidays in the coating. The holiday detector shall be a low pulse DC full circle electronic detectorwith audible alarm and precise voltage control with DIN VDE 0433 Part 2. The holiday detector shall be clearly identifiable by means of an individual number engraved in an identification tag attached to the apparatus. A certificate drawn up by the Supervisory Body, will attest that the apparatus complies with the recognized code. Verification is effected with a high voltage voltmeter HV-40, calibrated by a calibrated testing bench (ball diameter 20 mm) according to 50% method. For a preset scale value of 0.65, the maximum permitted deviation of the output voltage for 5 V can be 15%. For a preset scale value of 8.3 the maximum permitted deviation of the output voltage for 25V can be 10%. Besides the calibration, the HV-cable and handle, the sealing ring, the earthing cable and earthing as well as the carrying case must be accepted by the Supervisory Body. The maximum validity of the certificate is one year. The holiday detector may only be used when the coating is completely dry and after through removal of dirt from the surface. The set voltage for inspection shall be 25 kV. Travel speed shall notexceed 300 mm/s. CONTRACTOR shall calibrate the holiday detector at least once every 4hours of production. CONTRACTOR shall have necessary instruments ordevices for calibrating the holiday detector. Mark the areas on the line pipe surface where holiday observed with a marker not affecting the coating of the pipe. Keep records of the defect locations pipe wise with proper traceability. All arrangement w.r.t manpower, machinery, materials required for completing the above job shall be the responsibility of the contractor. Field repair of coating of line pipes having damaged coating as observed after holiday testing as per approved procedure For small defects following procedure shall be adopted:I. The repair shall be carried out using repair patch made of radiation crosslinked Polyolefin backing, coated on the inside with semi-crystalline thermoplastic Adhesive. II. The repair patch shall have thermal indicators to ensure correct heat is being applied III. The material shall not be older than their period of validity at the time of Application by CONTRACTOR. Deteriorated/decomposed materials shall not be used. IV. Material shall be stored in sheltered storages in the manufacturer's original packing andaway from direct sunlight and in accordance with manufacturer's recommendations.
4.4.3 4.4.4 4.4.5 4.4.6
4.4.7 4.4.8 4.4.9 4.4.10 4.4.11 4.4.12 4.5 4.5.1
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4.5.2
4.5.3
V. The repair material shall be : A. Repair patch shall be cross linked polyolefin with semi-crystalline thermoplasticadhesive (PERP 80patch make of Covalence Raychem or DensolenAS39P tape or equivalent). B. Filler mastic: PERPFILLER of make Covalence Raychem orDensolen mastic W or equivalent. C. Densolen Primer MT25 or equivalent D. PERP melt stick of make Covalence Raychem or equivalent. E. Certified by DIN to meet the requirement of EN12068 stress class CHT 80. VI. APPLICATION PROCEDURE A. The application procedure to be followed for Holiday type of damage shall be inaccordance with manufacturers instructions and minimum requirements specifiedbelow whichever is more stringent. B. Preparation: Remove coating from damaged area with knife, scraper or power brush until the factory coating fully adheres to the steel surface. Use the half round rasp to bevel the edges. C. Scrap off the damaged area and adjacent coating to remove oil, grease, ruse dirt andmoisture. D. Roughen up the surface of the factory coating with emery paper all-round the damaged area (approx. 100 mm). E. Apply Densolen Primer (MT 25) to the damaged area. At least 100 mm each side of the damaged area must be primed. F. Preheating: Preheat the exposed bare metal surface to about 80C and adjacent pipecoating to about 60C with a torch moved back and forth over the surface. G. Application of the Filler: Plastic filler shall be applied to all exposed metal surface. Themastic is heated and smoothed down with a paint scraper to cover all bare metal in amanner such that all entrapped air is removed. H. Application of repair tape : Cut three (03) patches of DensolenAS39P tape in a manner such that it extends50 mm beyond the damaged area in all sides, position it over the damaged area, heat until thetemperature sensitive paint on the outside of the patch changes colour. It shall besmoothed down to confirm with the contour of lap, and shall be freed of any airbubbles or wrinkles. I. Press firmly over the damaged area, one on top of the other, a hard rubber roller may be used to apply more pressure if required. If one patch does not cover the whole area then use 2 per layer. J. To secure the patches, wrap Densolen tape AS39P with a minimum overlap of 15mm around the damaged area and then use similar size R20HT tape system to wrap around AS39P tapes. K. Please follow Annexure-III wherein pictorial representation regarding the repair procedure and material to be used has been detailed. VII. INSPECTION, TEST A. A visual inspection shall be carried out for the following : i. Mastic extrusion on ends of the patch shall be examined. ii. There shall be no sign of punctures or pin holes or bend failure. The externalappearance of the patch shall be smooth, free from dimples, air entrapment orvoid formation. iii. The entire repair patch shall have changed colour uniformly. B. HOLIDAY INSPECTION i. The entire surface of the repaired section shall be inspected by means of a fullcircle holiday detector approved by owner set to a DC Voltage of at least 25KV. Inspection of repaired patch shall be conducted only after it has cooledbelow 50C. For cosmetic type of defects such as minor gauging tearing, scratches which do notindicate holiday during holiday inspection, following procedure shall be adopted : I. The defect area shall be roughened to remove loose polyethylene coating, oil grease,dirt etc. II. This shall be followed by application of repair patch, inspection & test as described above. For bigger defects following procedure shall be adopted I. Contractor shall supply joint coating materials, all equipment and manpower required for a skillful and adequate application of coating in the field in accordance with the guideline described below. II. Contractor shall submit and demonstrate to Company proposed materials and worksprocedures for applying field coating and repair procedures for same. Theseproposed procedures and all materials, equipment and tools used in the work shallbe subject to Companys approval. III. Field joint anti-corrosion coating material shall becold applied tape suitable for a maximum operating temperature of (+) 60C(Tmax) and shall conform to designation EN 12068 C HT 60 UV. In addition the fieldjoint anti-corrosion coating shall comply with the requirements specified below under the heading Functional requirements of Field Joint Coating. IV. Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap.The inner and outer wraps shall be
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asymmetric 3-ply tape with co-extrudedpolyethylene carrier film and butyl rubber adhesive layers on both sides. The innerlayer of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. Theinner and outer wraps are to be spirally wrapped with 55% overlap; equivalent to twolayers each providing a total minimum thickness of 3.0 mm on the pipe body and 2.5mm on the weld.The Contractor shall propose only those cold applied tape coating systems that havebeen previously used in pipelines of size 16" and above and a length of 50 km andabove in a single project for similar operating conditions. V. Please follow Annexure-IV wherein pictorial representation regarding the repair procedure and material to be used has been detailed 4.5.4 Functional Requirements of Field Joint Coating A. Properties of the PE backing and the as applied joint corrosion coating shall be asfollows :
SN 1 2 3 4 5 6
Property Tensile Strength @+25C Ultimate Elongation % @+25C Dielectric withstand KV with 1000Volts/sec Water absorption@+ 25C for 24 hours Volume Resistivity @+25C Resistance to thermal aging at 100C
Unit Requirement 2 N/mm 12 % 250 kv 30 % 0.05 Ohm-cm 1015 % Change inelongation 250
Test Method DIN EN 12068 DIN EN 12068 ASTM D 149 ASTM D 570 ASTM D257 DIN 30672
4.5.5
4.5.6
B. Functional Properties of Joint Coating System (As applied) As applied field joint coating system shall comply with the requirements of DIN EN 12068. Table 1 and 2 corresponding to designation DIN EN 12068 C HT 60 UV, except asmodified below: i. CathodicDisbondment Resistance at Tmaxi.e. 60Cshallbe20mm when tested as per Annexure K of DIN EN 12068. Test shall be carried out at (+)60C. ii. Peel Strength shall be as follows : Peel Strength Unit Requirement for Test Method as per DIN EN 12068 Mechanical Resistance Class C (Minimum) Inner to Inner + @23C N/mm 1.5 Outer to Inner @Tmax N/mm 0.3 Annexure-B Outer to Outer @23C N/mm 1.5 @Tmax N/mm 0.3 To Pipe Surface @23C N/mm 3.5 @Tmax N/mm 0.3 Annexure-C To Factory @23C N/mm 3.5 Coating @Tmax N/mm 0.3 Notes: -[Tmaxshall be (+) 60C] Contractor shall obtain prior approval from Company regarding the manufacturer of thejoint coating material. Complete technical details along with test certificates complyingwith the requirements of clause 4.5.3 and 4.5.4 shall be submitted to Company for thispurpose. The Contractor shall furnish test certificates from an independent DINrecognized / approved laboratory for all the properties required for the specified ENdesignation of field joint coating and the requirements of this specification. For Cold Applied Tape method, preferably following material shall be used:-Primer should be DENSOLEN MT 25. -Inner wrap shall be DENSOLENAS39P tapes having width of 100 mm. -Outer wrap shall be DENSOLENR20HT tapes having width of 100 mm. The materials shall not be older than their period of validity at the time of application byCONTRACTOR. Deteriorated/ decomposed material shall be disposed of and replacedby CONTRACTOR at his own expense. CONTRACTOR shall ensure that the coating materials supplied by him are properlypacked and clearly marked with the following :
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- Manufacturers name - Material qualification - Batch number - Date of manufacturing and date of expiry. 4.5.7 CONTRACTOR shall ensure that the manufacturer has carried out all quality control tests on each batch and manufacturer shall provide test certificates to certify that thesupplied materials meet the manufacturers specifications as indicated in the purchase order and as approved by COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall be submitted by CONTRACTOR to COMPANY prior to application. COMPANY reserves the right to have the materials tested by an independent laboratory. 4.5.8 Materials shall be stored in sheltered storage in the manufacturers original packingand away from direct sunlight and in accordance with manufacturers instructions. 4.5.9 CONTRACTOR shall provide and maintain mobile facilities which contains allnecessary equipment and its spares for cleaning, coating repairs, inspection and tests. 4.5.10 CONTRACTOR shall furnish sufficient number of the following equipment and therequired spares as a minimum for inspection and test purpose for each crew. a) Fully automatic full circle adjustable holiday detector with a visible and audible signal system for inspection of coatings. b) Thickness gauge for measuring thickness. c) Contact type temperature recording thermometer (Digital Pyrometer with flat probe type contact). d) Roughness profile measuring (Stylus) instrument 4.5.11 APPLICATION PROCEDURE 4.5.11.1 General 4.5.11.1.1 The application procedure shall be in accordance with manufacturers instruction andthe minimum requirements specified below whichever are the most stringent andshall be demonstrated to and approved by the Company. Manufacturers expertshall supervise the application and shall be available at site upon request duringqualification of application procedure and during construction at Contractors cost. 4.5.11.1.2 Operators for coating application shall be given necessary instructions and training before start of work, by the Contractor. To verify and qualify the applicationprocedures, all coating applied during the qualification test, shall be removed fordestructive testing until the requirements stated in sections Inspection and Testing of this specification are met. 4.5.11.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be used forthis purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed. 4.5.11.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or open expendable blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be used and Garnet material with the second one (in case the authority having jurisdiction have no objection, the contractor may adopt sand blasting instead of garnet material). During blast cleaning the pipe surface temperature shall be simultaneously more than 5 and more than 3C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than 85%. Prior to surface cleaning the surface shall be completely dry. The surface shall be cleaned to a grade Sa 2 in accordance with Swedish Standard SIS-055900 with a roughness profile of 50-70 microns. Surface roughness profile shall be measured using an approved profile comparator in accordance with ISO 8503-1 and shall be calibrated prior to the start of the work in accordance with ISO:8503-3 or ISO:8503-4. The blast cleanliness shall be checked on every joint and the roughness profile shall be checked 1 every 10 joints. Dust grit or foreign matter shall be removed from the cleaned surface by an industrial vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as perISO:8502-3. The frequency of checking for dust contamination shall be 1 every 10 joints. Blast cleaned field joint shall be coated within 2-4 hours according to the conditionsbelow: - Relative Humidity (RH) > 80% - 2 Hours - Relative Humidity (RH) 70-80% - 3 Hours - Relative Humidity (RH) < 70% - 4 Hours Pipes delayed beyond this point or pipes showing any visible rust stain shall be blast cleaned again. 4.5.11.1.5 The field joint surface shall be inspected immediately after blast cleaning and anyfeature of the steel surface such as weld spatter, scabs, laminations or otherimperfections considered injurious to the coating integrity made visible during blastcleaning shall be reported to the Company Representative and on permission fromCompany Representative, such defects shall be removed by filing or grinding. Pipesaffected in this manner shall be then re-blasted cleaned if the defective area is largerthan 50 mm in diameter. TENDER NO. Page 9 of 32OF SPECIFICATIONS & SOW SUB: TRANSPORTATION, HYDRO TESTING, WRAPPING COATING & PRESERVATION OF INSURANCE LINE PIPE OF HVJ& DV PIPELINES AT GAIL, JHABUA.
