Data Sheets, Approved Vendors

GUJARAT STATE PETRONET LIMITED PADAMLA – GODHARA GAS PIPELINE (PGPL)

TENDER DOCUMENT FOR LAYING OF PIPELINES, TERMINALS AND ASSOCIATED FACILITIES

EPC CONTRACT

VOLUME - IB OF V (PARTICULAR JOB SPECIFICATIONS) TENDER NO. 05/51/23JT/GSPL/001(EPC)

MECON LIMITED (A Govt. of India Undertaking) SCOPE MINAR th 15 Floor, North Tower Laxmi Nagar District Centre DELHI – 110 092

November,2006 D:\old data\Vijyant\GSPL\Tender\Const\master cover&content\Cover-Nov'06.doc

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Gujarat State Petronet Ltd.

Volume-IB of V

MECON LIMITED

TABLE OF CONTENT FOR VOLUME-IB OF V (GENERAL – TECHNICAL) Name of Project

:

EPC contract including Residual Engineering, Procurement, Installation, Testing and Commissioning of Pipelines, Terminals and Associated Facilities for Padmala – Godhara Pipeline Project of GSPL.

Tender Document No.

:

05/51/23JT/GSPL/001(EPC)

Sl.No. PART-D

Description 1)

Particular Job Specification (PJS) for Pipeline, Piping & Mechanical Works

2)

Particular Job Specification for Civil, Architectural & Structural Works

3)

Particular Job Specification for Electrical Works

4)

Particular Job Specification for Instrumentation Works

5)

Particular Job Specification for Telecommunication Works

6)

Particular Job Specification for Cathodic Protection Works

7)

Particular Job Specification for CO2 Flooding System

Note: Part-A, B & C covered in Volume-IA of V i.e. General – Commercial

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GUJARAT STATE PETRONET LIMITED PADAMLA – GODHARA GAS PIPELINE (PGPL)

TENDER DOCUMENT FOR LAYING OF PIPELINES, TERMINALS AND ASSOCIATED FACILITIES

EPC CONTRACT

(Volume-IA, IB, IC, II, III, IV & V) TENDER NO. 05/51/23JT/GSPL/001(EPC)

MECON LIMITED (A Govt. of India Undertaking) SCOPE MINAR th 15 Floor, North Tower Laxmi Nagar District Centre DELHI – 110 092

D:\old data\Vijyant\GSPL\Tender\Const\master cover&content\Cover-Nov'06.doc

November,2006

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts

Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

MECON LIMITED

MASTER TABLE OF CONTENT Name of Project

:

EPC contract including Residual Engineering, Procurement, Installation, Testing and Commissioning of Pipelines, Terminals and Associated Facilities for Padmala – Godhara Pipeline Project of GSPL.

Tender Document No.

:

05/51/23JT/GSPL/001(EPC)

Sl.No. Description 1)

Volume-IA of V

:

General – Commercial (IFB, ITB, GCC, SCC – Commercial)

2)

Volume-IB of V

:

General – Technical (Particular Jobs Specification)

3)

Volume-IC of V

:

Price Schedule

4)

Volume-II of V

:

Standard Technical Specification (Pipeline Laying, Piping & Mechanical)

5)

Volume-III of V

:

Standards Technical Specification (Civil, Architectural & Structural)

6)

Volume-IV of V

:

Standards Technical Specification (Electrical, Instrumentation, Telecommunication Works & CP Works)

7)

Volume-V of V

:

Tender Drawings & Standard Drawings

D:\old data\Vijyant\GSPL\Tender\Const\master cover&content\Master Table of Content.doc

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

1.0 PARTICULAR JOB SPECIFICATION (PIPELINE, PIPING, & MECHNICAL WORKS) [12” x 37.5 km Padmala – Godhara Gas Pipeline Project]

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Page 1 of 55

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

CONTENTS Sl.No.

Description

1.0

General & Project Description

2.0

Work Tendered

3.0

Scope of Work

4.0

Engineering Review for Pipeline & Terminal

5.0

Contractor Responsibilities

6.0

As-Built Documents

7.0

Resources/ Facilities

8.0

Project Scheduling & Monitoring

9.0

Other Construction Requirement

10.0

Documentation

11.0

Plan, Design, Drawing by Contractor

12.0

Survey and Level/ Setting out Work

13.0

Order of Works/ Permissions/ Right of Entry/ Care of Existing Services

14.0

Make of Material/ Bought Out Items

15.0

Inspection of Supply Items

16.0

Appendix to Particular Job Specification

16.1

Appendix-I (Design basis)

16.2

Appendix-II (Data Sheets for Mechanical Items etc.)

16.3

Appendix-III (QAP for Mechanical Items etc.)

16.4

Appendix-IV (List of Approved vendors for Bought out items)

16.5

Appendix-V (Amendment to pipeline standard and specification)

16.6

Appendix-VI (Scheme showing demarcation of M/L and Terminal)

16.7

Appendix-VII (Third Party Agency)

16.8

Appendix-VIII (List of minimum nos of construction equipment to be deployed)

16.9

Appendix-IX (Health, Safety & Environment)

16.10

Appendix-X (Minimum Criteria for Operational Acceptance)

16.11

Appendix-XI (Welding Specifications Chart for M/L & Terminal)

16.12

Appendix-XII (Transition Fitting)

16.13

Appendix-XIII [Pipeline Information Management System (PIMS)]

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Page 2 of 55

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

1.0

GENERAL & PROJECT DESCRIPTION

1.1

GENERAL

1.1.1

Special Condition of Contract shall be read in Conjunction with the General Conditions of Contract, specification of work, Drawing and any other documents forming part of this contract wherever the context so requires.

1.1.2

Notwithstanding the sub-division of the documents into these separate sections and volumes every part of each shall be deemed to be supplementary to and complementary of every other part and shall be read with and into the contract so far as it may be practicable to do so.

1.1.3

Where any portion of the General Condition of Contract is repugnant, to or at variance with any provisions of the Special Conditions of Contract, unless a different intention appears, the provisions of the Special Conditions of Contract shall be deemed to over-ride the provisions of the General Condition of Contract and shall to the extent of such repugnancy, or variations, prevail.

1.1.4

The materials, design and workmanship shall satisfy the relevant INDIAN STANDARDS, the TECHNICAL SPECIFICATIONS contained herein and CODES referred to. Where the technical specification stipulate requirements in addition to those contained in the standard codes and specifications, these additional requirements shall also be satisfied.

1.1.5

Wherever it is mentioned in the specifications that the CONTRACTOR shall perform certain work or provide certain facilities, it is understood that the CONTRACTOR shall do so at his cost and the VALUE OF CONTRACT shall be deemed to have included cost of such performance and provisions, so mentioned.

1.1.6

It will be Contractor’s responsibility to bring to the notice of Engineer-in-charge any irreconcilable conflict in the contract documents before starting the work(s) or making the supply with reference which the conflict exists.

1.1.7

In the absence of any specifications covering any material, design of work(s) the same shall be performed/ supplied/ executed in accordance with Standard Engineering Practice as per the instructions/ directions of the Engineer-in-charge, which will be binding on the Contractor.

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Page 3 of 55

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

1.2

PROJECT DESCRIPTION

1.2.1

M/s GSPL intend to lay a 12” x 37.5 km pipeline from Padamla tap-off near Baroda on 24” OD Baroda – Ahmedabad – Kalol pipeline. The proposed pipeline is approximately ~ 37.5 km long and 12” dia. and will transport ~ 1.5 MMSCMD intermingled RLNG & Natural Gas from Padamla tap-off to Halol for distribution to domestic, automobile, commercial & industrial consumers.

1.2.2

Detail of Existing Pipeline The tap-off shall be taken from existing SV at Padmala on Baroda – Ahmedabad – Kalol Pipeline. Status of Pipeline Line Size Length Maximum Allowable Operating Pressure

1.2.3

: : : :

Under Operation 24” OD ~134 km 95 bar (g)

Proposed Grid Line The proposed new pipeline shall be originated from Padamla tap-off at Baroda – Ahmedabad – Kalol Pipeline and shall be terminated at Halol. The new pipeline shall be of 12” OD and 37.5 km in length. Basic objective of the new pipeline is to cater to the need of industrial commercial & automobiles consumers in that area.

1.2.4

Details of Proposed Pipeline Line Size : Length, in km : Pipe Specification : Thickness : Operating Pressure : Maximum Allowance Operating Pressure : External Coating : Tap-off & Spurlines :

No. of SV Stations Pig Launcher cum Receiver Pig Receiver cum Launcher Filtration Metering Let Down Unit

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: : : : : :

12” OD ~37.5 API 5L Gr. X-65, PSL-2 6.4mm, 7.1mm & 8.7mm 50 bar(g) 95 bar(g) 3-LPE Five nos of chainage(chainage 1.0 km,1.07km,11.42km,23.870km, 37.23 km) each shall be originated from mainline. One No. At sokhada At Halol At Halol & end off Spur lines At Halol & end off Spur lines At Halol & end off Spur lines

Page 4 of 55

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

1.3

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Pipeline and Facilities The route of the proposed pipeline has been decided by M/s GSPL, the salient feature of the pipeline routes is described in the civil, mechanical document. The entire pipeline network has been divided into the following section.

1.3.1

Trunk Line •

1.3.2

Spurline •

1.3.3

GIDC Halol at ch. 37.230 km

Consumer Connection •

1.3.4

Padamla to Halol (~ 37.5 km)

Tap-off Station at ch. 37.230 km on 12” Padmala – Halol Pipeline to GIDC Halol through 12” NB pipeline.

Terminals At following location pipeline terminals are provided. • • •

1.3.5

Tap-off cum Despatch Terminal : Receipt Terminal : Tap-off Stations :

At Sokhada At Halol At sokhada at ch.1.0 km, For GIDC, Manjusar at ch. 11.42 km, for GIDC Savili at ch. 23.870 km & for General Motor Halol at ch. 37.230 km .

Pipeline Design Based on the optimization studies carried out the following design parameters have been considered for Mechanical Design of Pipeline System.

1.3.6

Pipeline diameter (NB) in inches Design Pressure, bar,g Design Temperature, °C

: : : :

12” / 8” 95 -20 to 65 (aboveground) 45 (buried)

Corrosion Allowance Material of Construction

: :

0 mm Carbon Steel

Pipeline Material Pipeline & its appurtenances shall be provided with carbon steel material suitable for the intended service as indicated above.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

a)

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Line Pipe Line pipe shall confirm to API Specification 5L, PSL-2 Quality. The grade of line pipe shall be API 5L Gr. X-65 / Gr. X-52 as indicated above. Pipe wall thickness shall confirm to ASME B31.8 and shall also meet the requirement of OISD 141. At river X-ing higher wall thickness shall be used.

b)

Pipeline Fitting and Flanges All pipeline materials such as pipe, valves, flanges and fittings etc. shall be of class 600#.

1.4 1.4.1

PIPELINE PARAMETERS Pipeline Details A)

Mainline Section Length of Pipeline Flow Rate, SCMD Pipeline Diameter Pipeline Thickness Material Pipeline Grade MOC Pipeline Rating Corrosion Allowance Roughness (micron)

B)

Padamla – Halol ~37.5 km 1.5 MMSCMD 12" NB 6.4mm, 7.1mm & 8.7mm API 5L X-65, PSL-2 CS (Carbon Steel) 600# Rating 0.5mm 45

: : : : : : : : :

Tap-off at ch. 37.230 to GIDC Halol 12" NB 7.4mm API 5L X-65, PSL-2 CS (Carbon Steel) 600# Rating nil 45

Spurline-I Section Pipeline Diameter Pipeline Thickness Material Pipeline Grade MOC Pipeline Rating Corrosion Allowance Roughness (micron)

i)

: : : : : : : : : : :

Despatch Termina lcum Tap-off at Sokhada – – – –

Hook-up with existing facilities at Sokhada. Pig launching cum receiving and pig handling facilities. Local mounted instrument such as PT, TG. Associated piping, civil, structural, architectural, instrumentation works.

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electrical

and

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

ii)

SV Station and tap-off points – Gas actuated extended stem valves, ball/ globe valves, and gas venting facility and, co2-flooding system shall be provided. – Scada system with battery backup, LEL system. – Associated piping, civil, architectural, structural, electrical & instrumentation works.

iii)

Receiving Terminal at Halol Equipment

:

Valves

:

Instrument/ SCADA

:

Scrapper launcher cum Receiver with handling system, cartridge filter Gear & hand operated valves of different size & types Gas actuated inlet valve, panel/ local mounted instrument, ultrasonic meters, pressure safety valves, pressure reducing & slam shut-off valves, LEL based leak detector system, RTU. Flow computers, gas chromatograph and other instrument, telecommunication & SCADA Works.

Electrical

:

Area lighting/ earthing of electrical & equipment, UPS and battery backup, -Building Lighting

Civil

:

Office/ Control room, SCADA, telecommunication, battery room and other civil works.

Associated piping civil, structural, architectural, electrical, telecommunication/ SCADA and instrumentation works. 2.0

WORK TENDERED

2.1

The work tendered in this bid package consists of detailed engineering, engineering for procurement, supply, fabrication, installation, testing, precommissioning and commissioning of the mainline, spur line, terminal facilities at Despatch, SV cum Tap-off, Tap-off, Receiving Terminals including all associated mechanical, civil, structural, electrical, telecommunication & Instrumentation works.

2.2

All works of the section & terminals included in the scope will be done simultaneously from the date of issue of FOI. Bidder will organize equipment and manpower accordingly to meet this requirement as per instruction of Engineer-in-charge. Contractor shall adopt suitable method of construction/ execution of work for restricted row and deployment of equipment its as required.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

3.0

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

SCOPE OF WORK

3.1 •

The detailed scope of work tendered for the project include detailed engineering, engineering for procurement, supply, fabrication, testing and commissioning alongwith all associated work pertaining to complete pipeline and terminal works. The scope of work shall be generally being, but not limited to the following: Detailed Engineering Owner has got the detailed survey carried out for the entire pipeline route. The plan and ground profile details to the extent available are being furnished to the Bidder along with bid document. Contractor shall carry out any additional topographic surveys required for local detours during execution of the project in a similar manner without any extra cost to the Owner. However, laying and construction of entire pipeline including detoured portion shall be within the scope of contractor and governed by SOR of tender without any cost implication. Contractor shall be deemed to have considered such eventualities while formulating his bid. Pipeline route maps/ alignment sheets showing the pipeline route are also enclosed with the bid package.

•

Preliminary Alignment Sheets and plot plan and piping GAD drawings for scraper launcher cum receiver stations, SV stations, tap-offs are included in the Bid package. These drawings are indicative only and are furnished to enable Bidder to estimate the quantum of work and to quote a firm price for the work..

•

Collection of data at site and carrying out residual engineering for pipeline system including terminals and crossings in accordance with design basis, codes & standards and project specifications contained in this bid package. Requirements of Indian standards and codes shall be complied with wherever applicable.

•

Preparation of pipeline construction drawing such as alignment sheets for detour portion if required, crossing details, final Piping general arrangement drawings (GADs) for dispatch & receipt terminal, all consumer terminals, SV stations, Tapoff Point including stress analysis, pipe supports, piping isometric. The typical drawings for the station layouts attached along with the bid package shall be considered as basis for developing the layouts. The owner shall hand over typical piping drawings for other installations to successful bidder for reference and development of GA drawings. All drawings/ methodology shall be subject to review and approval by the Company. The construction shall be carried out based on the Issued for Construction (IFC) drawings. ‘IFC’ alignment sheets for all pipelines shall be handed over to successful bidder for pipeline installation.

•

Preparation of design documents, procedures, manuals, drawings etc. as referred in relevant clause of this document.

•

Carrying out Material Take Off for the entire pipeline system including those materials supplied by Company if any and all piping at all terminals.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

•

3.2

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

The design shall take into consideration all stipulations, practices followed by various authorities for all types of crossings and specifically all the factors that are agreed upon between Company and state/local authorities as per agreements reached as a part of permissions for various crossings. Contractor shall provide all design data/drawings/calculations as required for statutory clearances including obtaining necessary approvals. Procurement & Supply

•

CONTRACTOR shall procure and supply all the materials other than OWNER supplied materials if any, required for permanent installation of main pipeline and terminals in sequence and at appropriate time. All equipment, materials, components etc. shall be suitable for the intended service. Approved vendor list has been indicated in the bid package for various items. For items, which are not covered in the vendor list, CONTRACTOR shall obtain Owner’s prior approval for the vendor. Equipment requiring specialized maintenance or operation shall be avoided as far as possible. Equipment offered shall be field proven.

•

CONTRACTOR shall procure all materials, components, equipment, consumable etc. required for successful completion of the pipeline system. CONTRACTOR shall also procure and supply spares required for pre-commissioning and commissioning/ start up as recommended for all items supplied by him as per specifications provided in the bid package. Where no specification is available in the contract, the same shall be prepared by the CONTRACTOR based on the piping material specification and shall be subject to Owner’s approval.

•

Material take-off with complete description of size, rating, material, thickness and specifications.

•

CONTRACTOR shall provide for inspection of the items at vendor's works by the OWNER/ Owner’s REPRESENTATIVE or by a reputed inspection agency and shall submit inspection reports for Owner’s clearance.

•

Stores management for contractor supply items as well as free issue materials if any including receipt, warehousing, preserving the material in good condition, issue of material to construction site, reconciling/ handing over surplus material to OWNER of OWNER supplied items at Owner’s store.

•

Carryout proper documentation of inspection and quality assurance programmes for all equipment and bulk materials duly approved by OWNER. CONTRACTOR shall maintain an accurate and traceable listing of procurement records for the location, quality and character of all permanent materials in the Project.

•

CONTRACTOR shall immediately report to the OWNER of all changes, which will affect material quality, and recommend any necessary corrective actions to be taken.

•

Submit periodic manufacturing progress reports highlighting hold ups and

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

slippages, if any, to OWNER and take remedial measures. •

Interact with authorities such as Sales Tax, Octroi, Excise, and Customs etc. as necessary and arrange for transportation of the materials under his scope of supply to site.

•

All purchase requisitions including purchase orders shall be approved by OWNER/ Owner’s REPRESENTATIVE.

•

Compliance with vendors and supplier's instructions and recommendations for transportation, handling, installation & commissioning.

3.3

Construction •

All construction works shall be carried out as per "Issued for Construction" drawings, procedures, specification and applicable codes and standards. Any changes at site shall also need prior approval from the OWNER and revision of drawings.

•

The Owner shall provide to the Contractor free of cost the construction right-of-use to lay the pipeline, systems as governed by the clauses defined elsewhere in the tender document.

•

The Contractor at his own cost and initiative shall obtain all other permissions, permits and licenses necessary for the performance of the work. Insofar as any such permission, permit or license required for the performance of the work by the contractor can only be granted at the request or recommendation of the Owner, the Owner shall at the request of the Contractor, provide recommendatory letters to the contractor to obtain or procure the same. The contractor shall not, however be entitled to any additional compensation over and above contracted rates of services for any hardship or increased cost caused by any idleness, suspension or disruption of work or any other account whatsoever as a result of the inability of the contractor to obtain the permission(s), permit(s), license(s) aforesaid to match with the progress of the work nor shall the same constitute a ground for extension of time. a) The approval from any authority required as per statutory rules and regulations of Central/ State Government, PWD, and Irrigation Dep’t. etc. shall be the contractor’s responsibility unless otherwise specified in the tender document. The application on behalf of the Owner for submission to relevant authorities alongwith copies of required certificates complete in all respects shall be prepared and submitted by the Contractor well ahead of time so that the actual construction/ commissioning of the work is not delayed for want of the approval/ inspection by concerned authorities. The Contractor shall arrange the inspection of the works by the authorities and necessary coordination and liaison work in this respect shall be the responsibility of the Contractor. However statutory fees paid, if the Owner shall reimburse any, for all inspections and approvals by such authorities at actuals to the Contractor on production of documentary evidence.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

b)

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Resulting from poor workmanship as pointed out by any statutory authority shall be rectified by the contractor at no extra cost to the Owner. Any change/ addition required to be made to meet the requirements of the statutory authorities, the same shall be carried out by the contractor free of charge. The inspection and acceptance of the work by statutory authorities shall, however, not absolve the contractor from any of his responsibilities under this contract.

•

The CONTRACTOR shall be responsible for claims if any arising out of damage/ obstruction to public utilities like lines of DOT etc. where the claims will cover the restoration costs as well as loss of revenue due to down time.

•

Contractor shall be carrying out engineering for major crossing and survey specification.

•

For all crossing, including above mentioned shall be crossed by heaviest wall thickness carrier pipe among available pipes at site or as per approved drawings/ as decided by Engineer-in-charge.

•

Obtaining all necessary approvals and work permits from Company/concerned local authorities having jurisdiction including hot work permit as applicable for performing the work in existing terminal facilities. Arranging of adequate fire fighting equipment viz. fire brigade, fire extinguisher, shielding from existing facilities, oxygen mask etc. for carrying out the work safely in existing terminals to the satisfaction of Company.

•

The Contractor shall start the execution work for entire length of mainline simultaneously and shall deploy adequate manpower, machinery, tool & tackles etc. accordingly.

•

However, Owner may, at its sole option, assign priority of construction to either any spread or any section in spread of total pipeline length or to any part/ segment of the work. Contractor shall comply with such priority of execution and their deployment without any time and cost implication to the Owner.

•

Owner has got the entire pipeline route surveyed and survey pillars have been established along the pipeline centerline or the ROW centerline and along the pipeline route. However, the pipeline route survey had been carried out sometime back and when Contractor mobilize at site, some of the survey pillars may be missing from ground. It shall be Contractor's responsibility to re-establish all missing survey pillars based on the survey data furnished by the Owner. Such work shall be done at no extra cost or time to Owner.

•

Bidders are advised to make site visits to familiarize themselves with all the salient features of subsoil, terrain and available infrastructure along the pipeline route. Contractor shall be deemed to have considered all constraints and eventualities on account of site conditions along pipeline route while formulating his bid. Contractor

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

shall not be eligible for any compensation in terms of cost and/ or time, on account of site conditions along pipeline route varying to any extent from whatever described in the Bid Package and the drawings furnished along with the Package. •

Providing schedules, progress reporting, organization chart at construction site, quality assurance plan and developing quality control procedures, as per requirements indicated elsewhere in the bid package.

•

Coordination and supervising the work of sub-contractors.

•

Transportation of appropriate materials and taking delivery of Company supply materials if any from Owners Store at store work site. Maintaining and operating an adequate material control procedure at worksite.

•

Fabrication of all piping, structural components as per approved drawings.

•

All civil/ structural works, Architectural, Telecommunication, CP, electrical and instrumentation, laying and commissioning works shall be performed in accordance with relevant specifications and requirements enclosed elsewhere in the bid package.

•

Materials and equipment required for all types of test such as radiography, magnetic particle and dye penetrate examination.

•

CONTRACTOR shall provide complete details of manpower, equipment etc. to be deployed. Mobilising and providing all equipments, manpower (skilled and unskilled), consumable and other resources etc. for each spread as required for the execution of the complete job defined herein and thereafter demobilising the same upon completion of work.

•

Provide, maintain and operate all temporary facilities required for the construction related works and remove after completion of work.

•

Hook up/ tie-in of pipeline and piping system with terminal facilities.

•

All works related to testing, dewatering, swabbing, drying pre-commissioning and commissioning of the work tendered.

•

Idle time preservation of pipeline, if required.

•

All incidental and associated works and any other works not specifically listed therein but are required to be carried out to complete entire work related to pipelines and terminals.

3.4

Main Pipeline Laying Works •

"Receiving and Taking-over" as defined in the specifications at stacking in the yards/ dump site and stringing of pipes to Right-of-use (ROU), including arranging

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

all necessary intermediate storage area(s) required thereof till the pipes are installed in permanent installation. •

Carrying out inspection of OWNER supplied materials if any at the time of receiving and taking-over.

•

Carrying out repairs of line pipe and pipe coating which will include repair of all defects/ damages occurring during transportation and / or handling.

•

For pipes where cutting out involves more than 25mm from pipe ends, ultrasonic inspection shall be carried out at pipe ends as per relevant clause of line pipe specification enclosed with the tender including supply of all equipments. Contractor shall take prior approval from Company for the agency engaged for carrying out ultrasonic inspection.

•

Loading, unloading, handling, stacking, storing and transportation to workshop/ work site of all materials that may be used for the construction of pipeline system supplied by Contractor at their designated stack yard/ dump site/ store.

•

The contractor shall notify the owner the probable date of commencement of work at ROU site at least two (2) weeks in advance to enable the owner to arrange handing over of the ROU/ site on the date requested. Should contractor fail in such notification, the owner shall not be liable for any claim by contractor, of whatsoever nature, for delay in the available of a ROU/ site.

•

Mobilizing and providing all equipments, manpower (skilled and unskilled), consumables and other resources etc. as required for the execution of complete work and thereafter demobilizing the same upon completion of work.

•

ROU acquisition/ permission of laying the pipeline shall be responsibility of Owner. Obtaining all necessary approvals and work permits from concerned local authorities and respective Owner’s having jurisdiction, as applicable for performing the work including shifting/ relocation and restoration of telephone/ electrical poles and underground pipes and other utilities etc. as required by local authorities and as directed by OWNER shall be responsibility of contractor.

•

Stacking, clearing, grading, fencing of Right-of-Use (ROU) as required, trenching to all depths in all types of soil including soft, hard rock, controlled rock blasting/ rock blasting by special techniques, chiseling or otherwise cutting etc. to a width to also accommodate the cable conduit as per relevant standards, drawings, specification etc. Transportation of coated pipes to ROU along the route, stringing, aligning, bending, welding, NDT including radiography by X-ray and ultrasonic (if required), inspection, field weld joint coating including supply of all materials, protective coating of long radius bends including supply of materials as per specifications, sand padding, laying and lowering of the pipeline, back filling, slope breakers as required, carrying out rail, road, canal, utility and submerged minor and major water course crossings including installation of carrier pipe inside casing pipe at cased crossings wherever required, bank stabilization of water course crossings as

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Volume-IB of V

MECON LIMITED

required, crossing of river/ canal by conventional method and arranging all additional temporary land/ area required for construction purposes. Supply and installation of anti buoyancy measures viz. continuous concrete coating, saddle weights, extra cover etc. on pipeline as shown in approved drawings and as directed by OWNER, installation of supports wherever required, supply of select backfill material as required, clean-up, pigging, flushing, gauging, hydrostatic testing with the quantity of inhibitor as required, dewatering with the additive, at required dosage, swabbing, pre-commissioning and commissioning of complete pipeline system, including all associated works as per relevant specifications, standards and approved drawings. •

Welding of all tie-in joints including tie-in joints and bends on either side of major river crossings/ with adjoining pipeline installed by others/ other facilities as required, cutting of test header, rebevelling and tie-in with adjacent pipeline segments.

•

Field weld joint coating shall be by heat shrink sleeve/ other suitable material as per specification enclosed with bid package compatible of pipe coating material.

•

Carrying out corrosion coating of Long Radius (LR) bends if any. Coating shall be carried out by heat shrink sleeve (Raychem or equivalent) / other suitable material as per specification enclosed with bid package for field joint coating.

•

Installation of casing pipes (by open cut/ jacking/ boring) assembly, including supply of all materials viz. casing pipe, casing insulators and end seals, vents and drains etc. complete, at cased crossings as per the drawings/ specifications enclosed with bid package.

•

Cased crossings shall be installed at locations indicated in alignment sheets. The number of crossings indicated in alignment sheets/crossing drgs is subject to change based on engineering, construction and statutory requirements or the requirements of the authority having jurisdiction over a utility crossing.

•

All works/ provisions including installation of slope breakers to be provided in the trench in areas where slope is more than 1 in 10.

•

Sand/ soft soil padding around pipe wherever required in areas where trenching has been done in rock including supply of sand/ soft soil. The thickness of sand/ soft soil padding at the bottom of pipe shall be 300mm in rocky areas.

•

Installation of all inline/ online instruments/ valves/ insulation appurtenances etc. as per requirements of approved drawings.

•

Providing 300-micron high built abrasive resistant epoxy on the external surface of all 6” CS conduits meant for OFC.

•

Indian Railways shall approve the general arrangement drawings for railway crossings and construction shall be carried out accordingly. The Contractor shall

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Volume-IB of V

MECON LIMITED

make these drawings available at appropriate time during the execution of the project. Pipeline at railway crossings shall be provided with a casing pipe. The casing pipe shall be double of the nominal pipe sizes of carrier and shall be installed by boring/ jacking. It should be noted that the extent of casing pipe generally specified by Railways, is 15.0m beyond centerlines of the outermost tracks on either side or 0.6 meter beyond the ROU limits of railways on either side, whichever is more. All railway crossings shall be cased crossings. The railway crossing shall comply with the requirements of API 1102 and Indian Railway regulations. The crossing angle shall be as close to 90° as possible. •

Contractor shall firm the method of crossing of roads such as open cut/ boring up in consultation with concerned authorities and Company. The Contractor shall also take due care to identify and take due precautions so as not to disturb or damage the utilities like cables, water lines and other structures.

•

After laying the pipeline in a road crossing by open cut method, the Contractor shall completely restore the road to its original condition.

•

While laying the pipeline in road crossings by open cut method the Contractor should ensure that the traffic is not stopped during the execution of work. This may be done by cutting half of the road at a time so as to enable the traffic to pass on the remaining half of the road. Alternatively, the Contractor can provide diversion roads to maintain the flow of traffic.

•

The Contractor shall provide proper caution boards during daytime and danger lights during nighttime when the cutting operation of the road is going on.

•

For cased crossings, the pipeline should be taken through the casing pipe which should be at least 1.2 metres below the road top as specified or as per the requirements of local authorities, whichever is higher.

•

Crossings of rivers/ streams/ canals by conventional method: i)

No damage should be caused to any irrigation sources, while laying the pipeline through canal crossings.

ii)

The flood banks of the River/ Canal should be brought to the original condition, if they are damaged while the laying of the pipeline. Stabilization of banks shall be carried out as per requirements of concerned authorities.

iii)

In general the top of the pipeline shall be taken at least 1.5 metre below the scour level of river crossing. If scour level is not known minimum 2.5m cover should be kept unless specified otherwise.

iv)

The top of pipeline shall be at least 1.5m to 2.0m below the drain/ canal bed unless specified other wise.

v)

Pre-construction survey, preparation of the detailed construction methodology/ plan and time etc. shall have to be finalized by Contractor in consultation with concerned authorities having jurisdiction over canals/ rivers. Company shall provide assistance by providing introductory letters.

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vi)

Pre-construction surveys, preparation of detailed construction method statement and calculations for Owner’s approval.

vii)

Surveys like Geo-technical, Hydrological and Topographical for pipeline route, Station plots, Rail and Road crossing etc and water crossings.

viii)

Site preparation, arranging required land for setting up of string fabrication yard and obtaining necessary permissions from concerned authorities.

ix)

Preparation of pipeline Launch way, continuous concrete coating of pipes, repair of damages to corrosion and concrete coating, string preparation, field welding, NDT including radiography, pretest of completed strings, corrosion and concrete coating of field joints. trenching, laying at approved depth, stabilisation of banks, post installation hydro-test, capping, providing and installing of markers, etc.

x)

The major canals with lining/ perennial canals need to be crossed by HDD/ boring method only.

•

Contractor shall cross the road/ canal etc. by HDD at locations as directed by Owner/ Consultant as per crossings survey drawing enclosed with tender. Before start of HDD, the contractor shall ascertain by pre-construction survey all underground obstacles namely electrical/ telecommunication cable, foreign pipeline, water line, drain/ sewerage line and prepare crossing profile drawings showing all elevations & levels. The contractor shall also ascertain, the type of soil & their terrain whether rocky or normal by way of trial pit etc. before start of job. The contractor shall submit procedure, profile drawing with complete design calculations of HDD as per requirement of ASME B31.8/ OISD norms and safety requirement that pipe is not under stress during and after crossing for Owner/ Consultant’s approval prior to start the execution of works.

•

Contractor shall ensure all safety norms regarding distances from end point or from bottom of crossing and also ensure that external coating of pipe is not damaged during pulling & handling of pipe for crossing. For field joint coating in pipeline string made for HDD, special type of heat shrink sleeve shall be used as per specification enclosed with the tender. For line pipe coating repair, special type of high shear strength repair patch material shall be used which characteristic shall be same or equivalent as original wrap round heat shrink sleeve used in pipeline string for HDD crossing.

•

The contractor shall ensure that no any u/g existing utilities/ pipelines/ cable etc. is damaged. It shall be responsibility of contractor to compensate any loss or damage to other agency if damaged while crossing. Contractor shall arrange all statutory permission from concerned authority before start of job. Contractor shall deploy only GSPL’s/ MECON approved HDD Agency and approval of agency shall be sought before deploying HDD agency.

•

Where the pipeline route passes through forest/ plantation areas, Contractor shall clear only the minimum width required for laying the pipeline as per Owner approved procedure for pipeline construction. Number of trees/ plants to be felled down shall be restricted to a minimum.

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Volume-IB of V

MECON LIMITED

•

Clean-up and restoration of ROW and other conveniences like road, rail, canals, cultivable land etc. to original conditions as per specification and drawings to the entire satisfaction of OWNER and/ or Authorities having jurisdiction over the same, including disposal of surplus construction materials to a location identified by CONTRACTOR approved by local authority without causing any disturbance to environment, locals and to the entire satisfaction of OWNER.

•

Upon restoration of ROU the Contractor shall furnish documentary evidence in support of acceptance of the same duly signed by land Owner without any extra cost.

•

Carrying out Magnetic cleaning and Electronic Geometrical Pigging (EGP) for 12” main line only including supply of all types of pigs, pig locating and tracking device, spares, consumables, manpower etc. as per specification enclosed with bid/ contract document.

•

Carrying out repair of all defects found during Electronic Geometrical Pigging (EGP) including locating, digging, cutting, welding, NDT etc.

•

Carrying out cleaning, flushing, swabbing (as applicable), dewatering, testing and pre-commissioning of pipeline and associated facilities at Dispatch Station, Sectionalizing Valve Stations, Tap-off and Receipt Station up to the respective battery limits. Locating all major and minor leaks during hydro testing if any.

•

Repair of any leaks/burst occurring during testing of main pipeline.

•

Tie-in with the pipeline at rail, road, river and other crossings including cutting of test headers as required and tie-in with terminal piping & with existing facilities as applicable.

•

Idle time preservation of the pipeline (if required) for the specified period by filling with nitrogen to a positive pressure of 0.5 bar (g) including supply of nitrogen etc. as required.

•

Installation of carrier pipe in canal/ road (NH/ Express highway)/ railway crossings by boring/ HDD/ Trench less method, as directed by Company. Contractor to note that the minimum elastic bend radius(R=800minimum) to be adopted, shall be as per pipeline engineering design basis enclosed with the tender.

•

Counting the number and type of trees to be cut (before cutting) during pipeline laying works in presence of DFO/ concerned authorities keeping record thereof and handing over the cut trees as directed by concerned authorities/ Company.

•

Obtaining hot work permits from Company/ concerned authorities having jurisdiction thereof to work within existing and operating terminals including strictly complying with all stipulations/conditions/recommendations of the

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Volume-IB of V

MECON LIMITED

concerned authorities and providing all safety appliances, gas detectors, fire screens required during execution of the work as per the direction of Company/Engineer-in-charge. Coordinating all activities with Company for movement of men and material from and to existing and operating terminals shall be the responsibility of the Contractor. •

Preparation and submission of as built drawings, pipe books, documents, photographs of major activities, and project records as per specification and instructions of the OWNER including furnishing of all Test Certificates/ Inspection Reports for all materials used for permanent installation in requisite numbers as mentioned elsewhere in this document.

•

All incidental and associated works and any other works not specifically listed herein but are required to be carried out to complete entire work related to pipelines and the associated facilities and making the entire pipeline system ready for operation.

3.5

Composite works at the Terminals, Tap-off Points and SV Stations The detailed Scope of work for Composite works related to fabrication, installation, testing and commissioning of piping at the terminals is as elaborated below: •

The Contractor’s scope of work shall consist of supply, installation, testing and pre-commissioning of terminal piping works along with other associated works including (installation of skids if any) for the execution of composite works at the terminals, tap-off, various consumer ends and SV Stations. Preliminary equipment layout and GADs for the terminals/stations/TOP are included in the tender. These drawings are indicative only and are furnished to enable the Bidder to understand the nature of work involved. Contractor shall carry out detailed engineering for the terminal works and final piping general arrangement drawings (GAD’s (including stress analysis) good for construction based on actual plot size/orientation provided by Company/consumer.

•

Carrying out all works strictly in accordance with the drawings duly approved by the Company and reference specifications/standards, P&IDs, documents, data sheets etc. enclosed with this tender document and instructions of Company/Engineer-in-Charge and other provisions of Contract document.

•

Providing all equipments, manpower, machinery, consumables for fabrication, installation, inspection, testing & pre-commissioning. Contractor shall also provide all types of safety tools, tackles, devices and apparatus, equipment complete as required, and facilities for inspection & interpretation of testing results by Company/Company’s Representative personnel.

•

Furnishing and mobilizing at site(s) all construction equipment, tools and tackles, fully equipped and fully manned with other required support facilities etc. needed for successful execution of the works.

