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DATA SHEET
SL. NO.
1.
DESCRIPTION
SERVICE
SPECFICATIONS / CRITERIA
Natural Gas
2.
SIZE
10 # 600
3.
DESIGN PRESSURE
72 Kg/cm2
4.
DESIGN TEMPERATURE
65 DEG C
5.
CORROSION ALLOWANCE
1.5 mm
6.
END CONNECTION
BW (butt-welded)
7.
DESIGN CODE
8.
DESIGN FACTOR
0.5
9.
108 Kg / cm2
fo r 1 5 m in u t es
10.
MATERIAL
BODY
ASTM A 105
P UP S
API 5L GR B
11.
CONNECTING PIPE
SEPCIFICATION
12.
ELECTRICAL RESISTANCE
Min. 25 MEGAOHMS
(1000 Volts DC applied)
13.
DI-ELECTRIC STRENGTH
5000 Volt AC
fo r 1 m in u t e
14.
PNEUMATIC PRESSURE
5 Kg / cm2
for 10 minutes
15.
VACUUM PRESSURE
1 millibar
fo r 5 m in u t es
16.
NO. OF CLEATS
04
17.
CHARPY TEST
R eq u ir ed a s p er sp ecifica t io n
18.
HARDNESS TEST
R eq u ir ed a s p er sp ecifica t io n
NOTE:
Page 1 of 12
Page 2 of 12
1.0
S CO P E
T h is s p e c if ic a t io n c o v e r t h e b a s ic r e q u ir e m e n t s fo r d e s ig n
m a n u f a c t u r e , t e s t in g a n d s u p p ly o f c a r b o n s t e e l in s u la t i n g
jo i n t s t o b e in s t a l le d i n o n s h o r e p i p e li n e s y s t e m s h a n d l in g
h y d r o c a r b o n s in li q u id o r g a s e o u s p h a s e .
2.0
REFERENCE DOCUMENTS
2.1
Reference has been made in this specificat ion to the latest edition of
following Codes, Standards and Specifications.
2.2
( a)
ASME B 31.8
(b)
ASME B 31.4
(c)
ASTM A 370
(d)
ANSI B 16.25
( e)
ASME Section
(f)
API 1104
( g)
SSPC-Vis-1
(h)
MSS-SP-53
(i)
MSS-SP-75
( j)
NACE RP 0286
Page 3 of 12
Page 4 of 12
3.0
MATERIALS
3. 1
Materials for the pressure containing parts of the insulating joints shall be
as indicated in the data sheets specifications for Insulating joints. Material
for pups shall be equivalent or superior to the material of connecting
pipeline which is indicated in t he data sheets. Other part shall be as per
manufact urers standard suitable for the service condition indicted in the
data sheets specificatio ns for Ins ulating joint s, which shall be subject to
approval by Purchaser.
Carbon steel used in the manufact ure of insulating joints shall be fully
killed.
3. 2
3. 3
3. 5
3. 6
Page 5 of 12
4.0
4.1
MECHANICAL
4.1.1 Insulating joints shall be of integral type fabricated by welding with pups
as shown in Figure #1. Bolted and threaded joints are not acceptable.
4.1.2 All materials used for the manufact ure of the insulating joint shall be in
accordance with clause 3.0 as stated above in this specification.
4.1.3 Insulating joints shall be designed using the design principles of ASME
Section VIII Div-1. The design shall be checked for the following two
cases:
CASE
# 1:
SHEET
F = 0.1 x S x A
Where, S = SMYS of connected Pipe
A = Metal cross-sectional area of connected pipe
The allowable stress in t his case shall be less than or equal to 0.5 x
SMYS of insulating joint.
CASE #2: HYDROSTATIC TEST PRESSURE
The allowable stress in this case shall be less than or equal to 90% of
SMYS of insulating joint material.
All design parameters shall be as per insul ating joint Data sheet
specificatio ns. Detail calculations shall be submitted to GAIL for
prior approval before manufact uring.
4.1.4 Insulating joint design and materials shall be capable of being vacuum
tested to 1 millibar.
4.1.5 The joint between pipe pup pieces and main forging shall be full
penetration butt weld type. Weld design shall be such as result ing in a
weld joint factor of 1.0.
Page 6 of 12
4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end
preparation for butt welding ends having unequal thickness with respect
to connecting pipe, shall be as per ASME B 31.4/ B31.8 as applicable.
4.1.7 The reinforcement of inside weld seam, in case pups fabricated from
LSAW pipes, shall be remo ved for a distance of atleast 50mm from each
end.
4.1.8 Insulating joints shall allow free passage of scrapper instrumented pigs.
The internal bore shall be same as that of connecting pipe including its
tolerances.
4.1.9 The insulating joint shall be formed by sandwiching and locking in
positions the insulating material in a bell and spigot type of joint. The joint
shall be assembled in s uch a way that its vario us components are firmly
locked in position and the completed joint s capable of withstanding
stresses due to designed operating conditions and field hydrostatic
testing.