4.5.11.1.6 The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating. 4.5.11.1.7 All steel joint surfaces shall be thoroughly examined before the application of thecoating in order to ensure the surface are free of soil, grease, rust, mud, earth or anyother foreign matter. All these substances shall be removed before coating, to theprocedures herein described. 4.5.11.1.8 Protection coating shall be applied on the joints immediately after the completion ofcleaning operation. 4.5.11.2 Application of Cold Applied Tapes In addition to general requirements stated above following shall be taken care of:4.5.11.2.1 Cold applied joint protection tapes shall be of the type which can be applied by spirallywrapping on the pipe. 4.5.11.2.2 Immediately after the completion of surface preparation the approved primer of wet film thickness 150 microns or as per manufacturers recommendation whichever is higher to cover the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating if recommended by the manufacturer. Any dirt on the primed surface shall be removed. If the primer is damaged, the damaged area shall be cleaned and re-primed. 4.5.11.2.3 Approximately 100 mm of tape interleaving paper shall be peeled back and tape shall be applied with the adhesive side to the pipe. Whilst continuously removing the interleaving paper, the tape shall be spirally applied to provide a minimum of 55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air pockets and also continuously smooth out as the wrapping proceeds. The wrapping shall start and finish to give a minimum of 50 mm overlap on to the adjoining yard applied coating. Outer wrap shall also be applied in similar method. 4.5.11.2.4 DENSOMAT wrapping machines to be used for wrapping of cold applied tapes over pipe surface. 4.5.11.2.5 Please follow Annexure-IV wherein pictorial representation regarding the repair procedure and material to be used has been detailed 4.5.11.3 Pre-Qualification of Field Joint Coating System The field joint coating system materials and the procedures proposed by the Contractorshall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shallbe coated with the requirements of this specification and then inspected and tested inaccordance with the requirements of this specification with respect to the following: i) Surface preparation cleanliness, roughness profile and dust contamination ii) Pre-heat temperature (as applicable) iii) Primer thickness iv) As applied coating thickness v) Holiday detection vi) Peel test at (+) 23C& (+) 60C on pipe surface & factory applied coating andat over laps (as applicable). If required to achieve the temperature of (+) 60C,suitable thermal blanket may be used. vii) Visual appearance and void after installation on the body, area adjoining theweld and area adjoining the factory applied coating. (To establish voidsadjoining the weld and factory coating a strip of 50 mm wide and 200 mm longshall be stripped and examined). Company Representative shall witness the tests and inspection. Regular application offield joint coating shall commence only upon successful completion of the prequalificationtesting. After successful completion of the pre-qualification testing as above, the entire fieldjoint coating shall be removed, the pipe surface re-blasted and field joint coating reappliedas per the requirements of this specification. 4.5.12 INSPECTION 4.5.12.1 A visual inspection shall be carried out for the following: - There shall be no sign of punctures or pinholes or bend failure. The external appearance of the coating shall be smooth, free of dimples, air entrapment or void formation. 4.5.12.2 Holiday Inspection The holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in direct contact with the surface of coatingto be inspected. The entire surface of the joint section shall be inspected by means of a full circle holiday detector approved by Company set to a DC voltage of at least 25 kV. 4.5.12.3 As-applied Coating Thickness
TENDER NO.
4.5.13 4.5.13.1
4.5.12.2 4.5.12.3 4.5.12.4 4.5.13 4.5.13.1
Coating thickness shall be checked by non-destructed methods for each field joint.Average thickness of the as-applied coating on pipe body shall be established basedon measurement at min. eight locations i.e. four measurement on either sides of thegirth weld at 3, 6, 9, & 12 Oclock positions. To establish the minimum thickness onthe girth weld, four measurements shall be taken on apex on the weld at 3, 6, 9 & 12Oclock positions. All such measurements shall be recorded. CompanyRepresentative reserves the right to ask for additional measurement at any locationon the field joint coating, whenever doubt arises. REPAIRS If a field joint is detected to be unacceptable after testing as per section 4.5.11 the Contractor shall, at his own cost : - Determine the cause of the faulty results of the field coating. - Mobilize the expert of manufacturer, if required. - Test to the complete satisfaction of the Company, already completed fieldcoatings. - stop field coating until remedial measures are taken against the causes of such faults, to the entire satisfaction of the Company. Contractor shall replace all joint coating found or expected to be unacceptable a persection 4.5.11 of this specification Contractor shall, at his own cost repair all areas where the coating has been removed for testing by the Company. After the coating work on welded joints, fittings and repairs to the coating have been completed the coating as a whole shall be again inspected as per section 4.5.11. DOCUMENTATION Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the Manufacturer and material: - Complete descriptive technical catalogs describing the materials offered along with samples of corrosion coating materials, its properties andapplication instruction as applicable specifically to the project. - Test certificates and results of previously conducted tests, for all properties listed in clause 4.5.4 of this specification. - Reference list of previous supplies, in last 5 years, of the similar materialindicating the project details such as diameter, quantity, operatingtemperature, years of supply, project name, contact person and feedback on performance.
Once the Companys approval has been given, any change in material or Manufacturer shall be notified to Company, whose approval in writing of all changesshall be obtained before the materials are manufactured. 4.5.13.2 Prior to shipment of materials from the Manufacturers Works, Contractor shall furnishthe following documents: i. Test certificates/ results as per Manufacturers Quality Control Procedure for each batch of materials. ii. Specific application instructions with pictorial illustrations. iii. Specific storage and handling instructions. 4.5.13.3 All documents shall be in English Language only. 4.6 4.6.1 Inside painting of pipes as per approved procedureas mentioned at para 3.3 above shall be consisting but not limited to the following:Surface Preparation: I. Surface preparation shall be done as per SSPC-SP-10, i.e.blast cleaning to near white metal cleanliness,unit at least 95% of each elements of surface area is free of all visible residues with desired surface profilefollowingSteel Structure Painting Council, U.S.A standard [surface preparations specifications standard(SSPC-SP)]. II. Surface preparation required as per other standards shall be as follows:a. SWEDISH STANDARD SIS-05-5900 1967 - SA 2 b. NACE USA - NACE #2 c. BRITISH STANDARD BS-4232:1967 SECOND QUALITY III. The contractor shall arrange, at his own cost, to keep a set of latest edition of the above standardsat site. IV. The paint manufacturers instructions shall be followed as far as practicable at alltimes. Particular attention shall be paid to the following: a. Instructions for storage to avoid exposure as well as extremes oftemperature. b. Surface preparations prior to painting. c. Mixing and thinning. d. Application of paints and the recommended limit on time intervalsbetween coats. V. EQUIPMENT
TENDER NO.
All tools, brushes, rollers, spray guns, abrasive materials hand/ power tools for cleaning and all equipment, scaffolding materials, shot/ wet abrasive blasting,water blasting equipment& air compressors etc. required to be used shall besuitable for the work and all in good order and shall be arranged by thecontractor at site and in sufficient quantity. Mechanical mixing shall be used for paint mixing operations in case of two packsystems except that the Engineer-inCharge may allow the hand mixing of smallquantities at his discretion. VI. In order to achieve the maximum durability, one or more of following methods ofsurface preparation shall be followed, depending on condition of steel surfaceand as instructed by Engineer-in-Charge. Adhesion of the paint film to surfacedepends largely on the degree of cleanliness of the metal surface. Propersurface preparation contributes more to the success of the paint protectivesystem: A. Manual or hand tools cleaning. B. Mechanical or power tool cleaning. C. Blast cleaning. VII. Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. The minimum acceptable standard incase of manual or hand tool cleaning shall be St. 2 or equivalent, in case ofmechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blastcleaning it shall be Sa 2 or equivalent as per Swedish Standard SIS-055900-1967/ ISO-8501-1-1988. Where highly corrosive condition exits, then blastcleaning shall be Sa3 as per Swedish Standard. Remove all other contaminants, oil, grease etc. by use of an aromatic solventprior to surface cleaning. VIII. Blast cleaning shall not be performed where dust can contaminate surfacesundergoing such cleaning or during humid weather conditions having humidityexceeding 85%. IX. Irrespective of the method of surface preparation, the first coat of primer must beapplied on dry surface. This should be done immediately and in any case within4 hours of cleaning of surface. However, at times of unfavorable weatherconditions, the Engineer-in-Charge shall have the liberty to control the timeperiod, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer application is taken up. In general, during unfavorable weatherconditions, blasting and painting shall be avoided as far as practicable. X. Procedure of Surface Preparation. A. Blast Cleaning i. Air Blast Cleaning The surface shall be blast cleaned using one of the abrasives: AL202 particleschilled casts iron or malleable iron and steel at pressure of 7kg/cm2gatappropriate distance and angle depending on nozzle size maintaining constantvelocity and pressure. Chilled cast iron, malleable iron and steel shall be in theform of shot or grit of size not greater than 0.055 maximum in case of steel andmalleable iron and 0.04 maximum in case of chilled iron. Compressed air shallbe free form moisture and oil. The blasting nozzles should be venturei style withtungsten carbide or boron carbide as the material for liners. Nozzles orifice mayvary from 3/16 to . On completion of blasting operation, the blasted surfaceshall be clean and free from any scale or rust and must show a grey whitemetallic lusture. Primer or first coat of paint shall be applied within 4 hours ofsurface preparation. Blast cleaning shall not be done outdoors in bad weatherwithout adequate protection or when there is dew on the metal which is to becleaned, surface profile shall be uniform to provide good key to the paintadhesion (i.e.35to 50). If possible vacuum collector shall be installed forcollecting the abrasive and recycling. ii. Water Blast cleaning Environmental, health and safety problems associated with abrasive blastcleaninglimit the application of air blast cleaning in many installations. In suchcase water blast cleaning is resorted to. Water blast cleaning can be applied with or without abrasive and high-pressure water blasting. The water used shall be inhibited with sodium chromate/phosphate. The blast cleaned surface shall be washed thoroughly withdetergents and wiped solvent and dried with compressed Air. For effectivecleaning abrasives are used. The most commonly used pressure for highpressure water blast cleaning for maintenance surface preparation is 3000 to6000 psi at 35-45 liters/ minute water volume and pressure up to 10000 psi andwater volume of 45 liters/ minute provide maximum cleaning. The water blast cleaned surface shall be comparable to SSPC-SP-12/ NACE No. 5. The operation shall be carried out as per SSPC guidelines for water blastcleaning. The indicative values for sand injection is Air : 300 to 400 Cu.ft/ min. Water : 5-10 liter/ min. with corrosion inhibitor Sand : 200-400 lbs/ hr.