•

“Receiving and taking over” of all Company supplied free issue materials if any from the designated place(s) of issue, transportation including loading,

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MECON LIMITED

unloading, handling, including arranging all necessary intermediate storage area(s) thereof as required till the permanent installation of materials. •

Procurement and supply of all materials, equipments that are included in the scope of supply of Contractor, transportation of all materials from manufacturer’s works including loading, unloading, handling, storing and transportation to work site(s)/work shop(s) including arranging all necessary intermediate storage area(s) thereof, as required.

•

Fabrication, erection, installation, testing of all above-ground/buried piping system consisting of pipes, valves (manual and actuated), filters, metering, flanges, fittings, pipeline items consisting of scraper traps, flow tees, pig signalers, insulating joints, L.R. bends etc; carrying out all applicable works associated with buried pipeline within the battery limit.

•

Installation of metering skids if any at various consumer ends as per the P&IDs, plot plans of consumer end terminals and carrying out all necessary hook up with associated piping as required.

•

Installation of bi-directional scraper launcher/receiver at Padamala and Halol and associated piping including all associated works and hook ups with existing piping.

•

Hook up with existing piping as per P &ID including all associated dismantling works, as required.

•

All piping for instrument air system including hook-up if any with existing instrument air system at consumer ends.

•

Carrying out welding including cutting, edge preparation (inclusive of grinding the edges of pipes, fittings, flanges, etc. to match with the matching edges of different thick nesses wherever required), fit-up, bending, pre-heating wherever required, NDT including radiography and other non-destructive tests as specified. NDT requirements for process and other piping shall be in accordance with relevant specifications enclosed with the contract document.

•

Installation of Sectionalising Valve stations at allocated locations including all above ground/underground piping at all elevations and depths including installation of buried sectionalizing valve & valve actuators and associated buried/above ground piping and carrying out all associated works. All SVs shall be gas actuator operated ball valves with remote operation.

•

The Contractor shall carry out repair of leaks/ burst.

•

MTO for all piping and pipeline items including line pipe based on IFC drawings.

•

Installation of all types of valves (manual/motor operated) including installation of all types of actuators including fixing of gaskets, bolts, studs and nuts of all sizes, ratings and materials.

•

All associated geo-technical, civil, structural, mechanical, electrical and architectural works including supply of all material required, including construction of foundations (PCC/RCC works) for equipment, pipe supports, brackets, structural column, valve operating platforms, pipe crossovers etc.

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MECON LIMITED

•

Obtaining all statutory clearances, doing required follow up, approvals and permissions for the works within existing facilities, as required. Obtaining hot work permits from Company/ concerned authorities having jurisdiction thereof to work within existing and operating terminals including strictly complying with all stipulations/ conditions/ recommendations of the concerned authorities and providing all safety appliances, gas detectors, fire screens required during execution of the work as per the direction of Company/Engineer-in-charge. Coordinating all activities with Company for movement of men and material from and to existing and operating terminals shall be the responsibility of the Contractor.

•

Supply, fabrication and erection of pipe/ equipment supports (for all sizes/ thickness) including shoes, pipes, cradles, turn buckles, T-posts for all types of guides, anchors, all necessary equipment, consumables, labour etc. for completing all works including supply of bolts, nuts, washers, U-clamps, wooden blocks etc. as required for supporting.

•

Hook-up of piping with equipments & vessels, with the existing facilities, with the main pipeline and at the battery limit with the facilities installed by others by welding or by flanged connection (as shown in IFC drawings) including cutting, fit-up, welding, NDT, radiography, interface/co-ordination as required with other Contractor(s)/Agencies.

•

Painting of all equipments, structural steel elements for pipe supports, above ground piping and all related miscellaneous items shall be provided suitable for low temperature application as per company specification enclosed with the bid document. Wherever touch up/repair of primer is required, high build epoxy zinc phosphate primer shall be used.

•

Protective coating of 500 micron thick two component high built epoxy duly approved by Company for all underground piping, valves, fittings, etc. including supply of all materials.

•

Hydro testing, dewatering, flushing & pre-commissioning activities of piping system of all sizes as per specifications enclosed including supply of all materials and manpower that are required during pre-commissioning and all associated works. Identification of leaks during hydro testing & repair of defects.

•

Final clean up and restoration of site, facilities etc. as per the requirement of Company/Engineer-in-Charge.

•

Preparation of isometrics and/or fabrication drawings required for the purpose of fabrication during execution of work.

•

Preparation of as-built drawings, documents and project records as per instructions of Engineer-in-Charge.

•

Co-ordination as required with other Agencies/Sub-Contractor(s) till the time the

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commissioning operations are complete. •

Preparation of detailed procedures for fabrication, installation, testing and precommissioning. Such procedures shall be submitted to Company/Engineer-inCharge for review and approval.

•

Any other works not specifically listed herein but required for completion of the works in all respects. All painting materials shall be suitable for highly corrosive environment.

3.6

Materials to be supplied by Contractor The procurement and supply, in sequence and at appropriate time, of all materials and consumables required for completion of the Work as defined in this bid document except the material as Company free issue material, shall be entirely the Contractor’s responsibility and price quoted for the execution of the Work shall be inclusive of supply of all these materials. All materials supplied by the Contractor shall be strictly in accordance with the requirements of relevant Company material specifications enclosed with the tender document. All equipments, materials, components etc. shall be new and specifically purchased for this job. All material to be supplied by the Contractor shall be purchased from the approved vendors of the Company, duly inspected by Third party inspection agencies. The list of approved vendor is enclosed along with bid document. As a minimum, the materials to be supplied by Contractor shall, but not limited by any way, be as follows: •

•

•

• • • •

Coated Line pipes and bare line pipe all valves of all sizes & ratings for mainline and at terminals, actuators, launcher cum receivers (Bi-directional), insulating joints, pig signalers, long radius bends (R=6D), flow tees etc., pipes for all sizes and thickness fittings, flanges, O’lets (weldolets, sockolets, nippolets, threadolets etc.), spectacle blinds, spacer & blinds required for permanent installation in the system. Each valve item shall be inclusive of commissioning spares. All stud bolts, nuts, jack screws, all type of gaskets (metallic spiral wound / ring type / non-metallic gaskets) in required quantities to be used for permanent installation into the system for all sizes and ratings of flanges and flanged valves, equipment etc. All consumable such as welding electrodes, oxygen, acetylene, inert gases, filler wires, solder wires, brazing rods, flux etc. for welding/cutting and soldering purposes. All equipments & consumables for Semi-Automatic welding and radiography. All materials for all types of markers including paints conforming to Corrosive environment as per spec, cement, sand, reinforcements, structural steel, etc. All materials, equipments, consumables including pigs required for magnetic cleaning and EGP. LR bends fabricated from 12” line pipes required at terminals and wherever required. All materials required for continuous concrete coating for providing negative

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• • • • •

•

• • •

•

• •

• •

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

buoyancy to the pipeline wherever required and at river crossings. All materials required for weld joint coating, corrosion coating of LR bends required at terminals pup pieces of sectionalizing valves and repair of damaged corrosion coating of line pipe. All materials required for sand/soft soil padding around pipeline and optical fibre cable, select backfill of approved quality, slope breakers, bank stabilization of water crossings wherever required. The size of gravel & stones used for back filling of balance portion of the trench shall be limited to 150 mm. All materials including consumables required for hook-up with adjoining pipeline section or wherever required. Supply of cohesion less soil like sand murrum, silty sand, etc. for complete backfilling of pipeline trench for a specified distance in areas prone to Seismic activity. Contractor shall obtain prior approval from Engineer-in-charge for rock shield material & its application procedure. Material for the maintenance of sand ridges and other materials for pipe stacking at Contractor’s warehouse/storage yards/work site/ROU. All temporary materials and consumables required for filling and pressurizing in connection with hydrostatic testing, dewatering, swabbing and precommissioning activities, etc. including pipes, flanges, fittings, gaskets, bolts, nuts, etc. required for fabrication of temporary pig traps and /or test headers. All materials required for repair/restoration of pavements, roads, canals, temporary irrigation pipe laid by villagers in their fields bunds, walls, other structures affected/damaged by Contractor’s construction activities. Materials shall be equivalent/superior to those used for original construction of the facility. All pigs for cleaning, gauging, de-watering, swabbing, filling, pre commissioning and commissioning of the pipeline. Pumps and water to be used for hydrostatic testing/ flushing. All materials & consumables such as Corrosion inhibitor, oxygen scavengers and bactericides, required during hydro testing as required. 6” NB (168.3 mm O. D.), 6.4 mm WT, API 5 L Gr. B or equivalent, EW, casing pipes for OFC cable sub ducted in HDPE conduit with 300 micron high built abrasive resistant external epoxy coating for crossings executed by jacking/ boring/ any other trench less technique. All casing pipes of size 450 mm O.D. (18”), API 5L Gr. B or equivalent, EW, 6.4 mm WT casing insulators and end seals including materials for vent and drain and strapping CS conduit with pipe and carbon steel pipes for optical fiber cable (OFC) conduits in required quantities for contractor supplied 6” casing pipes as well as 18” casing pipes. All consumables and equipments required for all types of tests and NDT such as radiography, ultrasonic testing, magnetic particle, dye penetrate examination etc. including radiography film etc. All safety tools and tackles, devices, apparatus, equipment, personal safety gazettes to be used as personal protective equipment (such as helmets, safety belts, safety shoes, etc.) including ladders and scaffolding etc. complete as recommended by Engineer-in-Charge as per relevant safety standards. All structural steel material for all types of supports. All materials and equipment related to blasting of rock for excavating trench or

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•

• •

• • • • •

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

grading the Right-Of-Use pipeline and pipe laying/ installation and other works. All steel materials such as structural steels, reinforcement steels and steel for all types of supports, foundations, ladders, platforms etc. including Bolts, nuts, washers, U bolts, clamps, clips, gaskets, Shims, wedges and packing plates (Machined wherever required) and materials required for fabrication of low friction sliding bearing supports. All fencing, gate and steel materials such as structural steels, reinforcement steels and steel for all types of supports, foundations, ladders, platforms, etc. All materials, manpower, spares, tools & tackles and consumables for carrying out pre-commissioning activities and during commissioning (including bidirectional and foam pigs, compressor, nitrogen required for achieving the specified criteria for pipeline inertisation prior to declaring pipeline fit for commissioning) necessary piping and instrumentation connection for measuring flow rate, pressure, temperature etc., temporary facilities for blow down/ venting/ flaring along with necessary piping, valves & instrumentation as well as consumables and manpower required during pre-commissioning and commissioning. High built two component epoxy for corrosion protection of buried piping (pipes, fittings, flanges, valves, etc.). Required quantities of Nitrogen for idle time preservation if pre-commissioning & commissioning works, as required. Corrosion resistant straps required for strapping CS/ HDPE conduit with mainline at crossings of water bodies and other crossings. All materials, equipment and personnel required for videography and all associated works. Any other material not specifically listed herein, but required for successful completion of the Work. All escalations/ extra materials procured by Contractor for contingencies shall be Contractor’s property and no payment shall be made for such materials. Detailed list of items to be procured and supplied by contractor for mainline & terminal shall be as indicated below: a) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv)

Pig Launcher cum Receiver with carriage Cartridge Filters QOEC Pig Signalers Globe Valves Check Valves Joint Coating Sleeves LR Bends Coating Repair Material HDPE Duct OFC Cable OFC Jointer etc. Battery Bank with charger All electrical area lighting and building lighting

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xv) xvi) xvii) xviii) xix) xx) xxi) xxii) xxiii) xxiv) xxv) xxvi) xxvii) xxviii) xxix)

xxx) xxxi) xxxii)

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Portable fire fighting equipments Portable Fire Hydrant System Air Conditioners Special Sleeves for HDD Strings Assorted Pipe Flanges Fittings Insulating Joints Flow Tee Pressure Safety Valves LEL Detector Flow Control Valve Control Panel & Field Mounted Instruments SCADA Telecommunication items a) HDPE Conduit b) OFC c) Jointing Kits etc. Electrical Items a) UPS b) LDB Instrumentation Items Any other item required to complete the job/ as indicated in SOR.

The rates quoted for the execution of the Work shall be inclusive of supply of all materials mentioned above unless specifically covered otherwise under Schedule of Rates. 3.7

Company Supplied Materials There shall be no free issue supplies except metering skid at consumer end by the Owner under this Contract.

3.8

Excess Material and Scrap All excess material related to Scope of Work of the Contractor shall revert to the Contractor, except for spare provisions made as a part of the construction programmed and supply of all materials and consumables for all the pipeline systems in Mainline & Terminals.

3.9

Repair of Pipe Defects All repairs of pipe shall be carried out as per specifications. All defective pipes shall be replaced during the Defects Liability Period without any limit on the quantum of the liability on the Contractor.

3.10

Conditions for Company Supplied Material (If any):

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• •

• • •

3.11

Volume-IB of V

MECON LIMITED

The Contractor shall be responsible for taking over of the material and subsequent handling, hauling, transportation to the actual work site(s)/fabrication yard(s) and storage & safe keeping of the materials. The Contractor shall inspect all Company supplied free issue materials at the time of taking over from the Company and defects noticed, if any, shall be brought to the notice of Company/Company representative and jointly recorded. Once the material has been taken over by the Contractor, all the responsibility for safe keeping of the materials and repair of damage/ defects to pipe & pipe coating shall rest with the Contractor. Rebuffing of dents in bevels less than 1 mm in depth shall be carried out by Contractor ahead of welding in the field at no extra cost to Company. On completion of the works Contractor shall submit a “Material Appropriation Statement” for all materials supplied by the Company as free issue materials. Every month the Contractor shall submit to the Company an account for the material issued to the Contractor in the Performa prescribed by Engineer-inCharge. Storage of Materials:

• •

• •

• • •

3.12

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

All materials shall be preserved against deterioration and corrosion due to poor or improper storage while under the custody of the Contractor. All materials shall be duly protected by the Contractor at his own cost with the appropriate preservatives like primer, lacquer, coating, grease etc. and shall be covered with suitable material to prevent them from direct exposure to sun, rain, wind and dust. Pipes shall be stacked according to the identification marks and stacks shall be arranged on sleepers / sand bags at least 300 mm above ground. The Contractor shall check that valves, fittings, specials etc are not subjected to corrosion from hydrostatic test water remaining in the piping. Any such condition when detected should be brought to the notice of Engineer-in-Charge and remedial measures taken as directed. All machined surface shall be properly greased and should be maintained and protected from damages. Openings of equipment, machinery, valves etc. shall be kept blocked / covered with blinds to prevent entry of foreign matter. As far as possible materials shall be transported to the site of erection only just prior to the actual erection and shall not be left around indefinitely on ground but kept on packing/sleepers etc. to maintain the minimum distance from the ground as specified and/or as per directions of Engineer-in-Charge. General All consumables for welding such as oxygen, acetylene, inert gases and all types of electrodes suitable for pipes of grades as specified in the specification, low hydrogen electrodes, filler wire, solder wire, brazing rods, flux etc. for welding / cutting and soldering purpose. Equipment like hydrostatic pump etc., water and corrosion inhibitor for water

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MECON LIMITED

used for hydrostatic testing including all pipes, fittings and equipment, metallic blinds, temporary gaskets as required for filling, pressurizing and dewatering in connection with hydrostatic testing completion. All pigs required for cleaning, gauging, filling, dewatering and swabbing of pipeline. All pipes, fittings and equipment metallic blinds temporary gaskets as required for filling, pressuring and dewatering in connection with hydrostatic testing completion. All consumables required for welding of structural steel. All safety tools/tackles, devices / apparatus / equipment etc. including ladders and scaffoldings etc. complete as required. Supply of nitrogen and other consumables, tools and tackles required for venting, pre-drying, purging and filling of station piping. Any other material not specifically listed herein, but required for the execution of the work. List of materials required to be supplied and quantities indicated are tentative. These quantities can vary during execution to any extent and the same unit rate shall be applicable for payment. Final quantities will be based on the drawing issued to the contractor for construction. Quantities covered in SOR are for as erected quantities. Bidder will procure additional materials as required to cover cutting, scraps, wastages and damages during erection, testing and commissioning. For these extra quantities no additional payment will be made. 3.13

Other Conditions of Bid

3.13.1

Survey •

•

Company has got the detailed survey carried out for all the pipeline routes and are enclosed with bid package. Apart from above, crossing details of rail, road and water crossings are also available. All available survey drawings, report, soil investigation, soil resistivity are enclosed with the bid. Contractor shall carry out any additional topographic/ geotechnical surveys required during execution of the project and for local detours during execution of the project without any extra cost. However, the Contractor shall carry out hydrological and geotechnical investigation of major rivers, as required. The surveyed pipeline alignment has been staked on ground. However the pipeline route survey had been carried out sometime back and when the Contractor mobilizes at site, some of these stakes may be missing. It shall be the responsibility of the Contractor to re-establish the missing stakes from the survey data made available by Company. Contractor shall maintain and preserve survey monuments (staked on ground) such as bench marks and intersection points, till construction is completed.

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3.13.2

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Description of Pipeline Route For all the details of pipeline routes for all the spur lines, terrain details & crossings, refer respective pipeline detailed route survey report and survey drawings enclosed with the bid package. Based on above design parameters, pipeline wall thickness and grade have been optimized and are indicated below :Pipeline Section

Class Location Refer alignment sheet Refer alignment sheet Refer alignment sheet Refer alignment sheet

Padamla to Halol (12” x37.5 km)

Dia. (NB) 12”

API 5L Grade X-65

W.T.

12”

X-65

6.4

12”

X-65

7.1

12”

X-65

8.7

12”

X-65

7.1

6.4

Length (in km) Refer alignmen t sheet Refer alignmen t sheet Refer alignmen t sheet Refer alignmen t sheet

TOTAL Spurline-I (To GIDC,Halol)

* For Crossing & LR Bends The number of crossings and features along the pipeline route described above are approximate. A list of all crossings identified is attached in the survey documents enclosed in the Bid Package for reference purpose. Contractor shall, however, not be entitled for any compensation in terms of time and cost in case of variation in the information provided or additional minor water crossings i.e. canal/stream/ PWD/ Panchayat/ village roads/ municipal road crossings encountered along the route. 3.13.3

Site visit Bidders are advised to make site visits along the pipeline routes prior to quoting to familiarize themselves with all the salient features of terrain, availability of ROU and infrastructure along the pipeline routes. Contractor shall be deemed to have considered all constraints and eventualities on account of site conditions along pipeline routes while formulating his bid. Contractor shall not be eligible for any compensation in terms of cost and/or time, on account of site conditions along pipeline routes varying to any extent from whatever is described in the bid package and the survey drawings/data furnished along with the bid package.

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3.13.4

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Soil Investigation and soil Resistivity survey Company has carried out soil investigation (visual classification/stratification) and resistivity survey along the pipeline routes. Data collected from such surveys is enclosed with the bid package. All soil data is issued to Contractor for his reference purposes only. It shall be Contractor’s responsibility to verify the data and satisfy himself with regard to accuracy and utility. Contractor shall carry out any additional soil data/ investigation required for execution of the job. Contractor shall not be entitled for any compensation in terms of time or cost in case of any variation in actual site conditions from the data furnished in the bid package. It shall be Bidder's responsibility to familiarize himself with sub-soil conditions along the pipeline route, and workout the lengths of pipeline to be laid in different subsoil conditions including the quantum of rock excavation that would be necessary. Price quoted by Bidder shall also be inclusive of all rock excavation. No extra compensation shall be payable to Contractor for any rock excavation whatsoever.

3.13.5

Repair of Coating Contractor using suitable material compatible with parent coating system and meeting the requirements of coating system shall carry out any repairs to 3layer polyethylene coating. The coating repair material and procedure for application shall be submitted to Company for approval prior to start of construction. Repair of PE coated pipes in field shall be carried out as follows in accordance with bid specification.

3.13.6

•

Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2.0 mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal.

•

Defects of size exceeding above mentioned area or holidays of width less than 300 mm shall be repaired with heat shrink repair patch by exposing the bare metal surface.

•

Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500mm shall be repaired using heat shrinkable sleeves/ cold applied tapes.

Long Radius (R=6D) Bends Long radius bends supplied by the Contractor shall be fabricated from contractor supplied 12” bare line pipe. Bends shall be fabricated in accordance with specification enclosed with the tender. Contractor shall firm up the exact

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Volume-IB of V

MECON LIMITED

quantity of LR bends required.. 3.13.7

Statutory Permissions The Company shall obtain a general permission from most of the authorities having jurisdiction over the area as necessary for construction of the pipeline. However, for some of the permissions, if not available, Contractor shall do the follow up with the concerned authorities to get the permissions to execute the job in time. However, Company shall reimburse all statutory payments required for such permissions at actual. Contractor shall also obtain the necessary permits like work permit/ excavation permit/ trench opening permit etc. for all works from the authorities having jurisdiction before the actual execution of various phases of the works and all stipulations/ conditions/ recommendations of the said authorities shall be strictly complied with no extra cost to Company. Contractor shall also obtain all necessary permissions from the concerned authorities for installation of pipeline at railways, roads, water crossings and at places where blasting is required. Company may, however, assist Contractor in obtaining such permissions, wherever required, by issuing recommendation letters etc. In case of damage to other utilities/infrastructure, Contractor shall be responsible and the Contractor shall pay the required compensation, as per the directions of concerned authorities. After completion of work, Contractor shall obtain a certificate from the concerned authorities that the job has been completed as per their requirement and the area/land has been restored to their satisfaction.

3.13.8

Environmental Restrictions The following measures shall be adopted during pipeline construction in order to minimize the impact of pipeline construction activities on the environment. •

While working in plantation areas, Contractor shall take due care to minimize the damage of trees. The number of trees felled shall be restricted to minimum based on working requirement for pipeline installation. In the paddy field area, Contractor shall exercise maximum care not to damage the crop outside the ROU. The compensation of damage of crop outside ROU, if any, shall be to Contractor’s account. Damage to any obstruction, temporary/ permanent structure, boundary walls etc. within ROU shall be repaired, restored and shall be to Contractor’s account.

•

Intake and discharge of water required/used for line flushing and testing should not cause unacceptable environmental disturbance. During dewatering process, proper drainage arrangement shall be made to discharge the hydro-test water to avoid flooding of the near by area.

In addition to above, relevant requirements of Pollution Control Boards, forest department and NOCs shall be complied with.

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3.13.9

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Typical Layout Drawings & Pipeline Alignment Sheets Typical terminal piping layout drawing and pipeline survey drawings are included in the bid package for the purpose of estimation of quantum and type of work involved. This piping drawing and pipeline survey drawings are indicative only and are furnished for Bidder’s information. Issued for Construction (IFC) drawings for terminals shall be prepared by Contractor and shall be subject to approval by Company. However, ‘IFC’ alignment sheets shall be prepared by the contractor and submit for approval.

3.13.10

R.O.U. For pipeline construction purposes, ROU of varying width shall be made available depending upon site condition. In cross country areas the ROU of 15 m width) shall normally be made available to Contractor to the extent feasible. Pipeline shall be laid 10 m from one side of boundary of ROU (to be advised by Engineerin-Charge). In Forest areas, hilly terrain and congested areas such as built-up areas etc., ROU of 10 m or less shall be available. The pipeline shall be laid at 2 m from the ROU edge in reserve forest areas. All these eventualities shall be taken into account. It shall be Contractor’s responsibility to make arrangement for any additional land required for fabrication, construction, storage and all other work areas. Contractor shall carry out construction work with in the width as made available to him. Where the pipeline route passes through forest/plantation areas, contractor shall clear only the minimum width required for laying the pipeline as per Company’s approved procedure for pipeline construction. Felling of trees/plants shall be minimized. Damage to any obstruction, temporary/permanent structure, boundary walls etc. within ROU shall be repaired and restored and shall be to Contractor’s account. The Contractor must ensure that during laying of the pipeline minimum damage occurs to the land. The land has to be restored to original condition. All construction activities shall be in accordance with the local Government regulations and shall be performed by the competent and qualified persons for providing adequate protection to the general public, livestock, wild life, forest, power lines, buildings etc. in the vicinity of the pipeline. During pipeline construction, measures shall be adopted in order to minimize the impact of pipeline construction activities on the environment. During ROU clearance, the vegetation shall be cut off at ground level leaving the roots intact. Only stumps and roots directly over the trench shall be removed for pipeline installation. Company has acquired the ROU free of any encroachments/ temporary/ permanent structures. However, in case any such encroachments or structures are encountered during execution, the contractor shall be removed the same. All costs towards such activities shall be to Contractor’s account.

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Volume-IB of V

MECON LIMITED

In case contractor wishes to propose any detour from the acquired alignment due to construct ability problems or otherwise, he may be permitted to do so only after explicit approval from the Company. All immediate measures for taking the land and compensations to land owner(s) shall be to Contractor’s account. Company shall proceed with regular notifications etc. in due course. All statutory fees shall be paid/ reimbursed by Company. However, such activity shall not affect the construction schedule and overall completion period. 3.13.11

Burial Depth The pipeline shall be buried normally at a depth of 1.0 meter below natural ground level except river/ rail/ road/ canal crossing..

3.14

Crossings For all rail, road, canal, river & other water crossings, Contractor shall liaison with relevant authorities and intimate them well in advance about the schedule and methodology of crossing. It shall be obligatory on the part of the Contractor to ensure that Authorized Representative of the authority under whose jurisdiction the crossing falls should be made available at site by the Contractor at the time of making crossing. After completion of works and complete restoration of ROU, Contractor shall provide NOC from the relevant official pertaining to complete restoration to their satisfaction and certification in respect of no other damage caused to their property outside the earmarked ROU

3.14.1

Railway Crossings The railway crossing shall comply with the requirements of API 1102 and Indian Railways regulations. The crossing angle shall be as close to 90° as possible. Cover of casing pipe for railway crossings shall be minimum 1.8 m. Casing shall be suitably insulated from underground conduits carrying electrical wires. The carrier pipe shall be electrically insulated from casing pipe and casing ends shall be sealed using durable electrically non-conducting material. Contractor shall obtain approval of crossing drawing from concerned authorities. Casing vent pipe shall be at least 1.2 m away vertically from aerial electrical wires and shall be suitable insulated from underground conduits carrying electrical wires on railway land.

3.14.2

Road Crossings •

•

The method of crossing of roads such as open cut / boring/ trench less technology shall be firmed up by Contractor in consultation with concerned authorities and Company. The Contractor shall also take due care to identify and take due precautions so as not to disturb or damage the utilities like cables, water lines and other structures. After laying the pipeline in a road crossing by open cut method, the Contractor shall completely restore the road to its original condition.

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•

• •

3.14.3 3.14.3.1

Volume-IB of V

MECON LIMITED

While laying the pipeline in road crossings by open cut method the Contractor should ensure that the traffic is not stopped during the execution of work. This may be done by cutting half of the road at a time so as to enable the traffic to pass on the remaining half of the road. Alternatively, the Contractor can provide diversion roads to maintain the flow of traffic. The Contractor shall provide proper caution boards during day time and danger lights during night time when the cutting operation of the road is going on. For cased crossings, the pipeline should be taken through the casing pipe. The top of casing should be at least1.2 metres below the road top as specified, or as per the requirements of the local authorities, whichever is higher.

Water Crossings Canal/Drain/Other minor water crossings • • • •

3.14.4

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Canal and other water crossings shall be carried out by open cut/boring/trench less technology method, to be firmed up by Contractor in consultation with concerned authorities and Company. No damage shall be caused to any irrigation sources, while laying the pipeline through canal crossings. The banks of the Canal should be brought to the original condition, if they are damaged by the laying of the pipeline. Stabilisation of banks shall be carried out as per requirements of concerned authorities. Pipeline shall be at least 1.5 metre below the bed for canal/drain crossing.

River Crossings ƒ

ƒ

ƒ

ƒ ƒ

Unless specified otherwise the top of pipeline for river crossings shall be taken at least 1.5 metre below the scour depth or 2.5m below bed (1.5m for rocky strata) whichever is more. The detailed construction methodology and schedule. shall have to be finalised by Contractor in consultation with concerned authorities having jurisdiction over rivers. Company shall provide assistance by providing introductory letters. Pipeline at river crossings as detailed in para (d) below are intended to be installed by open cut method, however Contractor may also propose HDD or any other equivalent method in place of open cut based on flow and soil conditions of individual rivers at the time of crossing. Company’s prior approval shall be obtained for the crossing method other than open cut. Contractor shall submit all design calculations, procedures & drawings for Company’s approval in case of HDD option. These river crossings shall be considered as a part of main line laying works irrespective of method of crossing adopted by the Contractor. Any additional land if required for string preparation for crossing of rivers

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MECON LIMITED

and canals shall be arranged by Contractor at no extra cost to Company. 3.14.5

Installation of Conduits for Optical Fibre Cable at Crossings At all crossing locations (viz., rail, road, canal and minor water course crossings) the optical fibre cable shall be installed inside a cable conduit to be installed by the Contractor. At all such crossings where the carrier pipe is installed by open-cut of the facility crossed, HDPE conduit shall be installed along with the pipeline for installation of the Optical Fiber Cable. At crossings of water bodies, where anti buoyancy measures are provided for the carrier pipe, HDPE conduit will be strapped to the mainline at 5m interval using high strength PE straps. For all river crossings by HDD, CS conduit shall be strapped with carrier pipe for bundle pulling or a separate drilling shall be performed for CS conduit. Required HDPE conduit shall be installed inside CS conduit. At all such crossings where the carrier pipe is installed by moiling/ jacking/boring of carrier pipe directly and at all cased crossings, i.e., where carrier pipe is installed inside casing pipe, 168 mm OD, 6.4 mm thk. API 5L Gr-B steel conduit with HDPE inter duct shall be installed by jacking/boring separately. Each casing end seal shall have a moulded opening suitable for HDPE conduit. The center to centre distance between pipeline and CS cable conduit shall be 4.0 m based on as installed dimensions.

3.15

Hydrostatic Testing The pipeline from tap-off point cum despatch terminal at Padamala to Halol (12” x 46 km) shall be hydrostatically tested to a minimum test pressure of 1.5 times the design pressure of 95 bar such that the highest point of the test section shall be subjected to the same but limited to 95% of SMYS of the pipe material.

3.16

Dewatering and Swabbing After successful completion of hydrostatic testing of the pipeline, Contractor shall dewater the pipeline. The dewatering operation shall consist of at least two dewatering runs of four-cup bi-directional pigs propelled by compressed air. As a minimum, Contractor shall continue the dewatering operation until the volume of water removed by the last pig train is less than volume of 2 metres of full pipe length. After completion of dewatering operations, Contractor shall carry out swabbing of pipeline by running several pig trains consisting of high/ medium/ low-density foam pigs propelled by compressed air through the pipeline. Prior to their launching, Contractor shall weigh the pigs. On arrival of the pigs at the receiving end they shall be re-weighed. The swabbing operation shall be repeated till the weight of the last received foam pig does not increase by more than 50% or 10 runs of foam pigs whichever is earlier. Drying the entire pipeline to the required degree of the

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MECON LIMITED

dryness as specified in technical specification. The pipeline/ section(s) of pipeline shall never be left empty (filled with air) after dewatering/ swabbing/drying.. Dewatering, swabbing and drying of pipeline after hydro testing shall be taken up by Contractor only when Contractor is ready for carrying out the drying operation immediately following pipeline swabbing. Till such time Contractor is ready to start drying of pipeline, the pipeline/ section(s) of pipeline after hydro testing shall be kept filled with inhibited water or the pipeline/ section(s) of pipeline shall not be dewatered. Preservation of pipeline using inhibited water from the time of completion of hydro testing till Contractor is ready for drying of pipeline, shall be carried out by Contractor as part of his scope of work at no extra cost to Owner. After the results of swabbing operation has been accepted by Owner, nitrogen purging of line may be started for pre-commissioning activities as per specification. 3.17

Terminal Facilities Piping facilities between the insulating joint and hook up point/battery limit and all above ground facilities installed by Contractor shall be hydrostatically tested to a test pressure. in accordance with “Standard specification for Inspection, Flushing and Testing of Piping System” enclosed with the Contract document. All valves in the piping network being hydro tested shall be kept in the crack open position. Holding time shall be six hours.

3.18

Leak Detection Contractor shall submit a detailed procedure for leak detection during hydro test. Such method of detection shall consume minimum possible time to complete the hydro test activity within contractual completion schedules. This procedure needs approval of the Engineer-in-charge. All works for locating and repair of major leak/burst occurred during hydrostatic testing including necessary repairing/replacing/ cutting and removing out defective pipe length as defined in the specification and shall not be payable as per relevant items of schedule of rates. Contractor shall carry out repairing / replacing of defective pipe length including cutting and removing of defective pipes, pre testing of replacement pipe for 24 hours and welding into main line, NDT of the welds, coating of the weld joints, clean up, re-testing of pipeline including providing all equipments, manpower & consumables.

3.19

Pipeline Information Management System All pipeline construction related activities and documentation including pipe book, weld book are required to be handed over to the Company in an electronic form in appropriate formats and systems.

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3.20

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Direction of Construction For all pipelines, the direction of construction shall be in the direction of flow i.e. from Padamala towards Halol and from all tap-off points to consumer ends unless specified otherwise. In case the Contractor proposes to carry out construction in direction opposite to direction of flow, the Contractor may do so at no extra time and cost to Company and subject to Company Approval.

3.21

Pre-Commissioning of pipeline Pipeline Contractors shall be responsible for pre-commissioning of all the pipelines and terminals being installed by them, including supply of manpower, materials, equipment including nitrogen along with necessary piping and instrumentation connections for monitoring flow rate, pressure, temperature etc. temporary venting along with necessary piping, valves and instrumentation as well as consumables.

3.22

Magnetic Cleaning, Caliper Pigging and Commissioning Pipeline Contractor shall carry out magnetic cleaning and Caliper pigging (EGP), of pipelines for 12” main line being installed by them as per requirements stipulated elsewhere in the bid document. Rectification of defects observed during pig run, shall be carried out by individual Contractor including digging, cutting, replacement, repair, welding, NDT etc.

3.23

Sub Contractors The successful Bidder shall furnish a list of sub-Contractors proposed for residual engineering along with their Commitment letter, Track record / experience and organization details commensurate with their experience for executing similar jobs associated with the work tendered. For design, engineering and procurement the leader or sub-Contractor / backup agencies wherever engaged, should have sufficient relevant experience for cross-country pipeline and terminal for hydrocarbon service and to establish the experience supported by copies of work orders and completion certificates shall be furnished for Company’s review and approval.

3.24

Overall Commissioning Overall commissioning including drying, nitrogen purging etc. for Contractors shall perform the pipelines including all terminals. Overall commissioning Contractor shall mobilize all equipment, consumables, nitrogen and manpower for carrying out pigging, drying, inertisation and commissioning activities. Commissioning activities shall be carried out as per applicable specifications

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MECON LIMITED

enclosed with Contract. 4.0

ENGINEERING REVIEW FOR PIPELINE AND TERMINALS Contractor shall submit all proposed designs, drawings, installation and testing procedures, work instructions with ITPs and inspection formats for review and approval by Company as mentioned in scope of work. This shall be done seven (7) days prior to the commencement of any phase of fabrication or installation. The work shall begin only after Company’s approval has been obtained. Calculations shall also be submitted for any other factors not listed in the bid package but which are necessary to prove the validity for Contractor’s design or proposed construction methods. Contractor shall furnish his document schedule indicating clearly sequencing of documents. As part of residual engineering, Contractor shall as a minimum, provide following deliverables for Company’s review and approval. • Piping stress analysis. • Design and engineering of piping and equipment supports, RCC sleepers for above ground piping, pipe racks, valve operating platforms, Detailed list and schedule of submission of relevant documents drawings and procedures. • Methodology for crossings of rivers, canals, major roads, difficult terrain (steep slope hilly terrain) etc. and detailed calculation & drawing as applicable in case HDD/ any other method being adopted. • Installation, hook-up, field testing and commissioning procedures/ specifications • Golden joint-2 Nos for each station, tap-off, mainline and 2Nos per HDD. • Pipeline Alignment Drawings for detoured areas. • IFC Piping General Arrangement drawing for all terminals and intermediate installations. • Pipeline approach/ departure drawings. • Operational & maintenance manual. • Work instructions, ITPs and inspection formats paved areas etc. • Equipment layout/ Overall plot plan.

5.0

CONTRACTOR’S RESPONSIBILITIES Contractor’s responsibilities, besides the scope of work to be performed by him defined earlier, shall also include the following:

5.1

The Contractor is deemed to have recognized any restrictive features and constraints of the site(s), pipeline route and /or specific requirements of the work and made due allowance for it in the work to be performed by him.

5.2

Company has provided the available information and survey data along pipeline route and crossings. Company gives no guarantee or warranty as to the accuracy or completeness of the information provided. It is the Contractor’s sole responsibility to obtain sufficient information / data along pipeline route and crossings to allow safe and sound design and installation of the proposed

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MECON LIMITED

pipeline. 5.3

Interpretation and verification of data/information furnished by Company in respect of pipeline route surveys, crossing details, contained in the bid package. Any additional information/data/surveys etc. required by Contractor for detailed engineering and execution of the works, shall be obtained by him. Company may assist him in obtaining such information/ data by issuing recommendatory letters.