4.1.10 Insulating joints shall be suitable for above gro und or undergro und
installations as indicted in data sheet specifications.
4.1.11 All welds shall be made by welders and welding procedures qualified in
accordance with t he provisio ns ASME Section IX. The procedure
qualification shall include impact test and shall meet the requirements of
clause 3.3, 3.5 of this specificatio n.
4.1.12 Repair welding o n parent metal is not allowed. Repair of welds shall be
carried o ut only after specific approval by purchasers representative for
each repair. The repair welding shall be carried o ut by welders and
welding procedures duly qualified as per ASME section IX and records
for each repair shall be maintained.
4.1.13 Internal diameter at the welding end shall not vary more than +1, -3 mm
from the nominal diameter.
4.1.14 Out of roundness measured at the root face of the welding ends shall not
be more than 0.5% of the specified inside diameter.
4.2
ELECTRICAL
Page 7 of 12
4.2.1 The average di-electric strength of the insulating joint shall be minium 15
kilovolts.
4.2.2 Two cleats as shown in data sheet shall be provided on t he pups on either
side of the insulating joint for connecting 10 mm2 and 50mm2 cables
fo r
measurement / shorting purposes. Cleats shall be attached to the
insulating joint by welding.
5.0
T h e m a n u f a c t u r e r s h a l l p e r f o r m a ll in s p e c t io n a n d t e s t s a s p e r t h e
r e q u ir e m e n t o f t h is s p e c ific a t io n a n d t h e r e le v a n t c o d e s , p r io r t o
s h ip m e n t a t h is w o r k . S u c h in s p e c t io n a n d t e s t s s h a ll b e , n o t li m it e d
t o , t h e fo llo w in g :
5. 1
5. 2
5. 3
5. 4
5.4.1 All butt and repair welds of pressure containing parts shall be
examined by 100% radiography. Acceptance limits shall be as
per API 1104. Welds which in purchasers opinion cannot be
inspected by radiographic met hods, shall be checked by
ult rasonic or magnetic particle met hods. Acceptance criteria as
per ASME section VIII.
5.4.2 All forgings shall be wet magnetic particle inspected on 100% of
forged surfaces. Met hod and acceptance shall comply MSS-SP53.
Page 8 of 12
5.4.3 All finished weld ends shall be 100% ultrasonically tested for
laminatio n type defects for a distance of 50mm from the ends.
Any lamination larger than 6.35mm shall not be applicable.
5.4.4 All fillet welds of thickness < 6mm shall be examined 100%
magnetic particle inspection and > 6mm shall be examined 100%
UT. Acceptance criteria for MPI and UT shall be as per ASME
Sec VIII.
5. 5
5. 6
5. 7
Di-electic test:
5. 8
5. 9
Page 9 of 12
the vendor must have his own Third party inspector other than
GAILs TPI. However the bidder may specify the TPIA at the
time of bidding in case of any deviatio n from the above
specified parties.
5. 10
6.0
TEST CERTIFICATES
T h e m a n u fa c t u r e r s h a l l s u b m it fo llo w i n g c e r t ific a t e s t o G A I L
c e r t ifie d b y t h ir d - p a r t y b e in g h ir e d :
7.0
6. 1
6. 2
6. 3
6. 4
6. 5
After all inspection and tests required have been carried o ut, the
insulating joint surface shall be thoro ughly cleaned, freed from
rust and grease and applied with sufficient coats of corrosion
resistant paint. Surface preparation shall be carries o ut by shot
blasting to SP-6, in accordance wit h Steel struct ures Painting
co uncil Visual standard SSPC-Vis-1. External surfaces of
insulating joint shall have one coat of primer Mastic epoxy
and two coats of finish paint of Polyurethane.
7. 2
Page 10 of 12
(c)
(d)
( e)
(f)
( g)
(h)
8.0
9.0
End thickness in mm
Material
Design pressure / Hydrostatic Test pressure
ANSI Class Rating
Tag No.
Year of Manufact ure
7. 3
7. 4
GUARANTEE
8. 1
8. 2
8. 3
8. 4
DOCUMENTATION
9. 1
9. 2
General arrangement drawing along wit h crosssectional view, overall dimensio ns and details of
insulating materials recommended.
Page 11 of 12
9. 3
9.2.2
9.2.3
9. 3. 2
9. 3. 3
Once the appro val has been given by purchaser any changes in
design, material and method of manufact ure shall be notified to
GAIL whose appro val in writing of all changes shall be
obtained before the insulating joint are manufact ured.
9. 4
With fo ur weeks from the appro val date manufact urer shall submit
one reproducible and fo ur copies of approved drawings,
documents and specifications as listed in 9.3 of this specification.
9. 5
Page 12 of 12