TENDER NO.
Nozzle : 0.5 to 1 dia Special equipment for water blast cleaning with abrasives now available shallbe used. iii. Mechanical of Power tool cleaning Power tool cleaning shall be done by using mechanical striking tools, chipping hammers,grinding wheels or rotating steelwire-brushes. Excessive burnish of surface shallbe avoided as it can reduce paint adhesion. On completion of cleaning, thedetached rust mill scale etc. shall be removed by clean rags and/ or washed bywater or stream and thoroughly dried with compressed air jet before applicationof paint. iv. Manual or hand tool cleaning Manual or hand tool cleaning is used only where safety problems limit theapplication of other surface preparation procedure and hence does not appearin the specifications of paint systems. Hand tool cleaning normally consists of the following: i. Hand descaling and/ or hammering ii. Hand scraping iii. Hand wire brushing Rust, mill scale spatters, old coating and other foreign matter, shall be removedby hammering, scrapping tools, emery paper cleaning, wire brushing orcombination of the above methods. On completion of cleaning, loose materialsshall be removed from the surface by clean rags and the surface shall bebrushed, swept, deducted and blown off with compressed air/ steam to remove all loose matter. Finally the surface may be washed with water and dried foreffective cleaning. Coating Procedure and Application: I. Surface shall not be coated in rain, wind or in environment where injuriousairborne elements exists, when the steel surface temperature is less than 5 Fabove dew point when the relative humidity is greater than 85% or when thetemperature is below 40 F. II. Blast cleaned surface shall be coated with one complete application of primer assoon as practicable but in no case later than 4 hrsthe same day. III. To the maximum extent practicable, each coat of material shall be applied as acontinuous film uniform thickness free of probes. Any spots or areas missed inapplication shall be recoated and permitted to dry before the next coat is applied.Applied paint should have the desired wet film thickness. IV. Each coat shall be proper state of cure or dryness before the application ofsucceeding coat. Material shall be considered dry for recoating when anadditional coat can applied without the development of any detrimental filmirregularities such as lifting or loose of adhesion of the under coat. Manufacturerinstruction shall be followed for intercoat interval. V. When the successive coat of the same colour have been specified, alternatecoat shall be tinted, when practical, sufficiently to produce enough contrast toindicate complete coverage of the surface. The tinting material shall becompatible with the material and not detrimental to its service life. VI. Air spray application shall be in accordance with the following: A. The equipment used shall be suitable for the intended purpose, shall becapable of properly atomizing the paint to be applied, and shall beequipped with suitable pressure regulators and gauges. The air caps,nozzles, and needles shall be those recommended by the manufacturerof the equipment for the material being sprayed. The equipment shall bekept in satisfactory condition to permit proper paint application. B. Traps or separators shall be provided to remove oil and condensed waterfrom the air. These traps or separators must be of adequate size andmust be drained periodically during operations. The air from the spraygun impinging against the surface shall show condensed water or oil. C. Ingredients shall be kept properly mixed in the spray pots orcontainers during application by continuous mechanical agitation. D. The pressure on the material in the pot and of the air at the gun shall beadjusted for optimum spraying effectiveness. The pressure on thematerial in the pot shall be adjusted when necessary for change inelevation of the gun above the pot. The atomizing air pressure at the gunshall be high enough to properly atomize the paint but not so high as tocause excessive fogging of paint, excessive evaporation of solvent, orless by overspray. E. Spray equipment shall be kept sufficiently clean so that dirt, dried paint,and other foreign materials are not deposited in the paint film.Any solvents left in the equipment shall be completely removed beforeapplying paint to the surface being painted.
4.6.2
TENDER NO.
F. Paint shall be applied in a uniform layer, with overlapping at the edge ofthe spray pattern. The spray patterns shall be adjusted so that the paintis deposited uniformly. During application the gun shall be heldperpendicular to the surface and at a distance which will ensure that awet layer of paint is deposited on the surface. The trigger of the gunshould be released at the end of each stroke. G. All runs and sags shall be brushed out immediately or the paint shall beremoved and the surface repainted. H. Areas inaccessible to the spray gun shall be painted by brush: if notaccessible by brush, daubers or sheepking shall be used. I. All nameplates, manufacturers identification tags, machined surfaceinstrument glass, finished flange faces, control valve items and similaritems shall be masked to prohibit coating disposition. If these surfaces arecoated, the component shall be cleaned and restored to its originalcondition. J. Edges of structural shapes and irregular coated surface shall be coatedfirst and an extra pass made later. K. If spray gun shown choking, immediately dechoking procedure shall befollowed. VII. Airless spray application shall be in accordance with the following procedure: asper steel structure paint manual vol. 1 & vol. 2. By SSPC, U.S.A., Air less sprayrelies on hydraulic pressure rather than air atomization to produce the desiredspray. An air compressor or electric motor is used to operate a pump to producepressures of 1,000 to 6.000 psi. Paint is delivered to the spray gun at thispressure through a single hose within the gun; a single paint stream is dividedinto separate streams, which are forced through a small orifice resulting inatomization of paint without the use of air. This result in more repaid coveragewith less overspray. Airless spray usually is faster, cleaner, more economical andeasier to use than conventional air spray. Airless spray equipment is mounted on wheels, and paint is aspirated in a hosethat sucks paint from any container, including drums. The unit shall have in builtagitator that keep the paint uniformly mixed during the spraying. The unit shallconsist of in built strainer. Usually very small quantities of thinning are requiredbefore spray. In case of High Build epoxy coating (two pack), 30:1 pump ratiosand 0.020-0.023 tip size will provide a good spray pattern. Ideally fluid hosesshould not be less than 3/8 ID and not longer than 50ft to obtain optimumresults. In case of gun choking, decoking steps shall be followed immediately. VIII. Brush application of paint shall be in accordance with the following: A. Brushes shall be of a style and quality that will enable proper applicationof paint B. Round or oval brushes are most suitable for rivets, bolts, irregularsurfaces and rough or pitted steel. Wide flat brushes are suitable forlarge flat areas, but they shall not have width over five inches. C. Paints shall be applied into all corners. D. Any runs or sags shall be brushed out. E. There shall be minimum of brush marks left in the applied paint F. Surface not accessible to brushes shall be painted by spray, daubers, orsheepkin. G. Manual application by sling (where 6 O clock position of pipe is notapproachable) A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m longsis hold under the pipe by two men. Liquid coating poured on the sling at eachside of the pipe. The men holding this sling move it up and down and walk slowlyforward while fresh coating is poured on the pipe and they manipulate the slingso that an even coating is obtainedall-round the bottom. This work shall be donevery carefully and by experienced personnel. There shall not be any formation ofWhiskers and holes in the coating. The coating film shall be inspected bymirror. IX. For each coat the painter should know the WFT corresponding to the specifiedDFT and standardise the paint application technique to achieve the desiredWFT. This is to be ensured in the qualification trial. 4.6.3 Drying of Coated Surface I. No coat shall be applied unit the preceding coat has dried. The material shall beconsidered dry for re-coating when another coat can be applied without thedevelopment of any film irregularities such as lifting or loss of adhesion ofundercoats. Drying time of the applied coat should not exceed maximum specifiedfor it as a first coat; if it exceeds the paint material has possible deteriorated ormixing is faulty. II. No paint shall be force dried under condition which will cause checking, wrinklingblistering formation of pores, or detrimentally after the condition of the paint.No drier shall be added to paint on the job unless specifically called for in themanufacturers specification for the paint. Paint shall be protected from rain, condensation, contamination snow andfreezing until dry to the fullest extent practicable.
TENDER NO.
4.6.4
Repair of damaged paint surface. I. Where paint has been damaged in handling and in transportation, the repair of damage coating of pre-creation/ fabrication shall be as given below. II. Repair of damaged inorganic zinc silicate primer after erection/ weldding: Quickly remove the primer from damaged area by mechanical scraping andemery paper to expose the white metal. Blasts clean the surfaces possible.Feather the primer over the intact adjacent surface surrounding the damaged area by emery paper. III. Repair of damaged pre-erection and shop priming in the design temperature of90 C to 500 C. - Surface preparation shall be done as per procedure 4.6.4(II) - One coat of F-9 shall be applied wherever damaged was observed on pre-erection/ pre fabrication/ shop primer of inorganic zinc silicate coating(F-9) shall not be applied if damaged area is not more than 5 x 5 cm. 4.6.5 PAINT APPLICATION I. For large flat surface field painting shall be done by airless spray otherwise brushcan be used. 4.6.6 PAINT MATERIALS Paint manufacturers shall furnish all the characteristics of paint materialon printed literature, along with the test certificate for all the specifiedcharacteristics given in thisspecification. All the paint materials shall beof first quality and conform to the following general characteristics as perthe table below. S No. Description Primer(P-6) Finish Paint(F-7) 1 Technical Name Epoxy zinc phosphate High build coaltar epoxy primer coating. 2 Type and composition Two component Two pack polyamide cured polyamide cured epoxy epoxy resin blended with coal/ resin medium, pigmented tar medium, suitably pigmented. with zinc phosphate. 3 Volume solids (approx) 40% 65% 4 DFT (Dry dilm thickness) per coat (approx) 40-50 100-125 2 5 8-10 5.2-6.5 Theoretical covering capacity in M /coat/litre (approx) 6 Welght per litre in kgs/ litre (approx) 1.4 1.5 7 Touch dry at 30 C (approx) After 30 minutes 4 hrs. 8 Hard dry at 30 C (approx) Min.: 8 hrs. 48 hrs. Max.: 3-6 months 9 Over Coating Interval (approx.) Min : 8 hrs Min.: 24 hrs. Max : 3-6 months Max.: 5 day 10 Pot life (approx) at 30 C for two components paints 8 hrs. 4-6 hrs. (approx). 11 Temperature Resistance 80C 125C Notes: 1. Covering capacity and DFT depends on method of application. Covering capacity specified above is theoretical. Allowing the loose during theapplication, minimum specified DFT should be maintained. 2. All primers and finish coats should be cold cured and air drying unless otherwise specified. 3. All paints shall be applied in accordance with manufacturers instruction for surface preparation, intervals, curing and application. The surface preparation, quality and workmanship should be ensured. 4.6.7
List of recommended manufacturers