5.4

Drawings and installation procedures, engineering for procurement & fabrication, engineering for installation including drawings, QA/QC procedures, etc performed by the Contractor for complete pipeline system shall be reviewed and approved by Company. Contractor shall submit six sets of engineering documents, drawings, and procedures as described under relevant clause for Company’s review and approval. All works shall be executed based on approved documents only.

5.5

Review and approval of Contractor’s work(s) by Company shall in no way relieve the Contractor of his sole responsibility for safe and efficient design, engineering, installation and subsequent operation of pipeline system.

5.6

Furnishing and mobilizing at site(s) of all construction equipment, manpower, tools and tackles, construction spreads, fully equipped and fully manned with other required support facilities etc. commensurate for spreads needed for successful execution of the works.

5.7

Pre-commissioning/ commissioning of all the pipeline/piping systems.

5.8

Preparing and furnishing calculation books, pipe books, material/ purchase requisitions, final purchase orders including specifications, Vendor's data books (including Guarantees), fabrication and construction drawings, all survey reports, inspection and testing reports, as-built records for all phases of work.

5.9

The Contractor is cautioned to exercise extreme care and take necessary precautions to prevent damage to the existing pipeline(s), facilities, electrical and other cables during execution of the entire works. Contractor shall carry out Restoration/ reconstruction of all structures/ facilities affected during pipeline construction.

5.10

Wherever Contractor comes across water lines/open channels/drains in the fields used for cultivation, suitable arrangements similar to the existing type shall be made by the Contractor for ensuring water supplies across the fields and maintain the same till construction is completed in that stretch. Any claims arising out of non-compliance to the above requirements, as granted by competent authorities shall be to Contractor’s account.

5.11

Contractor shall carry out all testing and inspection of materials, equipment etc. in independent testing institutions, laboratories, if so desired by Company.

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Volume-IB of V

MECON LIMITED

5.12

Disposal and treatment of treated hydro-testing water, excavated materials, surplus materials etc. as per local authorities requirements.

5.13

Blasting if required, in all types of rocks for excavation shall be carried out in controlled manner so as to protect the existing facilities, men, environment and property etc from any damage, whatsoever. Blasting in all types of rock shall be allowed subject to concerned central/state government and regulatory authorities permitting the same.

5.14

Any other work not specifically listed but required for successful completion of entire pipeline system.

5.15

DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING No technical documents are required to be submitted at the time of bidding. Bidder is advised to comply with all the requirements of bid document without any deviations. Company reserves the right to reject any bid with deviations without making any reference to bidder.

6.0

DOCUMENTS, SPECIFICATIONS, STANDARDS AND DRAWINGS

6.1

Owner shall furnish piping and Instrumentation diagrams (P & I D), preliminary plot plan for the construction of Terminal alongwith the tender. Contractor shall submit the design & engineering drawings and construction drawings including general arrangement drawings for piping, electrical, mechanical & instrumentation systems and other related/ required systems, at appropriate times for Owner/ EIC approval.

6.2

Contractor shall prepare isometric drawings & bill of materials and submit the same for Owner/ Consultant’s approval/ record. Contractor shall prepare drawing for utilities line as required as per SOR and submit the same for Owner/ Consultant’s approval/ record.

6.3

No construction small or big shall be carried out without proper construction drawings duly approved by Owner's Engineers or site office or Owner's representative duly authorised to do so. For Mainline route survey alignment sheets and crossing survey details shall be furnished alongwith bid by Owner. However, detail-crossing drawings with crossing methodology shall be submitted by Contractor for prior approval. Any additional survey and data required to complete above should be done by Contractor without any extra cost.

6.4

After Completion of construction & commissioning of Terminal, Contractor shall incorporate all the correction in drawings, prepare and issue the drawings "as-built drawings" as listed below to Owner as final submission of drawings. For Mainline

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Volume-IB of V

MECON LIMITED

pipeline alignment sheet, all X-ing details, all CP drawings, pipe book etc. and for Terminals P&ID, layout drg., piping GAD, Isometric, all electrical & instrumentation drg., all civil drawings. For final submission only 4 sets of documents plus the original transparencies shall be handed over by Contractor. Any construction done by Contractor without duly approved drawings shall be wholly at his risk and cost. Contractor shall also submit soft copy of pipe book in excel alongwith hard copy. Soft copy of all as-built drawings shall be also submitted in AutoCAD. Video graphy/ photograph of all major activities/ milestone achieved shall also be arranged and submitted by the Contractor. For details of documentation to be submitted for mainline and terminal refer enclosed specification for documentation for pipeline construction Specification NO. MEC/S/05/62/09R enclosed elsewhere with the tender. 6.5

Specifications The work shall be carried out by CONTRACTOR strictly in accordance with the following specifications enclosed in Volume-II of V this document :-

VOLUME-II OF V 1.

SPECIFICATION FOR MAINLINE CONSTRUCTION

MEC/S/05/62/01A

2.

SPECIFICATION FOR WELDING OF ONSHORE CROSS-COUNTRY PIPELINE WITH ADDENDUM-I TO ABOVE SPECIFICATION

MEC/S/05/62/02A

3.

SPECIFICATION FOR HYDROSTATIC TESTING OF ONSHORE PIPELINES

MEC/S/05/62/03A

4.

SPECIFICATION FOR MAJOR WATER CROSSINGS (CONVENTIONAL)

MEC/S/05/62/04

5.

SPECIFICATION FOR PIPELINE CROSSING ROADS, RAILROADS, MINOR WATER AND OTHER CROSSINGS

MEC/S/05/62/05

6.

SPECIFICATION FOR PIPING, FABRICATION AND ERECTION

MEC/S/05/62/06

7.

SPECIFICATION FOR SHOP AND FIELD PAINTING

MEC/S/05/62/07A

8.

SPECIFICATION FOR REPAIR OF PIPELINE CORROSION COATING MEC/S/05/62/08

9.

SPECIFICATION FOR PIPELINE MARKERS

MEC/S/05/62/10

10.

SPECIFICATION FOR FLUSHING AND TESTING

MEC/S/05/62/11

11.

SPECIFICATION FOR CASING INSULATORS AND END SEALS

MEC/S/05/62/12

12.

SPECIFICATION FOR FIELD JOINT COATING (ON-SHORE PIPELINE)

MEC/PTS/05/62/13

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MECON LIMITED

13.

SPECIFICATION FOR 3 LPE COATING OF PIPE

MEC/S/05/62/014

14.

SPECIFICATION FOR 3 LPP COATING OF PIPE

MEC/S/05/21/014B,R0

15.

SPECIFICATION FOR VENTS, DRAINS AND WELLS

MEC/S/05/62/15

16.

SPECIFICATION FOR GASKETS, NUTS AND BOLTS

MEC/S/05/62/019

17.

PIPING MATERIAL SPECIFICATIONS

MEC/23JT/05/21/S/021

18.

SPECIFICATION FOR PRE-COMMISSIONING/ COMMISSIONING

MEC/S/05/62/61

19.

SPECIFICATION FOR CORROSION PROTECTION COALTAR BASED TAPE COATING OF U/G STEEL P/L FOR WATER SERVICE SPECIFICATION FOR HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT (HSE)

MEC/S/05/62/63

20. 21. 22.

SPECIFICATION FOR QUALITY ASSURANCE SYSTEM REQUIREMENTS SPECIFICATION FOR DOCUMENTATION FOR PIPELINE CONSTRUCTION

MEC/S/05/62/65 MEC/S/05/62/66 MEC/S/05/62/69

23.

SPECIFICATION FOR CALIPER PIGGING

MEC/S/05/62/70

24.

SPECIFICATION FOR INTELLIGENT PIGGING

MEC/S/05/21/70A-R0

25.

SPECIFICATION FOR FIELD JOINT COATING OF PIPELINE FOR HDD CROSSING

MEC/S/05/62/74

26.

SPECIFICATION FOR PIPELINE CROSSING USING DIRECTIONAL DRILLING METHOD

MEC/S/05/62/75

27.

SPECIFICATION FOR BALL VALVES

MEC/TS/05/62/002

28.

SPECIFICATION FOR CHECK VALVES

MEC/TS/05/62/004

29.

SPECIFICATION FOR GLOBE VALVE

MEC/TS/05/62/005

30.

SPECIFICATION FOR SCRAPPER TRAP

MEC/S/05/62/007

31.

SPECIFICATION FOR INSULATING JOINTS

MEC/TS/05/62/009

32.

SPECIFICATION FOR FLOW TEE

MEC/S/05/62/011

33.

SPECIFICATION FOR LINE PIPE (ON SHORE)

MEC/TS/05/21/012D

34.

SPECIFICATION FOR QOEC

MEC/S/05/62/013

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Volume-IB of V

MECON LIMITED

35.

SPECIFICATION FOR LONG RADIUS BENDS

MEC/TS/05/62/015

36.

SPECIFICATION FOR CARTRIDGE FILTER

MEC/TS/05/62/017

37.

SPECIFICATION FOR FITTINGS & FLANGES UPTO 16” SIZE

MEC/TS/05/62/025

38.

SPECIFICATION FOR PIG SIGNALLERS

MEC/S/05/62/048

39.

SPECIFICATION FOR PRESSURE SAFETY VALVE

MEC/TS/05/62/056

40.

SPECIFICATION FOR ASSORTED PIPES FOR TERMINALS

MEC/TS/05/62/59A

41.

PARTICULAR TECHNICAL SPECIFICATION OF CO2 FLOODING SYSTEM

MEC/05/14/23JT/01

Drawings 6.5

The following drawings are included in Volume-V of V of the bid package for BIDDER’s reference purpose only; Bidders are advised to go through these drawings and also visit the site before submitting their bids. The Contractor shall develop the drawings for all crossings and detour of pipeline alignment.

VOLUME – V of V 1.

MECHANICAL DRAWINGS

Sl. No. 1.1 1.2 a) b) c) d) e) f) 1.3 a) b) c) d) e)

Description of Drawings SCHEMATIC LINE DIAGRAM P&I DIAGRAM FOR TAP-OFF POINT-I AT PADAMALA P&I DIAGRAM FOR TAP-OFF-II CUM DESPATCH TERMINAL AT SOKHADA P&I DIAGRAM FOR TAP-OFF POINT-III FOR GIDC MAJUSAR at Ch. 11.42 P&I DIAGRAM FOR TAP-OFF POINT-IV AND SV-1 AT SAVALI GIDC AT CH. 23.87 KM P&I DIAGRAM FOR RECEIVING TERMINAL AT HALOL LEGEND / DRAWING SYMBOLS PLOT PLAN FOR TAP-OFF POINT – I AT PADAMALA PLOT PLAN FOR DESPATCH TERMINAL CUM TAP-OFF POINT-II AT SOKHADA PLOT PLAN FOR TAP-OFF-III AT CH. 11.42 KM PLOT PLAN FOR SV-1 AND TAP-OFF-IV AT CH. 23.87 km PLOT PLAN FOR TAP-OFF-V AND RECEIVING TERMINAL AT HALOL

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Drawings No. MEC/23JT/05/21/M/LD/0001 Rev. 2 MEC/23JT/05/21/M/001/0101, Rev. 5, Sheet 1 of 5 MEC/23JT/05/21/M/001/0101, Rev. 5, Sheet 2 of 5 MEC/23JT/05/21/M/001/0101, Rev. 4, Sheet 3 of 5 MEC/23JT/05/21/M/001/0101, Rev. 4, Sheet 4 of 5 MEC/23JT/05/21/M/001/0101, Rev. 5, Sheet 5 of 5 MEC/23JT/05/62/M/001/0002, Rev. 0, MEC/23JT/05/21/M/001/1011, Rev. 2 MEC/23JT/05/21/M/002/1011, Rev. 2 MEC/23JT/05/21/M/003/1011, Rev. 2 MEC/23JT/05/21/M/004/1011, Rev. 2 MEC/23JT/05/21/M/006/1011, Rev. 2

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Sl. No. 1.4 a)

b) c) d) 1.5 1.6

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

Description of Drawings PIPING GAD FOR DESPATCH TERMINAL CUM TAP-OFF POINT-II AT SOKHADA PIPING GAD FOR TAP-OFF-III AT CH. 11.42 KM PIPING GAD FOR SV-1 AND TAP-OFF-IV AT CH. 23.87 km PIPING GAD FOR TAP-OFF-V AND RECEIVING TERMINAL AT HALOL ALIGNMENT SHEET (CD) CROSSING DRAWINGS (CD)

MECON LIMITED

Drawings No. MEC/23JT/05/21/M/002/1031, Rev. 2 (Sheet 1 of 2) MEC/23JT/05/21/M/002/1031, Rev. 1 (Sheet 2 of 2) MEC/23JT/05/21/M/003/1031, Rev. 1 MEC/23JT/05/21/M/004/1031, Rev. 1 MEC/23JT/05/21/M/005/1031, Rev. 2 MMIPL/GSPL/VGPL/AL-01 to 15 MMIPL/GSPL/VGPL/CS-01 to 49

6.7

Drawing and Documents

6.7.1

The drawings accompanying the Bid document are indicative of scope of work and issued for tendering / bidding purpose only. These drawings indicate the general scheme as well as the layout to enable the contractor to make an offer in line with the requirements of the owner. Final construction shall be done as per approved construction drawings issued by COMPANY.

6.7.2

"Approved for Construction" drawings will be furnished to the contractor progressively based on construction progress achieved by Contractor. No extra claims whatsoever shall be entertained for any variation between Bid Drawings and Approved for Construction Drawing.

7.0

RESOURCES FACILITIES

7.1

Recruitment of Personnel by Contractor The Contractor shall not recruit personnel of any category from among those who are already employed by the other agencies working at the sites but shall make maximum use of local labour available.

7.2

Land for Residential Accommodation Owner shall not provide any land for residential accommodation of contractors staff and labour.

8.0

PROJECT SCHEDULING & MONITORING The following schedules/documents/reports shall be prepared and submitted by the Bidder/Contractor for review/approval at various stages of the contract.

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8.1

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Alongwith Bid a)

Time Schedule The Completion Time Schedule for the work (including mobilization period) as per Appendix-I to Invitation for bid, PART-A of Tender in all respect, from the date of issue of telex/telegram/letter/Fax of Intent. The Bidder is required to submit a Project Time Schedule in Bar Chart Form, alongwith the Bid. The Schedule shall cover all aspects like sub-ordering, manufacturing and delivery, indicated in the Bid Document. The Owner interface activities shall be clearly identified with their latest required dates. Owner reserves the right to disqualify the Bidder if the above Schedule submitted by the Bidder is not in line with the over all Project requirement.

b)

Scheduling & Monitoring System The Bidders should describe their system of Project Scheduling and monitoring, the extent of computerization, level of detailing, tracing methodology etc. with the name of computer package and sample outputs.

8.2

After the Award of Contract a)

Overall Project Schedule The Contractor shall submit within 1 week of Fax of Intent, a sufficiently detailed over all Project Schedule in the activity network form, clearly indicating the major milestones, interrelationship/ interdependence between various activities together with analysis of critical path and floats. The network will be reviewed and approved by Engineer- in-Charge and the comments if any shall be incorporated in the network before issuing the same for implementation. The network thus finalised shall form part of the contract document and the same shall not be revised without the prior permission from Engineer-in- Charge during the entire period of contract.

b)

Progress Measurement Methodology The contractor is required to submit within 1 week of award of WORK, the methodology of progress measurement of sub-ordering, manufacturing/ delivery, sub- contracting construction and commissioning works and the basis of computation of overall services/physical progress informed. Owner reserves the right to modify the methodology in part or in full.

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c)

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Volume-IB of V

MECON LIMITED

Functional Schedules The contractor should prepare detailed functional schedules in line with network for functional monitoring and control and submit scheduled progress covers for each function viz. ordering, delivery and construction.

8.3

Project Review Meetings The Contractor shall present the programme and status at various review meetings as required. a)

Weekly Review Meeting Level of Participation

:

Contractor’s/Consultant’s RCM/ Site Incharge & Job Engineers.

Agenda

:

a) b) c)

Venue b)

8.4

:

Weekly programme v/s actual achieved in the past week & programme for next week. Remedial Actions and hold up analysis. Client query/ approval.

Site Office

Monthly Review Meeting Level of Participation

:

Senior Officers of GSPL/MECON and Contractors.

Agenda

:

a) b) c) d) e) f)

Venue

:

GSPL/MECON Office/ Site at the discretion of Owner/ MECON

Progress Status/ Statistics Completion Outlook Major hold ups/slippages Assistance required Critical issues Client query/ approval

Progress Reporting Proforma A)

Monthly Progress Report This report shall be submitted on a monthly basis within 10(ten) calendar days from cut-off date, as agreed upon covering overall scenarios of the work. The report shall include, but not limited to the following :

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Gujarat State Petronet Ltd.

a) b) c)

d) e) f) g) B)

Volume-IB of V

MECON LIMITED

Brief Introduction of the work. Activities executed/ achievements during the month. Schedule versus actual percentage progress and progress curves for Detail Engg. Sub-ordering, Manufacturing/ Delivery, Subcontracting, Construction, Commissioning and Overall and quantum wise status & purchase orders against schedule. Area of concern/ problem/ hold-ups, impacts and action plans. Resources deployment status. Annexures giving status summary for drawings, MRs, deliveries, sub-contracting and construction. Procurement status for items to be supplied by Contractor.

Weekly Reports The report will be prepared and submitted by the Contractor on weekly basis and will cover following items : a) Activities programmed and completed during the week. b) Resource deployed men and machines. c) Quantities achieved against target in construction d) Record of Man days lost. e) Construction percentage progress schedule and actual.

C)

Daily Repots a) b) c)

Activity programme for the day Progress of the previous day and commutative progress. Manpower & machinery deployed.

8.5

Progress Reports

8.5.1

CONTRACTOR shall make every effort to keep the OWNER adequately informed as to the progress of the WORK throughout the CONTRACT period. CONTRACTOR shall keep the OWNER informed well in advance of the construction schedule so as to permit the OWNER to arrange for requisite inspection to be carried out in such a manner as to minimize interference with progress of WORK. It is imperative that close coordination be maintained with the OWNER during all phases of WORK.

8.5.2

By the 10th (tenth) of each month, CONTRACTOR shall furnish the OWNER a detailed report covering the progress as of the last day of the previous month. These reports will indicate actual and scheduled percentage of completion of construction as well as general comments of interest or the progress of various phases of the WORK. The frequency of progress reporting by the CONTRACTOR shall be weekly.

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Volume-IB of V

MECON LIMITED

8.5.3

Once a week, CONTRACTOR shall submit a summary of the WORK accomplished during the preceding week in form of percentage completion of the various phases of the WORK, to the OWNER.

8.5.4

Progress reports shall be supplied by CONTRACTOR with documents such as chart, networks, photographs, test certificate etc. Such progress reports shall be in the form and size as may be required by the OWNER and shall be submitted in at least 3 (three) copies.

8.5.5

Contractor shall prepare daily progress report (DPR) in the desired format and submit it to Engineer-in-charge alongwith schedule of next day to Engineer-incharge.

9.0

OTHER CONSTRUCTION REQUIREMENT OWNER reserves the right to inspect all phases of CONTRACTOR's operations to ensure conformity to the SPECIFICATIONS. Owner will have Engineers, Inspectors or other duly authorised representatives, made known to the CONTRCTOR present during progress of the WORK and such representatives shall have free access to the WORK at all times. The presence or absence of a OWNER's representative does not relieve the CONTRACTOR of the responsibility for quality control in all phases of the WORK. In the event that any of the WORK being done by the CONTRACTOR or any SUB-CONTRACTOR is found by OWNER's representatives to be unsatisfactory or not in accordance with the DRAWINGS, procedures and SPECIFICATIONS, the CONTRACTOR shall, upon verbal notice of such, revise the work in a manner to conform to the relevant DRAWINGS, procedures and SPECIFICATIONS.

9.1

Rules & Regulations CONTRACTOR shall observe in addition to Codes specified in respective specification, all National and Local Laws, Ordinances, Rules and Regulations and requirements pertaining to the WORK and shall be responsible for extra costs arising from violations of the same.

9.2

Procedures Various procedures and method statements to be adopted by CONTRACTOR during the construction as required in the respective specifications shall be submitted to OWNER in due time for APPROVAL. No such construction activity shall commence unless approved by OWNER in writing.

9.3

Field Inspection CONTRACTOR shall have at all times during the performance of the WORK, a Competent Superintendent on the premises. Any instruction given to such superintendent shall be construed as having been given to the CONTRACTOR.

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9.4

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Erection and Installation The CONTRACTOR shall carry out required supervision and inspection as per quality Assurance plan and furnish all assistance required by the OWNER in carrying out inspection work during this phase. The OWNER will have engineers, inspectors or other authorised representatives present who are to have free access to the WORK at all times. If an OWNER's representative notifies the CONTRACTOR's authorised representative not lower than a Foreman of any deficiency, or recommends action regarding compliance with the SPECIFICATIONS, the CONTRACTOR shall make every effort to carry out such instructions to complete the WORK conforming to the SPECIFICATIONS and approved DRAWINGS in the fullest degree consistent with best industry practice.

9.5

Construction Aids, Equipment, Tools & Tackles CONTRACTOR shall be solely responsible for making available for executing the work, all requisite Construction Equipments, Special Aids, Cranes, Tools, Tackles and testing equipments and appliances. Such construction equipments etc. shall be subject to examination by owner and approval for the same being in first class operating condition. Any discrepencies pointed out by OWNER shall be immediately got rectified, repaired or the equipment replaced altogether, by CONTRACTOR. OWNER shall not in any way be responsible for providing any such equipment, machinery, tools and tackles. The OWNER reserves the right to rearrange such deployment depending upon the progress and priority of work in various sections. Tie-end between main line and starting point of terminal is included in the scope of contract, as and when main line section is available for Tie-ins.

10.0

DOCUMENTATION

10.1

"As Built" Drawings Notwithstanding the provisions contained in standard specifications, upon completion of WORK, the CONTRACTOR shall complete all of the related drawings to the "AS BUILT" stage and provide the OWNER, the following: a) b) c)

One complete set of all original tracings. Six complete bound sets of Contractor’s specifications including design calculations. Six complete sets, in the form of hand bound volumes, of the manufacturer's data book for all the equipments, instruments etc. including certified prints and data. Data books shall be completed with index as to tag numbers associated with manufacturer's data shown, Equipment data shall include as a minimum requirement the principle and descriptions of operations, installation and maintenance instructions, drawings and dimensions, parts list and priced purchase orders including those of major

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d) e) f)

g) 10.2

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

sub-vendors and suppliers. Requirements pertaining to "VENDOR DATA REQUIREMENT" attached with standard specifications for the documents to be included in the Data Book for each equipment, instruments etc. shall also be complied with. Six bound copies each of the Spare Parts Data Books and the Lubricants Inventory Schedule. Soft copy of all the as built drawings prepared in AutoCAD in one set of rewritable compact Disc and photographs covering measure activities at site. The Contractor shall submit coloured photographs covering all the activities of pipeline constructions highlighting the progress or other areas of work in 2 sets to Engineer-in-charge at site office alongwith monthly progress report. Similarly photographs for problem areas should be submitted well in advance with a proposed methodology to execute the works and meet the construction schedule. The cost of same shall be deemed to be inclusive in the rates and no separate payment shall be made. All as-built drawings as mentioned in specification for documentation enclosed elsewhere in the tender.

Completion Document The following documents shall be submitted in hard binder by the CONTRACTOR in THREE sets, as a part of completion documents :a) Welding Procedure Qualification Report. b) Welder Qualification Report. c) Radiographic Procedure Qualification. d) Radiographic Report alongwith radiographs (Radiographs only with the original). e) Batch Test Certificate from manufacturers for electrodes. f) Pretesting and final Hydrostatic and other Test results and reports. g) All other requirements as specified in the respective specifications. h) Test results and reports. i) Pre-commissioning/commissioning check list. j) Completion Certificate issued by Owner’s Site Engineer. k) No claim certificate by the Contractor. l) Consumption statements of steel and cement certified by Owner’s Site Engineer. m) Completion certificate for embedded and covered up works wherever applicable. n) Recovery statement, if any. o) Statement for reconciliation of all the payments and recoveries made in the progress bills. p) Copies of deviation statement and order of extension of time, if granted.

10.3

Submission of Coloured Photographs The Contractor shall shoot, prepare and submit coloured photographs in 2 sets to MECON site office along with monthly progress report covering all the activities of pipeline constructions highlighting the progress or other areas of

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Volume-IB of V

MECON LIMITED

work. Similarly photographs for problem areas should be submitted well in advance with a proposed methodology to execute the works and meet the construction schedule. The cost of same shall be deemed to be inclusive in the rates and no separate payment shall be made. 10.4

Videotape Contractor shall develop and submit a videotape of three hours duration covering the construction activities showing the nature and magnitude of the work. The tape shall be shot and edited to Indian broadcast standards. Professional camerapersons shall shoot videotape recorded in field. Tape shall cover, but not limited to the following construction activities: • Mobilization of equipment/ machinery • ROW cleaning/grading • Trenching • Stringing • Automatic Welding • Automatic UTS • Pipe laying • Back filling • River crossings • Rail/Road/Canal crossings • Hydro testing Pre-drying and drying • Restoration of ROU • Laying of optical fibre cable • Various construction and installation at sectionalizing valve stations etc. Videotape shall also have coverage on new/special techniques used in the Contract and major problems encountered, if any, and the measures taken to resolve them. The tape shall be supplemented with suitable narration and subtitles explaining the job, techniques and methodology, etc. The video shall be prepared with two narration tracks, one in Hindi one in English. Professional narrators shall voice both. The script shall include explanations of job activities techniques used methodologies etc. Elements of the video programme sequencing and editing techniques shall be discussed with Owner and mutually agreed to before videotaping begins. Draft script shall be submitted to Owner for approval before editing commences.

11.0

Following completion of editing and review and approval of programme by Owner, Contractor shall deliver edited master tape to Owner plus six VHSFormat copies of the programme PLANS, DESIGNS, DRAWINGS BY CONTRACTOR The Contractor shall be responsible for the Detailed Engineering of the Project. The Contractor shall, within the scope of his work, prepare detailed working and other plans, drawings and designs required for or in connection with the performance of the work or selection, procurement of making of any supply, and

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

these plans/drawings shall be approved by the Owner / Project Manager before the Contractor can commence with the performance of the relative work or with making the relative supply. The Contractor shall within the scope of his work also carry out investigative and design studies and prepare detailed design for the various materials and works covered in the Contract Documents. Such detailed designs along with referred codes, standards and practices, back-up calculations, and other details on basis of which the designs have been prepared shall be subject to the Owner’ s approval. Detailed working drawings and material specifications shall be prepared and established on the basis of the approved design(s) and shall also be subject to the Owner’ s approval. Where the Contractor shall be required under the Contract to prepare or furnish any plan(s), drawing(s), design(s) or specification(s) or other items for thing in respect of the work or any particular work and/or supplies or any particular supply, the Contractor shall within 30 (thirty) days (or such other period as the Project Manager may prescribe in this behalf) on receipt of notification of Acceptance of Bid or not less than 60 (sixty) days before the proposed date of commencement of the relative work or supply, whichever shall be earlier, submit to the Project Manager or other authority specified by the Owner in this behalf for approval the relative plan(s) / drawing(s) / design(s) / specification(s) / or item(s) or thing(s) concerned. The Owner / shall be entitled at any time to suggest any amendment(s) or modification(s) in the plans/drawings and/or specifications and the Contractor shall thereupon either convince the Owner/Project Manager of the necessity in whole or part of such amendment or modification or shall implement the same and shall cause the plan(s)/ drawing(s)/ design(s) / specification(s) or item(s) or thing(s) concerned to be accordingly amended, provided that no such approval of or amendments / modifications in the plans/ drawings/ designs/ specifications by or suggested by the Owner / Project Manager shall any way absolve the Contractor of any of his obligations, responsibilities or liabilities under the Contract, inclusive of an relative to the utility and suitability of the Contractor(s) plans / drawings / designs / specifications or items or things concerned in or for the relative work(s) or supply and fulfillment of all specifications and performance and other guarantees of the consequent works/supplies, any such approval or suggestion by the Owner / Project Manager as aforesaid being intended only by way of assistance to the Contractor and prima facie satisfaction of the Owner without any attendant liability upon the Project Manager / Owner in this behalf and without any estoppel against the Owner from assenting that notwithstanding such approval, the plan, drawing, design, specification or other items or thin approved and any resultant works or supply were faulty and/or not in accordance with the contractual requirements. The Contractor shall furnish seven (6) prints each of the drawings for approval of the Project Manager.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

The Contractor shall not permit any work to be done or any material to be supplied or fabricated or manufactured at variance with drawings, designs, specifications reviewed / approved by the Project Manager / Owner as the case may be and / or as amended or modified. The reviewed/approved drawings may be released to the Contractor for fabrication/installation progressively. Unless otherwise required at least 3 (three) sets of direct reading reproducibles no lower in quality than auto positive of extra thin paper able to produce class legible prints (the reproducibles to be submitted in roll forms) and 3 (three) sets of prints of all approved plan, drawings, designs, specifications prepared by the Contractor, together with similar sets of the reproducible and prints of all revisions/amendments/ modifications therein shall be lodged with the Project Manager for the record of the Owner, such sets of plans, drawings, designs, specifications to be signed by the Contractor and to indicate thereon the number and date of each revision/amendment and of the communication of the Project Manager for the approval thereof by which the approval was given. 12.0

SURVEY AND LEVEL/SETTING OUT WORK

12.1

Before the WORK or any part thereof are begun, the Contractor’s agent and the Engineer-in-Charge's representative shall together survey and take levels of the SITE and decide all particulars on which the survey is to be made, and on which measurements of the WORK are to be based. Such particulars shall be plotted by the CONTRACTOR and after agreement the drawings shall be signed by the Engineer-in-Charge.

12.2

The CONTRACTOR shall be entirely responsible for the horizontal and vertical alignment, the level and correctness of every part of the WORK and shall rectify any errors or imperfections therein. The CONTRACTOR at his own cost shall carry out such rectifications, when the Engineer-in-Charge or his representative issues instructions to this effect.

12.3

The Engineer-in-Charge shall furnish the relevant existing grid point with Bench Mark on the land. It shall be Contractor’s responsibility to set out the necessary control points in and to set out the alignment of the various works. The CONTRACTOR shall have to employ efficient survey team for this purpose and the accuracy of such setting out work shall be Contractor’s responsibility.

12.4

The CONTRACTOR shall give the Engineer-in-Charge not less than 24 (twenty four) hours notice in writing of his intention to set out or give levels for any part of the WORK so that arrangements may be made checking the same.

12.5

WORK shall be suspended for such times as necessary for checking lines and levels on any part of the WORK.

12.6

The CONTRACTOR shall at his own expense provide all assistance, which the Engineer-in-Charge may require for checking the setting out ot WORKS.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

12.7

Before commencement of any activity, contractor's quality control set up duly approved by company must be available at site.

13.0

ORDER OF WORKS/ PERMISSIONS/ RIGHT OF ENTRY/ CARE OF EXISTING SERVICES

13.1

The order in which the WORK shall be carried out shall be subject to the approval of the Engineer-in-charge and shall be so as to suit the detailed method of construction adopted by the CONTRACTOR, as well as the agreed joint programme. The WORK shall be carried out in a manner so as to enable the other contractors, if any, to work concurrently. OWNER reserves right to fix up priorities, which will be conveyed, by Engineer-in-Charge and the CONTRACTOR shall plan and execute work accordingly.

13.2

Existing Service

13.2.1

Drains, pipes, cables, overhead wires and similar services encountered in course of the works shall be guarded from injury by the CONTRACTOR at his own cost, so that they may continue in full and uninterrupted use to the satisfaction of the Owners thereof, or otherwise occupy any part of the SITE in a manner likely to hinder the operation of such services.

13.2.2

Should any damage be done by the CONTRACTOR to any mains, pipes, cables or lines (whether above or below ground etc.), whether or not shown on the drawings the CONTRACTOR must make good or bear the cost of making good the same without delay to the satisfaction of the Engineer-in-Charge.

14.0

MAKE OF MATERIAL/BOUGHT OUT ITEMS An Appendix-I of approved vendors for various major items is enclosed with this tender specification. The bidder shall consider such names only as indicated in the aforesaid list and clearly indicate in the bid the name(s) as selected against these items. For any other item not covered in the list enclosed with this tender document, prior approval shall be obtained by the contractor for its make/ supplier’s name.

15.0

TESTS, INSPECTION AND COMPLETION

15.1

Tests and Inspection The Contractor shall carry out the various tests as enumerated in the technical specifications of this Bidding Document and technical documents that will be furnished to him during the performance of the work at no extra cost to the Owner.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

All the tests either on the field or at outside laboratories concerning the execution of the work and supply of materials by the Contractor shall be carried out by Contractor at his own cost. The work is subject to inspection at all times by the Engineer-in-Charge. The Contractor shall follow all instructions given during inspection and shall ensure that the work is being carried out according to the technical specifications of this Bidding Document, the technical documents that will be furnished to him during performance of work and the relevant codes of practice. The Contractor shall provide for purposes of inspection access ladders, lighting equipment for testing, necessary instruments etc. at his own cost, low voltage lighting equipment for tray fixing and inspection work. Compressed air for carrying out works shall be arranged by the Contractor at his own cost. For material supplied by Owner, Contractor shall carryout the tests, if required by the Engineer-in-Charge, and the cost of such tests shall be reimbursed by the Owner at actual to the Contractor on production of documentary evidence. All results of inspection and tests will be recorded in the inspection reports, proforma of which will be approved by the Engineer-in-Charge. These reports shall form part of the completion documents. Any work not conforming to execution drawings, specifications or codes shall be rejected and the Contractor shall carryout the rectifications at his own cost. For materials supplied by Owner, contractor shall carryout the tests, if required by the Engineer-in- charge, and the cost of such tests shall be reimbursed by the Owner at actual to the Contractor on production of documentary evidence. Contractor shall inspect carefully all equipment before receiving them from Owner for installation purposes. Any damage or defect noticed shall be brought to the notice of Engineer-in- Charge immediately. Inspection and acceptance of the work shall not relieve the Contractor from any of his responsibilities under this Contract. 15.2

Inspection of Supply Items

15.2.1

All inspection and tests on bought out items shall be made as per the specifications forming part of this contract. Various stages of inspection and testing shall be identified after receipt of Quality Assurance Programme from the Contractor/ Manufacturer.

15.2.2

Inspection calls shall be given for associations of Owner/ MECON ’s representative as per mutually agreed programme in prescribed proforma with 15 days margin, giving details of equipment and attaching relevant test certificates and internal inspection report of the Contractor. All drawings, General Arrangement and other contract drawings, specifications, catalogues etc. pertaining to equipment offered for inspection shall be got approved from

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

Owner/ MECON and copies shall be made available to owner/ MECON before hand for undertaking inspection. 15.2.3

The contractor shall ensure full and free access to the inspection engineer of Owner/ MECON at the Contractor’s or their sub-contractor’s premises at any time during contract period to facilitate him to carry out inspection and testing assignments.

15.2.4

The contractor/ sub-contractor shall provide all instruments, tools, necessary testing and other inspection facilities to inspection engineer of Owner/ MECON free of cost for carrying out inspection.

15.2.5

Where facilities for testing do not exist in the Contractor’s/ sub-contractor’s laboratories, samples and test pieces shall be drawn by the Contractor/ SubContractor in presence of Inspection Engineer of a Owner/ MECON and duly sealed by the later and sent for testing in Government approved Test House or any other testing laboratories approved by the Inspection Engineer at the Contractor’s cost.

15.3

Test Certificates

15.3.1

Bidder shall be required to submit recent test certificates for the material being used in works from the recognized laboratories. These certificates should indicate all properties of the materials as required in relevant IS Standards or International Standards.

15.3.2

Contractor shall also submit the test certificate with every batch of material supplied which will be approved by Engineer-in-Charge. No secured advance will be given for the materials not having test certificate. In case any test is to be carried out, the same shall be got done in the approved laboratory at the cost of contractor.

15.4

Third Party Inspection Agency

15.4.1

Contractor is required to employ Third party inspection agency (TPIA) for inspection, witnessing tests and certification of works at Contractor’ s work centers for procurement of line pipes, coating of line pipes, equipment manufacturing, construction, etc. The owner shall approve the agency and it shall not be same TPIA engaged by owner.

15.4.2

Owner reserves the right to employ his own TPIA as indicated in the subsequent sections.

15.4.3

Owner will appoint an independent TPIA for construction of total pipeline.

15.4.4

Owner reserves the right to appoint agencies for quality surveyor lance during the time of production and supply of major items.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

15.4.5

GSPL reserves the rights of access for audit and inspection at Contractor, subcontractor / vendor’ s plants / work sites at any stage during the Project.

15.4.6

First day production and quality checks shall be carried out in presence of Owner / Owner’ s representatives.

15.4.7

EPC Contractor shall ensure that TPI inspectors have sufficient experience and qualification to fulfill the inspection of specified items. EPC contractor shall submit the CVs of proposed personnel before putting them on to the job. At least not less than 3 (three) working days are to be given top GSPL for approval.