Company Name P-6 (Epoxy Zinc Phosphate Brand Names F-7 (High Build Coaltar Epoxy
Primer)
ASIAN PAINTS (I) LTD. BARGER PAINT LTD. NEROLAC PAINTS LTD. JENSON &NICHOSONPAINTS LTD. APCODURHB. RO.ZP-PC433 EPILUX 610 AMERCOAT 71 EPILAC ZINC PHOSPHATE PRIMER
Coating)
APCODUR CF 300 EPILUX 555 AMERCOAT 78 HB EPILACSOLVENTLESS COAL TAR EPOXY COATING
TENDER NO.
4.6.8
PAINT SYSTEM
SURFACE PREPARATION
SSPC-SP-10
PAINT SYSTEM PRIMER

1 COATS OF P-6 @40DFT/ COAT
FINISH PAINT
2 COATS OF F-7 @125DFT/ COAT 2 x 125 = 250
TOTAL DFT IN MICRONS(MIN) 290
4.6.9
STORAGE
All paints and painting materials shall be stored only in rooms to bearranged by contractor and approved by Engineer-in Charge for thepurpose. All necessary precautions shall be taken to prevent fire. Thestorage building shall preferably be separate from adjacent building. Asignboard bearing the words PAINT STORAGE NO NAKED LIGHT HIGHLYINFLAMMABLE shall be clearly displayed outside.
4.6.10
COLOUR CODE FOR PIPING