15.4.8

Inspection and test plans (ITP) are to be developed for all items of supply and items of construction as per his QA/QC plan by Contractor and submit the same to Owner for his review / approval within fifteen (15) days after award of work. Owner will review the ITPs and approve the same for implementation in the work. All inspections and tests shall be made as required by the specifications forming part of this contract. Contractor shall advise Owner/ Consultant in writing at least 10 days in advance of the date of final inspection/tests. Manufactures inspection or testing certificates for equipment and materials supplied, may be considered for acceptance at the discretion of Owner/ Consultant. All costs towards testing etc. shall be borne by the contractor within their quoted rates. All inspection of various items shall be carried out based on Quality Assurance Plan, which will be submitted by the Contractor and duly approved by Owner/ Consultant.

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APPENDIX-I DESIGN BASIS

Gujarat State Petronet Limited BRIEF PROJECT DETAIL & BASIC ENGINEERING DESIGN BASIS PADMALA – HALOL NATURAL GAS PIPELINE

12” NB – 37.23 KM PIPELINE FROM TAP-OFF AT PADMALA IN 24” SERKHI – PADMALA PIPELINE

ENGINEERING DOCUMENT NO. MEC/23JT/05/21/M/002/0001, R-4

(OIL & GAS SBU)

MECON LIMITED DELHI

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

December, 2006

OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 1 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

CONTENTS Sl.No.

Description

Page No.

1.0

BRIEF PROJECT DETAIL

2

2.0

DESIGN BASIS

8

2.1

INTRODUCTION

8

2.2

SCOPE

8

2.3

GAS COMPOSITION PARAMETER

8

2.4

STATIONS B/L CONDITIONS

9

2.5

PIPELINE PARAMETERS

9

2.6

INSTRUMENTATION & CONTROL

14

2.7

TERMINALS

17

2.8

SCADA FACILITY

18

2.9

LEAK DETECTION SYSTEM

18

2.10

TELECOMMUNICATION SYSTEM

19

2.11

ELECTRICAL

19

2.12

CIVIL/ STRUCTURE

20

2.13

SERVICES

20

2.14

LIST OF ASSUMPTIONS

21

3.0

LIST OF STANDARD

22

PREPARED BY R.SHUKLA

S.RAM

CHECKED BY

APPROVED BY

D.G.MAJUMDER G.V. WALIMBE

( A.K. JOHRI )

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

1.0

BRIEF PROJECT DETAIL

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OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 2 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

1.0

BRIEF PROJECT DETAIL

1.1

M/s GSPL intend to lay a 12” NB x 37.23 km pipeline from Padamla tap-off near Baroda on 24” OD Baroda – Ahmedabad – Kalol pipeline. The proposed pipeline is approximately ~ 37.23 km long and 12” NB and will transport ~ 1.5 MMSCMD intermingled RLNG & Natural Gas from Padamla tap-off to Halol for distribution to domestic, automobile, commercial & industrial consumers.

1.1.1

Detail of Existing Pipeline The tap-off shall be taken from existing SV at Padmala on Baroda – Ahmedabad – Kalol Pipeline. Status of Pipeline Line Size Length : Maximum Allowable Operating Pressure

1.1.2

: Under Operation : 24” OD ~134 km : 95 bar (g)

Proposed Grid Line The proposed new pipeline shall be originated from Padamla tap-off at Baroda – Ahmedabad – Kalol Pipeline and shall be terminated at Halol. The new pipeline shall be of 12.75” OD and 37.23 km in length. Basic objective of the new pipeline is to cater for the need of industrial, commercial & automobile consumers in that area.

1.1.3

Details of Proposed Pipeline Line Size Length, in km Pipe Specification Thickness Operating Pressure Maximum Allowance Operating Pressure External Coating Tap-off’s

12” NB ~ 37.23 ERW, API 5L Gr. X-65, PSL-2 6.4mm, 7.1mm & 8.7mm 50 bar(g) 95 bar(g) 3-LPE Five nos. of Tap-off (at 1.00 km, 11.42 km, 23.87 km, 37.23 km ) each shall be originated from main line. No. of SV Stations : One No. Pig Launcher cum Receiver : At Sokhada Pig Receiver cum Launcher : At Halol Filtration : At Halol Metering : At Halol Let Down Unit : At Halol *However, Filtration, Pressure Reduction & Metering system shall be supplied by M/s GSPL as free issue items.

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: : : : : : : :

OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

1.2

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 3 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Pipeline and Facilities The route of the proposed pipeline has been decided by M/s GSPL, the salient feature of the pipeline routes is described in the civil, mechanical document. The entire pipeline network has been divided into the following section.

1.2.1

Trunk Line •

1.2.2

Tap-Off • • • • •

1.2.3

Tap-off I at Sokhada, Ch. 1.00 km Tap-off II for GIDC, Majusar at Ch. 11.42 km Tap-off III for GIDC, Savili at Ch. 23.87 km Future Tap-off IV for GIDC, Kalol at Ch. 37.23 km Future Tap-off V for ,Godhara at Ch. 37.23 km

Consumer Connection •

1.2.4

Padamla to Halol (~ 37.23 km)

Receving Terminal at Ch. 37.23 km on 12” NB Padmala – Halol Pipeline to Halol consumers through 12” NB pipeline.

Terminals At following location pipeline terminals are provided. • • • •

1.2.5

Tap-off Despatch Terminal Receipt Terminal Tap-off Stations

: : : :

At Padamla Sokhada At Halol At Sokhada ch. 1.00 km, For GIDC, Manjusar at ch.11.42 km, For GIDC Savili at ch. 23.87 km. Tap-off shall be provided (Ch. 37.23 km), at receiving terminal for GIDC, Kalol and for Godhra.

Pipeline Design Based on the optimization studies carried out the following design parameters have been considered for Mechanical Design of Pipeline System. Pipeline diameter Design Pressure, bar,g

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:12” NB :

95

OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

Design Temperature, °C

ENGINEERING DOCUMENT NO.

PAGE 4 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Corrosion Allowance

: : :

-20 to 65 (aboveground) 45 (buried) 0.0 mm

Material of Construction

:

Carbon Steel

Based on above design parameters, pipeline wall thickness and grade have been optimised and are indicated below :Pipeline Section Padamla to Halol (12” NB x 37.23 km)

Class Location Class-II Class-III Class-IV *

Dia. (NB) 12” NB 12” NB 12” NB

API 5L Grade X-65 X-65 X-65

W.T. 6.4 7.1 8.7

TOTAL

1.2.6

Pipeline Material Pipeline & its appurtenances shall be provided with carbon steel material suitable for the intended service as indicated above. a)

Line Pipe ERW, Line pipe shall confirm to API Specification 5L, PSL-2 Quality. The grade of line pipe shall be API 5L Gr. X-65 as indicated above. Pipe wall thickness shall confirm to ASME B31.8 and shall also meet the requirement of OISD 141. At river crossing higher wall thickness shall be used.

b)

Pipeline Fitting and Flanges All pipeline materials such as pipe, valves, flanges and fittings etc. shall be of class 600#.

c)

Mainline Valves/ Station Valves All mainline valves/ station valves are full bore type and designed as per API 6D and API 6FA/ API 607 fire safe design requirements. All mainline valves shall be double block & bleed type, double piston effect for low temperature services. First isolation valve in mainline shall be butt welded type. All mainline valves including launcher & receiver valves are gas operated and have body material conforming to LF2.

d)

Flanges, Terminal Pipes & Fittings

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OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 5 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

All aboveground piping system shall be of low temperature seamless pipes of equivalent grade to match 600# pressure and temperature rating. All fittings shall conform to ANSI 600# and low temperature application. e)

Ball Valves All ball valves for terminals shall be full bore type. TMBV underground ball valve shall have welded configuration and aboveground station valves can be a bolted configuration.

f)

Flow Tees All branch connection on the main line which are greater than 40% of mainline would be provided with flow tees to allow smooth passage of pigs. Flow tees material would be same as that of line pipe.

g)

Insulating Joint Insulating joints would be provided at transition point of aboveground & underground portion of pipeline for electrical isolation. These will be mono-block type suitable for both above/ underground installation.

h)

Sectionalizing Valve / Station Block Valves Sectionalizing Valve and station block valves shall be gas actuated. All Sectionalising Valve shall have provision for remote operation (ROV). Sectionalising Valve shall be buried and provided with stem extension. Mainline valve shall be full bore type ball valves, to allow smooth passage of scrappers or pigs through them. All other valves used in terminals shall also be full bore ball valves. These valves shall conform to API 6D.

i)

Scrapper Traps By directional scrapper receiver/ launcher shall be provided in Dispatch and Receiving Terminal for facilitating intelligent pigging and cleaning pigging. Scrapper traps shall be designed as per ASME B31.8 ASME SEC VIII, Div. 1,2004. The material of scrapper traps shall be compatible with line pipe material. Design factor and corrosion allowance for designing scrapper traps shall be considered as 0.5 and 3mm respectively.

j)

LR Bends Cold field bends shall be in accordance with codes but in no case with a radius below 40 times diameters. Induction bend shall only be used where ever space constraint is there. However at stations it can be used. 6D bends shall be acceptable only in mainline stations.

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OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

k)

ENGINEERING DOCUMENT NO.

PAGE 6 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Gas Chromatograph Gas Chromatograph shall be installed in Distribution cum Receipt Terminal to measured gas composition, gas gross heating valve, specific gravity. Gas composition shall be used for calculating the energy flow in flow computers.

l)

SCADA Foxboro make C-50 RTU shall be installed at despatch, SV’s & Receiving Station & Terminal at the end of Spurlines. However M/s GSPL shall finalize all SCADA equipment shall be free issue item to contractor & scheme.

m)

Telecom System OFC based telecom system shall be provided 24 fiber unarmored OFC shall be laid in selflubricated in φ 40mm / 50mm HDPE conduit. At crossing a spare φ 40mm / 50mm HDPE conduit shall be laid in 6” casing pipeline. Telecom system shall comprise of minimum STM-1 equipment at each station, SVs & tap-off points. Telecom equipment shall be free issue item to contractor & scheme shall be finalized by M/s GSPL.

1.2.7

Corrosion Coating The selected corrosion coating shall be suitable for the temperature range specified in the process design basis. It is proposed to provide corrosion protection of the buried pipeline using 3-Layer Side Extruded Polyethylene (PE) Coating for the pipeline. The minimum total thickness of 3LPE Coating shall be as given below :For pipe size (OD) 12.75” - Minimum 3.2mm Field weld joints shall be coated with heat shrinkable sleeves or cold applied taps. In addition to the corrosion coating, the entire buried portion of the pipeline system shall be provided with cathodic protection system. No internal coating shall be provided.

1.3

Pipeline Construction Pipeline and associated facilities shall be constructed in accordance with ASME B31.8 and other applicable standards. The pipeline shall be laid underground with minimum 1(one) meter cover. Additional cover, wherever required, shall be provided in accordance with OISD 141. Welding shall be carried out as per API 1104. All welds shall be 100% radiographed. After the installation is completed, the entire pipeline shall be hydrostatically tested. The hydrostatic test pressure at any test section shall 1.25 – 1.4 times the design pressure for respective class location. The maximum hydrostatic test pressure at any location in

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 7 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

the pipeline during testing shall be not exceed the pressure required to produce hoop stress equal to 95% SMYS of pipe material. The test duration shall be 24 hours for pipeline. Despatch/ Receipt Terminals as well as other intermediate facilities shall also be tested at 1.4 times the design pressure. The test duration shall be 6 hours. 1.4

CONSTRUCTION METHODOLOGY

1.4.1

Main Pipeline In case of soft soil, conventional trenching and backfilling can be considered for laying of pipeline. In case of sub surface encountered being weathered rock, a minimum of 150mm thick layer of soft back-fill material shall be provided all around the pipeline prior to backfilling the trench with excavated material. Where blasting can not be carried out due to close proximity of existing facilities, mechanical equipment for rock excavation can be used. Conventional trenching and back-filling using trenching machine has been considered for laying of the pipeline in the soft soil areas other than described above. The type of corrosion coating selected (PE) for the pipeline has adequate mechanical properties to withstand the hard surface features. A typical cover of one (1) meter over the top of pipeline is considered.

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 8 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Pipeline Crossings a)

Rail Boring method shall cross railway lines. Approval of designs and construction methodology shall be obtained from concerned railway authorities. Pipeline at railway crossing shall be provided with casing pipe. The carrier pipe shall be installed inside casing pipe. The casing pipe shall be three nominal sizes larger than carrier pipe. The minimum clear cover at the crossing above top of pipeline shall be 1.7mm. The crossing angle shall be as close to 90° as possible. The railway crossing shall comply with the requirement of API 1102 and Indian Railway authorities. Casing insulator and seals shall be provided to isolate carrier and casing pipes.

b)

Road & Canal Road crossing shall comply with the requirement of API 1102 and requirements of the concerned road authorities. Pipeline at National Highways and State Highways Crossing (wherever required) shall be provided with the casing pipe. Metalled roads other than the national highways and state highways shall be crossed by open cut method. However at locations where it is not possible to cross the road by open cut method boring/ jacking method shall be used. No casing pipe shall be considered at such locations. All the cart tracks crossings shall be carried out by open cut method. The road crossing shall be provided with minimum cover of 1.2mm measured from top of the carrier pipe. Irrigation land canals shall be crossed by boring method wherever required the statutory authorities. All other minor canals and nulls crossings shall carried out with conventional open cut method unless directed other-wise concerned authorities. The canal crossings and other water crossing shall provided with a minimum clear cover of 1.5m.

c)

by be by be

River Crossing All rivers crossing are proposed to be crossed by conventional open cut method except for the rivers specifically proposed to be crossed by HDD Method. Pipeline shall be installed approx. 1.5m (for rocky) / 2.5m (for normal soil) below the lowest bed level. Lowest bed level shall be calculated after giving due consideration to scour depth of such water crossings. The line pipe shall be concrete coated, if required to sufficient negative buoyancy. At all major crossing two nos. of HDPE conduits shall be laid in steel casing pipe to take care of future requirement.

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2.0

DESIGN BASIS

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DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

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TITLE

BASIC ENGINEERING DESIGN BASIS

2.0

DESIGN BASIS

2.1

INTRODUCTION

ENGINEERING DOCUMENT NO.

PAGE 9 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

M/s GSPL proposes to lay 12” NB and 37.23 km long pipeline from Padamla Tap-off for supplying 1.50 MMSCMD Natural Gas to industrial consumers in Halol and nearby areas. 2.2

SCOPE • • • • • • • • • • • •

2.3

12” NB x ~ 37.23 km pipeline from tap-off at Padmala to Halol. Despatch Terminal at Sokhada Tap-off-I : Tap-off point at Sokhada ch. 1.00 km on mainline . Tap-off-II : Tap-off point at ch. 11.42 km on mainline (12” NB Padmala – Halol Pipeline) to GIDC, Manjusar. Tap-off-III : Tap-off point at ch. 23.87 km on mainline (12” NB Padmala – Halol Pipeline) for GIDC, Savili. SV Station at ch. 23.87 km. Future Tap-off-IV : Future Tap-off-IV at ch. 37.23 km on mainline (12” NB Padmala – Halol Pipeline) for GIDC, Kalol. Future Tap-off V : Future Tap-off V at ch. 37.23 km on mainline (12” NB Padmala – Halol Pipeline) for Godhara Gas Distribution/ Receipt Terminal at Halol at ch. 37.23 km. TCP & Impressed Current Permanent Cathodic Protection System. Optical Fiber Cable Laying, Jointing & temperature SCADA & Telecom System (scheme shall be decided by M/s GSPL based on Inhouse engineering). All SCADA & Telecom equipment shall be supplied as a free issue item to contractor.

GAS COMPOSITION/ PARAMETER Components C1 : C2 : C3 : i-C4 : n-C4 : i-C5 : n-C5 : C6+ : N2 : CO2 : Gas Quality : Specific Gravity : 0.62 MW : 3 Calorific Value, MJ/Sm Gross :41.65

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

Mol% 89.68 6.34 2.49 0.48 0.59 0.040 0.040 0.0 0.34 0 Dry Gas 18.17

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3

2.4

Calorific Value, MJ/Sm Net : STATIONS B/L CONDITIONS 2

Gas Pressure, kg/cm g (at Tap-off) Aboveground Temperature, °C : Aboveground Temperature, °C Sub Soil Temperature, °C Sub Soil Temperature, °C 2.5

PIPELINE PARAMETERS

2.5.1

Pipeline Details

ENGINEERING DOCUMENT NO.

PAGE 10 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

37.86 : 50 bar 5°C (Minimum) : 50°C (Maximum) : 20°C (Minimum) – GSPL to Confirm : 25°C (Maximum) – GSPL to Confirm

Mainline Section Length of Pipeline Flow Rate, MMSCMD Pipeline Diameter Pipeline Thickness Material Pipeline Grade MOC Pipeline Rating Corrosion Allowance Roughness (micron) 2.5.2

: : : : : : :

40 Years 365 12” NB 37.23 km ANSI/ ASME B31.8 (latest edition) Buried 20 - 25°C through out the entire length of pipeline (1.0m below ground)

: :

95 bar(g) 49 bar(g)

: :

-20°C to 45°C -20°C to 60°C

2

Design Pressure, kg/cm (g) U/S of Pressure Control Valve D/S of Pressure Control Valve

2.5.4

Padamla – Halol ~ 37.23 km 1.5 MMSCMD 12” NB 6.4mm, 7.1mm & 8.7mm API 5L (ERW) X-65, PSL-2 CS (Carbon Steel) 600# Rating Nil 45

Pipeline Design Parameters Pipeline Operating Life Onstream Days/ Year Pipeline Diameter Pipeline Length Design Code Pipeline Laying Sub-Soil Temperature

2.5.3

: : : : : : : : : : :

Design Temperature, °C Buried Above ground

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2.5.5

BASIC ENGINEERING DESIGN BASIS

: : :

50 bar(g) 5 to 50°C 1.5

: : :

49.50 5 to 50°C 1.5

Operating Conditions at Tap-off-III, Ch. 23.87 km 2

Pressure, kg/cm g Temperature, °C Gas Flow, MMSCMD

: : :

46.5 5 to 50°C 1.5

Delivery Conditions at Receiving end ch. 37.23 km 2

Pressure, kg/cm g Temperature, °C Gas Flow, MMSCMD 2.5.10

Nil [50 bar(g) Inlet Pressure] Nil

Operating Conditions at Tap-off-II, Ch. 11.42 km 2

2.5.9

REVISION 4

Operating Conditions at Tap-off-I & Dispatch Terminal

Pressure, kg/cm (g) Temperature, °C Gas Flow, MMSCMD 2.5.8

MEC/23JT/05/21/M/002/0001

: :

Pressure Temperature, °C Gas Flow, MMSCMD 2.5.7

PAGE 11 of 22

Design Margin On Gas Flow On Pipe Length

2.5.6

ENGINEERING DOCUMENT NO.

: : :

40 - 50 5 – 50 1.5

Pipeline External Corrosion Protection To protect pipeline from external corrosion three layers of polyethylene coating will be provided, the minimum thickness of coating shall be 3.2mm. This include 180 micron thickness of epoxy, adhesive thickness of 200 micron. Design basis for cathodic protection system has been attached as Appendix I

2.5.11

Pig Launching & Receiving Facility For effective maintenance of pipeline, pig launching & receiving facilities will be provided at the ends of pipeline that is at Sokhada despatch terminal & Halol Receiving Terminal. Provision shall be kept for intelligent pigging.

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BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 12 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Flow Tees All branch connection on the main line which are greater than 40% of mainline would be provided with flow tees to allow smooth passage of pigs. Flow tees material would be same as that of line pipe.

2.5.13

Insulating Joint Insulating joints would be provided at transition point of aboveground & underground portion of pipeline for electrical isolation. These will be mono-block type suitable for both above/ underground installation.

2.6

INSTRUMENTATION & CONTROL SYSTEM

2.6.1

Instrumentation & control system will be provided for safe reliable and efficient control of natural gas transportation in pipeline. For this purpose, microprocessor based electronic instruments having 4-20 mA DC current signal as input/output have been envisaged. The basic function of the instrumentation system shall be to monitor and control of natural gas parameters viz , pressure , temperature, flow, % of LEL, Actuated Valve’s status , pig signaling , gas analysis, etc as indicated in the P&ID diagram. Instrumentation for measurement of control will be combination of both local and remote operation from the control room.

a)

Despatch Terminal at Sokhada One control panel shall be provided in Despatch Terminal at Sokhada. Control panel shall be used for mentoring of inlet pressure, temperature, pig signaling, LEL detection system and actuated valve’s, status indication & control. Fire gas alarm system shall be provided. Provision shall be kept to hook-up all parameters with SCADA through RTU. However the SCADA System including RTU shall be finalized by M/S GSPL and shall be executed by other contractors.

(b)

SV Station & Tap-off-III One control panel shall be provided in SV-I for pressure, temperature indication, actuated valve’s status indication & control. Provision shall be kept to hook-up all parameters with SCADA through RTU.

(c)

Gas Distribution cum Receipt Terminal Control panel shall be provided in gas distribution cum receipt terminal. Control panel shall be used for indication of inlet/ outlet pressure, temperature, differential pressure indication across cartridge filter, pig signaling, LEL detection, actuated valve’s status indication, outlet flow, status indication of Pressure Control Valve, Slam Shut Valve, and inputs from Flow Computers. Provision shall be kept to hook-up all parameters including TR Unit on-line data

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ENGINEERING DOCUMENT NO.

PAGE 13 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

with SCADA through RTU. However the SCADA System including RTU shall be finalized by M/S GSPL and shall be executed by other contractors. Fire & Gas Alarm System and CO2 Flooding System shall also be provided in all control rooms. 2.6.2

The design shall employ the latest technology of proven capabilities. The selection of equipment shall be such as to offer flexibility for future modification and expansion without affecting the system reliability.

2.6.3

All instruments shall be capable of operating for the specified turndown conditions. All instruments unless otherwise specified, shall be electronic type. However, final control element shall be pneumatically operated.

2.6.4

The type of instrument as specified in the Instrument Data Sheet shall be invariably selected unless the vendor has valid technical reasons for proposing a change. Any deviation on the type of instrument from the data sheet shall be specifically highlighted with technical reason and approval sought from MECON/GSPL. Contractor to note that the ultimate responsibility to select the particular instrument to suit process conditions shall be Contractor’s responsibility.

2.6.5

All safety shutdown and interlocks shall be carried out using electromagnetic relays.

2.6.6

All field instruments, junction boxes and cable glands shall be certified for use in hazardous area as per area classification mentioned elsewhere in the tender document. The Instrumentation shall be certified intrinsically safe in general, as per IEC-79. However, field switches, solenoid valves shall be certified flameproof for use in classified area as applicable (IS-2148/ IEC-79). Moreover, all field instruments junction boxes, cable glands shall be weather proof to NEMA-4 / IP 55 as per IS:2147 / IEC-529 and explosion proof/ flame proof to NEMA-7 or equivalent IS Standard.

2.6.7

The philosophy of power supplies for Instrumentation purposes are as follows :i) ii) iii)

230 VAC, 50 Hz , UPS for Min incoming power supply to control panel. 24 VDC (Dual redundant) for panel mounted instrument, field transmitters, solenoid valve LEL gas detectors and interlock based relay systems. 230 VAC , 50 HZ , non-UPS for panel lighting, electrical heat tracing.

2.6.8

Isolated 230V AC @50 Hz, 24V DC and its distribution within the battery limits including UPS and battery backup shall be Contractor’s responsibility. AC distribution board and DC distribution board shall be provided in control room with suitable isolator for each feeder.

2.6.9

All open and close loops shall have an individual MCB in the panel for isolating the field instruments for maintenance (i.e. for field switches, transmitters, SOV, Control Valve etc.)

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PAGE 14 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

2.6.10

The design and installation of instruments shall be generally in accordance with ISA / API recommended practices and other applicable standards like ASI, IBR etc. Material specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. All standards, code of practice shall be of the latest edition.

2.6.11

All instruments and equipments shall be suitable for use in hot, humid and tropical industrial climate in which corrosive gases and/ or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof, weather proof to NEMA 4 (IP 55) and secure against the ingress of fumes, damages, insects and vermin. All external surfaces shall be suitably treated to provide anti corrosion protection against plant atmosphere.

2.6.12

Materials of construction of instruments shall be consistent with temperature, pressure, corrosion conditions and other process requirements. In case where suitable material procurement is not feasible, diaphragm seal shall be provided.

2.6.13

Ranges for instruments shall be selected, in general, such that in normal process operation the indication on the indicator or chart is between 40% to 60% of span for linear scale and 60% to 80% of span for square root scale.

2.6.14

The complete instrument system shall be designed for safe operation, by using normally contacts which open on fault conditions.

2.6.15

The design of the alarm annunciation system shall be such that the transient alarms of less than 330 milli seconds duration shall be automatically discounted.

2.6.16

All lamps on control panels shall be provided with lamp test facility

2.6.17

All process switches shall be provided with DPDT (two nos.) switches with contact rating, as a minimum of 110V, 0.5 A DC or 230 V 5.0 Amp (Inductive) AC as applicable. For all field switches (except limit switches), differential of switch shall be less than 40% of difference between set value & normal operating value.

2.6.18

Control valve sizing formula shall, in general, be as per ISA 75.01. Control valves shall be sized for the available pressure drop at normal flow and in addition shall permit upto 150% of normal flow or 110% of the maximum flow, whichever is higher. Vendor shall submit the sizing calculations for all control valves.

2.6.19

All transmitters shall be of SMART type provided with in-built output meter/ output gauge at the transmitter end.

2.6.20

All solenoid valves shall be of three way “universal “ type and continuous rated type.

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2.7

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 15 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

TERMINALS To supply gas to consumers. The following station has been envisaged. a) Despatch Terminal at Sokhada b) Gas Distribution Terminal at Halol c) Sectionalising Valve Station d) Tap-off-I at a chainage of 1.00 km. e) Tap-off-II at a chainage of 11.42 km for GIDC, Manjusar f) Tap-off-III at a chainage of 23.87 km for GIDC, Savili g) Future Tap-off-V at chainage of 37.23 km for GIDC, Kalol h) Future Tap-off-VI at chainage of 37.23 km for Godhara

2.7.1

Dispatch Terminal at Padamla A 12” NB tap-off available at Padamla shall be used to supply gas. terminal at Sokhada will have following facilities. 1. 2. 3. 4. 5. 6. 7.

The despatch

Scrapper Launcher cum Receiver (16” x 12” NB) – 1 No. Local & panel mounted instruments such as PT, TG & Pig Signalers, GoV Valves Operation. Control Panel Civil Building DG Set LEL Detection System F&G Alarm

2.7.2

Sectionalising Block Valve-I

2.7.2.1

A sectionalising valve will be provided at a distance of 23.87 km from dispatch terminal for shut down of the pipeline. SV-1 gas over-oil valves shall be made remoteopera table from SCADA Control Room. However SCADA & RTU shall not be in EPC contractor scope.

2.7.2.1.1

Mode of Operation Sectionalising valve Bypass/ blow down valve

2.7.3

Terminal After despatch terminal gas flow through the pipeline will be distributed through Gas Distribution/ Receipt Terminal at Halol. The following facilities have been envisaged at Receiving Terminal. 1. Scrapper Receiver cum Launcher with pig signaler (16” x 12” NB) – 1 No. 2. Control Panel 3. Control Room Building 4. LEL Detection System 5. F&G Alarm

: :

GoV (Gas over-oil type) Manual

Metering skid (Free issue, supplied by M/s GSPL) C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

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2.8

BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 16 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

SCADA FACILITY The purpose of SCADA System is to ensure effective and reliable control, management & supervision of the pipeline from centralized location using remote terminal units located along the pipeline at suitable locations. Central SCADA control centre will be interlocked through Optical Fiber Cable (OFC) link with Remote Terminal Units (RTUs) located along the pipeline. The following pipeline facilities have been considered for telemetry operation. i) ii) iii) iv)

Despatch terminal Sectionalising Valve Station SV-1 Gas Distribution Terminal at Halol . Pipeline and skid mounted terminal for industrial consumer at Manjusar, Savili and Receiving Terminal at Halol. However Metering Skid shall be free use item to EPC contractor.

RTU’s have been envisaged in the future for SCADA system covering the requirements of above mentioned points. The RTU shall be integrated with SCADA Master Stations by M/s GSPL. The RTU’s will be used for scanning and telemetering of pipeline parameters such as flow , temperature , pressure, valve status, scraper pig signaling ,density, CP parameters etc to update the main computer database for monitoring the entire pipeline operation. The SCADA system will also be used for remote operation and monitoring of sectionalized valve. However, the future SCADA system including RTU shall be finalized by M/s GSPL and executed by other contractor. 2.9

LEAK DETECTION SYSTEM

2.9.1

IR Based Gas Detection System IR based detection system having adequate nos. of fixed gas detectors at various critical locations in the Receiving Terminal shall be provided for continuous monitoring of hydrocarbon level in the air in the proximity of filtration, pressure reduction & metering unit, piping etc. the basis of location for the same shall be based on wind direction, gas component density and coverage of gas detections in Receiving Terminal & same shall be integrated with SCADA, RTU through serial communication. The panel (completely wired) for housing the monitor/ controller for gas detectors with relays, hooters/ annunciators indicating the location shall be provided in the control room. The single channel monitor to be used with two channels as spare. The gas detection system shall give high gas alarm on 20% low explosion level (LEL) and very high gas alarm of 40% LEL detection in the gas detectors. One no. of calibration kit complete with calibration gas cylinders for gas detector calibration shall be provided. in each station/terminal.

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BASIC ENGINEERING DESIGN BASIS

ENGINEERING DOCUMENT NO.

PAGE 17 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Fire and Gas Alarm System Suitable fire and gas detection system for control room and field area are to be provided, with receiver instruments in control room with separate alarm. The supply shall include fire detectors, monitor/ controllers, and enunciators in fire panel to be placed in the control room (CR). The fire and gas detector layout shall cover the entire plant area system following NFPA-72 standard. Develop the detailed layout and same will be finalized during detailed engineering. The location & type of fire and gas detection system to be provided in different areas is as follows:Type Fixed type thermal detectors

Location (Typical) Control room

Manual call point/ break glass

Exit doors of the building in Receiving Terminal.

All the connections for fire/ gas/ smoke detection system will lead for annunciation to the fire panel to be placed in the control room. The receiver instrument will be placed in the control room. 2.10

TELECOMMUNICATION SYSTEM To facilitate proper operational and management control of the pipeline, a reliable and dedicated Telecommunication System is proposed to be setup in future connecting the various attended and unattended stations along the pipelines. At present only Optical fiber cable shall be laid in HDPE Duct along with the pipeline The future Communication System proposed will provide for remote operation of SV-I along the pipeline along with communication amongst other attended stations. The system will also provide for voice communication from unmanned stations to the attended stations and also remote monitoring of the cathodic protection. STM-1 equipment shall be installed at each station/ tap-off points in future. However, the future Telecommunication System including STM equipments shall be finalized by M/s GSPL and executed by other Contractor.

2.11

ELECTRICAL

2.11

Design basis for Electrical has been attached as Appendix II

2.12

CIVIL/ STRUCTURE Control room building to be provided in following stations.

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i) ii) iii)

ENGINEERING DOCUMENT NO.

PAGE 18 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Dispatch Terminal SV Station & Tap-off-III Receiving Terminal

For detail of control room building refer civil design basis. • • •

Bore well shall be provided in each station (such as Dispatch, SV, Tap-off and Receipt Terminal). Boundary wall with gate shall be provided in Dispatch, SV & Receipt Terminal while in tap-off only fencing with gates are to be provided. Civil work such as pavement, pipes support & equipment foundation in Dispatch, SV, tap-off and receipt terminal.

Detail design basis for Civil/Structural has been attached as Appendix III 2.13

SERVICES

2.13.1

Air conditioners (Split and Window) will be provided in control room shift-in-charge room and SCADA & Telecom room in Dispatch, Receiving Terminal and in control SV and tap-off Stations control room.

2.13.2

Portable fire extinguisher will be provided.

2.13.3

Utility Requirement The requirement of utilities to GSPL terminal at following technical parameters as per requirement.

2.13.3.2

Power Supply * a) b) c) d)

Source & Battery Limit : Incoming Electric Power : No. of Feeders : Emergency Power :

M/s GSPL to Indicate (*) 415 V/ 50 HZ/ 3 Phase + Neutral

* Power supply for critical services such as Instrument/ Telecom/ SCADA & Control Panel and total for non-critical services shall be furnished by MECON during detail engineering. 2.13.4

Fire Fighting Facilities It has been considered that fire fighting facilities such as static fire fighting equipment such as DCP type fire extinguisher at station will be provided to cover the pipeline facilities at the despatch station SV, tap-off and Receiving Terminal.

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PAGE 19 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

2.14

LIST OF ASSUMPTIONS

2.14.1

The total route length shall be decided based on survey drawings.

2.14.2

No instrumentation, plant air shall be available. However, instruments shall be gas operated only.

2.14.3

An existing plot of 105m x 70m is provided as indicated by GSPL at Dispatch Terminal at Sokhada. The plot sizes considered for different locations are as follows :– i) i) ii) iii) iv)

Tap –off I at Padmala Despatch terminal (with building) Tap-off Point-II (without building) SV-1 / Tap-off Point-III (with building) Receipt Terminal (With Building)

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

-

56mx121m 105X70 m 40m x 40m 100m x 60m 60m x 60m

3.0

LIST OF STANDARDS

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LIST OF STANDARD

3.1

Pipeline Codes and Standards a)

ENGINEERING DOCUMENT NO.

PAGE 20 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

American Society of Mechanical Engineers (ASME) ASME ASME ASME ASME ASME

B31.8 B16.25 B16.9 B31.3 B31.4

: : : : :

Gas Transmission and Distribution Piping System Gas Transmission and Distribution Piping System Factory – Made Wrought Iron Steel Butt-Welding Fittings Process Piping Pipeline Transportation System for Liquid Hydrocarbons and others ASME B16.5 : Pipe Flanges and Flanged Fittings ASME B16.9 : Factory Made Wrought Steel Butt Welding Fittings ASME B16.10 : Face to Face and End to End – Dimensions of Valves ASME B16.11 : Forged Fittings, Socket-Welding and Threaded ASME B16.20 : Metallic Gaskets for Pipe Flanges – Ring Joint, Spiral Wound and Jacketed. ASME B16.21 : Non-Metallic Flat Gaskets for Pipe Flanges ASME B16.25 : Butt Welding Ends ASME B16.28 : Wrought Steel Butt Welding Short Radius Elbows ASME B16.34 : Valves – Flanged, Threaded & Welding Ends ASME B16.36 : Orifice Flanges ASME B16.47 Series “A” : Large Diameter Steel Flanges NPS 26 through NPS 60 ASME B18.2.1 : Square and Hex. Bolts and Screws ASME B18.2.2 : Square and Hex. Nuts ASME B31.3 : Process Piping ASME B36.10M : Welded and Seamless Wrought Steel Pipe ASME Boiler & Pressure : Section-IX – Qualification standard for welding and Brazing Vessel Code procedures, welders, brazes, and welding and brazing operators ASME Boiler & Pressure : Part C – Specifications for Welding Rods, Electrodes, and Vessel Code-II Filter Metals ASME Boiler & Pressure : Section-V, Nondestructive Examination Vessel Code ASME Boiler & Pressure : Section-II Materials Part A – Ferrous Materials Specifications Vessel Code b)

American Petroleum Institute (API) API Spec 5L API RP 1102

: :

API Std 1104

:

Specification for Line Pipe Recommended Practice for Liquid Petroleum Pipelines Crossing Railroads and Highways Standard for Welding Pipeline and Related Facilities

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OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

c)

ENGINEERING DOCUMENT NO.

PAGE 21 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

API RP 1110

:

Recommended Practice for the Pressure Testing of Liquid Petroleum Pipelines

API Std 607 API RP 500

: :

Spec 6FA STD 590 STD 594 STD 598 STD 600

: : : : :

STD 602

:

STD 607

:

Fire Test for Soft Seated Quarter Turn Valves Recommended practice for classification of locations of Electrical installations at Petroleum Facilities classified as Class I, Div. 1 and 2. Specification for Fire Test for Valves Steel Line Blanks Check Valves, Wafer, Wafer Lug and Double Flanged Type Valve Inspection and Testing Steel Gate Valves Flanged or Butt Welding Ends, Bolted and Pressure Seal Bonnets Compact Steel Gate Valves – Flanged, Threaded, Welding and Extended Body Ends. Fire Test for Soft-Seated Quarter-Turn Valves

British Standard Institute BS1868

:

BS1873

:

BS5154

:

BS5351

:

BS5352

:

BS6755 Part-I

:

BS6755 Part-2

:

EN 288-9

:

NDB EN 1594

:

NBN EN 10208-2

:

ISO-15590-1

:

DIN 30672

:

Steel Check Valve (Flanged and Butt-Welding Ends) for Petroleum, Petro-Chemical and Allied Industries Steel Globe, Globe Stop and Check Valves (Flanged and Butt Welding Ends) for the Petroleum, Petrochemical and Allied Industries Copper Alloy Globe, Globe Stop and Check, Check and Gate Valves Steel Ball Valves for Petroleum, Petrochemical and Allied Industries Steel Wedge Gate, Globe and Check Valves 50mm and Smaller for Petroleum, Petro-Chemical and Allied Industries Testing of Valves Part-1 : Production Pressure Testing Requirements Testing of Valves Part-2 : Specification for Fire Type Testing Requirements. Specification and approval of welding procedures for metallic materials – part 9. Welding procedure test for pipeline welding on land and offshore site butt welding of transmission pipeline Gas supply systems – pipeline for maximum operating pressure over 16 bar – Functional requirements Steel pipes for pipelines for combustible fluids – Technical delivery conditions - Part 2 International Standard for Petroleum and natural gas industries – Induction bends, fittings and flanges for pipeline transportation systems Coatings of corrosion protection tapes and heat-shrinking products for pipelines for operational temperatures up to 50°C

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

OIL & GAS SBU

DESIGN BASIS FOR 12” NB x 37.23 KM PIPELINE FROM PADMALA TO HALOL MECON LTD., DELHI

GUJARAT STATE PETRONET LIMITED

TITLE

BASIC ENGINEERING DESIGN BASIS

st

SEL 072 – 1 Edition DIN 20670 DIN 2413 Part-II ISO/TR 5168 d)

: : : :

ENGINEERING DOCUMENT NO.