For identification of pipeline, the colour code shall be as per below Table. Paint material for color-coding shall be as specified in clause- 4.6.6. DESCRIPTION GROUND COLOUR FIRST COLOUR BAND SECOND COLOUR BAND Canary Yellow Grey Dark Violet Natural Gas
4.6.11
Colour Bands
As a rule minimum width of colour band for pipes of 36OD& higher shall be 100 mm. Colour band(s) shall be arranged in the sequence shown in clause 4.6.10 and the sequence follows the direction of flow. The relative proportionalwidth of the first colour band to the subsequent bands shall be 4:1,minimum width of any band shall be as per Clause 4.6.11.Paint material for color-coding shall be as specified inclause- 4.6.6.
4.6.12 INSPECTION AND TESTING 4.6.12.1 All painting materials including primers and thinners brought to site bycontractor for application shall be procured directly from manufacturers asper specifications and shall be accompanied by manufacturers testcertificates. Paint formulations without certificates are not acceptable. 4.6.12.2 Engineer-in-Charge at his discretion may call for tests for paintformulations. Contractor shall arrange to have such tests performedincluding batch wise test of wet paints for physical & chemical analysis. Allcosts there shall be borne by the contractor. 4.6.12.3 The painting work shall be subject to inspection by Engineer-in-Charge atall times. In particular, following stagewise inspection will be performedand contractor shall offer the work for inspection and approval of everystage before proceeding with the next stage. The record of inspectionshall be maintained in the registers. Stages of inspection are as follows: a. Surface preparation b. Primer application c. Each coat of paint Any defect noticed during the various stages of inspection shall berectified by the contractor to the entire satisfaction of Engineer-in-Chargebefore proceeding further. Irrespective of the inspection, repair andapproval at intermediate stages of workContractor shall be responsiblefor making good any defects found during final inspection/ guaranteeperiod/ defect liability period as defined in general condition of contract.Dry film thickness (DFT) shall be checked and recorded after applicationof each coat and extra coat of paint should be applied to make-up theDFT specified without any extra cost toowner, the extra cost should haveprior approval of Engineer-in-Charge. 4.6.13 Primer Application After surface preparation the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence of inspector nominated by Engineer-in-Charge. 4.6.13.1 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats, the thickness of each coat and complete coverage should be checked as per provision of this specification. This should be approved by Engineer-in-Charge before application of successive coats.
TENDER NO.
4.6.13.2 The contractor shall provide standard thickness measurement instrumentwith appropriate ranges(s) for measuring.Dry film thickness of each coat, surface profile guage for checking ofsurface profile in case of blast cleaning. Holiday directors and pinholedetector and positector whenever required for checking in case ofimmersion conditions. 4.6.13.3 At the discretion of Engineer-in-Charge, the paint manufacturer mustprovide the expert technical service at site as and when required. Thisservice should be free of cost and without any obligation to the owner, asit would be in the interest of the manufacturer to ensure that both surfacepreparation and application are carried out as per their recommendations. 4.6.13.4 Final inspection shall include measurement of paint dry film thickness.Adhesion Holiday detection check of finish and workmanship. Thethickness should be measured at as many points/ locations as decided by Engineer-in-Charge and shall be within + 10% of the dry thickness,specified in the specifications. 4.6.13.5 The contractor shall arrange for spot checking of paint materials for Sp.Gr.,flow time (ford cup) and spreading rate. 4.6.14 GUARANTEE 4.6.14.1 The contractor shall guarantee that the chemical and physical properties of paint materials used are in accordance with the specificationscontained herein/ to be provided during execution of work. 4.6.14.2 The contractor shall produce test report from manufacturer regarding the quality of the particular batch of paint supplied. The Engineer-in-Charge shall have the right the test wet samples of paint at random, for quality of same as stipulated in clause 4.6.6 above. Batch test report of manufacturers for each batch paint supplied shall be made available bythe contractor. 4.6.15 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND
MANUFACTURERS
Following procedure is recommended to be followed for approval of newmanufacturers. 4.6.15.1 The manufacturer should arrange testing of the inorganic zinc silicatecoating materials as per the list of tests given in para 4.6.15.5 below from oneof the reputed Government laboratories. 4.6.15.2 Samples of coating should be submitted to the Govt. laboratory in sealed containers with batch no. and test certificate on regular format of manufacturers testing laboratory. The sampling shall be certificate and sealed by a citifying agency. 4.6.15.3 All test panels should be prepared by govt. testing agency colouredphotographs of test panels should be taken before and after the test should be enclosed alongwith test report. Sample batch. No. and manufacturers test certificate should be enclosed alongwith the report. Test reports contain details of observation and rusting if any, as per the testing code. Suggested government laboratories are: RRL, Hayderabad HBTI, Kanpur DMSRDE, Kanpur IIT, Mumbai BIS Laboratory UDCT, Mumbai RITES, Calcutta PDIL 4.6.15.4 Manufacturers should intimate the company, details of sample submittedfor testing name of Govt. testing agency, date, contact personnel of theGovt. testing agency. At the end of the test the manufacturer should submit the test report to the company for approval. The manufacturer(s) shall be qualified based on the result of these tests and other assessment and the Companys decision in this regard shall be final and binding on the manufacturer. 4.6.15.5 Tests required for evaluation of acceptance of coating materials foroffshore application. Test ASTM Test Method Density D 1475 Dipping properties D 823 Film Characteristics Drying time Flexibility Hardness Adhesion Abrasion resistance DFT/ Coat Storage Stability Resistance to Humidity for 2000 hrs. TENDER NO. D 1640 D 1737/ D 522 D 3363 D 2197 D 968/ D 1044 AS PER SSPC GUIDELINES D 1849 D 2247
Salt Spray for 2000 hrs. Accelerated Weathering % Zn in DFT 4.7 4.7.1 4.7.1.1
B 117 D 822 G 53
4.7.1.2
4.7.1.3
4.7.2 4.7.3 4.7.4 4.8 4.8.1
Stenciling/ painting of pipe details on its outer & inner surface as per approved procedureas mentioned at para 3.4 above shall be consisting but not limited to the following:Subsequent to completion of hydro testing, holiday testing & its repair, painting of internal surfaces, following things to be written:On each hydro tested pipe (as detailed at para 3.2 above) at both ends on internal surface:A. Pipe OD (e.g. 42) B. Pipe Material (e.g. API 5L GR X-70) C. Wall Thickness (e.g. 20.6 mm) D. Pipe Length (e.g. 11.42 meter) E. Heat No. F. Hydro test Pressure (e.g. 128.8 kg/cm2g) G. Date of Hydro testing (e.g. 15.05.2012) H. GAIL Material Code (e.g 1234567890) On each non hydro tested pipe (out of the lot as detailed at para 3.4 above) at both ends on internal surface:A. Pipe OD (e.g. 42) B. Pipe Material (e.g. API 5L GR X-70) C. Wall Thickness (e.g. 20.6 mm) D. Pipe Length (e.g. 11.42 meter) E. Heat No. F. GAIL Material Code (e.g 1234567890) Oneach pipe as detailed at para 3.4 above on the outer surface at two locations (approximately diametrically opposite) A. HYDRO TESTED / NON-HYDRO TESTED INSURANCE PIPE (as the case may be) AGAINST HBJ / DVPL-I / DVPL-II (as the case may be) B. Pipe OD (e.g. 42) C. Pipe Material (e.g. API 5L GR X-70) D. Wall Thickness (e.g. 20.6 mm) E. Pipe Length (e.g. 11.42 meter) F. GAIL Material Code (e.g 1234567890) Font style & its size shall be decided later on considering its visibility & space availability. Paint color shall be contrast to background color for easy visibility. Paint material shall be suitable considering pipe coating material. Stacking of pipes as detailed at para 3.4 above as per approved procedure The CONTRACTOR shall load, unload, transport and stockpile the coated pipes usingapproved suitable means and in a manner to avoid damage to the pipe and coating.CONTRACTOR shall submit to the COMPANY, a complete procedure indicating themanner and arrangement used for handling and stacking of coated pipes for COMPANYapproval prior to commencement of handling operations. Use of vacuum lifting equipment is preferred. Hooks may also be used for handling the pipes provided they have sufficient width and depth to fit the inside of the pipe andcovered with soft material like rubber, teflon or equivalent, so as not to cause damages to bevel or pipe ends. During hoisting, cables/wire ropes shall have sufficient inclination compared to pipe axis so that they do not come into contact with external coating. Coated pipes may be handled by means of slings and belts of proper width (minimum60mm) made of non-metallic/non abrasive materials. In this case, pipes to bestacked shall be separated row by row to avoid damage by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings is prohibited. During handling, suitable handling equipment with proper length of booms shall be used. Before lifting operations it is essential to ensure that the pipe surface is free from foreign material with sharp edges. Belts/slings when used shall be cleaned to remove hard materials such as stone, gravel etc. Coated pipes shall not be bumped against any other pipe or any other objects. Rolling, skiding or dragging shall be strictly forbidden. Coated pipes at all times shall be stacked completely clear from the ground so that thebottom rows of pipes remain free
4.8.2
4.8.3 4.8.4
4.8.5
TENDER NO.
4.8.6
4.8.7
4.8.8 4.8.9 4.8.10 4.8.11 4.8.12 4.8.13 4.8.14
4.8.15 4.8.16 4.8.17 4.8.18 4.8.19 4.9 4.9.1 4.9.2 4.9.3 4.9.4 5.0 5.1
from any surface water. The coated pipes at all times shall be stacked by placing them on wooden supports provided with suitable cover. This cover can, for example, consist of dry, germ free straw with a plastic film, otherwise foam rubber (each having thickness of minimum 0.5) may be used. Thickness of The supports shall be spaced in such a manner so as to avoid permanent bending of the pipes. The pipes shall be stacked so that theuncoated beveled ends are in line at one end thus making differences in length clearly noticeable. Stacks shall consist of limited number of layers so that the pressure exercised by thepipe's own weight does not cause damages to the coating. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld bead of pipes shall be positioned in such a manner so as not to touch the adjacent pipes. The CONTRACTOR shall prepare and furnish to COMPANY aprocedure/ calculation generally in compliance with API 5L RP 5L1 for pipe stacking, which shall be approved by COMPANY prior to commencement. However in general no. of layers during stacking shall not exceed four (04) which can be increased if only supported by calculation as per API 5L RP 5L1. All mobile cranes shall have adequately long slings to prevent buckling of pipes and must have hooks with Teflon padding. Coated pipes shall be handled using suitable means & in a manner to avoid damage to coating pipe walls & beveled ends. Cranes of proper capacity and having valid test certificates (issued by any competent authority) shall be used for lifting, loading & unloading of coated pipes. In any case Fork Lifts should not be used for handling of coated pipes. Notarized copy of valid fitness certificate & load test certificate issued by competent authority w.r.t crane & slings (metallic, nonmetallic) deployed for the job shall be submitted to EIC prior to start of the job. Direct contact with steel or hemp slings or with any material whose shape or nature may deteriorate the pipe shall be strictly prohibited. Wooden slipper on which pipes shall be stacked shall be made from good quality SHISHAM.Wooden slipper having width & thickness: 12 and length: as per requirement of pipes, shall be provided by contractor and suitable profile/curvature shall be cut in the wooden slipper to stack the line pipes (The radius of curvature of the wooden sleeper shall not be less than the pipe radius). For an approximately 12mtr length pipe three(03) nos. wooden sleeper shall be provided along the length of the pipe& three nos. dust pad separator/ nylon bound saw (dimension 670 x 75 x 35 mm) shall be provided in between each pipe which is stacked over other pipe(s). The bearing supports to be spaced equidistant & the distance of supports from pipe end shall not be less than 85 cm and not more than 1.8 mtr. Pipes having same OD, thickness & gradeshall be stacked together. Persons engaged in handling, storage & transportation shall follow safety norms. All arrangement w.r.t manpower, machinery, materials required for proper stacking of the pipes as detailed above shall be in the scope of the contractor. Supply/ fabrication & installation of end caps for line pipes as detailed at para 3.4 above End cap for the line pipes mentioned in 3.4 shall be fabricated/supplied and installed by the contractor and it shall consist but not limited to followings; Supply & installation of end cap for the line pipes mentioned in 3.4. End cap shall be made of either plastic/rubber/GI sheet/MS sheet. End covers should have provision for easy taking out & refitting so that in case of requirement of inspection of internal surfaces of the line pipes at a later date, same can be done easily. These end caps are required as a measure against corrosion prevention. MATERIAL TO BE SUPPLIED BY CONTRACTOR All the materials, equipment, instruments, manpower (skilled, unskilled), consumables, tool-tackles, required to carry out the jobs are in the scope of contractor. The contractor will famish the details of the tools tackles/equipment, instruments etc deployed at the site. All the material required (like nipple, weldolet/Sockolet/thredolet, valves, line pipes etc) for fabrication of test header shall be in the scope of contractor. Any special tool-tackles, recorders, dead weight tester, pressure recorder/plotter, power source etc. including any other requisite materials for carrying out the work shall be arranged and brought to the site by the contractor without any extra cost of GAIL.
5.2 5.3
TENDER NO.
5.4 5.5 5.6 5.7
5.8
The contractor shall arrange & deploy the requisite qualified manpower to carry out the job mentioned in tender document. Materials required for stacking & holding the pipes during welding & hydro testing. During hydro testing pipes shall be hold firmly to avoid any deflection/movement and all the arrangement shall be done by the contractor. Arrangements of Cranes, trailers, vehicles suitable for lifting and transportation of line pipes to carry out the tendered works. Arrangement like water for hydro testing & their disposal after hydro testing, hydro testing pumps, manpower, data recorder etc& other tools required for hydro testing. Utilities like water, electricity etc. may be provided by GAIL on request of contractor on chargeable basis as per terms & conditions of GAIL which shall be completely binding on contractor. Arrangement of water and power/electricity to carry out the tendered work. Utilities like water, electricity etc. may be provided by GAIL on request of contractor on chargeable basis as per terms & conditions of GAIL which shall be completely binding on contractor. WORK PROCEDURE/ HYDROSTATIC TEST PROCEDURE Before commencement of work, contractor shall submit a hydro test procedure in detail for the above mentioned line pipe for the approval of EIC. The procedure shall strictly comply with the requirements of this tender and shall be submitted to EICfor approval well in advance. The pipeline shall be tested in accordance with the requirements of the latest edition of ANSI B 31.8 or ANSI B 31.4, OISD 226, API-1110 as applicable, and requirements as laid down below. The line pipe shall be hydrostatically tested at pressure 128.8 Kg/Cm2g; however, the maximum hydrostatic pressure shall not exceed the pressure required to produce a hoop stress equal to 95 percent of SMYS of the pipe material based on minimum wall thickness in the test section. The test duration shall be a minimum 04(four) hours. Pressure variations during testing shall be acceptable, if caused by factors other than leakage, like temperature variations. Welding shall be done as per API 1104. Only qualified welder shall be deputed on the site. Welder qualified by EIL/BV/Tractabel/Mecon/JP Kenny for welding of similar line pipes shall be acceptable & welder should not be idle for more than six months. Before starting welding, contractor shall submit the welding procedure as per API 1104 for approval of EIC. Contractor shall also submit the detail of electrode to be used along with their batch test certificate.Arrangement of welding electrode shall be in the scope of the contractor. HYDROSTATIC TEST PROCEDURE MANUAL Hydro testing procedure to be submitted by bidder shall also have following information in addition to information given in 6.1. A schematic diagram indicating all fillings, vents, valves, temporary connections and other provision of test header. The diagram shall also indicate injection locations, intake and discharge lines. Estimated amount of test water, water sourcesincluding required concentration ofcorrosion inhibitors and additives, procedure for inhibitor injection and control ofconcentration. Filling and flushing procedures, including a complete description of all proposedequipment and instruments (including spares), their location and set-up. Procedures for leveling and stabilization after filling and for pressurization and to allowfor temperature stabilization. Pressure testing procedure including a complete description of all proposed equipment and Instruments (Including spares), their location and set-up and proposed system for observation and recording of data during the pressure test. Procedure for deflection and location of leaks. Procedure for dewatering the pipeline section(s) after testing, including a complete description of all proposed equipment and instruments, (including spares), their location and set-up. Forms for recording the test data. The entire work shall be carried out in the presence of GAILs authorized representative deputed by the EIC Before stacking holiday testing of line pipes shall be done & if defect found shall be repaired. However, material required for repairing the same shall be done by supplied by GAIL as free issue material.
6.0 6.1
6.2 6.3
6.4 6.5 6.6
6.7
6.8
6.8.1 6.8.2 6.8.3 6.8.4 6.8.5 6.8.6 6.8.7 6.8.8 6.9 6.10
TENDER NO.
6.11 6.12 6.13
If required, necessary clearance from competent authority shall be obtained by the contractor to carry out the job. Entire area shall be barricaded by means of barricading tapes. EQUIPMENT AND INSTRUMENTATION Contractor shall also submit the detail of equipment to be deployed on the site. Minimum recourses to be deployed shall be following but not limited; Crane/hydra/ side boom of appropriate/suitable capacity for lifting of pipes Trailer of suitable capacity for transportation of pipes. Welding machines along with power sources & related tools, tackles, equipment: minimum 02 Nos. Minimum 02 team of welder, rigger, fitter grinder, etc. Fill pumps: The CONTRACTOR shall determine the type and number of fill pumpsin order to guarantee the following: Differential head 20% greater than the maximum required. Flow rate:400m3 / hr. min.;1000m3 / hr. max.If a single pump is used, a standby unit must be available. Minimum two numbers of variable speed positive displacement pumpsequipped with a stroke counter topressurize the line with a known stroke and capable of exceeding the maximum testpressure by at least 20 bar. Two positive displacement meters to measure the volume of water used for fillingthe line. These meters shall be provided with a calibration certificate not older thanone month. Portable tanks of sufficient size to provide a continuous supply of water to the pump during pressurizing. Bourdon Pressure gauges of suitable pressure range and accuracy. Dead weight testers with an accuracy of 0.01 bar measuring in increments of 0.05 bars provide with a calibration certificates not older than one month. Two 10 hours recording pressure gauges tested with charts and ink gauges tested withdead weight tester prior to use. These shall be installed atthe test heads. Pressure recording charts. Means to measure the volume of water necessary to drop the line pressure by 0.5 bar(container on scales or graduated cylinder). Injection facilities to inject additives into the test medium in the required proportions. PROCEDURES The test medium shall be soft non-aggressive water furnished by the CONTRACTOR. Thewater to be used shall be filtered, shall not be contaminated, and free from sand or silt.CONTRACTOR shall provide COMPANY approved corrosion inhibitors, oxygenscavengers and bactericides to be added to the test water. The CONTRACTOR shall furnishand install all temporary piping which may be necessary to connect from source of water to itspumps and manifolds/ tankage. Before filling operation the CONTRACTOR shall clean the pipeline by air to remove all mill scale rust/ sand from the inside ofpipe section. For these purpose temporary headers for air cleaning shall be attached to thepipeline. Pressurization Pressurization shall be performed in the presence of EIC or his authorized representative at moderate and constant rate not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel with thedead weight tester. The pressurizing shall be cycled according to the following sequence: a) Pressurize to 50% of test pressure, hold pressure for 1 hour. b) Drop pressure to Zero (0) Kg/Cm2g. c) Pressurize to 75% of test pressure, hold pressure for 1 hour. d) Drop pressure to Zero (0) Kg/Cm2g. e) Pressurize to test pressure. f) Hold pressure for 4(Four) hrs.