PAGE 22 of 22

MEC/23JT/05/21/M/002/0001

REVISION 4

Ultrasonically tested heavy plate Polyethylene coatings for steel pipes and fittings Design of steel bends used in pressure pipelines Measurement of fluid flow-Evaluation of uncertainties

Oil Industry Safety Directorate (OISD Standards) OISD-GDN-115

Guidelines on Fire Fighting, Equipment and appliances in Petroleum Industry Fire Protection Manual : Fire Engines, Trailer Pumps and Hydrant Systems - TAC OISD-Standard-141 : Design and construction requirements for cross country hydrocarbon pipelines OISD-Standard-118 : Layouts for oil and gas installations e)

f)

American Society for Testing and Materials (ASTM) ASTM A82

:

ASTM A185

:

ASTM E92

:

ASTM E94 ASTM E165 ASTM E709

: : :

Standard Specification for Steel Wire, Plain, for Concrete Reinforcement Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement Standard Test Method for Vickers Hardness Testing of Metallic Materials Standard Practice for Radiographic Testing Standard Practice for Liquid Penetrant Inspection Method Standard Guide for Magnetic Particle Examinations

MSS Standard Practices MSS SP 75

g)

:

:

Specification for High Test Wrought Welding Fittings

Manufacturers Standardization Society (MSS) MSS-SP-6 MSS-SP-9 MSS-SP-25

: : :

Standard Finishes for Contact Faces Spot Facing for Bronze, Iron and Steel Flanges Standard Marking Systems for Valves, Fittings, Flanges and Union

C:\Documents and Settings\GV _kavl\Desktop\GSPL_13.03.07\Design Basis - GSPL-0001-R-4.doc

APPENDIX-II DATA SHEETS FOR MECHANICAL ITEMS ETC.

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

LIST OF DATA SHEETS FOR MECHANICAL ITEMS Sl. No.

Description

Data Sheet No.

1.

LONG RADIUS BENDS

MEC/23JT/05/21/M/002/0001/DS-015-1 R-0

2.

FLOW TEE

MEC/23JT/05/21/M/002/0001/DS/011-01, R-0

3.

FLOW TEE

MEC/23JT/05/21/M/002/0001/DS/011-02, R-0

4.

INSULATING JOINTS

MEC/23JT/05/21/M/002/0001/DS-009-01, R-0

5.

INSULATING JOINTS

MEC/23JT/05/21/M/002/0001/DS-009-02, R-0

6.

INSULATING JOINTS

MEC/23JT/05/21/M/002/0001/DS-009-03 R-0

7.

INSULATING JOINTS

MEC/23JT/05/21/M/002/0001/DS-009-04 R-0

8.

PRESSURE SAFETY VALVES

MEC/23JT/05/21/DS/PSV-001, R-1

9.

BALL VALVES (NB<2”)

MEC/23JT/05/21/M/001/BV-001, R-1

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-002, R-1

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-003, R-1

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-004, R-1

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-005, R-1

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-006, R-1

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-006A, R-0

BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-007, R-1

BALL VALVES (NB>2”) BALL VALVES (NB>2”)

MEC/23JT/05/21/M/001/BV-008, R-1 MEC/23JT/05/21/M/001/BV-008A, R-0

10.

GLOBE VALVE

MEC/23JT/05/21/M/001/DS/GV-001, R-1

11.

GLOBE VALVE

MEC/23JT/05/21/M/001/DS/GV-002, R-1

12.

GLOBE VALVE

MEC/23JT/05/21/M/001/DS/GV-002A, R-0

13.

CHECK VALVE

MEC/23JT/05/21/DS/VC-01, R-1

13.

i) SCRAPPER TRAP

MEC/23JT/05/21/M/001/SL-0001/0002, R-1

ii) PIG SIGNALLER

MEC/23JT/05/21/M/001/DS-001

D:\old data\Vijyant\GSPL\Tender\Const\list of data sheet IB of V.doc

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

INSTRUMENTATION - DATA SHEETS SR. NO. 1

INSTRUMENT Pressure Gauge

DATA SHEET NO. MEC/23JT/05/E5/DS-PG

REV

2

Pressure Transmitter

MEC/23JT/05/E5/DS-PT

1 1

3

Temperature Transmitter

MEC/23JT/05/E5/DS-TT

1

4

Resistance Temperature Detector

MEC/23JT/05/E5/DS-RTD

1

5

Differential Pressure Switch

MEC/23JT/05/E5/DS-DPS

1

6

LEL Gas Detection System

MEC/23JT/05/E5/DS-LEL

1

7

Control Panel

MEC/23JT/05/E5/DS-CP

1

8

Indicator

MEC/23JT/05/E5/DS-IND

1

9

Signal Distributor

MEC/23JT/05/E5/DS-SDC

1

10 11

Zener Barrier Alarm Annunciator

MEC/23JT/05/E5/DS-ZB MEC/23JT/05/E5/DS-ANN

1 1

D:\old data\Vijyant\GSPL\Tender\Const\list of data sheet IB of V.doc

DATA SHEET FOR LONG RADIUS BENDS 1)

LR BEND MFR.

:

2)

PURCHASER SPECIFICATION NO.

: MEC/TS/05/62/015 Rev 01

3)

MANUFACTURING CODE

: MSS-SP-75

4)

DIMENSIONAL TESTING

: REQUIRED AS PER SPEC.

5)

DESTRUCTIVE TESTING

: REQUIRED AT (-) 20 0C

(TENSILE / CHARPY /HARDNESS)

: REQUIRED AS PER SPEC.

6)

NON-DESTRUCTUVE TESTING

: REQUIRED AS PER SPEC.

7)

PIGGING

: REQUIRED AS PER NOTE NO.3

8)

HYDROSTATIC TEST PRESSURE

: 142.5 bar (g)

CV (Avg.) - 35 J/cm2 / CV (Min.) - 28 J/cm2

TABLE-I Sl. No.

Details of P/L material Thk. Material mm

Bend Radius (R)

End Type

NB

1.

12"

CONTRACTOR API 5L Gr X - 65 TO INDICATE

6D

BW

Qty. (Nos.)

Angle

CONTRACTOR TO INDICATE

CONTRACTOR TO INDICATE

Strainght Length after curvature (mm) '

Pipe length reqd. to fabricate the bend m/ bend Total @ length (m) @

500 mm

TABLE-II Pipe length required for fabrication of bends NB x Thk. (mm) @Total Length (m) From Table-I

@Total Nos. of double random length of pipe (11.5 to 12.5m length) required

12 x Thk.

* BE @ '

= "D" - denotes nominal dia. of pipe = Bevel End = Vendor to indicate = Straight length after curvature will be minimum 300mm.

Note: 1) Test Bend shall be of 90° 2) Quantity & angles of LR Bends shall be finalized during detailed engineering activities 3) A check shall be performed on each bend by passing gauging pig consisting of two discs having a diameter equal to 95% of the nominal internal diameter of the pipe, connected rigidly together at a distance equal to 300mm. Details of the gauging pig, including its dimensions shall be approved by Purchaser.

REV. NO. DATE

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION PROCESS & PIPING NAME

DATE

CHKD

REFERENCES

CLIENT :

GUJARAT STATE PETRONET LIMITED

PROJECT :

PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

MECON LIMITED

DATE

DSGN

DRG. NO.

DRWN

SCALE :

APPROVED

A.K.JOHRI

TRoy/D:/Revised-GSPL-PADM-Documents/Copy of DATA SHEET-LRB-015 GSPL REV-1LRB

DATA SHEET FOR LONG RADIUS BENDS

DATA SHEET NO.: MEC/23JT/05/21/M/002//0001/DS-015-1

REV 0

DATA SHEET FOR FLOW TEES

DESIGN DATA 1.

FLOW TEE MFR.

2.

PURCHASER'S SPECIFICATION NO : MEC/TS/05/62/011

3.

RATING

: 600#

4.

DESIGN PRESSURE

: 95 bar(g)

5.

DESIGN TEMPERATURE

: -20 to 60°C

6.

SERVICE

: R-LNG

7.

CORROSION ALLOWANCE

: 1.5 MM

8.

SIZE NB (INCHES)

: 12 X 12 X12

9.

END CONNECTION

: BUTT-WELD AT BOTH ENDS

10.

DESIGN CODE

: ASME B31.8

11.

DESIGN FACTOR

: 0.5

12.

HYDROSTATIC TEST PRESSURE

: 142.5 bar(g)

13.

CHARPY TEST

: REQUIRED AT (-) 200C, CV (Avg.) - 35 J/cm2 / CV (Min.) - 28 J/cm 2

14.

HARDNESS TEST

: REQUIRED AS PER SPEC.

15

SUITABILITY OF FLOW TEE

: FOR PIGS AND SPHERES

16

FLOW DIRECTION

: BI - DIRECTIONAL

17

MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) TEE B) END PIECES C) INTERNAL SLEEVE

: MSS-SP-75 WPHY-65 : ASTM A 694 F-65 : API 5L Gr. B

18

CONNECTING PIPE SPECIFICATION TAG NO. RUN PIPE DETAILS SL. NO. D1 THK. MATERIALS 1 2 3

NOTE:

NB (INCH)

(MM)

12 12 12

-

FWT - 0101 FWT - 0601 FWT - 0701

API 5L Gr. X - 65 API 5L Gr. X - 65 API 5L Gr. X - 65

BRANCH PIPE DETAILS THK. MATERIALS

NB (INCH)

(MM)

12 12 12

-

API 5L Gr. X - 65 API 5L Gr. X - 65 API 5L Gr. X - 65

SPECIAL REQUIREMENTS

1 2

MANUFACTURE TO INDICATE DIMENIONS MARKED A & B IN THE SKETCH ABOVE. MANUFACTURER TO FURNISH DETAILS OF THE HOLES IN INTERNAL SLEEVE. THE AREA OF THE HOLES SHALL BE MINIMUM EQUAL TO THE INTERNAL AREA OF THE BRANCH PIPE. RELEVENT CALCULATIONS TO THIS EXTENT SHALL BE FURNISHED. THE THICKESS OF PIPE SHALL BE IN VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING.

DATE

ZONE

DESCRIPTIONS

SECTION OIL & GAS NAME TR

DRWN

APPROVED

DATE

CLIENT : CHKD TRAY

Qty. Nos.

3

: FLOW TEES SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION

BY

APPRD

REVISIONS

DSGN

D2

19

3 REV. NO.

:

REFERENCES

DRG. NO.

GUJARAT STATE PETRONET LIMITED

MECON LIMITED

DATE

PROJECT : PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

DATA SHEET FOR FLOW TEES (12"X12"X12")

TRoy/D:/Revised-GSPL-PADM-Documents/Data Sheet - Flow Tee GSPL(12- inches)-Rev-0Flow Tee - 12"

SCALE :

NTS

DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-011-01

REV 0

DATA SHEET FOR FLOW TEES

DESIGN DATA 1.

FLOW TEE MFR.

2.

PURCHASER'S SPECIFICATION NO. : MEC/TS/05/62/011

3.

RATING

: 600#

4.

DESIGN PRESSURE

: 95 bar(g)

5.

DESIGN TEMPERATURE

: -20 to 60°C

6.

SERVICE

: R-LNG

7.

CORROSION ALLOWANCE

: 1.5 MM

8.

SIZE NB (INCHES)

: 12 X 12 X 8

9.

END CONNECTION

: BUTT-WELD AT BOTH ENDS

10.

DESIGN CODE

: ASME B31.8

11.

DESIGN FACTOR

: 0.5

12.

HYDROSTATIC TEST PRESSURE

: 142.5 bar (g)

13.

CHARPY TEST

: REQUIRED AT (-) 200C, CV (Avg.) - 35 J/cm2 / CV (Min.) - 28 J/cm 2

14.

HARDNESS TEST

: REQUIRED AS PER SPEC.

15.

SUITABILITY OF FLOW TEE

: FOR PIGS AND SPHERES

16.

FLOW DIRECTION

: BI - DIRECTIONAL

17.

MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) TEE B) END PIECES C) INTERNAL SLEEVE

: MSS-SP-75 WPHY-65 : ASTM A 694 F-65 : API 5L Gr. B

18.

CONNECTING PIPE SPECIFICATION TAG NO. RUN PIPE DETAILS SL. NO. D1 THK. MATERIALS 1 2

NOTE:

NB (INCH)

(MM)

12 12

-

FWT - 0301 FWT - 0401

D2

BRANCH PIPE DETAILS THK. MATERIALS

NB (INCH)

(MM)

8 8

-

API 5L Gr. X - 65 API 5L Gr. X - 65

API 5L Gr. X - 65 API 5L Gr. X - 65

19.

SPECIAL REQUIREMENTS

1. 2.

MANUFACTURE TO INDICATE DIMENIONS MARKED A & B IN THE SKETCH ABOVE. MANUFACTURER TO FURNISH DETAILS OF THE HOLES IN INTERNAL SLEEVE. THE AREA OF THE HOLES SHALL BE MINIMUM EQUAL TO THE INTERNAL AREA OF THE BRANCH PIPE. RELEVENT CALCULATIONS TO THIS EXTENT SHALL BE FURNISHED. THE THICKESS OF PIPE SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING.

3 REV. NO.

:

DATE

ZONE

DESCRIPTIONS

NAME

DATE

CLIENT : CHKD

BY

2

APPRD REFERENCES

DRG. NO.

GUJARAT STATE PETRONET LIMITED

MECON LIMITED

DATE

PROJECT : PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

DSGN DRWN

APPROVED

Nos.

: FLOW TEES SHALL BE SUITABLE FOR UNDER GROUND INSTALLATION

REVISIONS

SECTION OIL & GAS

Qty.

A.K.JOHRI

DATA SHEET FOR FLOW TEES ( 12"X12" X 8" )

TRoy/D:/Revised-GSPL-PADM-Documents/Data Sheet - Flow Tee GSPL(8- inches)-Rev-0Flow Tee - 8"

SCALE :

NTS

DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-011-02

REV 0

DATA SHEET FOR INSULATING JOINTS

A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER. 1.

INSULATING JOINTS MFR.

:

2.

PURCHASER'S SPECIFICATION NO.

: MEC/TS/05/62/009

3.

RATING

: 600#

4.

DESIGN PRESSURE

: 95 bar (g)

5.

DESIGN TEMPERATURE

: -20 to 60°C

6.

SERVICE

: Natural Gas

7.

CORROSION ALLOWANCE

: 1.5 MM

8.

SIZE NB (INCHES)

: 12"

9.

END CONNECTION

: BUTT-WELD AT BOTH ENDS

10.

DESIGN CODE

: ASME SECTION-VIII DIV-I

11.

DESIGN FACTOR

: 0.5

12.

HYDROSTATIC TEST PRESSURE

: 142.5 bar (g)

13.

CHARPY TEST

14.

HARDNESS TEST

: REQUIRED AT (-) 20 0C CV (Avg.) - 35 J/cm2 CV (Min.) - 28 J/cm2 : REQUIRED AS PER SPEC.

15.

MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) BODY B) PUPS C) INSULATING MATERIAL

: ASTM A 694 F 65 : API 5L Gr. X-65, : AS PER MANUFACTURER'S STANDARD

16.

NOTE: REV. NO.

CONNECTING PIPE SPECIFICATION SIZE, NB, MM (INCHES) 300(12") WALL THICKNESS, MM MATERIAL API 5L Gr.X-65 17. SPECIAL REQUIREMENTS : INSULATION JOINT SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION 18. TAG NOS. : 0101/ 0102/ 0701 19. QUANTITY : CONTRACTOR TO VERIFY THE THICKNESS OF PIPE/ PUP SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING DATE

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION OIL & GAS NAME

DATE

CHKD

REFERENCES

CLIENT :

GUJARAT STATE PETRONET LIMITED

PROJECT :

PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

MECON LIMITED

DATE

DSGN DRWN

SCALE :

APPROVED

A.K.JOHRI

DRG. NO.

DATA SHEET FOR INSULATING JOINTS ( 12" DIA., 600# SIZE )

TRoy/D:/Revised-GSPL-PADM-Documents/Data Sheet - IJ 009 GSPL(12- inches)-Rev-01IJ 009 - 12"- R01

NTS

DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-009-01

REV 0

DATA SHEET FOR INSULATING JOINTS

A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER. 1.

INSULATING JOINTS MFR.

:

2.

PURCHASER'S SPECIFICATION NO.

: MEC/TS/05/62/009

3.

RATING

: 600#

4.

DESIGN PRESSURE

: 95 bar (g)

5.

DESIGN TEMPERATURE

: -20 to 60°C

6.

SERVICE

: Natural Gas

7.

CORROSION ALLOWANCE

: 1.5 MM

8.

SIZE NB (INCHES)

: 12"

9.

END CONNECTION

: BUTT-WELD AT BOTH ENDS

10.

DESIGN CODE

: ASME SECTION-VIII DIV-I

11.

DESIGN FACTOR

: 0.5

12.

HYDROSTATIC TEST PRESSURE

: 142.5 bar (g)

13.

CHARPY TEST

14.

HARDNESS TEST

: REQUIRED AT (-) 20 0C CV (Avg.) - 35 J/cm2 CV (Min.) - 28 J/cm2 : REQUIRED AS PER SPEC.

15.

MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) BODY B) PUPS C) INSULATING MATERIAL

: ASTM A 350 Gr. LF2 Cl.1 : ASTM A-333, Gr. 6 : AS PER MANUFACTURER'S STANDARD

16.

NOTE: REV. NO.

CONNECTING PIPE SPECIFICATION SIZE, NB, MM (INCHES) 300(12") WALL THICKNESS, MM S 80 MATERIAL ASTM A-333, Gr. 6 17. SPECIAL REQUIREMENTS : INSULATION JOINT SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION 18. TAG NOS. : 0601 19. QUANTITY : CONTRACTOR TO VERIFY THE THICKNESS OF PIPE/ PUP SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING DATE

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION OIL & GAS NAME

DATE

CHKD

REFERENCES

CLIENT :

GUJARAT STATE PETRONET LIMITED

PROJECT :

PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

MECON LIMITED

DATE

DSGN DRWN

SCALE :

APPROVED

A.K.JOHRI

DRG. NO.

DATA SHEET FOR INSULATING JOINTS ( 12" DIA., 600# SIZE )

TRoy/D:/Revised-GSPL-PADM-Documents/Data Sheet - IJ 009 GSPL(12- inches)-Rev-02IJ 009-12"- R02

NTS

DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-009-02

REV 0

DATA SHEET FOR INSULATING JOINTS

A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER. 1.

INSULATING JOINTS MFR.

:

2.

PURCHASER'S SPECIFICATION NO.

: MEC/TS/05/62/009

3.

RATING

: 600#

4.

DESIGN PRESSURE

: 95 bar (g)

5.

DESIGN TEMPERATURE

: -20 to 60°C

6.

SERVICE

: Natural Gas

7.

CORROSION ALLOWANCE

:1.5 MM

8.

SIZE NB (INCHES)

: 8"

9.

END CONNECTION

: BUTT-WELD AT BOTH ENDS

10.

DESIGN CODE

: ASME SECTION-VIII DIV-I

11.

DESIGN FACTOR

: 1.5

12.

HYDROSTATIC TEST PRESSURE

: 142.5 bar (g)

13.

CHARPY TESTS

: REQUIRED AT AS PER SPECIFIED MATERIAL CODE

14.

HARDNESS TEST

: REQUIRED AS PER SPEC.

15.

MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) BODY B) PUPS C) INSULATING MATERIAL

: ASTM A 350 Gr. LF2 Cl. 1 : ASTM A 333 Gr. 6 : AS PER MANUFACTURER'S STANDARD

16.

17. 18. 19. NOTE: REV. NO.

CONNECTING PIPE SPECIFICATION SIZE, NB, MM (INCHES) 200(8") WALL THICKNESS, MM XS MATERIAL ASTM A 333 Gr.6 SPECIAL REQUIREMENTS : INSULATION JOINT SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION TAG NOS. : 0301/ 0401 QUANTITY : CONTRACTOR TO VERIFY THE THICKNESS OF PIPE/ PUP SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING

DATE

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION OIL & GAS NAME

DATE

CHKD

REFERENCES

CLIENT :

GUJARAT STATE PETRONET LIMITED

PROJECT :

PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

MECON LIMITED

DATE

DSGN DRWN

SCALE :

APPROVED

AK.JOHRI

DRG. NO.

DATA SHEET FOR INSULATING JOINTS ( 8" DIA., 600# SIZE )

TRoy/D:/Revised-GSPL-PADM-Documents/Data Sheet - IJ 009 GSPL (8- inches)Rev-0IJ 099 - 8"

NTS

DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-009-03

REV 0

DATA SHEET FOR INSULATING JOINTS

A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER. 1.

INSULATING JOINTS MFR.

:

2.

PURCHASER'S SPECIFICATION NO.

: MEC/TS/05/62/009

3.

RATING

: 600#

4.

DESIGN PRESSURE

: 95 bar(g)

5.

DESIGN TEMPERATURE

: -20 to 60°C

6.

SERVICE

: Natural Gas

7.

CORROSION ALLOWANCE

: 1.5 MM

8.

SIZE NB (INCHES)

: 4"

9.

END CONNECTION

: BUTT-WELD AT BOTH ENDS

10.

DESIGN CODE

: ASME SECTION-VIII DIV-I

11.

DESIGN FACTOR

: 0.5

12.

HYDROSTATIC TEST PRESSURE

: 142.5 bar (g)

13.

CHARPY TESTS

: REQUIRED AS PER SPECIFIED MATERIAL CODE

14.

HARDNESS TESTS

: REQUIRED AS PER MATERIAL CODE

15.

MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) BODY B) PUPS C) INSULATING MATERIAL

: ASTM A 350 Gr. LF2 Cl. 1 : ASTM A333 GR. 6 : AS PER MANUFACTURER'S STANDARD

16.

17. 18. 19. NOTE: REV. NO.

CONNECTING PIPE SPECIFICATION SIZE, NB, MM (INCHES) 100(4") WALL THICKNESS, MM STD ASTM A333 GR. 6 MATERIAL SPECIAL REQUIREMENTS : INSULATION JOINT SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION TAG NOS. : 0503 QUANTITY : CONTRACTOR TO VERIFY THE THICKNESS OF PIPE/ PUP SHALL BE VERIFIED BY CONTRACTOR DURING DETAILED ENGINEERING

DATE

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION OIL & GAS NAME DSGN

TR

DATE

CHKD

REFERENCES

CLIENT :

GUJARAT STATE PETRONET LIMITED

PROJECT :

PADAMLA - HALAOL NATURAL GAS PIPELINE PROJECT OF GSPL IN GUJARAT

MECON LIMITED

DATE

TRAY

DRWN

SCALE :

APPROVED

A.K.JOHRI

DRG. NO.

DATA SHEET FOR INSULATING JOINTS ( 4" DIA., 600# SIZE )

TRoy/D:/Revised-GSPL-PADM-Documents/Data Sheet - IJ 009 GSPL (4- inches)-Rev-0IJ 009 - 4"

NTS

DATA SHEET NO.: MEC/23JT/05/21/M/002/0001/DS-009-04

REV 0

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

:(20)3/4", (25)1'', (40)11/2''

3.0

Connecting Pipeline Design Pressure, kg/cm2(g)

4.0 4.1 4.2 4.3

Connecting Pipe Specification Material Diameter (OD), mm (inch) Thickness, mm

: : : :

5.0 5.1 5.2

Valve Construction Design Bore End Connections

:

5.3

Flanges (wherever applicable) Valve Type

6.0

Valve Material Specification Part Specified Material

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

Body Ball Body Seat Gland Stem Body Seal Stem Seal Body Studs/Nuts

N.A.

Reduced Full  Flanged End raised face (as per ASME B16.5) FF RTJ Smooth (125 to 200 microinches AARH)

1.5 mm

8.0

Location

:

Above Ground

9.0

Stem Extension Requirement

:

Yes

No



10.0

Gear Operator Requirement

:

Yes

No



11.0

Gas Powered Actuator Requirement

:

Yes

12.0

Fire Resistant Design Requirement

:

13.0

Valve Testing Requirement

13.1

Hydrostatic Test

13.2

Air Test

Test Pressure (min.), kg/cm2(g) Minimum Duration, minutes 157 2 2 114 7.0 15

Anti-Static Testing Requirement

:

15.0 15.1 15.2 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

REV. NO. 1

Body Seat

Service : Natural Gas 

Buried Length of Stem Extension, m : N.A.



Actuator Specification No.: N.A. Actuator Data Sheet No.: N.A. Type-Test as per Standard API 607/ BS:6755 (Part-II) No

As per Standard BS:5351

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : As indicated in Material Requisition Lock Open/ Lock Close Requirement Notes: Charpy V- notch test for body, ball, gland, stem & studs/ nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. Material test certificates and hydrostatic test reports shall be furnished prior to despatch. Detailed dimensional drawings showing cross-section with part numbers and materials shall be submitted for Purchaser's approval prior to manufacture of the valves. All tests shall be as per BS:6755 (Part-I). Valves shall have ball position indicator. Stops shall be provided to ensure positive alignment of ball with ports and ensure proper installation of handle. Each valve shall be provided with a wrench. Valves shall be inspected and approved by Purchaser before despatch. Gland packing assembly shall permit repair of gland packing under full line pressure. Inspection and Testing shall be as per this specification, BS:6755 (Part-I) and other relevant standards and clause no. 5.0 of T.S. No.: MEC/TS/05/62/002, Rev-2. * Minimum thickness of ENP coating on Ball & stem shall be 25 microns. DATE

ZONE

30.12.06

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME

DSGN

NA NA

Material Offered

:

14



ASTM A 350 LF2 Class 1 ASTM A 350 LF2 Class 1/SS 316, with ENP coating* RPTFE/ DELRIN SS 316 SS 316 with ENP coating* (No casting) Grafoil Grafoil ASTM A 320 L 7/ A194 Gr. 4

Corrosion Allowance

7

Design Standard : BS:5351

Design Temperature, °C :-20 to +60°C

: 96.87

: a) RF  b) Serrated : Floating Ball

5.4

ANSI Rating :600#

BB

DATE

CHKD

GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

PROJECT :Padamla (Baroda) Godhra Pipeline Project

MECON LIMITED

DRWN

APPROVED

SPECIFICATION AND DATA SHEET FOR BALL VALVES (NB < 2'')

SCALE : NO. : MEC/23JT/05/21/M/001/BV001

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

: 50(2"),100(4'')

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification : Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

6.4 7.0

Valve Type Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

9.0

Location

:

Above Ground

10.0

Stem Extension Requirement

:

Yes

No



11.0

Gear Operator Requirement

:

Yes

No



12.0

Gas Powered Actuator Requirement

:

Yes

No



13.0

Fire Resistant Design Requirement

:

API 6FA.

14.0

Valve Testing Requirement

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 : 96.87

2'' A 333 Gr 6 60.3 5.54

Design Temperature, °C : -20 to +60°C

4" A 333 Gr 6 114.3 6.02

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm pup pieces as per above connecting pipe specification. : a) RF FF RTJ NA  b) Serrated Smooth (125 to 200 microinches AARH) NA  :

Trunnion Mounted Specified Material

Material Offered

A350 Gr. LF2 Class 1 / A352 Gr. LCB ASTM A 350 LF2 Class1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* (No Casting) VITON/ PTFE ASTM A 320 Gr. L7/ A 194 Gr. 4

Service : Natural Gas 

Buried

Test Pressure (min.), kg/cm2(g)

Actuator Specification No.: N.A.

Minimum Duration, minutes 2", 4"NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

17.0

REV. NO. 1

DATE

Body Seat

Length of Stem Extension, mm : N.A

ZONE

30.12.06

:

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME

157 114 7.0

DATE

CHKD

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :Padamla (Baroda) -Godhra Pipeline Project DSGN

BB

MECON LIMITED

GS

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2")

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV002

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

: 300(12'')

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification : Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm Pup Pieces as per above connecting pipe specification. : a) RF FF RTJ NA 

6.4

Valve Type

:

7.0

Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

9.0

Location

:

Above Ground

10.0

Stem Extension Requirement

:

Yes

11.0

Manual Hydraulic Operator Requirement

12.0

Gas Powered Actuator Requirement

:

Yes

13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 : 96.87

Design Temperature, °C : -20 to +60°C

12'' A 333 Gr 6 323.8 17.48

b) Serrated Trunnion Mounted

Smooth (125 to 200 microinches AARH)

NA



Material Offered

Specified Material

ASTM A 350 LF2 Class 1 / A 352 Gr. LCB ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1 / SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No Casting) VITON/ PTFE ASTM A 320 Gr. L7/ A 194 Gr. 4

Service : Natural Gas 

Buried No

:

Yes

 No

Test Pressure (min.), kg/cm2(g)

Length of Stem Extension, mm : N.A No



Actuator Specification No.: N.A.

Minimum Duration, minutes 12'' NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

17.0

REV. NO. 1

DATE

Body Seat



ZONE

30.12.06

:

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME

157 114 7.0

DATE

CHKD

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :Padamla (Baroda) -Godhra Pipeline Project DSGN

BB

MECON LIMITED

GS

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2")

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV003

REV 0

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

: 50(2"), 100(4'')

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

: 96.87

5.0 5.1 5.2 5.3

Connecting Pipe Specification Material Diameter (OD), mm (inch) Thickness, mm

:

6.0 6.1. 6.2. 6.3.

Valve Construction Design Bore End Connections Flanges (wherever applicable)

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 Design Temperature, °C : -20°C to +60°C

N.A.

: Reduced Full  : Flanged as per ASME B16.5 : a) RF  FF RTJ b) Serrated Smooth (125 to 200 microinches AARH) : Trunnion Mounted

6.4

Valve Type

7.0

Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

9.0

Location

:

Above Ground

10.0

Stem Extension Requirement

:

Yes

No



11.0

Gear Operator Requirement

:

Yes

No



12.0

Gas Powered Actuator Requirement

:

Yes

No



13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

Specified Material

Material Offered

Service : Natural Gas (Composition as per Annex-I to T.S.) 

Length of Stem Extension, m : N.A.

Actuator Specification No.: N.A.

Minimum Duration, minutes 2", 4'' NB As per API 6D As per API 6D As per API 6D

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement

REV. NO. 1

DATE

Body Seat

Buried

14.1

Notes: 1. 2. 3. 4. 5

:

ZONE

BB

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS REVISIONS: As per GSPL

SECTION PROCESS & PIPING

DSGN

157 114 7

This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

30.12.06

NAME

NA NA

ASTM A 350 LF2 Class 1/ A 352 Gr. LCB ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No Casting) VITON/PTFE ASTM A 320 Gr. L7/ A194 Gr. 4

Test Pressure (min.), kg/cm2(g)

17.0



DATE

CHKD GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

PROJECT :Padamla (Baroda) Godhra Pipeline Project

MECON LIMITED

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2'')

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV004

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

: 300(12'')

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

: 96.87

5.0 5.1 5.2 5.3

Connecting Pipe Specification Material Diameter (OD), mm (inch) Thickness, mm

:

6.0 6.1. 6.2. 6.3.

Valve Construction Design Bore End Connections Flanges (wherever applicable)

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 Design Temperature, °C : -20°C to +60°C

N.A.

: Reduced Full  : Flanged as per ASME B16.5 : a) RF  FF RTJ b) Serrated Smooth (125 to 200 microinches AARH) : Trunnion Mounted

6.4

Valve Type

7.0

Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

9.0

Location

:

Above Ground

10.0

Stem Extension Requirement

:

Yes

11.0

Manual Hydraulic Qperator Requirement:

12.0

Gas Powered Actuator Requirement

:

13.0

Fire Resistant Design Requirement

:

14.0

Valve Testing Requirement

NA NA

Material Offered

Specified Material

ASTM A 350 LF2 Class 1/ A 352 Gr. LCB ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* (No Casting) VITON/PTFE ASTM A 320 Gr. L7/ A194 Gr. 4

Service : Natural Gas (Composition as per Annex-I to T.S.) 

Buried 

No 

Yes Yes

Length of Stem Extension, m : N.A. No



No

Actuator Specification No.: N.A.

API 6FA

Test Pressure (min.), kg/cm2(g) Body Seat

Minimum Duration, minutes 12'' NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement

17.0



157 114 7 :

As per Standard API 6D (2002 Ed.)

Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns. REV. NO.

DATE

ZONE

1 30.12.06

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME DSGN

BB

DATE

CHKD GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

PROJECT :Padamla (Baroda) Godhra Pipeline Project

MECON LIMITED

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2'')

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV005

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

:

300(12'') ,200(8")

3.0

MECON's Technical Specification No.

:

MEC/TS/05/62/002, Rev-2

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

6.4 7.0

Valve Type Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

Service : Natural Gas

9.0

Location

:

Above Ground

Buried

10.0

Stem Extension Requirement

:

Yes

11.0

Gear Operator Requirement

:

Yes

12.0

Gas Powered Actuator Requirement

:

Yes

13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

ANSI Rating : 600#

: 96.87

Design Standard : API 6D

Design Temperature, °C : -20 to +60°C

12'' API 5L Gr X65 323.8 8.7

8'' A 333 Gr 6 219.1 12.7

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm Pup Pieces as per above connecting pipe specification. : a) RF FF RTJ NA  :

b) Serrated Trunnion Mounted

Smooth (125 to 200 microinches AARH)

Specified Material

NA

Material Offered

ASTM A 350 LF2 Class 1 / A352 Gr. LCB ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No casting) VITON/PTFE ASTM A 320 Gr. L7/ A194 Gr. 4



Length of Stem Extension, mm : 2500+/-250 (From finished ground level) 

No 

No

Actuator Specification No.: MEC/TS/05/26/002 Data Sheet No.: MEC/DS/05/26/23JT/002/01 (Gas over Oil)

Minimum Duration, minutes 8", 12'' NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Valves seat shall have double piston effect. 6 Valve body material shall be of minimum yield strength 44000psi, so as to weld with API 5L X-65,8.7 thk or else . with welded spool piece of 500 length of API 5l-X65, 8.7 thk. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

REV. NO. 1

DATE

Body Seat



No

Test Pressure (min.), kg/cm2(g)

17.0

ZONE

30.12.06

DSGN

BB

157 114 7.0 :

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME

DATE



CHKD

GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

PROJECT :Padamla (Baroda) Godhra Pipeline Project

MECON LIMITED

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB >2'')

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV006

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

:

300(12'') ,200(8")

3.0

MECON's Technical Specification No.

:

MEC/TS/05/62/002, Rev-2

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

6.4 7.0

Valve Type Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

Service : Natural Gas

9.0

Location

:

Above Ground

Buried

10.0

Stem Extension Requirement

:

Yes

11.0

Gear Operator Requirement

:

Yes

12.0

Gas Powered Actuator Requirement

:

Yes

13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

ANSI Rating : 600#

: 96.87

Design Standard : API 6D

Design Temperature, °C : -20 to +60°C

12'' API 5L Gr X65 323.8 8.7

8'' A 333 Gr 6 219.1 12.7

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm Pup Pieces as per above connecting pipe specification. : a) RF FF RTJ NA  :

b) Serrated Trunnion Mounted

Smooth (125 to 200 microinches AARH)

NA

Material Offered

Specified Material

ASTM A 350 LF2 Class 1 ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No casting) VITON/PTFE ASTM A 320 Gr. L7/ A194 Gr. 4



Length of Stem Extension, mm : 2500+/-250 (From finished ground level) 

No 

No

157 114 7.0

Actuator Specification No.: MEC/TS/05/26/002 Data Sheet No.: MEC/DS/05/26/23JT/002/01 (Gas over Oil)

Minimum Duration, minutes 8", 12'' NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Valves seat shall have double piston effect. 6 Valve body material shall be of minimum yield strength 44000psi, so as to weld with API 5L X-65,8.7 thk or else . with welded spool piece of 500 length of API 5l-X65, 8.7 thk. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

REV. NO. 0

DATE

Body Seat



No

Test Pressure (min.), kg/cm2(g)

17.0

ZONE

:

DESCRIPTIONS

SECTION PROCESS & PIPING

DSGN

As per Standard API 6D (2002 Ed.)