6.13.1 6.13.2 6.13.3 6.13.4 6.13.5
6.13.6 6.13.7 6.13.8 6.13.9 6.13.10 6.13.11 6.13.12 6.13.13 6.13.14 6.14 6.14.1
6.14.2 6.14.3
TENDER NO.
6.14.4
In case, during the hold pressure periods indicated above, a decrease in pressure is observed, the operations shall not be repeated more than twice, after which the line shall not beconsidered capable of test,until the CONTRACTOR has isolated and eliminated the cause forthe lack of water tightness. Testing After the section has been pressurized to test pressure (i.e128.8 Kg/Cm2g) the pressure shall be held for a minimum of 04 hours after stabilization. After temperatureand pressure has stabilized, the injection pump shall be disconnected and all connections atthe test heads shall be checked for leakage. The pressure recorders shall then be started withthe charts in a real time orientation for continuous recording throughout the test. During the testing period the following measurements shall be recorded: - every one hour pressure measurements form dead weight testers. All data shall be recorded on appropriate forms. Care shall be taken that the maximum test pressures are not exceeded. ACCEPTANCE The hydrostatic test shall be considered as passed if pressure has kept a constant value throughout the test duration, except for change due to temperature effects. If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shalldetermine by search the location of leakage or failure. All leaks and failures [if caused due to lapses (e.g exceeding the test pressure/ not following the test procedure systematically etc.) on the part of contractor] within the pipewall or weld seam shall be repaired by replacement of entire joint or joints in which leakage orfailure occurs by the contractor. In circumferential welds the method of repair shall be determined by theCOMPANY. After completion of leakage arresting &repairs, the hydrostatic test shall be repeated infull, as per the procedure stated above. In case the failure is not due to contractors lapses then test for that particular section shall be deemed to be completed. The cost of repairs or replacements, followed by refilling and repressurizing the line, due to poor workmanship, shall be borne by the CONTRACTOR. In the event of leaks or failures resulting from faulty GAIL furnished materials, CONTRACTOR shall be reimbursed for furnishing all labour, equipment, materials, except those materials furnished by the COMPANY, and transportation necessary to repair and repressurize the section of the pipeline to thepressure at the time of recognition of leak or line failure. CONTRACTOR shall be entitled forcompensation as per the provisions of the CONTRACT. All work of reinstalling line pipe, toreplace pipe failures shall be done in accordance with the relevant specification as decided by EIC. CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations designated by the COMPANY. All cracks and splice resulting from failures shall be coated with an application of grease to preserve the characteristics of failures from corrosion. Joint of failed pipes shall be marked with paint, with a tag indicating failure details, date and location of failure and pressure at which failure occurred. TERMINATION After the positive results of testing and collection of all data the test shall be terminated uponwritten approval given by the EIC. CONTRACTOR shall dewater the tested line in a moderate rate as per the following requirement after test acceptance. During dewatering, care shall be taken to properly dispose the discharging water in order toavoid pollution, damages to fields under cultivation and/or existing structures and interferencewith the traffic. Before start of dewatering and disposal of hydrotest water, a procedure fortreatment of inhibited water to prevent pollution shall be submitted by contractor to EICfor review and approval. TEST REPORT A complete report signed by CONTRACTOR and the EIC or his authorized representative shall be submitted uponcompletion of the hydrostatic test for each test section. This report shall contain as a minimum: - The cleaning, flushing, filling and testing procedures used; - Schematic layout of cleaning, filling and testing facilities; - Instruments calibration certificates; - A profile of the pipeline that shows the test sites, all instrument and injection connections; - Pipe filling logs and records;
6.15 6.15.1 6.15.2
6.15.3
6.15.4
6.16
6.16.1 6.16.2
6.17 6.17.1
TENDER NO.
6.18 6.18.1
- Additive specification, required concentration and additive injection records; - Pressurization and stabilization records; - Pressurerecording charts with appropriate information inscribed thereon; - Dead weight tester logs and recording; - Depressurization logs and records; - Dewatering procedure and schematic layout of relevant facilities; - Dewatering logs and records; - Records and photograph of all leaks. MEASUREMENTS Pressure Measurement Pressure shall be measured with a dead weight tester with an accuracy of 0.01 bar that shall permit readings ofat least 0.05 bar. During the test the pressure shall be recorded by means of a pressure recorder featuring the following specifications: Accuracy: 0.1% of the full-scale value Recording: continuous on tape or disk, graph width 100 mm Feed: 20 mm/h for tape diagrams, 7.5/h for disk diagrams Recording: to be such as to record pressure between 50% and 90% of the diagram width. The pressure recorder shall be checked by means of dead weight tester at the beginning, during and at the end of the hydrostatic test. A pressure gauge tested with dead weight tester shall be connected in parallel to the dead weight tester at the test head. PRECAUTIONS DURING THE TEST In addition to all that has been expressly described in the procedures for carrying out thetests, the following additional requirements shall be complied with: Provision shall be made for the installation of no-admittance signs to unauthorized personnel. Signs stating "PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed where the pipeline is tested. Such areas shall be suitably fenced in such a way as to prevent access ofunauthorized personnel. No unauthorized personnel shall be closer than 40 m to the pipelineunder test. The test station shall be placed in such a location as to prevent it from being affected by acatastrophic failure in the test head. Identity cards should be issued to all the persons deployed by the contractor for carrying out the job. A list of all the persons deployed shall be given to EIC prior to commencement of work.
6.19 6.19.1 6.19.2 6.19.3 6.19.4
TENDER NO.
STANDARD PROCEDURE SPECIFICATION NO. HYDROSTATIC TEST REPORT Pump Location __________________________________________________________________________ Length of Section _________________ ____Volume of Section ___________________________________ Test Press: Recorded ______________ KG/CM2, Max _______ KG/CM2, Min._______ KG/CM2, Pipe Tested (Size, W.T., Grade, Type and Manufacturer) _________________________________________ Type and source of test Medium: ___________________________________________________________ Time and Date of Test started A.M.____________________________________________________ P.M.____________________________________________________ Time and Date of Test completed A.M._____________________________________________________ P.M._____________________________________________________ Section Accepted _____________ Section leaking ________________ Section Ruptured________ Location and type of failure:
Remarks :
Signature of GAIL Representative with Seal
ContractorsSignature
with
Seal
TENDER NO.
HYDROSTATIC TEST REPORT DATE: _________ TEST SECTION REF.NO. __________ TEST NO. ____________________ 1. Min. Pressure 2. Max. Pressure Test started on ___________________ Test Pr. Stabilized on ______________ Test completed on ________________ Pressure gauge reading Least count: ________________________ Gauge type _______________ Time (in hrs.) Pressure Tester Reading Gauge Pressure Reading Bar/G Pipe Temp. Time (in hrs.) Pressure ------------------------------Pressure Test Reading Gauge Pressure Pipe Temp. at _____________________ at _____________________ at _____________________
Work Interruption if any:
Remarks (If any):
Signature of GAIL Representative with Seal TENDER NO.
Contractors Signature with Seal
ANNEXURE I STACKING ARRANGEMENT OF COATED PIPES ON TRAILER FOR TRANSPORTATION
TENDER NO.
ANNEXURE II COATED PIPES TRANSPORTATION ARRANGEMENT ON TRAILER
TENDER NO.
ANNEXURE III COATING REPAIRS PROCEDURE WITH MASTIC
Materials:
Densolen Primer Densit mastic W Densolen Tape AS39/R20HT Wire brush Emery paper Half round rasp Knife Scissors
Equipment:
Cut away the damaged area until the factory coating fully adheres to the steel surface. Use the half round rasp to bevel the edges.
TENDER NO.
Roughen-up the surface of the factory coating with emery paper all aroundthe damaged area(approx. 100 mm).
Apply Densolen Primer to the damaged area and the full circumference of the pipe, at least 100 mm each side of the damaged area must be primed
Firmly press Densit mastic into the damaged area ensuring that no hollow spaces are left below the mastic, leave a slight mushroom head
TENDER NO.
Cut 3 patches of DensolenAS39P tape, the patches must cover the whole damaged area plus 50 mm around all sides
Remove the release film from the patches and press firmly over the damaged area; one on top of the other, a hard rubber roller may be used to apply more pressure if necessary. If one patch does not cover the whole area then use 2 per layer. To secure the patches, wrap Densolen tape AS39P with a minimum overlap of 15 mm around the damaged area and then use similar sizes of R20HT tape system to wrap around AS39P tapes.
TENDER NO.
ANNEXURE IV COLD APPLIED TAPE APPLICATION PROCEDURE
TENDER NO.
TENDER NO.

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GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

SECTION-V SPECIFICATIONS & SCOPE OF WORK [SOW]

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

SCOPE OF WORK & TECHNICAL SPECIFICATION

1.4 1.5 1.6 2.0 2.1

Approximate Total No. of Coated Line Pipe to be Shifted 27

Approximate Total Length of Coated Line Pipe to be Hydro tested in meter 72 72 72

Approximate Total No. of Coated Line Pipe to be Hydro tested 06 06 06

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

Approximate Total No. of Coated Line Pipe 27 14 25 16

4.0 4.1 4.1.1 4.1.2

4.2.2 4.2.3 4.2.4

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11

4.2.12 4.2.13 4.2.14 4.2.15 4.2.16 4.2.17 4.2.18

4.3 4.3.1 4.3.2

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

4.3.28 4.3.29 4.3.30 4.3.31

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

4.3.32 4.3.33 4.3.34 4.4 4.4.1 4.4.2

4.4.3 4.4.4 4.4.5 4.4.6

4.4.7 4.4.8 4.4.9 4.4.10 4.4.11 4.4.12 4.5 4.5.1

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

4.5.12.2 4.5.12.3 4.5.12.4 4.5.13 4.5.13.1

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

List of recommended manufacturers

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

PAINT SYSTEM PRIMER

TOTAL DFT IN MICRONS(MIN) 290

COLOUR CODE FOR PIPING

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

4.7.2 4.7.3 4.7.4 4.8 4.8.1

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

4.8.8 4.8.9 4.8.10 4.8.11 4.8.12 4.8.13 4.8.14

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

5.4 5.5 5.6 5.7

6.4 6.5 6.6

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

6.11 6.12 6.13

6.13.1 6.13.2 6.13.3 6.13.4 6.13.5

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

6.15 6.15.1 6.15.2

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

6.19 6.19.1 6.19.2 6.19.3 6.19.4

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

Signature of GAIL Representative with Seal

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

Work Interruption if any:

Remarks (If any):

Signature of GAIL Representative with Seal TENDER NO.

Contractors Signature with Seal

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

ANNEXURE I STACKING ARRANGEMENT OF COATED PIPES ON TRAILER FOR TRANSPORTATION

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

ANNEXURE II COATED PIPES TRANSPORTATION ARRANGEMENT ON TRAILER

GAIL (India) Limited (A Government of India Undertaking) (A Navratna Company)

Specifications & Sow

Specifications & Sow