07.03.07

NAME

BB

DATE



CHKD

GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

PROJECT :Padamla (Baroda) Godhra Pipeline Project

MECON LIMITED

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES MAINLINE VALVES (NB >2'')

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV006A

REV 0

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

: 100(4''), 200(8'')

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification : Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

6.4

Valve Type

7.0

Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

Service : Natural Gas

9.0

Location

:

Above Ground

Buried

10.0

Stem Extension Requirement

:

Yes

11.0

Gear Operator Requirement

:

Yes

No



12.0

Gas Powered Actuator Requirement

:

Yes

No



13.0

Fire Resistant Design Requirement

:

14.0

Valve Testing Requirement

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 : 96.87

4'' A 333 Gr 6 114.3 6.02

Design Temperature, °C : -20 to +60°C

8'' A 333 Gr 6 219.1 12.7

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm Pup Pieces as per above connecting pipe specification. : a) RF b) Serrated : Trunnion Mounted

FF RTJ Smooth (125 to 200 microinches AARH)

Specified Material

NA NA

Material Offered





No

Length of Stem Extension, mm : 2500+/-250 (From Finished Ground Level)

Actuator Specification No.: N.A.

API 6FA

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Valves seat shall have double piston effect. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/ nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

1

DATE

Body Seat

Minimum Duration, minutes 4'', 8'' NB As per API 6D As per API 6D As per API 6D

14.1

REV. NO.

ZONE

30.12.06

157 114 7.0 :

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS REVISIONS: As per discussions withGSPL

SECTION PROCESS & PIPING NAME

DATE



ASTM A 350 LF2 Class 1 / A352 Gr. LCB ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No Casting) VITON/ PTFE ASTM A 320 Gr. L7/ A194 Gr. 4

Test Pressure (min.), kg/cm2(g)

17.0



CHKD

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :Padamla (Baroda) -Godhra Pipeline Project DSGN

BB

MECON LIMITED

GS

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2")

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV007

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

:300(12")

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification : Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

6.4

Valve Type

7.0

Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

Service : Natural Gas

9.0

Location

:

Above Ground

Buried

10.0

Stem Extension Requirement

:

Yes

11.0

Manual Hydraulic Operator Requirement

12.0

Gas Powered Actuator Requirement

:

Yes

13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 : 96.87

Design Temperature, °C : -20 to +60°C

12'' A 333 Gr 6 323.8 17.48

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm Pup Pieces as per above connecting pipe specification. : a) RF FF RTJ NA  b) Serrated Smooth (125 to 200 microinches AARH) NA  :

Trunnion Mounted

Specified Material

Material Offered

ASTM A 350 LF2 Class 1 / A352 Gr. LCB ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No casting) VITON/ PTFE ASTM A 320 Gr. L7/ A194 Gr. 4



No :

Yes

Length of Stem Extension, mm : 2500+/-250 (From Finished Ground Level)



No 

No

Test Pressure (min.), kg/cm2(g)

Actuator Specification No.: N.A.

Minimum Duration, minutes 12'' NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Valves seat shall have double piston effect. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

17.0

REV. NO. 1

DATE

Body Seat



ZONE

30.12.06

:

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME

157 114 7.0

DATE

CHKD

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :Padamla (Baroda) -Godhra Pipeline Project DSGN

BB

MECON LIMITED

GS

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2")

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV008

REV 1

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

:300(12")

3.0

MECON's Technical Specification No.

:

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification : Material Diameter (OD), mm Thickness, mm

6.0 6.1.

Valve Construction Design Bore

6.2. 6.3.

End Connections Flanges (wherever applicable)

6.4

Valve Type

7.0

Valve Material Specification Part

7.1 7.2 7.3 7.4 7.5 7.6 7.7

Body Ball Body Seat Rings Seat Seal Stem Stem Seals Stud Bolts/ Nuts

8.0

Corrosion Allowance

:

1.5 mm

Service : Natural Gas

9.0

Location

:

Above Ground

Buried

10.0

Stem Extension Requirement

:

Yes

11.0

Manual Hydraulic Operator Requirement

12.0

Gas Powered Actuator Requirement

:

Yes

13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

ANSI Rating : 600#

Design Standard : API 6D

MEC/TS/05/62/002, Rev-2 : 96.87

Design Temperature, °C : -20 to +60°C

12'' API 5L Gr X 65 323.8 8.7

: Reduced Full  : Butt Weld as per ASME B 16.25 with 300mm Pup Pieces as per above connecting pipe specification. : a) RF FF RTJ NA  b) Serrated Smooth (125 to 200 microinches AARH) NA  :

Trunnion Mounted

Specified Material

Material Offered

ASTM A 350 LF2 Class 1 ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* ASTM A 350 LF2 Class 1/ SS 316 VITON ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* (No casting) VITON/ PTFE ASTM A 320 Gr. L7/ A194 Gr. 4



No :

Yes

Length of Stem Extension, mm : 2500+/-250 (From Finished Ground Level)



No 

No

Test Pressure (min.), kg/cm2(g) 157 114 7.0

Actuator Specification No.: N.A.

Minimum Duration, minutes 12'' NB As per API 6D As per API 6D As per API 6D

14.1

Hydrostatic Test

14.2

Air Test

15.0

Anti-Static Testing Requirement

16.0 16.1 16.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) : N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/002, Rev-2 2. Inspection and Testing shall be as per attached QAP, this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Stops shall be provided for positive alignment of ball with ports and ensure proper installation of handle. 4. Short pattern valves as per API 6D are not permitted, only long pattern valves are to be supplied. 5 Valves seat shall have double piston effect. 5 Charpy V- notch test for body, ball, body seat rings, stem & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Ball & stem shall be ENP coated for minimum thickness of 25 microns.

17.0

REV. NO. 0

DATE

Body Seat



ZONE

:

As per Standard API 6D (2002 Ed.)

DESCRIPTIONS

07.03.07

SECTION PROCESS & PIPING NAME

DATE

CHKD

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :Padamla (Baroda) -Godhra Pipeline Project DSGN

BB

MECON LIMITED

GS

DRWN SCALE :

APPROVED

DATA SHEET FOR BALL VALVES (NB > 2")

DATA SHEET NO.:MEC/23JT/05/21/M/001/BV008A

REV 0

1.0

Valve Manufacturer

:

2.0

Valve Size (NB), mm (inch)

:

300(12")

3.0

MECON's Technical Specification No.

:

MEC/TS/05/62/004, Rev-1

4.0

Connecting Pipeline Design Pressure, kg/cm2(g)

5.0 5.1 5.2 5.3

Connecting Pipe Specification Material Diameter (OD), mm (inch) Thickness, mm

: : : :

6.0 6.1.

Valve Construction Design Port

:

Full

6.2.

End Connections

: :

Flanged both ends Butt Weld both ends Flanged one end, butt weld other end

6.3.

Flanges (wherever applicable)

: a) RF  b) Serrated

7.0

ANSI Rating : 600#

: 96.87

Design Standard : API 6D/ BS:1868/

Design Temperature, °C :-20 to +60

N.A.

Regular





FF RTJ Smooth (125 to 200 microinches AARH)

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10

Valve Material Specification Part Specified Material Body ASTM A 350 Gr LF2 class 1/A352 Gr LCB. Cover ASTM A 350 Gr LF2 class 1/A352 Gr LCB. Disc/ Plates ASTM A 350 LF2 Class 1 / SS 316, with ENP coating* Body Seat Rings (See Note-3) ASTM A 350 LF2 Class 1/ SS 316, with ENP coating* Disc Hinge SS 316 Hinge Pin SS 316 Cover Stud Bolts ASTM A 320 Gr. L7 Nuts ASTM A 194 Gr. 4 Cover Gasket SS 304 Spiral Wound with C.A. Filler Spring Inconel X-750

8.0

Corrosion Allowance

:

1.5 mm

9.0

Location

:

Above Ground

10.0

Stem Extension Requirement

:

N.A.

11.0

Gear Operator Requirement

:

N.A.

12.0

Gas Powered Actuator Requirement

:

N.A.

13.0

Fire Resistant Design Requirement

:

API 6FA

14.0

Valve Testing Requirement

Flanged (as per ASME B16.5)

NA NA

Material Offered (Equivalent or Superior

Service : Natural Gas 

Test Pressure (min.), kg/cm2(g)

Buried

Minimum Duration, minutes

14.1

Hydrostatic Test

15.0 15.1 15.2

Valve Painting Specification Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.)

16.0

: N.A. Lock Open/ Lock Close Requirement Notes: 1. This Valve Data Sheet shall be read in conjunction with MECON's Technical Specification No. MEC/TS/05/62/004. 2. Inspection and Testing shall be as per this Data Sheet, MECON's T.S., API 6D and other relevant standards. 3. Seats shall be non-renewable integral type. 4 Charpy V- notch test for body, cover, disc, body seat rings & studs/ nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Minimum thickness of ENP coating shall be 25 microns.

REV. NO. 1

DATE

Body Seat



ZONE

30.12.06

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME DSGN

BB

157 114

DATE

CHKD

CLIENT :

API 6D API 6D

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

MECON LIMITED

PROJECT : Natural Gas Supply To Padmala- Godhra Pipeline

GS

DRWN

SCALE :

APPROVED

A.K. JOHRI

DATA SHEET FOR CHECK VALVES (NB > 2")

d:\fateh\narimanam-kuthalam\tender rfq\check valve\Data Sheet - CV - 01

DATA SHEET NO. : MEC/23JT/05/21/DS/VC-01

REV 1

DATA SHEET FOR GLOBE VALVES 1.

Valve Manufacturer

:

2.

Size

:

2", 4''

3.

Purchaser's Specification

:

MEC/05/62/S/005

4.

Design Pressure

:

96.87 kg/cm2(g)

5

Corrosion Allowance

:

1.5mm

6

End Connections

:

7

Flanges (where applicable)

Rating : ANSI 600#

Design Temperature

Flanged both ends  Butt Weld both ends as per ASME B 16.25 with 300mm Pup Pieces on both sides as per pipe specifications Flanged one end butt weld other end : a) RF FF RTJ NA 

:

Smooth (125 to 200 AARH)

8

Pipe Specification

9

Valve Material Specification (or Equivalent/ Superior) : a) Body : ASTM A352 Gr. LCB b) Bonnet (Bolted) : ASTM A352 Gr. LCB c) Stem (Rising) : SS 316 (No casting) b) Disc(Loose Plug/Ball Type) : SS 316 with ENP coating* e) Body Seat Ring : SS 316 f) Stem Packing (Renewable : Graphited Braided Asbestos with sacrifical with valve open on stream) inhibitor & Inconel wire reinforcement g) Hand Wheel (Rising) : Malleable Iron/ Cast Steel/ Fab. Steel h) Bonnet Bolts : ASTM A 320 Gr. L7 i) Bonnet Nuts : ASTM A194 Gr. 4 j) Bonnet Gasket : Spiral Wound SS 304 + CA Filler

2'' A 333 Gr. 6 60.3 3.54

NA



4'' A 333 Gr. 6 114.3 6.02

Hydrostatic Test Pressure a) Body b) Seat

: :

157 kg/cm 2(g) 114 kg/cm 2(g)

11

Test Pressure with Air

:

7.0 kg/cm (g)

12

Schedule of Quantity Valve Size, NB 2" 4''

: -20 to + 60°C

Services : Natural Gas

b) Serrated

10

Design Standard : BS:1873

Material Offered : : : : : : : : : :

2

: Quantity (Nos.) As per SOR As per SOR

Notes: 1. Valve shall be designed for intristically fire safe. 2. Testing shall be asper BS:6755 (Part-I) 3. Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided for . Wherever bidder agrees with MECON's data sheet, bidder shall clearly indicate "agreed". 4 Charpy V- notch test for body, bonnet, stem, disc, body seat rings & studs/nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Minimum thickness of ENP coating shall be 25 microns Painting Specifications: 1 Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. 2 Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) REV. NO. 1

DATE

ZONE

30.12.06

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME DSGN DRWN

BB

DATE

CHKD GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

MECON LIMITED

Padamla (Baroda) - Godhra Pipeline Project SCALE :

APPROVED

A.K. JOHRI DATA SHEET FOR GLOBE VALVES

DATA SHEET NO. MEC/23JT/05/21/M/001/DS/GV-001

REV 1

DATA SHEET FOR GLOBE VALVES 1.

Valve Manufacturer

:

2.

Size

: 2'' to 12"

3.

Purchaser's Specification

:

MEC/05/62/S/005

4.

Design Pressure

:

96.87 kg/cm2(g)

5

Corrosion Allowance

:

1.5mm

6

End Connections

:

Flanged both ends as per ASME B 16.5 Butt Weld both ends Flanged one end butt weld other end

7

Flanges (where applicable)

: a) RF



Rating : ANSI 600#

Design Temperature : -20 to + 60°C Services : Natural Gas

FF

b) Serrated



RTJ Smooth (125 to 200 AARH)

8

Pipe Specification

9

Valve Material Specification (or Equivalent/ Superior) : a) Body : ASTM A352 Gr. LCB : b) Bonnet (Bolted) : ASTM A352 Gr. LCB : c) Stem (Rising) : SS 316 (No casting) : b) Disc(Loose Plug/Ball Type) : SS 316 with ENP coating* : e) Body Seat Ring : SS 316 : f) Stem Packing (Renewable : Graphited Braided Asbestos with sacrifica : with valve open on stream) inhibitor & Inconel wire reinforcement g) Hand Wheel (Rising) : Malleable Iron/ Cast Steel/ Fab. Steel : h) Bonnet Bolts : ASTM A320 Gr. L7 : i) Bonnet Nuts : ASTM A194 Gr. 4 : j) Bonnet Gasket : Spiral Wound SS 304 + CA Filler :

10

Hydrostatic Test Pressure a) Body b) Seat

: :

157 kg/cm2(g) 114 kg/cm2(g)

11

Test Pressure with Air

:

7.0 kg/cm2(g)

12

Schedule of Quantity Valve Size, NB 2'' 4'' 12''

:

Design Standard : BS:1873



N.A Material Offered

: Quantity (Nos.) As per SOR As per SOR As per SOR

Notes: 1. Valve shall be designed for intristically fire safe. 2. Testing shall be asper BS:6755 (Part-I) 3. Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided for . Wherever bidder agrees with MECON's data sheet, bidder shall clearly indicate "agreed". 4 Charpy V- notch test for body, bonnet, stem, disc, body seat rings & studs/ nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Minimum thickness of ENP coating shall be 25 microns. Painting Specifications: 1 Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. 2 Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) REV. NO.

DATE

1

30.12.06

ZONE

DESCRIPTIONS REVISIONS: As per discussions with GSPL

SECTION PROCESS & PIPING NAME DSGN

BB

DRWN

DATE

CHKD GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

MECON LIMITED

Padamla (Baroda) to Godhra Pipeline Project SCALE :

APPROVED

A.K. JOHRI DATA SHEET FOR GLOBE VALVES

DATA SHEET NO. MEC/23JT/05/21/M/001/DS/GV-002

REV 1

DATA SHEET FOR INTELLIGENT PIG SIGNALLERS Pig Signaller Tag No. On Equipment On Line Pig Signaller Manufacturer

XXLS-0003 on SR-0002 XXLS-0001, 0002 on 12" dia. Pipeline :

Purchaser's Specification

MEC/S/05/62/048 :

Pig Signaller Model Quantity (No.)

3

DESIGN CONDITIONS Maximumk Allowable Operating Pressure, kg/cm2(g)

96.87

Temperature, °C

(-) 20 to (+) 60

Design Code

ASME B31.8

Corrosion Allowance (MM) ANSI Rating (#)

1.5 600 #

Design Factor

0.5

Service

RLNG

End Connection Installation

BE Aboveground

Electrical Area Classification

IEC - Zone-1, Gas Group-IIA & IIB, Temp. Class-T3

DETAILS OF PIPELINE ON WHICH PIG SIGNALLERS SHALL BE MOUNTED Diameter (NB, mm) x Thk. (mm)

300 (12") x17.48

Material PIG SIGNALLERS MATERIAL SPECIFICATION

ASTM A 333 Gr 6

Body

ASTM A105

Internals

SS-316

MICRO SWITCH DETAILS Rating

Potential Free Contact of Rating 24V DC, 2A, SPDT

Enclosure

Weather Proof to IP55 & Flame Proof Exd. Enclosure certified for area classification

Cable Connection

NOTES:

REV. NO.

½" NPTF

1) : - VENDOR TO INICATE 2) PIG SIGNALLERS SHALL BE PROVIDED WITH ISOLATION VALVE FOR ON-LINE REPAIR. 3) PAINTING SPECIFICATIONS: a) SURFACE PREPARATION AS PER GRADE SA21/2, SWEDISH STANDARD SIS-055909. b) THREE COATS OF PAINT SHALL BE APPLIED OF MINIMUM 3 MICRONS THICKNESS. (PERMISSIBLE THICKNESS IN EACH COATS SHALL BE WITHIN 80 TO 120 MICRONS) 4) CHARPY V-NOTCH TEST (IF APPLICABLE) WILL BE CONDUCTED AT -20°C ON FIVE SAMPLES HAVING AVERAGE VALUE OF 35J AND MINIMUM VALUE SHALL BE 28J.

DATE

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION PROCESS & PIPING NAME DSGN

REFERENCES

DRG. NO.

CLIENT : GAIL (India) Limited DATE

SS

CHKD

DATE

PROJECT : Natural Gas Pipeline project

MECON LIMITED

From Padmala to Godhra

GS

DRWN

APPROVED

D:\Vijaynt\IPPS KG Basin\DS - PS - 0501

A.K. JOHRI

PIG SIGNALLERS (XXLS-0001, 0002 & 0003)

SCALE : DATA SHEET NO.:MEC/23JT/05/21/M/001/DS 001

REV 1

DATA SHEET FOR GLOBE VALVES 1.

Valve Manufacturer

:

2.

Size

: 2'' to 12"

3.

Purchaser's Specification

:

MEC/05/62/S/005

4.

Design Pressure

:

96.87 kg/cm2(g)

5

Corrosion Allowance

:

1.5mm

6

End Connections

:

Flanged both ends as per ASME B 16.5 Butt Weld both ends Flanged one end butt weld other end

7

Flanges (where applicable)

: a) RF

Rating : ANSI 600#

Design Temperature

: -20 to + 60°C

Services : Natural Gas



FF

b) Serrated



RTJ Smooth (125 to 200 AARH)



8

Stem Extension Requirement

:

Yes

9

Pipe Specification

:

N.A

10

Valve Material Specification (or Equivalent/ Superior) : a) Body : ASTM A352 Gr. LCB b) Bonnet (Bolted) : ASTM A352 Gr. LCB c) Stem (Rising) : SS 316 (No casting) b) Disc(Loose Plug/Ball Type) : SS 316 with ENP coating* e) Body Seat Ring : SS 316 f) Stem Packing (Renewable : Graphited Braided Asbestos with sacrifical with valve open on stream) inhibitor & Inconel wire reinforcement g) Hand Wheel (Rising) : Malleable Iron/ Cast Steel/ Fab. Steel h) Bonnet Bolts : ASTM A320 Gr. L7 i) Bonnet Nuts : ASTM A194 Gr. 4 j) Bonnet Gasket : Spiral Wound SS 304 + CA Filler

11

Design Standard : BS:1873

No

Hydrostatic Test Pressure a) Body b) Seat

: :

157 kg/cm 2(g) 2 114 kg/cm (g)

12

Test Pressure with Air

:

2 7.0 kg/cm (g)

13

Schedule of Quantity Valve Size, NB

:



Length of Stem Extension, mm : 2500+/-250 (From finished ground level)

Material Offered : : : : : : : : : :

2'' 4'' 12'' Notes: 1. Valve shall be designed for intristically fire safe. 2. Testing shall be asper BS:6755 (Part-I) 3. Bidder shall clearly write all/ any deviation against each part/ material of valve in the space provided for . Wherever bidder agrees with MECON's data sheet, bidder shall clearly indicate "agreed". 4 Charpy V- notch test for body, bonnet, stem, disc, body seat rings & studs/ nuts will be conducted at -20°C on five samples having average value of 35J and minimum value shall be 28J. * Minimum thickness of ENP coating shall be 25 microns. Painting Specifications: 1 Surface preparation by Short Blasting as per grade SA 2 1/2, Swedish Standard SIS-055 909. 2 Three coats of paint shall be applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be within 80 to 120 micron.) REV. NO. 0

DATE

ZONE

DESCRIPTIONS

07.03.07

SECTION PROCESS & PIPING NAME DSGN

BB

DRWN

DATE

CHKD GS

CLIENT :

BY

APPRD

BB

GS

REFERENCES

DRG. NO.

GSPL

DATE

PROJECT :

MECON LIMITED

Padamla (Baroda) to Godhra Pipeline Project SCALE :

APPROVED

A.K. JOHRI DATA SHEET FOR GLOBE VALVES

DATA SHEET NO. MEC/23JT/05/21/M/001/DS/GV-002A

REV 0

PRESSURE SAFETY VALVES 3

UNITS : Flow > Liquid - m* /hr , Gas-Sm /day, Steam - kg/hr. Pressure -> kg/cm*2(g), Temperature-°C, Level/ Length-> mm 01 Tag No. 42-PSV-0101 42-PSV-0701 General 02 Line No./ Size 03 Vessel Protected SL-0101 SR-0701 04 Quantity 01 No. 01 No. 05 Safety/ Relief Safety Relief Safety Relief 06 Vendor 07 Type Standard Standard 08 Full Nozzle Full Lift Mod. Nozzle Full Nozzle Full Lift Full Nozzle Full Lift 09 Bonnet Type Closed Closed 10 Conv./ Bellows/ Pllot Operated Conventional Conventional 600# 600# 11 Inlet Conn. : Size & Rating 12 Inlet Conn. : Facing & Finish(Note-5) Smooth Finish Smooth Finish 600# 600# Valve 13 Outlet Conn. : Size & Rating RF, RF, 14 Outlet Conn. : Facing & Finish(Note-5) 15 Cap Over Adj. Bolt : Required Required 16 Screwed Bolted Bolted Bolted 17 Lifting Gear - Type 18 Test Gag Required Required 19 Body and Bonnet ASTM A350 LF2/A352Gr.LCB ASTM A350 LF2/352Gr.LCB 20 Nozzle and Disc SS 316 SS 316 21 Spring SS 316 SS 316 Material 22 Bellows 23 24 25 Resilient Seat Seal Options 26 27 28 Code API 520 & 526 API 520 & 526 Basis 29 Basis of Selection Vessel Under Ext. Fire Vessel Under Ext. Fire 30 31 Fluid and State Natural Gas Vapour Natural Gas Vapour CO2 (0.18%)/ 2.0mm CO2 (0.18%)/ 2.0mm 32 Corrosive Constituent/ Corr. Allow. 33 Required Flow Capacity 34 Mol. Wgt. S.G. at Rel. Temp. 17.089 0.58 17.089 0.58 35 Oper. Pressure,bar(g) 50 42-50 36 Oper. Temp.°C Rel. Temp.°C 5.0-50 60 5 - 50 60 Service 37 Valve Discharges to Atm. Atm. Conditions 38 Back Press. Const. Or Variable Atm. Constant Atm. Constant 39 Set Pressure, bar(g) 95 95 40 Cold Bench Test Pressure 41 % Over Pressure % Blow Down 20 20 42 Cp/Cv Compressibility Factor 1.4213 0.917 1.4213 0.917 43 Viscosity at Rel. Temp. (cP) 0.0128 0.0128 Vess. : Wall Temp.°C Surf. Area-m2 593 593 44 45 2 Calculated Area-inch 46 Sel. Area-inch2 Orifice Design 47 48 No. of Valves Reqd. for capacity Total Area-inch2 Orifice 49 50 Actual Flow Capacity, SCFM 51 Relief Load 52 Model No. 53 Radiography Reqd. (100%) Reqd. (100%) 54 IBR Certification Not Required Not Required Notes: VENDOR TO SPECIFY/ CONFIRM 1 VENDOR SHALL FURNISH SIZING CALCULATIONS TO SUPPORT HIS VALVE SELECTION. 2 VALVES SHALL BE 100% RADIOGRAPHED 3 VENDOR TO CONSIDER COEFFICIENT OF DISCHARGE DERATED BY A FACTOR OF 0.9 AS PER ASME-VIII 4 FOR SAFETY VALVE SIZING, FURNISH CERTIFIED CAPACITIES AS PER API-520. 5 PSV's SHALL BE SUPPLIED WITH INLET & OUTLET COMPANION FLANGES. 6 VENDOR TO CONSIDER HYDRO-TEST PRESSURE 1.4 TIMES OF DESIGN PRESSURE

REV. NO.

DATE

3

ZONE

DESCRIPTIONS

BY

APPRD

REVISIONS

SECTION : OIL & GAS (LDP) NAME

DATE

REFERENCES

DRG. NO.

CLIENT : GUJARAT STATE PETRONET LIMITED CHKD

DATE

PROJECT : PADMALA-HALOL GAS PIPELINE PROJECT

MECON LIMITED

DSGN DRWN

APPROVED

PRESSURE SAFETY VALVES TAG NO. : 42-PSV 0101,0701

SCALE : DATA SHEET NO. : MEC/23JT/05/21/DS/PSV-001

This document and the design it covers are the property of MECON and issued for the specific project mentioned therein. This is not to be copies or used for other projects unless expressly permitted by MECON.

REV 1

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No.:MEC/23JT/05/E5/DS-PG

PRESSURE GAUGES Gas-Nm3/hr Steam- kg/hr Pressure-Bar Temperature- °C Level/Length-mm Direct 17 Type --Local 18 Wetted parts material --150 mm Element --White(Non rusting plastic Lower body --with black engraving) 4 Case material Cast aluminium 19 Non wetted parts --5 Bezel ring Screwed 20 Process connection --6 Window material Shatter proof glass Size --7 Enclosure IP 55 / NEMA 4 Rating --8 Pressure element Bourdon tube 21 Facing &Finish --9 Element material SS 316 22 Capillary material --10 Socket material SS 316 23 Capillary length --11 Accuracy 24 Flushing & Filling --± 1% FSD 12 Zero adjustment Micrometer pointer 25 Over range protection 130% of range (Internal) 26 Blow out protection Required 13 Connections ½” NPT (M) 27 Options Conn. Location Bottom a) Snubber 14 Movement SS 304 b) Syphon 15 Diaphragm seal --c) Gauge saver 16 d) Liquid filled casing e) Solid front Pressure Design Temp. Tag No. Range Operatin Fluid Service Options Design g Natural Gas 42-PI-0103 * 42 – 50 95 60 N.GAS Natural Gas 42-PI-0104 * 42 – 50 95 60 N.GAS Natural Gas 42-PI-0104A * 42 – 50 95 60 N.GAS C, Natural Gas 42-PI-0601 * 42 – 50 95 60 N.GAS Natural Gas 42-PI-0602 * 42 – 50 95 60 N.GAS Units:- Flow : Liquid-m3/hr 1 Type 2 Mounting 3 Dial size Colour

NOTES: 1) Offered Instruments shall be suitable for corrosive constituents CO2 – 1.5 % .

1

08.03.07

REV.

DATE

Data Sht No.:MEC/23JT/05/E5/DS-PG BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No.: MEC/23JT/05/E5/DS-PT

PRESSURE TRANSMITTERS Units:- Flow : Liquid-m /hr Gas-Nm3/hr Steam- kg/hr Pressure-Kg/cm2g Temperature- °C Level/Length-mm 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14

GENERAL Transmit & Indicate Electronic Smart µP Based Mfg. Std. Yoke Weather proof to IS2147 Enclosure Explosion proof to IS2148 Enclosure class NEMA 4 & NEMA 7 Elec. Area Class. Zone-I, Gr.IIA & IIB, T3 Intrinsically safe Required Air supply Power supply 24 VDC Cable entry ½” NPT(F) Accuracy + 0.075% of SPAN Repeatability + 0.05% TRANSMITTER Output 4 – 20 mA DC, Two wire Trans. Power supply 24 V DC CONTROLLER Function Type Case Mounting

15

Output

16 17

A/M switch No. of positions Set Point Adj.

18

Manual Regulator

19

Mode

Service Element Body Material Element Material

28

Process Connections

29

30 31

RECORDER 20 21 22 23

Chart Chart Drive Moving Parts Matl. Chart speed

Tag No. 42-PT-0101 42-PT-0102 42-PT-0501 42-PT-0502 42-PT-0603 42-PT-0604

MEASURING UNIT Pressure Diaphragm Carbon Steel 316 SS

24 25 26 27

32

½” NPT(F)

Process Conn. Locn. Diaphragm Seal:Type Wetted Parts Matl. Other Material Process Conn.:Size and Rating Facing and Finish Capillary Material:Armour Flexible Armour Flexible Matl. Capillary length, mm Flush / Filling Conn. with plug MISCALLANEOUS Over Range Protection 130% of Range Options Intrinsically safe Digital Output a) meter 2-way manifold - SS316 body & b) Trim Mounting accessories for 2” c) Pipe Mounting Make & Model No.

*

Range

Operating Pressure

Design Press.

Design Temp.

Span

Set

42-50 42-50 42-50 42-50 42-50 42-50

95 95 95 95 95 95

65 65 65 65 65 65

* * * * * *

0 – 100 0 – 100 0 – 100 0 – 100 0 -100 0 – 100

Service

Options

N.GAS N.GAS N.GAS N.GAS N.GAS N.GAS

a, b,c a, b,c a, b,c a, b,c a, b,c a, b,c

NOTES: 1) Offered instruments shall be suitable for corrosive constituents CO2 – 1.5% 2) ‘*’ – Information to be furnished by Contractor/ Vendor.

1

08.03.07

REV.

DATE

Data Sht No.: MEC/23JT/05/E5/DS-PT BY

CHKD

APPD

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

MECON LTD. DELHI

CLIENT : GUJARAT STATE PETRONET LIMITED(GSPL)

Data Sht. No. : MEC / 23JT/ 05 /E5/DS-TT

TEMPERATURE TRANSMITTERS UNITS :Flow : Liquid --> M3/Hr, Gas --> Nm3/Hr, Steam --> Kg/Hr, Pressure --> Kg/Cm2G, Temp --> °C, Level/Length > mm

TRANSMIT 1

INDICATE

11

POWER SUPPLY

24 V DC

12

CONDUIT CONN.

1/2" NP TF

13

LINEARISATION

UPSCALE

FUNCTION BLIND ELECTRONIC

2

TYPE

3

CASE

(SMART)

MFR STD.

DOWNSCALE DIRECT ON RTD/TC 4

YOKE

14

ACCURACY

+ / - 0.1% FSD

EX. PROOF

15

RFI / EMI

REQD.

MOUNTING OTHER W. PROOF

5

ENCLOSURE CLASS : IP - 65

PROTECTION

INTRINISICALLY SAFE

6

AREA CLASSIFICATION

7

INPUT

8

OUTPUT

9

10

16

LOAD

6000 OH MS AT

DRIVING CAABILITY

24 V DC

17

MAKE

*

FROM RTD

18

MODEL NO.

*

4-20 mA

19

OPTIONS

a)

Output Meter

b)

Mounting

NEC, CLASS-1, DIVL.-2, GROUP C&D

COLD JUNCTION COMPENSATION

Accessories For 2" Pipe

BURN OUT PROTECTION TAG NO.

WP/EX PROOF/INTR SAFE

c) RANGE SPAN * * * * *

SS Tag Plate SERVICE

SET 0 - 100 0 - 100 0 - 100 0 - 100 0 - 100

OPTION

Natural Gas 42-TT 0101 a, b, c Natural Gas 42-TT 0501 a, b, c Natural Gas 42-TT 0502 a, b, c Natural Gas 42-TT 0601 a, b, c Natural Gas 42-TT 0602 a, b, c NOTES: 1 *CONTRACTOR / VENDOR TO FILLUP THE DATA SHEET BASED ON PROCESS DATA & P&ID AND SUBMIT FOR APPROVAL. 2 THE DIGITAL OUTPUT METER SHOULD INDICATE THE TEMPERATURE IN DEG. C. 3 ENVIRONMENTAL COVER TO BE PROVIDED FOR EACH TRANSMITTER (DRAWING ENCLOSED ELSEWHERE IN BID DOCUMENT). 1

08.03.07

REV

DATE

Data Sht. No. : MEC / 23JT/ 05 /E5/DS-TT BY

CHKD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No: MEC/23JT/05/E5/DS-RTD

RESISTANCE TEMPERATURE DETECTOR Units:- Flow : Liquid-m3/hr Gas-Nm3/hr Steam- kg/hr Pressure-Kg/cm2g Temperature- °C Level/Length-mm GENERAL 13 Cable entry ½” NPT (F) 1 Assembly as per Drg. enclosed 14 No. of entries Single drg. 15 Enclosure type Weather proof to IP55 ELEMENT THERMOWELL 3 No. of elements Simplex 16 Material SS 316 4 Calibration As per DIN 43760 17 Construction Drilled bar stock 5 Element material Platinum (Pt 100) 18 Process connection 1 ½” Flanged 6 Resistance at 0°C 100 ohms 19 Inst. connection ½” NPT (F) 7 Leads Standard 20 Thermowell as per D No. MEC/23JT/05/E5/003 drawings enclosed D No. MEC/23JT/05/E5/007 8 Sheath O.D. 8 mm Material SS 316 21 Make & Model No. * 9 Nipple & Union mtl. SS 316 10 No. Of wires 4 Wire HEAD 11 Head Cover type Screwed cap & SS chain 12 Material Cast Aluminium

Temperature Tag No.

Rang e

Nor

42-TE – 0101 42-TE – 0501 42-TE – 0502

0-100 0-100

5 - 50 5 - 50

Desi gn 65 65

0-100

5 - 50

42-TE – 0601 42- TE – 0602

0-100 0-100

5 - 50 5 - 50

Well Dimensio ns U T

Flange Service Material

Rating/Face/ Finish

380 380

* *

ASTM A 105 ASTM A 105

600# RF 125 AARH 600# RF 125 AARH

N.GAS N.GAS

65

380

*

ASTM A 105

600# RF 125 AARH

N.GAS

65 65

380 380

* *

ASTM A 105 ASTM A 105

600# RF 125 AARH 600# RF 125 AARH

N.GAS N.GAS

Option

NOTES: ‘*’: Information to be supplied by Contractor. 1) Offered Instruments shall be suitable for corrosive constituents CO2 – 1.5 %.

1

08.03.07

REV.

DATE

Data Sht No: MEC/23JT/05/E5/DS-RTD BY

CHKD

APPD

PROJECT : PADMALA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL) MECON LTD. DELHI

CLIENT : GUJARAT STATE PETRONET LIMITED(GSPL)

Data Sht No : MEC / 23JT/ 05 /E5/DS-DPS

DIFFERENTIAL PRESSURE SWITCH 3

3

UNITS : Flow --> Liquid M /Hr Gas --> M /Hr Steam --> Kg/Hr Pressure --> Kg/Cm2G Temp --> °C Level / Length -->MM 1

TYPE

BLIND/PRESSURE/DIRECT

2

MOUNTING

3

DIAL

-

14

ELEMENT TYPE

a. SIZE

-

15

ELEMENT MATERIAL

-

16

PROCESS CONN.

17

DIAPHRAGM SEAL

YOKE

b. COLOUR 4

CASE MATERIAL

5

WINDOW MATERIAL

6

AREA CLASSIFICATION

7

INTRINICALLY SAFE

8

ENCLOSURE

*

1/2" NPT (F)

DIE. CAST ALUMINIUM WITH EPOXY PAINT AS PER ELECTRICAL AREA CLASSIFICATION

TYPE

-

WETTED PARTS MATERIAL OTHER MATERIAL

AS PER ELECTRICAL AREA CLASSIFICATION

a. TYPE b. CLASS

PROCESS CONNECTION

IS-2147, NEMA-4 AS MIN.

FACING AND FINISH SIZE

9

SS-316

OUTPUT

RATING

ARMOUR FLEABLE

a. ELECTRICAL CONTACTS

YES

b. QTY. c. FORMS

ARMOUR MATERIAL

TWO

CAPILLARY MATERIAL

DPDT

CAPILLARY LENGTH

MICRO SWITCH, SNAP ACTION HERMATICALLY

d. TYPE e. CONTACT PLATING

GOLD PLATED

18

OVER RANGE PROTECTION

19

BLOW OUT PROTECTION

f. RATING VOLT, AMP

24 VDC, 1A

20

MOUNTING ACCESSORIES

g. LOAD TYPE

INDUCTIVE

21

OPTIONS

h. CABLE ENTRY

1/2" NPT (F)

i. NO. OF ENTRIES

NOTE - 1 REQD.

a. SNUBBER

DUAL

b. GAUGE SAVER c. AIR FILTER REGULATOR

INTERNAL WITH INDICATED SCALE

10

SET PT. ADJ.

11

DIFF.

12

ACCURACY

± 1% OF SET POINT

13

REPEATABILITY

± 1% OF SET POINT

SL. NO.

TAG NO.

d. VACCUM PROTECTION

MIN. (FIXED)

RANGE

SET POINT

PRESSURE OPER.

PRESSURE MAX.

TEMP. OPER.

TEMP MAX.

SERVICE

1

42 - DPSH 0101

*

3.0

50.0

95.0

5 To 50

- 20 To 60

42 - GOV - 0101

2

42 - DPSH 0501

*

3.0

50.0

95.0

5 To 50

- 20 To 60

42 - GOV - 0501

3

42 - DPSH 0601

*

3.0

50.0

95.0

5 To 50

- 20 To 60

42 - GOV - 0601

1

08.03.07

REV

DATE

BY

CHKD

NOTES: 1 2 3

130% OF RANGE OF MAX. PROCESS WHICHEVER IS GREATER SET POINT SHOULD BE ADJUTABLE THROUGHT THE RANGE. (*) BY VENDOR

Data Sht. No. : MEC / 23JT/ 05 /E5/ DS-DPS

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

GAS DETECTION SYSTEM Design And Construction 1. The System Shall comprise of the following: a. Field Mounted Gas Detectors. b. Monitors/ Controllers for Gas Detectors. c. Portable Purge Calibrator(s) for the Gas Detection System d. Portable Gas Detectors. e. Gas Detection Panel housing the monitors, alarm annunciator, switches and relays, etc. for carrying out necessary monitoring and shutdown functions. 2. Gas Detection System shall be designed based on “fail safe” philosophy 3. The design of electronic instruments shall be in compliance with the electromagnetic compatibility requirement as “ IEC – 801” . 4. Constructions and performance of gas detection system shall be in general as per BS – EN – 50054 and BS – EN – 50057 standards. 5. Both open path and point gas detectors shall be provided for each station Open path gas detectors of Infrared Absorption type shall be suitable for specified hazardous area and shall be installed in the most adequate location . Point gas detectors shall be provided in metering/filtration/letdown skids. 6. The low and high gas concentrations and a failure/default state shall be detected and signalized by the Control Unit. 7. Analog signals ( i.e. LEL indication ) and High Alarm from each gas detectors shall be required at SCADA. For that necessary provision shall be made available at Gas Detection Panel. 8. Hooter / Flasher for LEL High Alarms shall be provided in Local Gas Detection Panel and also in outdoor remote position.

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 1 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Gas Sensor( Open Path & Point Gas Detector) TYPE

:

Infrared Absorption type (Both Open Path and Point type)

CONSTRUCTION

:

Explosion proof, SS 316 body with stainless steel flame arrestors, dust cover, Weather Proof as per NEMA 4X or IP 65 (NOTE-1). Sensor element shall be replaceable type / plug in type. Terminal box shall be provided for further cabling. Flying leads are not acceptable. Cable entry shall be ¾” NPT (F) (NOTE-2).

ELECTRICAL : AREA CLASSIFICATION

Zone –1, Gr. II A & II B, T3

POWER SUPPLY

:

From Monitor / Control Unit.( Panel)

OPERATING VOLTAGE

:

24 V DC

RANGE

:

0 –100 % LEL (Low Explosive Limit)

ACCURACY

:

± 3 % of gas reading @ ≤50% LEL, ± 5 % of gas reading @ > 50% to 100% LEL

REPEATABILITY

:

Better than +/- 3% of Full Scale.

RESPONSE TIME

:

< 5 Sec

MOUNTING ACCESSORIES

:

Vendor to indicate.

NOTE 1: Splash guard & weatherproof cap for protection against dust and rain shall be provided. NOTE 2: The junction box shall be weatherproof to IP 55 and certified to Explosion proof.

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 2 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Gas Monitor / Controller : TYPE

:

Solid state electronic , panel mounted plug in modular construction

NO. OF CHANNELS :

Maximum 16 sensors with common indicating meter. However, single loop integrity shall be maintained by individual monitoring card per sensor.

POWER SUPPLY

24V DC ,

:

RANGE AND : METER CALIBRATION ANALOG OUTPUT : ALARM OUTPUT :

Adjustable between 0-100 % LEL 4 – 20 mA DC. Adjustable Low and High Alarms(DPDT potential free relay contacts)

INDICATOR LIGHTS : Power On (by a confidence flash for every 2 seconds). (Separate for each channel) - 20 % LEL – Alarm level High - 40 % LEL – Alarm level Very High. -Malfunction (Malfunction shall include short circuit., line breaking, over range and earth fault. ) OTHER FEATURES :

a) Dual adjustable setpoints for gas level alarm. b) DPDT latching type relay contacts shall be provided for following: i) 20 % LEL (each channel) -Alarm High (adjustable) ii) 40 % LEL (each channel ) -Alarm Very High (adjustable) iii) Malfunction (common) c) Relay contacts shall be suitably rated for the specified power requirements. d) Reset push button ( common ) e) Sensor calibration without alarm outputs shall be achieved by inhibit switch on relevant channel(Calibration /Test Switch)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 3 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Portable Calibrator (Calibration Kit) One Portable Purge Calibrators consisting of a Volume Bottle containing a known gas/air mixture, a Pressure Regulator with gauge, a Flexible Hose and Adaptor Cap (to fit the sensor head) shall be supplied at each station to enable calibration of the sensors in the field without dismantling them. Calibration range of all sensors will be 0-100% LEL for Hydrocarbon. Sufficient quantity of calibration gas shall be supplied to enable calibration of all sensing heads atleast for six months. Calibration gas cylinder/bottle shall have validity of 1 year. Portable Gas Detector (Portable Methanometer) 2 Nos. hand-held , Portable Gas Detector shall be supplied. These gas detectors / analysers shall be capable of measuring methane from 0% to 100% by volume, 0% to 100% LEL and 0% to 100% by volume oxygen as well. Portable Gas Detectors shall be supplied complete with its controller, audio visual alarm and shall be suitable (preferably intrinsically safe) for use in hazardous area specified. Such units shall be certified by BASEEFA, CENRLEC, FM, PTB, CMRI etc. These units shall be supplied with rechargeable batteries and 240V, 50 Hz ac battery,. Sufficient number of battery charger/nimber of points per charge shall be provided based on quantity of such portable units. These units shall be supplied complete with all accessories like carrying case, maintenance kit, calibration kit etc. Gas Detection Panel The Panel shall be designed to house the following instruments accessories: i. ii. iii. iv. v.

Monitors / Conrollers. Alarm Annunciator. Relays / Logic Cards for shutdown / protection system. Push buttons / Switches as required ( including Lamp Test Push Buttons). Any other items which are not listed above but essential to make the system operational and meet the requirements as specified.

The panel shall be provided with 5% installed spares ( minimum one number) for items like monitors/ controllers, relays / logic cards etc. Alarm Annunciator shall have installed 20% spare points. Panel shall have spare space (10%) for future expansion.

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 4 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Panel Construction 1.

Type

:

Self-supported, Free Standing, enclosed cubicle and Nongraphic.

2.

Lighting

:

Required for inside panel with door switch.

3.

Ventilation

:

Required with louvers backed by wirefly screen & fan. Fan Failure alarm required

4.

Doors

:

Rear Double removable hinged doors with flush pull type handles & with locking arrangement.

5.

Door width

:

Shall suit the width of panel. The Panel width is indicative only. The sizes shall be sufficient to accommodate the required hardware specified in MR. However the depth and height shall be 800 & 1800 respectively.

6.

Cable Entry

:

Bottom, Cable Glands shall be double compression type for external armoured cables. All unused entries shall be plugged.

7.

Receptacles

:

Required for 230VAC UPS / NON UPS

8.

Painting

:

The finish shall include sand blasting, grinding, chemical cleaning, surface finishing by suitable filter and two coats of high grade lacquer with wet sanding between coats.. Two coats of paint in panel colour shall be given for Non-glossy high stain finish. Panel face final colour shall be of the following: a) Siemens Grey (RAL 7032) Powder coating b) Panel internal shall have a finish color of Brilliant White/Siemens Grey(RAL 7032) c) Channel Base shall have a finish color of black

9.

Name Plates

:

Front of Panel Instrument name plates shall be black laminated plastic with white core. Nameplate shall be provided on the rear of the panel also.

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 5 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Dimensions & Material Of Construction

1.

Panel dimension

:

800(W) mm x 1800(H) mm x 800(D) mm (Including channel base of 100 mm height).

2.

Front Plate

:

3.2 mm thick CRCA steel/5.0 mm thick HRCA steel, Welded to frame

3.

Side & Top plates

:

2 mm thick CRCA steel, Welded to frame

4.

Door panel

:

1.6-mm thick CRCA steel. Double side hinged, concealed hinges and flush pull chrome-plated handles.

5.

Cable gland plate

:

3 mm thick CRCA steel

6.

Anchor Bolt Size

:

By Vendor

7.

Channel Base

:

100X50X6 MM, MS material

8.

Lifting Eye Bolt

:

Required (4 Nos.)

Note : Panel shall be electrically isolated from base channel

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 6 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Wiring 1. Type

Data Sht No. : MEC/23JT/05/E5/DS-LEL

:

General purpose, Intrinsically safe

230 VAC UPS Wiring External to Cabinet

:

Inside the cabinet

:

240 VAC Wiring (Non UPS) Low Voltage internal

: :

Min. 3x2.5 mm²/copper conductor PVC insulated armoured Min. 19 Strands, 16 AWG copper conductor PVC insulated 3x2.5mm² copper conductor PVC insulated armoured Min. 19 Strands, 16 AWG copper conductor PVC insulated to cabinet

2. Wiring details

3. Signal Wiring 3.1 External to Cabinet

:

1.0 mm² twin twisted individual shielded overall s shielded with overall drain PVC insulated armoured

3.2 Inside the cabinet

:

Multi stranded min. 0.5mm² copper conductor PVC insulated twin twisted and shielded.

4. Terminal type 4.1 Terminal size for signal 4.2 Terminal size for power dist.

: : :

4.3 5. 5.1 5.2 5.3 5.4 5.5 5.6

: : : : : : :

Screw clamp type with Pressure Plate Suitable for min. 2.5 mm² size conductor Suitable for min. 4.0 mm² size conductor and higher as per actual cable sizes. Clip-on type

Terminal block Wiring colour code Power Supply DC Wiring Alarm System Control & shutdown Analog signals (IS) Identification of Cable Termination

:

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Hot – Red, Neutral - Black, Earth – Green Positive – Red, Negative – Black White Yellow Light blue Criss – Crossing PVC tube Ferruling.

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 7 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Specifications For Accessories 1. MCB Make Qty. 2.

3.

4.

Lamps Type Voltage Make / Model No. Quantity

: LED Type : 24 VDC : By Vendor : As reqd.

Push Buttons Type Contacts Contact rating Make Color Quantity

: Spring return : 2 No. + 2 NC : 2A 24V DC : ESBEE / SIEMENS/ TEKNIC : As per standard : As reqd.

Selector switch Type Specification

5.

6.

: SIEMENS/ L&T/ MDS. : As required.

Rating Make Quantity Relays Type Contact Type Contact No. Rating Make / Model No. Quantity Space Heater Rating Make

Data Sht No. : MEC/23JT/05/E5/DS-LEL

: As per functional switches( 3 Position, 4 Pole) : Silver alloy gold plated contacts To military specification with SS shaft dust covers with water Proof covering and contact shall Be made before break type : 10A 230V 50Hz / 2A 24V DC : KAYCEE/ SIEMENS/TEKNIC : As reqd. : Plug in relays : Potential free contact : 3 NO. + 3 NC : 24V DC, 5.0 A : OEN/ OMRON : As reqd. : 60 W, 230 V AC with Thermostat. : KEC

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 8 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-LEL

Alarm Annunciator Alarm annunciator shall be provided at top of panel to display group alarms, shutdown alarms etc. Alarm annunciator shall be solid state electronic type provided with single input type logic module and solid state audio alarm unit. It shall be provided with first out type sequence (ISA F3A) with function test, acknowledge and reset push buttons. Each window shall be of 75 mm X 50 mm size and provided with two lamps. Lamps shall be removable from panel front.

Quantity Of LEL Gas Detectors DESPATCH TERMINAL 1) FLAMMABLE GAS DETECTORS. 2) EXPLOSION GAS DETECTORS. 3) WEATHERPROOOF CAP QUANTITY 2 Nos. Open Path type & 2 Nos. Point type. Calibration Kit : 1 set. SV TERMINAL 1) FLAMMABLE GAS DETECTORS. 2) EXPLOSION GAS DETECTORS. 3) WEATHERPROOOF CAP QUANTITY 2 Nos. Open Path type & 2 Nos. Point type. Calibration Kit : 1 set. RECEIVING TERMINAL 1) FLAMMABLE GAS DETECTORS. 2) EXPLOSION GAS DETECTORS. 3) WEATHERPROOOF CAP QUANTITY 6 Nos. Open Path type & 6 Nos. Point type. Calibration Kit : 1 set. SPARE QUANTITY 2 Nos. Open Path type & 2 Nos. Point type.

Data Sht No. : MEC/23JT/05/E5/DS-LEL

1

08.03.07

REV.

DATE

BY

CHKD APPD Page 9 of 9

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-CP

SPECIFICATIONS FOR CONTROL PANEL & ACCESSORIES

GENERAL Site of Installation

1. Plant and Location

: Despatch Terminal (SOKHADA), SV1 (SAVALI) & Receiving Terminal.(HALOL)

2. Owner

: GSPL

3. Consultant

: MECON LIMITED.

4. Location of control panel and accessories

: Indoor

5. Floor

: Concrete.

6. Air conditioning

: Yes.

7. Control Panels Quantity

: 3 Nos.

Data Sht No. : MEC/23JT/05/E5/DS-CP

1

08.03.07

REV.

DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-CP

CONTROL PANEL CONSTRUCTION 1.

Type

:

Self-supported, Free Standing, enclosed cubicle and Nongraphic.

2.

Lighting

:

Required for inside panel with door switch.

3.

Ventilation

:

Required with louvers backed by wirefly screen & fan. Fan Failure alarm required

4.

Doors

:

Rear Double removable hinged doors with flush pull type handles & with locking arrangement.

5.

Door width

:

Each max. of 600mm and shall suit width of the panel. Panel width is indicative only. The sizes shall be sufficient to accommodate the required hardware specified in MR. However the depth and height shall be 800 & 2100 respectively.

6.

Cable Entry

:

Bottom, Cable Glands shall be double compression type for external armoured cables. All unused entries shall be plugged.

7.

Receptacles

:

Required for 230VAC UPS / NON UPS

8.

Painting

:

The finish shall include sand blasting, grinding, chemical cleaning, surface finishing by suitable filter and two coats of high grade lacquer with wet sanding between coats.. Two coats of paint in panel colour shall be given for Non-glossy high stain finish. Panel face final colour shall be of the following: a) Siemens Grey (RAL 7032) Powder coating b) Panel internal shall have a finish color of Brilliant White/Siemens Grey(RAL 7032) c) Channel Base shall have a finish color of Black

9.

Name Plates

:

Front of Panel Instrument name plates shall be black laminated plastic with white core. Nameplate shall be provided on the rear of the panel also.

Data Sht No. : MEC/23JT/05/E5/DS-CP

1

08.03.07

REV.

DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-CP

DIMENSIONS & MATERIAL OF CONSTRUCTION

1.

Panel dimension

:

1200(W) mm x 2200(H) mm x 800(D) mm (Including channel base of 100 mm height).

2.

Front Plate

:

3.2 mm thick CRCA steel/5.0 mm thick HRCA steel, Welded to frame

3.

Side & Top plates

:

2 mm thick CRCA steel, Welded to frame

4.

Door panel

:

1.6-mm thick CRCA steel. Double side hinged. Concealed Hinges and Flush pull chrome-plated handles.

5.

Cable gland plate

:

3 mm thick CRCA steel

6.

Anchor Bolt Size

:

By vendor

7.

Channel Base

:

100X50X6 MM, MS material

8.

Frame base

:

50mm×50mm×6mm MS material

9.

Lifting Eye Bolt

:

Required (4 Nos.)

10.

Anti Vibration Pad

:

Required (15mm thick rubber pad).

Note : Panel shall be electrically isolated from base frame.

Data Sht No. : MEC/23JT/05/E5/DS-CP

1

08.03.07

REV.

DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

WIRING 1. Type

Data Sht No. : MEC/23JT/05/E5/DS-CP

:

General purpose, Intrinsically safe

230 VAC UPS Wiring External to Cabinet

:

Inside the cabinet

:

240 VAC Wiring (Non UPS) Low Voltage internal

: :

Min. 3x2.5 mm²/copper conductor PVC insulated armoured Min. 19 Strands, 16 AWG copper conductor PVC insulated 3x2.5mm² copper conductor PVC insulated armoured Min. 19 Strands, 16 AWG copper conductor PVC insulated to cabinet

2. Wiring details

3. Signal Wiring 3.1 External to Cabinet

:

1.0 mm² twin twisted individual shielded overall s shielded with overall drain PVC insulated armoured

3.2 Inside the cabinet

:

Multi stranded min. 0.5mm² copper conductor PVC insulated twin twisted and shielded.

4. Terminal type 4.1 Terminal size for signal 4.2 Terminal size for power dist.

: : :

4.3 5. 5.1 5.2 5.3 5.4 5.5 5.6

: : : : : : :

Screw clamp type with Pressure Plate Suitable for min. 2.5 mm² size conductor Suitable for min. 4.0 mm² size conductor and higher as per actual cable sizes. Clip-on type

Terminal block Wiring colour code Power Supply DC Wiring Alarm System Control & shutdown Analog signals (IS) Identification of Cable Termination

:

Hot – Red, Neutral - Black, Earth – Green Positive – Red, Negative – Black White Yellow Light blue Criss – Crossing PVC tube ferruling.

BULK POWER SUPPLY UNIT 1.

Input

: 230 VAC, 50 Hz.(UPS)

2.

Output

: 24 VDC

3.

Rating

: 1 KW Min. (25% spare capacity)

4.

Quantity

: 2 Nos. for each Panel (Dual Redundant)

Data Sht No. : MEC/23JT/05/E5/DS-CP

1

08.03.07

REV.

DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. : MEC/23JT/05/E5/DS-CP

SPECIFICATIONS FOR ACCESSORIES 1.

2.

3.

4.

MCB Make Qty.

: SIEMENS/ L&T/ MDS. : As required.

Lamps Type Voltage Make / Model No. Quantity

: LED Type : 24 VDC : By Vendor : As reqd.

Push Buttons Type Contacts Contact rating Make Color Quantity

: Spring return : 2 No. + 2 NC : 2A 24V DC : ESBEE / SIEMENS/ TEKNIC : As per standard : As reqd.

Selector switch Type

Rating Make Quantity

: As per functional switches( 3 Position, 4 Pole) : Silver alloy gold plated contacts To military specification with SS shaft dust covers with water Proof covering and contact shall Be made before break type : 10A 230V 50Hz / 2A 24V DC : KAYCEE/ SIEMENS/TEKNIC : As reqd.

Relays Type Contact Type Contact No. Rating Make / Model No. Quantity

: Plug in relays : Potential free contact : 3 NO. + 3 NC : 24V DC, 5.0 A : OEN/ OMRON : As reqd.

Space Heater Rating Make

: 60 W, 230 V AC with Thermostat. : KEC

Specification

5.

6.

Data Sht No. : MEC/23JT/05/E5/DS-CP

1

08.03.07

REV.

DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht.No.: MEC/23JT/05/E5/DS-IND

INDICATOR SL .NO

DESCRIPTION

1.0

Type

2.0 3.0 4.0

Mounting Enclosure To be used in intrinsically safe system Power for transmitters Inputs Outputs Capacity

5.0 6.0 7.0 8.0

9.0

Facia Details

9.1

Indications

10.0 11.0 12.0 13.0 14.0 15.0 16.0

Scan time A/D converter Resolution D/A converter Resolution Load driving capability Configuration On line diagnostic messages Memory type

17.0

Indicator functions Arithmatic functions

Linearisation

18.0 19.0 20.0 21.0 22.0

Power supply Accuracy Repeatability Qty. & Tag No. Make & Model

•

TECHNICAL

REQUIREMENTS

TO BE CONFIRMED BY VENDOR

Microprocessor based Dual Channel Indicating Flush Panel General Purpose With Extl. Zener Barrier/Isolator 24V DC (From Bulk Power Supply/SDC) 4-20mA DC (2 wire) 4-20mA DC No. of Analog inputs Other inputs Other outputs – Retransmission Max. No. of Alarms settings B.ar graph display with 4 digit 7 segment LCD/LED digital display of PV. Continuos Bargraph Digital Required for Process variable 500 msec. Max 1500 steps min. 1500 steps min. 750 ohms From Indicator Required If retentive:Erasive Erasing by If volatile:Battery backup for min. 72 hrs. Battery type chargeable Continuous. Battery type chargeable Configuration protection time (In case of power failure) Battery drain indication required.

* *

Addition / Subtraction Multiplication Division Square Root Bias Summation (Integration) Sq. Root Extraction Flow computation (Press and Temp. compensation) 24 V DC +/- 0.5% + / - 0.5 % As per the P& ID and attached sheet. *

- By contractor / vendor 1

08.03.2007

REV.

DATE

Data Sht.No.: MEC/23JT/05/E5/DS-IND BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht.No.: MEC/23JT/05/E5/DS-IND

Sl No.

Tag No.

Range

1

42-PI -0101

0 – 100 KG / CM2

2

42-PI – 0102

0 – 100 KG / CM2

3

42-TI – 0101

0 – 100 ° C

4

42-PI – 0501

0 – 100 KG / CM2

5

42-PI – 0502

0 – 100 KG / CM2

6

42-TI - 0501

0 – 100 ° C

7

42-TI - 0502

0 – 100 ° C

8

42-PI – 0603

0 – 100 KG / CM2

9

42-PI – 0604

0 – 100 KG / CM2

10

42-TI – 0601

0 – 100 ° C

11

42-TI - 0602

0 – 100 ° C

1

08.03.2007

REV.

DATE

Data Sht.No.: MEC/23JT/05/E5/DS-IND BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No: MEC/23JT/05/E5/DS-SDC

SIGNAL DISTRIBUTION CARDS SL.NO.

DESCRIPTION

DETAILS

1.

TYPE

DUAL OUTPUT CURRENT ISOLATOR

2.

INPUT

4-20 mA D.C

3.

OUTPUT

TWO NOS. 4-20 mA ISOLATED OUTPUTS AS MINIMUM

4.

ISOLATION

BETWEEN INPUT & OUTPUT, BETWEEN INPUT & OUTPUT WITH POWER SUPPLY, BETWEEN OUTPUT & OUTPUT

5.

ACCURACY

± 0.1%

6.

POWER SUPPLY

24 V DC

7.

TRANSMITTER POWER SUPPLY

24 V DC

8.

OUTPUT LOAD DRIVING CAPACITY

750 Ohms MINIMUM FOR EACH OUTPUT

9.

MOUNTING

DIN RAIL (BACK OF THE PANEL)

10.

MAKE

MTL/P&F

11.

MODEL NO

By Vendor

12.

QUANTITY

As Reqd.

Data Sht No: MEC/23JT/05/E5/DS-SDC

1

08.03.07

REV.

DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. - MEC/23JT/05/E5/DS-ZB-01

ZENER BARRIERS SL. NO.

DESCRIPTION

DETAILS

1.

TYPE

SHUNT DIODE SAFETY BARRIER

2.

APPLICATION INSTRUMENT TYPE & QUANTITY

(i) 4-20 mA Analog I/P from 2 wire transmitter–

3.

HAZARDOUS AREA CLASSIFICATION

ZONE-I, GR. I, IIA & IIB, T3

4.

APPROVAL AUTHORITY

FM/BASEEFA/CSA/SA/CMRS

5.

SUPPLY VOLTAGE

24 V DC

6.

FUSE RATING

*

7.

END TO END RESISTANCE

*

8.

POLARITY

*

9.

MOUNTING

DIN RAIL (BACK OF THE PANEL)

10.

OPERATING TEMP

-20° C TO 60° C

11.

OPEN CIRCUIT VOLTAGE

*

12.

SHORT CIRCUIT CURRENT

*

14.

MAKE

MTL/P&F

15.

MODEL NO

*

16

Qty.

As Reqd.

(ii) 4-20 mA Analog O/P to I/P Converter – .

NOTE:- * --By Vendor

1

08.03.07

REV.

DATE

Data Sht No. - MEC/23JT/05/E5/DS-ZB-01 BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. - MEC/23JT/05/E5/DS-ZB-02

ZENER BARRIERS SL.NO.

DESCRIPTION

DETAILS

1.

TYPE

SHUNT DIODE SAFETY BARRIER

2.

APPLICATION INSTRUMENT TYPE & QUANTITY

RTD (4-WIRE) –

3.

HAZARDOUS AREA CLASSIFICATION

ZONE-I, GR. I, IIA & IIB, T3

4.

APPROVAL AUTHORITY

FM/BASEEFA/CSA/SA/CMRS

5.

SUPPLY VOLTAGE

6.

FUSE RATING

*

7.

END TO END RESISTANCE

*

8.

POLARITY

*

9.

MOUNTING

DIN RAIL (BACK OF THE PANEL)

10.

OPERATING TEMP

-20° C TO 60° C

11.

OPEN CIRCUIT VOLTAGE

*

12.

SHORT CIRCUIT CURRENT

*

14.

MAKE

MTL/P&F

15.

MODEL NO

*

16

Qty.

As Reqd.

NOTES:- * --By Vendor

1 Data Sht No. - MEC/23JT/05/E5/DS-ZB-02

REV .

08.03.07 DATE

BY

CHKD

APPD

MECON LIMITED DELHI

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

CLIENT: GUJARAT STATE PETRONET LIMITED (GSPL)

Data Sht No. - MEC/23JT/05/E5/DS-ZB-03

ZENER BARRIERS SL.NO.

DESCRIPTION

DETAILS

1.

TYPE

SHUNT DIODE SAFETY BARRIER

2.

APPLICATION INSTRUMENT TYPE & QUANTITY

(i)

Limit switches (SPDT snap action Micro type) –

(ii)

R/L status of AV-valves -

(iii)

Push buttons for AV-Valves –

(iv)

Pig Signaller –

(v)

Spares –

3.

HAZARDOUS AREA CLASSIFICATION

ZONE-I, GR. I, IIA & IIB, T3

4.

APPROVAL AUTHORITY

FM/BASEEFA/CSA/SA/CMRS

5.

SUPPLY VOLTAGE

24 V DC

6.

FUSE RATING

*

7.

END TO END RESISTANCE

*

8.

POLARITY

*

9.

MOUNTING

DIN RAIL (BACK OF THE PANEL)

10.

OPERATING TEMP

-20° C TO 60° C

11.

OPEN CIRCUIT VOLTAGE

*

12.

SHORT CIRCUIT CURRENT

*

14.

MAKE

MTL/P&F

15.

MODEL NO

*

Qty.

As Reqd

NOTE:- * --By Vendor

1 Data Sht No. - MEC/23JT/05/E5/DS-ZB-03

REV .

08.03.07 DATE

BY

CHKD

APPD

PROJECT: PADAMLA-GODHARA (HALOL) NATURAL GAS PIPELINE (PGPL)

MECON LTD. DELHI

CLIENT : GUJARAT STATE PETRONET LIMITED(GSPL)

Data Sht. No.: MEC/23JT/05/E5/DS-ANN

ALARM ANNUNCIATOR GENERAL

DISPLAY

1 TYPE

Audio & Visual

12 Type

Back Lighted

Bull's Eye

2 Mounting

Panel Mounting

13 Alarm per Window

One ( X )

Two

3 Enclosure

Gen Purpose

14 Lamps Per Alarm

One

Two ( X )

4

Intrinsically Safe

15 Window Size

As per P& Id.

5

Area Safe Classification

16 Inscription

Lines / Window Character / Line

6 Cabinet Style Side Swing Door OPTIONS 7 Volatage

24V DC, Pot. Free

17 Hooter

POWER SUPPLY UNIT 8 Location

With Logic / Separate

9 Enclosure

General Purpose

Explosion Proof

Gen Purpose ( X )

Intrinsically Safe Integral

Weather Proof Separate

Pneumatic

Solid State

Industrial Tone adj( X ) Volume Adj ( X ) Solenoid Valve for Hooter

10 Power Supply 24V DC

18

Push Buttons per Cabinet Test ( X )

Acknowledge ( X )

Reset ( X )

Integral / Remote

LOGIC UNIT 11 Logic

Integral ( X ) Remote

19 No. of Hooters One Notes 1 . No. of Windows to be Decided by Vendor From P&ID and Control Panel Specifications. 10% Spare window shall be provided fully wired upto Terminal Block in CP. 2.Refer General Specifications / Write up for Details 3. Vendor to Submit the List of Alarms in the Filled in the data Sheet for Review / Approval.

Data Sht. No.:MEC/23JT/05/E5/DS-ANN

1

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REV

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BY

CHKD

APPENDIX-III QAP FOR MECHANICAL ITEMS ETC.

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

LIST OF QAP FOR MECHANICAL ITEMS 1.

SCRAPPER TRAP

2.

BALL VALVES

3.

FLANGE & FITTING

4.

REDUCER

5.

GLOBE VALVES

6.

CHECK VALVES

7.

ASSORTED PIPE

8.

FLOW TEE

9.

INSULATING JOINT

10.

SPECTACLE BLIND

11.

PRESSURE SAFETY VALVE

12.

LINE PIPE

D:\old data\Vijyant\GSPL\Tender\Const\Vol IB of V\list of qap IB of V.doc

MECON LIMITED

Page 1 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

CLIENT :

MECON Ltd.

M/s GUJARAT STATE PETRONET LIMITED

PO NO : CLIENT TECH SPEC NO. : Manufacturing specification : API 5L 43RD Edition, 2004 & MECON Spec. No.: MEC/TS/D5/21/012D Rev-0

QAP NO :

05/28/23JT/M-001

SIZE OD (MM)

WALL THICK.(MM)

SPECIFICATION

GR

323.9

6.4

API 5L

X-65 (PSL-2)

323.9

7.1

API 5L

X-65 (PSL-2)

323.9

8.7

API 5L

X-65 (PSL-2)

219.1

7.1

API 5L

X-65 (PSL-2)

Approved By Prepared By

Reviewed and Approved by

Page 2 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

1 1

DESCRIPTION

CHARACTERISTICS/ TYPES OF CHECK

2 3 RAW MATERIAL i) Chem. Analysis (Fully filled Cast, Grain ASTM 7 or fine) ii) Carbon Eqivalent (CE)

SIZE

SIZE: SPEC.

:-

REFERENCE STANDERED/SPEC.

TESTING FREQUENCY

4 Customer Tech. Spec.Cl 6.1.1

5 1 sample / heat

Customer Tech. Spec. and

1 sample / heat

API 5L Cl. 6.1.3

2

Mill Control

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

6 As per attached 'Annexure A' & Client Specification

CEL (PCM) < 0.2 CE(IIW) _< 4.0

SCOPE OF INSPECTION

FORMAT OF RECORDS

Mill Test Certificate

MFRS./ SUPPLIER 9 R

Mill Test Certificate

R

R

8

TPIA 10 R

(Boron content shall be considered even it is less than 0.001%)

iii)Tensile Test

ASTM A 370 / API 5L Table3B/Cust Tech spec 6.2.1

1 sample / heat

As per attached 'Annexure B' & Client Specification

Mill Test Certificate

R

R

iv) Grain Size

ASTM A - 370

1 sample / heat

ASTM 7 or final as per ASTM E-112

Mill Test Certificate

R

R

i) Chem. Analysis

Customer Tech. Spec.Cl

1 Sample/Heat

As per attached 'Annexure A'

Chemical Test Report

W

R

ii)Mill Control Tensile Test

ASTM A 370 / API 5L Table3B/Cust Tech spec 6.2.1

1 Samples/Heat

As per attached 'Annexure B'

Mechanical Test Report

W

10%W

API 5 L & Customer TS. & BS 5996-1993 level E2 Ref. Standard 6.35 mm Dia. X 1/2 t flat bottom hide.

Each coil

Strip UT report

W

W

iii) Ultrasonic testing (not mandatory if UT of pipe is done) a) Skelp edged

No imperfection of length less than 20 mm shall be considered for population density assesment. Maximum length of imperfection shall be in any direction shall not exceed 30 mm. Maximum area of individual imperfection shall not exceed 560 sq. mm. Maximum population density (No. of imperfection smaller than the max. permissible imperfection size and longer than 20 mm / one mtr. length shall not exceed 4) Disposition of defects shall be as per API 5L 9.9.

Approved By Prepared By

Reviewed and Approved by

Page 3 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd. QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

CHARACTERISTICS/ TYPES OF CHECK

2

3 b) Skelp body

3

PIPE

i) Welding Parameter

MECON Ltd. SIZE

REFERENCE STANDERED/SPEC.

TESTING FREQUENCY

4 API 5 L & Customer TS. & BS 5996-1993 level B4 Ref. Standard Eight slots of 35 mm X 8 mm x 1/2 t size

Approved MPS for pipe Minimum Welding Frequency-250 KHz)

SIZE: SPEC.

:-

(

5 Each coil

At least once per coil

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

FORMAT OF RECORDS

SCOPE OF INSPECTION

8 Strip UT report

MFRS./ SUPPLIER 9 W

Log Book

W

M

800-960 deg C

Rolling Report

W

R

I) Flatten to 1/2 of original OD without weld opening. II) Continue flattening to 1/3 of Specified OD without cracks other than in weld. iii) Continue flattening until opposite walls of pipe meet. No evidence of lamination on material during the test.

Rolling Report

W

W

A specimen which fractures completely prior to the specified engagement of mandral and specimen, or which reveals cracks or ruptures in the weld or HAZ longer than 4 mm shall be rejected. Cracks less than 6 mm long at the edges of the specimen shall not be cause for rejection.

Rolling Report

W

W

6 No individual imperfection that does not exceed all the following dimension area = 300 sq. mm, length = 35 mm width = 8 mm is parallel to scan Maximum no. of imperfection per 1 mm x 1 mm = 10. Maximum area of any individual discontinuity shall not exceed 1000 sq. mm. Any imperfection exceeding 100 mm length shall not be acceptable and any planner imperfection not parallel to the plate surface is not acceptable. Disposition of defects shall be as per API 5L 9.9. As per approved Procedure.

TPIA 10 W

a) Time b) Welding speed c) Current / Voltage d) Welding Temperature e) Heat treatment temperature ii) Seam Normalizing

API 5L Spec. Cl. 5.1.3.3.2 & 5.4 of Cust Tech Spec

Once Per coil

iii) Flattening Test

API 5L Cl 6.2.2 & 6.2.2 of cust tech spec

4 SAMPLES /COIL, 2 SAMPLE EACH FROM START AND LAST PIPE OF COIL. THE SAMPLES SHALL BE FLATTENED AT 0 AND 90 DEG. IN CASE OF WELD STOP, 1 SAMPLE FROM EACH CROP END SHALL BE TESTED AT 90 DEG

iv) Reverse Bend Test

Customer Tech. Spec. 6.2.7

One Sample Per coil

Approved By Prepared By

Reviewed and Approved by

Page 4 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

CHARACTERISTICS/ TYPES OF CHECK

2

3

SIZE

SIZE: SPEC.

:-

REFERENCE STANDERED/SPEC.

4

TESTING FREQUENCY

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

5

6

v) Hydrostatic Test

Customer Tech. Spec.9.4

Each pipe( Calibration of No leakage for 15 sec. Holding Time pressure guage weekly) (Pressure calculation based on 95% SMYS). P=2St*0.95/D, where S=SMYS Hydro Pressure as per attached 'Annexure C'

vi) Cyclic Hydro Test

Customer Tech. Spec. 9.4

vii) Burst Test

Customer Tech. Spec. 9.4 one pipe for entire at 130% of SMYS campaign (lowest thickness)

viii) Product Analysis (Spectro)

Customer Tech. Spec.Cl 6.1.1

ix) Tensile Test (Transverse Body & Transverse Weld)

ASTM A 370 / API 5L Table3B/Cust Tech spec 6.2.1

1/50 pipes/ heat

As per attached 'Annexure B'

Customer Tech. Spec. 6.2.6

1/50 pipes/ heat

No untempered martensite remains & uniformly distributed ferritic structure shall be established and fusion line shall be clearly visible. Grain size shall be finer than 7.

1 Pipe every 500 pipes including one PQT test pipe

FORMAT OF RECORDS

8

SCOPE OF INSPECTION MFRS./ SUPPLIER 9

TPIA 10

Hydro Test Report and Graph

W

W

Testing shall be done as per approved procedures. There should not be any leakage or bulging of the pipes or flaring up of the pipe ends.

Cyclic Test Report

W

W

As per approved procedure Pressure as per attached 'Annexure C'

Burst Test Report

W

W

Chemical Test Report

W

R

Mechanical Test Report

W

W

Metellographic Examination Report

W

W

2 Sample per Heat per lot As per attached 'Annexure A' of 50 pipes. One at the beginning of heat and one at the end of heat.

x) Metallographic Examination a) Microscopic/macro Analysis

Approved By Prepared By

Reviewed and Approved by

Page 5 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

2

SIZE

CHARACTERISTICS/ TYPES OF CHECK

REFERENCE STANDERED/SPEC.

3 b) Vicker Hardness Test-HV 10

4 Customer Tech. Spec. 6.2.6

xi) Fracture Toughness Test( API 5L SR5 & Cust Tech Charpy V-notch Impact Test-)- at 0 -Spec 6.2.5 20 and - 25 degree C for first day production from body, FL, FL+2 and FL+ 4mm

xii) Drop weight Tear Test (DWTT)

SIZE: SPEC.

:-

TESTING FREQUENCY

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

5

6

1/50 pipes/ heat

Maximum Hardness 250 HV 10 Max. The maximum difference in hardness between the base metal and any reading taken on weld or HAZ shall be less than 80 HV 10

One set per lot of 100 pipes per Heat. Each set shall consisting of 3 specimen with notch in base material, . For 8" x 7.1, 3 specimen with notch in base material, pieces with notch in fusion line, 3 pieces with notch in fusion line+2 mm, Fusion Line +4 mm.

Absorbed energy at -20, 25 & 0 deg.Centigrade (for full size specimen ) as per Appendix d' attached. and percentage shear area for base metal- min 75 %. And Heat Average 85 % Minimum.

API 5L SR 6.2 through 6.8 The test shall be conducted at ( - ) 20°C.

At least 80% of the heats shall be exhibit & fracture appearance shear area of 75% or more for specified test temperature.

xiii) Ultrasonic Test a) Automatic Ultrasonic Test

Customer Tech. Spec. 9.8

N5 longitudinal notch each at the center of weld seam on inside and outside surface of the pipe. A drilled hole each-one at edge of the seam and other at the centre of weld seam of daimeter equal to 1.6 mm. Acceptance Limit-100% of reference std.

b) Ends UT (Manual)

do

Each pipe weld area (100%) in auto weld tracking condition.

Each pipe, pipe weld at Ref Std. -1/4" Dia FBH for lamination & 1.6 ends (100 mm from both mm drilled hole for weld ends) , sprayed portion in Acceptance Limit-100% of reference std. auto UT , & 25 mm circumferentially by TR probe for lamination

FORMAT OF RECORDS

8 Metellographic Examination Report

SCOPE OF INSPECTION MFRS./ SUPPLIER 9

TPIA 10

W

W

W

W

W

W

Final Ultrasonic Test Report-Weld Seam

W

W

-do-

W

W

Impact Test Report

Approved By Prepared By

Reviewed and Approved by

Page 6 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

SIZE

CHARACTERISTICS/ TYPES OF CHECK

2

REFERENCE STANDERED/SPEC.

3

4

c) Pipe Body UT (Not mandatory if do UT of skelp edge and body is done)

SIZE: SPEC.

:-

TESTING FREQUENCY

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

5

6

100 % Body each pipe

FORMAT OF RECORDS

8

Ref Standerd 35 x 8 x t/2 Flat Bottom Notch. Ultrasonic Test Report-Pipe Body Acceptance as per BS 5996

SCOPE OF INSPECTION MFRS./ SUPPLIER 9

TPIA 10

W

W

W

10%W

d) Magnetic Particle Inspection

do

Bevel Face & 100 mm No lamination and cracks. The Residual circumferential width from Megnetism shall not exceed 20 Gauss the end measured by Gauss Meter.

e) Radiography ( X Ray)

do

0.5% of length

Reference Standered: ASTM Hole Type/ ISO X Ray Inspection Report Wire Type IQI. Acceptance Criteria: Cracks, Lack of panetration , LOF and imperfection greater in size and /or distribution shown in table 21 & 22 of API 5L shall be considered defect.. Such defect shall be dispossed of AS per API 5L Cl 9.9

W

100% Film review

f) Manual UT of Pipe weld (100 % Weld seam)

do

One pipe in 200 pipes

Ref Std. -1.6 mm drilled hole for weld Acceptance Limit-100% of reference std.

Manual Ultrasonic Test Report

W

W

Inspection Report

W

10%W

Nominal Thickness -0.0%, +10.0%

do

W

W

0.2 % of length

do

W

10%W

xiv) Dimensions a) Outer Dia. (mm)

Body: +/-2.4 mm End : -0.40 mm, +1.60 mm -0.80 mm, +2.40 mm

Magnetic Particle Inspection Report

API 5L & Customer Tech. Spec. 7.2

Once per four hr. production in a shift

b) Thickness(mm)

Customer Tech. Spec.Cl 7.3 and annex. of spec.

Each Pipe

c) Straightness

API 5L

d) Length

Customer Tech. Spec. 7.5

Each Pipe

11.5-12.5 M with a average of 12 M minimum. Sample pipe length 10.5 M is also acceptable

do

W

10%W

e)Weight

Table 10 of API 5L

Each Pipe

(+10%, -3.5%) of Standerd Weight

do

W

10%W

f) Out of roundness

Cl 7.2 of cust tech spec

Each Pipe

-0.79 mm, +2 mm

do

W

W

five pipes per shift

Approved By Prepared By

Reviewed and Approved by

Page 7 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

2

CHARACTERISTICS/ TYPES OF CHECK

SIZE

REFERENCE STANDERED/SPEC.

3 xv) Workmanship & defects

4

SIZE: SPEC.

:-

TESTING FREQUENCY

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

FORMAT OF RECORDS

SCOPE OF INSPECTION

5

6

8

MFRS./ SUPPLIER 9

TPIA 10

a)Dents

API-5L Cl.7.8.1 & cust Tech spec 7.8.1

Each Pipe

The depth of dent shall not be more than 3mm or grinding / jacking work shall not be allowed on pipe to remove the dent. Dents on weld and HAZ are not acceptable.

do

W

10%W

b) Off set of plate edges

API-5L Cl.7.8.2

Each pipe

Radial offset of plate edges plus flash trim shall not be greater than 1.5 mm

do

W

10%W

c) Height of Flash

API-5L

Each Pipe

The height of flash at weld seam shall be 0, +1.0 mm.and Outside flash shall be trimmed to flush condition.

do

W

10%W

d)Trimmed Inside Flash

API-5L Cl.7.8.7

3 Times per operating shift

The Depth of groove after the resulting of internal flash shall be 0.40 mm max ,

do

W

10%W

e) Hard Spot

API 5L Cl 7.8.8

Each Pipe

Hardness Max 345 HV10 at hard spot. Min. Dimension in any direction shall not be more then 50.8 mm if it exceed then section of pipe containing the hard spot shall be cut-off as cylinder.

do

W

10%W

e) Cracks, Sweats and Leaks

API 5L Cl 7.8.9

Each Pipe

All cracks, sweats and leaks shall be considered defects.

Inspection Report

W

10%W

f) Lamination

API 5L Cl 7.8.10

Each Pipe

No lamination > 6.4 mm at the bevel face, Geater than 19.0 mm at the body of the pipe and area not greater than 7742 mm2.

do

W

10%W

g) Arc Burn

Cust Tech Spec. Cl 7.8.11

Each Pipe

Arc burns are shall be buffed with wire brush or sanding disc and etched with 5% nital solution, however , not more than 3 arc burns per pipe is permitted, However UT shall be performed to check for harmful defects at arc area.

do

W

10%W

-

Approved By Prepared By

Reviewed and Approved by

Page 8 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

CHARACTERISTICS/ TYPES OF CHECK

2

SIZE

REFERENCE STANDERED/SPEC.

3

4

SIZE: SPEC.

:-

TESTING FREQUENCY

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

FORMAT OF RECORDS

SCOPE OF INSPECTION

5

6

8

MFRS./ SUPPLIER 9

TPIA 10

h) Other Defects

Cust Tech Spec. Cl 7.8.14

Each Pipe

Any Imperfection depth >5 % of Wall thickness shall be considered unacceptable

do

W

10%W

xvi) End Bevelling

Cust Tech Spec. Cl 7.9.3

Each Pipe

I) Bevel angel 32.5 deg. , (+2deg. ,-2 deg)

do

W

10%W

ii) Root face 1.60 mm (+ / - 0.80 mm) xvii) Marking

API 5L Spec. Cl. 10 & Customer Tech. Spec.10

Each pipe

Marking shall be as per API 5l. Marking shall be in English. It shall include Manufacturer’s name, API monogram, Manufacturing date, Nominal Diameter, Wall Thickness, Grade, Hydrostatic test pressure, Pipe Number, Heat Number, Length ASL No etc. Marking shall be done by paint stencil on outside surface. Additionally pipe no & Length shall be marked on ID surface at one end by Permanant marker.

-

W

R

xviii) Coating and End Protection

As per PO

Each Pipe

Both ends of pipe shall be protected by plastic/Metallic end protectors. The pipe shall be delivered bare.

-

W

-

xix) Pipe Loading

API RP 5L1

The finished pipes shall be loaded on a trailor. The pipe shall be placed on wooden blocks.

-

W

-

Mechanical, NDT, Hydro Test Reports as per API 5L SR 15 and Raw material TC

W

R

xx) Test Reports and Certifications API 5L

Each Pipe

-

Approved By Prepared By

Reviewed and Approved by

Page 9 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

2

4

First Day Production Tests

I)

ii)

CHARACTERISTICS/ TYPES OF CHECK

SIZE

REFERENCE STANDERED/SPEC.

3

4

SIZE: SPEC.

:-

TESTING FREQUENCY

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

5

6

Cust Spec. Annex.-II (New) Two pipe each from 3 Different Heats

SCOPE OF INSPECTION

FORMAT OF RECORDS

8

MFRS./ SUPPLIER 9

As above

TPIA 10

W

W

Chemical Composition a) Heat Analysis

One per Heat

b) product Analysis

Two per Heat

Mechanical test a) Raw Materail Tensile Test

One per heat

b) Product Tensile Test

2 Set Per Pipe

c) Flattening Test

One Set Per Pipe, One at 90 Deg and One at 0 Deg

d) Macro,Micro, Vicker Hardness Test

All Selected Pipe( 6 sample from each Pipe end). Out of these , 2 specimen shall be tested for hardness from each pipe.

e) Charpy V Notch Impact Test

one set ( 3 Transverse specimen of Weld, HAZ, body) per Pipe at -25 Deg C.

f) Transition curve for Impact

One Pipe

f) Cyclic hydro Test g) Reverse Bend test

One pipe 2 Sample per pipe

iii)

Hydro Test

All Selected Pipe

iv)

UT Testing(Body & Weld)

All Selected Pipe

Weldablity test v)

MPI

All Selected Pipe

vi)

Dimensional and Visual

All Selected Pipe

R=Review of Records

W=Witness

W/R=Witness at Random

M= Monitor

Approved By Prepared By

Reviewed and Approved by

Page 10 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

2

CHARACTERISTICS/ TYPES OF CHECK

3

SIZE

REFERENCE STANDERED/SPEC.

4

SIZE: SPEC.

:-

TESTING FREQUENCY

5

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

6

FORMAT OF RECORDS

8

SCOPE OF INSPECTION MFRS./ SUPPLIER 9

TPIA 10

ANNEXURE A

Chemical Requirements Element C Mn Si S P Nb V Ti Al Cu Ni Mo Cr N B V+Nb+Ti Cu+Ni AL/N CE CE(Pcm)

Maximum % 0.15 1.60 0.45 0.01 0.02 0.05 0.05 0.10 0.07 0.35 0.20 0.08 0.20 0.012 0.0005 0.15 0.4 2 (Min) 0.40 0.20

Minimum for Si is not applicable for Aluminium Killed Steel

Approved By Prepared By

Reviewed and Approved by

Page 11 of 11

QUALITY ASSURANCE PLAN Gujarat State Petronet Ltd.

MECON Ltd.

QAP NO. : 05/28/23JT/M-001 CLIENT:- GUJARAT STATE PETRONET LIMITED S.NO.

DESCRIPTION

1

2

SIZE

CHARACTERISTICS/ TYPES OF CHECK

REFERENCE STANDERED/SPEC.

3

SIZE: SPEC.

:-

TESTING FREQUENCY

4

5

AS PER COVER PAGE AS PER COVER PAGE

ACCEPTANCE CRIETERIA

6

FORMAT OF RECORDS

8

SCOPE OF INSPECTION MFRS./ SUPPLIER 9

TPIA 10

ANNEXURE 'B'

GRADE

YIELD STRENGTH (Mpa)

TENSILE STRENGTH (Mpa)

% ELONGATION ( 2" GL)

X65

448 - 600

531 - 758

20

THE RATIO OF YS AND TS SHALL BE 0.90 Max

ANNEXURE 'C' OD WALL HYDRO PRESSURE (MM) THICK.(MM) (MPa) 323.9 323.9 323.9 219.1

6.4 7.1 8.7 7.1

ANNEXURE 'D'

16.81 18.65

BURST TEST PRESSURE (MPa) 23.00 25.52

22.86 26.13

31.28 35.75

Absorbed Energy (J) / Shear Area %

Item Absorbed Energy Base Metal & Weld Shear Area

0 °C AVE Sin (Min) Av. 3 specimen Sin (Min)

100 80

Range -20°C /-25°C 35 28

85%

85%

75%

75%

Approved By Prepared By

Reviewed and Approved by

Page 1 of 1

QUALITY ASSURANCE PLAN SEAMLESS PIPE (A 333 Gr. B)

QAP No. : 05/28/23JT/M-002 Date : Prepared : Approved :

Gujarat State Petronet Ltd. Sr. Description No. A Raw Material Inspection 1 Manufacture of Pipes

Applied Standards

Frequency * (Extent of Check)

Reference Documents

ASTM A 333 Gr. 6

Manufacturer Test Certificate 1 sample to be check tested for each Heat Lot at Lab. 1 sample to be check tested for each Heat Lot at Lab. Review & correlation of Test Certificate with materials

MECON's TS and relevant Std. MECON's TS and relevant Std. MECON's TS and relevant Std. MECON's TS and relevant Std.

2

Chemical Analysis

ASTM A 333 Gr. 6

3

Mechanical & Tensile Test

ASTM A 333 Gr. 6

4

Impact (-20°) Test

B 1

In-Process Inspection Impact (-20°) & Flattening Test

ASTM A 333 Gr. 6

2

Chemical Analysis

ASTM A 333 Gr. 6

3

Hydrostatic Test

Tech. Spec.

2 sets of 3 specimens per each Heat Lot to be tested at Lab. One pipe per lot 5% from each lot All pipes

4

Non Distructive Testing

ASTM A 333

All pipes

5

Visual & Dimension Test

ASTM A 530

All pipes

6

Marking & Upgrading Test

MSS SP 25

7

Final Inspection

Tech. Spec.

All marking shall be checked by TPI & released for despatch All pipes

8

Documentation for Despatch Clearance

Tech. Spec.

ASTM A 370

All marking shall be checked by TPI & released for despatch 9 Inspection Release note Tech. Spec. Submit TC & Lab. Test Reports LEGENDS : R : REVIEW, W : WITNESS, H - HOLD, TPIA : INSPECTION AGENCY

Rev. 0 Check :

MECON Limited

Document Type

Vendor

TPIA / Client

Test Certificate

H/R

R

Test Certificate

H/R

R

Test Certificate

H/R

R

Test Certificate

H/R

R

MECON's TS and relevant Std.

Test Certificate

H

W

MECON's TS and relevant Std. MECON's TS and relevant Std. MECON's TS and relevant Std. MECON's TS and relevant Std. MECON's TS and relevant Std.

Test Certificate

H

R

Test Certificate

H

W

Test Certificate

H

R

Test Certificate

H

W

Test Certificate

H

W

MECON's TS and relevant Std. Inspection Report

Test Certificate

H

W

Inspection Release note

H

H

Inspection Report

Inspection Release note

H

H

Remarks

1 Sample per each Heat Lot

* Notes : The frequency given above is applicable only if the heat lot is established alongwith original MTC. Otherwise all above test shall be done for each pipe.

Prepared By

Approved By

Reviewed and Approved BY

Page 1 of 1 QAP No. : 05/28/23JT/M-003 Date : Prepared : Approved :

QUALITY ASSURANCE PLAN FLANGES

Rev. 0 Check :

Gujarat State Petronet Ltd.

MECON Limited Inspection Agency Vendor TPIA R -

Ref. No.

Operation

Characteristic

Category

Type Method Check

Extent of Check

Reference Document

Acceptance Norms

Format of Record

1

Review of PO / Drg.

Review of PO Doc. / Drg.

Critical

Scrutiny / Varification

Each doc. of P.O.

Appl. Spec. / STD

-

-

2

Raw Material

1

Manufacturing process of steel

Critical

Varification with M.T.C.

Each Heat

Appl. Material Specification / STD

As per tender document / Material Specification / STD

Material Test Certificate and MI Register

R

R

2

Chemical Composition

Spectro Analysis

Each Heat

1

Reduction Ratio

Measurement

Minimum 1 per size

Standard Manufacturing Procedure

Std. Procedure

Forging process record / internal Register

P

R

2

Temperature During Forging

3

Forging Dimensions

T.P.M. Sheet, Heat Treatment Graph

P/W

R

Mechanical Test Report & T.C.

H

W

Mechanical Test Report & T.C.

W

W

Dimension Report Format

P/W

W

P/W

R

Release Note & TC

P

P

As per Tender Doc. / As per Tender Doc. / Shipping documents Material Specification / Material Specification / STD STD

P

-

3

Forgins

4

Heat Treatment (as applicable)

5

Mechanical Testing (as applicable)

6

NDT

7

Final Inspection

8

Making, Colour Coding, Rust Prevension & Packing

9

10

Heat Treatment Cycle

1

Tensile Test (TS, YS, RA%, EL%)

2

Hardness

3

IMPACT (-20 °C)

1

DP

2

UT

3

MPI

Visual & Dimensions

Critical

Optical Pyrometer

Remarks Check MTC Register Tractability to be checked.

As per Std. AMSE B16.5

Measurement Major

Verification of Heat Treatment Cycle

Each Heat / HT Lot

Major

Tensile Testing

One / HT / Lot / Group

IMPACT Testing

Major

DP Testing

100%

Ultrasonic Flaw Detector MPI Testing

As per Tender Doc. / As per Tender Doc. / Material Specification / Material Specification / STD STD

As per Tender Doc. / Material Specification / STD As per Material Specification ASTM A350 LF2

ASTM E-165

ASTM E-388 ASTM A-275

Std. Procedure

Test Specimen to Mark after Verification to Heat Treatment.

As per Material Specification ASTM A350 LF2

As per article 9.2 of appendix 9 of ASME Spec. VIII, Div. 2 AM 203.2 of ASME Spec. VIII, Div. 2 As per article 9.1 of appendix 9 of ASME Spec. VIII, Div. 2

Major

Visual / Measurement

100%

As per Tender Doc. / As per Tender Doc. / Material Specification / Material Specification / STD STD

Making, Colour Coding, Rust Prevension & Packing

Major

Visual

100%

As per Tender Doc. / As per Tender Doc. / Packing List & Ruboff Material Specification / Material Specification / 1 item per size STD STD

Certification

TPI Inspection Release Note & TC

Major

Verification of PO Spec. & QAP

100%

As per Tender Doc. / As per Tender Doc. / Material Specification / Material Specification / STD STD

Shipping

Verification of surface coating / type of packing

Major

-

-

LEGENDS : W : WITNESS, M : MONITOR, R : REVIEW, P - PERFORM, TPIA : INSPECTION AGENCY, SPEC.: TECHNICAL SPECIFICATION

Prepared By

Approved By

Reviewed and Approved By

Page 1 of 1 QAP No. : 05/28/23JT/M-004 Date : Prepared : Approved :

QUALITY ASSURANCE PLAN CS FLANGES (ABOVE 10")

Rev. 0 Check :

Gujarat State Petronet Ltd. Ref. No.

Operation

1

Review of PO / TDC / Drg.

2

Raw Material

3

Forgins

4

Heat Treatment (as applicable)

5

Mechanical Testing (as applicable)

6

NDT

7

Final Inspection

8

Making, Colour Coding, Rust Prevension & Packing

9

10

MECON Limited Characteristic

Inspection Agency Vendor TPIA R -

Category

Type Method Check

Extent of Check

Reference Document

Acceptance Norms

Format of Record

Review of PO Doc. / Drg. & TDC

Critical

Scrutiny / Varification

Each doc. of P.O.

Appl. Spec. / STD

-

-

1

Manufacturing process of steel

Critical

Varification with M.T.C.

Eact Heat

Appl. Material Specification / STD

As per tender document / Material Specification / STD

Material Test Certificate and MI Register

R

R

2

Chemical Composition

Spectro Analysis

Eact Heat

1

Reduction Ratio

Measurement

Minimum 1 per size

Standard Manufacturing Procedure

Std. Procedure

Forging process record / internal Register

P

R

2

Temperature During Forging

3

Forging Dimensions

T.P.M. Sheet, Heat Treatment Graph

P/W

R

Mechanical Test Report & T.C.

H

W

As per article 9.2 of appendix 9 of ASME Spec. VIII, Div. 2 AM 203.2 of ASME Spec. VIII, Div. 2 As per article 9.1 of appendix 9 of ASME Spec. VIII, Div. 2

Mechanical Test Report & T.C.

W

W

ASME B16.5 / ASME B16.47 A

Dimension Report Format

P/W

W

P/W

R

Release Note & TC

P

P

As per Tender Doc. / As per Tender Doc. / Shipping documents Material Specification / Material Specification / STD STD

P

-

Heat Treatment Cycle

1

Tensile Test (TS, YS, RA%, EL%)

2

Hardness

3

IMPACT (-20 °C)

1

DP

2

UT

3

MPI

Visual & Dimensions

Critical

Optical Pyrometer 100%

Major

Verification of Heat Treatment Cycle

Each Heat / HT Lot

Major

Tensile Testing

One / HT / Lot / Group

IMPACT Testing

DP Testing

Check

MTC Register Tractability to be checked.

As per Std. AMSE B16.5

Measurement

Major

Remarks

100%

Ultrasonic Flow Detector MPI Testing

As per Tender Doc. / ASTM A694 F 65 or A860 WPHY 65

As per Tender Doc. / ASTM A694 F 65 or A860 WPHY 65

As per Tender Doc. / As per Tender Doc. / Material Specification / Material Specification / STD STD As per Material As per Material Specification ASTM Specification ASTM A350 LF2 A350 LF2

ASTM E-165

ASTM E-388 ASTM A-275

Major

Visual / Measurement

100%

As per Tender Doc. / Material Specification / STD

Making, Colour Coding, Rust Prevension & Packing

Major

Visual

100%

As per Tender Doc. / As per Tender Doc. / Packing List & Ruboff Material Specification / Material Specification / 1 item per size STD STD

Certification

TPI Inspection Release Note & TC

Major

Verification of PO Spec. & QAP

100%

As per Tender Doc. / As per Tender Doc. / Material Specification / Material Specification / STD STD

Shipping

Verification of surface coating / type of packing

Major

-

-

Test Specimen to Mark after Verification to Heat Treatment.

LEGENDS : W : WITNESS, M : MONITOR, R : REVIEW, RW : RANDOM WITNESS, TPIA : INSPECTION AGENCY, SPEC.: TECHNICAL SPECIFICATION

Prepared By

Approved By

Reviewed and Approved BY

Page 1 of 1

QUALITY CONTROL TABLE BUTT WELDED FITTING Gujarat State Petronet Ltd. Sr. No.

Inspection & Testing

QAP No. : 05/28/23JT/M-005 Date : Prepared : Approved :

Rev. 0 Check :

MECON Limited Inspection TPIA / Client R

Procedure

Acceptance Criteria and Certificate

As per Tender Doc. / Material Spec.

Mill Test Certificate

Vendor R

As per ASTM A370 / Tender Doc. / Material Spec.

As per Tender Doc.

P

10% W 100% R

ASME V, Art. 2

ASME VIII-UW 51 Div.-1

P

R

1

Chemical Analysis

2

Mechanical Properties

3

R T of each Welded Fittings

4

Heat Treatment

As per Tender Doc. / Material Spec.

As per Tender Doc. / Material Spec.

P

R

5

Visual Test

As per Tender Doc. / Material Spec.

As per Tender Doc. / Material Spec.

P

10% W 100% R

6

Mechanical Test

As per ASTM A370 / Tender Doc.

As per ASTM A370 / Tender Doc.

P

10% W 100% R

7

Impact Test (at -20 °C)

As per Tender Doc.

As per Tender Doc.

P

10% W 100% R

8

NDT Test

As per Tender Doc. / Material Spec.

As per Tender Doc. / Material Spec.

P

10% W 100% R

Remarks

LEGENDS : R : REVIEW, W : WITNESS, H - HOLD, P : PERFORM, TPIA : INSPECTION AGENCY, SPEC.: TECHNICAL SPECIFICATION Notes : 1 2 3 4 5 6

The above Testing and acceptance criteria are minimum requirements, however, equipment shall ensure and that the product also comply to the additional requirements as per Technical Specifications and data sheets. The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA. Supplier shall submit calibration certificates of all Instruments / Equipments to be usd for Inspection and Testing to TPIA with relevant procedures and updates standards for TPIA review / approval. TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above. TPIA alongwith with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / drawings etc. submitted by supplier. Contractor shall in coordination with Supplier / Sub vendor shall issued detailed Production and Inspection schedule including the dates and the locations to facilite Owner / Owner's representative and TPIA to organise Inspection.

Prepared By

Approved By

Reviewed and Approved BY

Page 1 of 1

QUALITY ASSURANCE PLAN PIG LAUNCHER / RECEIVER

QAP No. : 05/28/23JT/M-006 Date : Prepared : Approved :

Gujarat State Petronet Ltd. Sr. No.

Inspection & Testing

1

Chemical Analysis

2

Mechanical Properties

3

R T each piece

4

Procedure API / ASTM E350 each heat and product

Acceptance Criteria API / ASTM

Document Type

Rev. 0 Check :

MECON Limited

Certificate

Vendor P

Inspection TPIA / Client 100% W

API / ASTM A370 on samples taken from mill.

API / ASTM

Certificate

P

100% W

ASME V, Art. 2

ASME VIII-UW 51

Certificate

P

100% W

Low temperature certificate charpy test at -20°C

ASTM A-370

35 J/cm (A) / 28 J/cm2(S)

2

Certificate with impact test

P

100% W

5

HT Each heat treatment batch

ASTM A-370

API / ASTM

Certificate

P

100% W

6

VT Each piece

ASME V, Art. 9

API / ANSI

Certificate

P

100% W

As per specification

135.38 during 4 hours As per specification As per specification As per specification As per specification

Certificate

P

100% W

Report Report Report Certificate

P P P P

100% W 100% W 100% W 100% W

FINAL INSPECTION TEST 7 Hydrostatic Test 8 Visual examination 9 Dimensional examination 10 Making 11 Final Certificates LEGENDS : RT : Radiographic Test P : Performed TPIA : Third Party Inspection Agency Notes : 1 2 3 4 5 6 7

As per specification As per specification As per specification As per specification PT : Liquid Penetrant Test R : Review

Remarks

VT : Visual Test HT : Hardness Test

The above Testing and acceptance criteria are minimum requirements, however, equipment shall ensure and that the product also comply to the additional requirements as per Technical Specifications and data sheets. The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative. Supplier shall submit calibration certificates of all Instruments / Equipments to be usd for Inspection and Testing to TPIA with relevant procedures and updates standards for TPIA review / approval. TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above. TPIA alongwith with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / drawings etc. submitted by supplier. Supplier shall in coordination with sub vendor shall issued detailed production and Inspection schedule including the dates and the locations to facilite Owner / Owner's representative and TPIA to organise Inspection. Certification requirements shall comply with European Standard EN 10204 (latest edition).

Prepared By

Approved By

Reviewed and Approved BY

Page 1 of 2 QAP No. : 05/28/23JT/M-007 Date : Prepared : Approved :

QUALITY ASSURANCE PLAN GLOBE VALVE

Rev. 0 Check :

Gujarat State Petronet Ltd. SR. No.

COMPONENT & OPERATIONS

1

RAW MATERIAL

1.1

BODY & BONNET

MECON Limited ACTIVITIES

CHEM. TEST PHY. TEST VISUAL IMPACT TEST (-20oC)

DISC & SEAT RING

SPINDLE

3

3.1

INTERMEDIATE AUDIT BODY & BONNET

INSPECTION

FORMET OF RECORD

VENDOR

TPI

PER HEAT PER HEAT 100%

ASTM A 350 LF2 & Tender doc. ASTM A 350 LF2 & Tender doc. MSS-SP-55/API 1104

ASTM A 350 LF2 & Tender doc. ASTM A 350 LF2 & Tender doc. MSS-SP-55/API 1104

FOUNDARY T.C. FOUNDARY T.C. INSPECTION REPORT

R P P

R W W

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

P

W

ASME B 16.34

ASME B 16.34

INSPECTION REPORT

P

R

- DO A 182 F 316 + STELLITED & Tender doc. A 182 F 316 + STELLITED & Tender doc. MSS-SP-55/API 1104

INSPECTION REPORT

P

W

SUPPLIER T.C.

R

R

CHEM. TEST

PER HEAT

PHY. TEST

PER HEAT

VISUAL IMPACT TEST (-20oC) MPT

100%

- DO A 182 F 316 + STELLITED & Tender doc. A 182 F 316 + STELLITED & Tender doc. MSS-SP-55/API 1104

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

P

W

100% 3 Sample < 6", 100% > 8"

ASME B 16.34

ASME B 16.34

INSPECTION REPORT

P

W

ASME B 16.34

INSPECTION REPORT

P

R

LAB. T.C.

R

R

LAB. T.C.

P

W

INSPECTION REPORT

R

W

ASME B 16.34

ASTM STANDARD A 182 F6 ASTM STANDARD A 182 F6

SUPPLIER T.C.

P

W

INSPECTION REPORT

P

W

CHEM. TEST

PER HEAT

AS PER APPROVED DRAWING

PHY. TEST

PER HEAT

AS PER APPROVED DRAWING

IMPACT TEST (-20oC)

PER HEAT

AS PER TENDER ASME B 16.34

ASME B 16.34

INSPECTION REPORT

R

R

VISUAL

3 Sample < 6", 100% > 8" 100%

MSS-SP-55/API 1104

MSS-SP-55/API 1104

INSPECTION REPORT

P

W

TRANSFER OF HEAT NO.

100%

ANSI B 16.34

ANSI B 16.34

INSPECTION REPORT

W

DIMENSIONS

100%

AS PER APPROVED DRAWING

AS PER APPROVED DRAWING

INSPECTION REPORT

H

100% 100% 100%

ASNI B 16.34 AS PER APPROVED DRAWING ANSI B 16.34

ASNI B 16.34 AS PER APPROVED DRAWING ANSI B 16.34

INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT

P P W

R/W R W-1 sample per size per lot R/W R/W R/W

PER LOT PER LOT 10%

A 320 GR. L7 & A 194 GR. 7 A 320 GR. L7 & A 194 GR. 7 AS PER APPROVED DRAWING

A 320 GR. L7 & A 194 GR. 7 A 320 GR. L7 & A 194 GR. 7 AS PER APPROVED DRAWING

SUPPLIER T.C. SUPPLIER T.C. INSPECTION REPORT

R R P

R W W

PER LOT

ASTM A 370 / A 194 GR 7

AS PER TENDER DOC.

SUPPLIER T.C.

P

W

RADIOGRAPHY 2 2.1

ACCEPTANC NORMS

MPT

RADIOGRAPHY

1.3

REFERENCE DOCUMENTS

3 Sample < 6", 100% > 8" 100%

RADIOGRAPHY

1.2

QUANTAM OF CHECK

35 / 28 JOULE

BROUGHTOUT ITEM

FASTERNS

Prepared By

CHEMICAL PHYSICAL DIMENSIONS IMPACT TEST (-20oC)

Approved By

Reviewed and Approved By

Page 2 of 2 QAP No. : 05/28/23JT/M-007 Date : Prepared : Approved :

QUALITY ASSURANCE PLAN GLOBE VALVE

Rev. 0 Check :

Gujarat State Petronet Ltd. SR. No.

COMPONENT & OPERATIONS

4

FINAL INSPECTION

AS PER API 598 / B.S.6755 PART-1

4.1

5

MECON Limited ACTIVITIES

VISUAL DIMENSIONS HYD. BODY TEST HIGH PRESSURE CLOSER TEST LOW PRESSURE CLOSER TEST BACKSEAT TEST PERFORMANCE

QUANTAM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANC NORMS

INSPECTION

FORMET OF RECORD

VENDOR

TPI

100% 100% 100%

MSS-SP-55/API 1104 APPVD. DRG. API 598 APPVD. DRG. API 598

MSS-SP-55/API 1104 APPVD. DRG. API 598 APPVD. DRG. API 598

INSPECTION REPORT ASSEMBLY CARD ASSEMBLY CARD

P P P

100% W 100% W 100% W

100%

APPVD. DRG. API 598

APPVD. DRG. API 598

-- DO --

P

100% W

100%

APPVD. DRG. API 598

APPVD. DRG. API 598

-- DO --

P

100% W

100% 100%

APPVD. DRG. API 598 API 598

APPVD. DRG. API 598 API 598

-- DO -REPORT

P P

100% W 100% W

SURFACE PREPARATION

100%

DATA SHEET

DATA SHEET

INSP. REPORT

P

10% W, 100% R

PRIMER COAT

MEASUREMENT OF DFT

DATA SHEET

DATA SHEET

PAINT INSP REPORT

P

10% W, 100% R

FINAL COAT

MEASUREMENT OF DFT

DATA SHEET

DATA SHEET

PAINT INSP REPORT

P

10% W, 100% R

VISUAL

100%

P

R

100%

COMPLIANCE CERTIFICATE

P

R

MARKING / TAG DETAILS

100%

MSS-SP-55 AS PER SPEC. / APPVD. DRG. / ANSI B 16.34 AS PER APPVD. DRG. / TENDER DOC.

…

REVIEW

… AS PER SPEC. / APPVD. DRG. / ANSI B 16.34 AS PER APPVD. DRG. / TENDER DOC.

COMPLIANCE CERTIFICATE

P

W

P - PERFORM,

R - REVIEW,

W - WITNESS,

H - HOLD

PAINTING

AS PER DATA SHEET

6

FINAL DOCUMENTS

6.1 LEGENDS :

TPIA - THIRD PARTY INSPECTION AGENCY

Notes ;1 The Above Testing and acceptable criteria are minimum requirement, however, equipment supplier shall ensure and that the product also comply to the additional requirements as per Technical specifications and data sheets. 2

The supplier shall submit their own details QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA.

3

Supplier shall submit Calibration certificates of all Instruments/Equipments to be used for Inspection and Testing to TPIA with relavent procedures and update standards for TPIA review / Approval.

4

TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.

5

TPIA along with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / Drawings etc. submitted by supplier.

6

Contractor shall in coordination with Supplier / Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilities Owner/Owner's representative and TPIA to organise Inspection.

Prepared By

Approved By

Reviewed and Approved By

Page 1 of 2

QAP No. : 05/28/23JT/M-008 Date : Prepared : Approved :

QUALITY ASSURANCE PLAN BALL VALVE

Rev. 0 Check :

Gujarat State Petronet Ltd. SR. No. 1

1.1

COMPONENT & OPERATIONS

MECON Limited ACTIVITIES

BODY & SIDE PIECE

BALL & SEAT RING

1.3

STEM

1.4

PUP PIECE

2

INTERMEDIATE AUDIT

2.1

2.2 2.3

REFERENCE DOCUMENTS

ACCEPTANC NORMS

FORMET OF RECORD

INSPECTION VENDOR

TPI

RAW MATERIAL CHEM. TEST PHY. TEST VISUAL IMPACT TEST (-20oC) RADIOGRAPHY

1.2

QUANTAM OF CHECK

BODY & SIDE PIECE

BALL & SEAT RING STEM

2.4

PUP PIECE WELDING

3 3.1 3.2 3.3

BROUGHT ITEM

FASTERNS

3.4 3.5

Prepared By

MPT OF BUTTENDS CHEM. TEST PHY. TEST VISUAL IMPACT TEST (-20oC)

PER HEAT PER HEAT 100%

ASTM A 350 LF2 & Tender doc. ASTM A 350 LF2 & Tender doc. API 1104/MSS-SP-55

ASTM A 350 LF2 & Tender doc. ASTM A 350 LF2 & Tender doc. API 1104/MSS-SP-55

FOUNDRY T.C. FOUNDRY T.C. CERTIFICATE

P P P

R W W

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

P

W

3 Sample < 6" 100% > 8" 100% PER HEAT PER HEAT 100%

ASME B 16.34 ASME SEC VIII /ASME V ASME VIII /ASME V A 350 LF2 + ENP & Tender doc. A 350 LF2 + ENP & Tender doc. API 1104/MSS-SP-55

ASME / ANSI B 16.34

INSPECTION REPORT

P

R

ASME SEC VIII /ASME V A 350 LF2 + ENP & Tender doc. A 350 LF2 + ENP & Tender doc. MSS-SP-55/API 1104

CERTIFICATE CERTIFICATE CERTIFICATE CERTIFICATE

P R P P

W R W W

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

R

W

RADIOGRAPHY

3 Sample < 6" 100% > 8"

ASME B 16.34 ASME SEC VIII /ASME V

ASME B 16.34 ASME SEC VIII / SEC V

INSPECTION REPORT

P

R

CHEM. TEST

PER HEAT

AS PER APR DRG. / TENDER DOC.

AS PER APR DRG. / TENDER DOC.

LAB T.C.

P

R

PHY. TEST

PER HEAT

AS PER APR DRG. / TENDER DOC.

AS PER APR DRG. / TENDER DOC.

LAB T.C.

P

W

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

P

W

PER HEAT PER HEAT 100%

AS PER DATA SHEET AS PER DATA SHEET

35 / 28 JOULE AS PER DATA SHEET AS PER DATA SHEET

SUPPLIER TEST CERTIFICATE SUPPLIER TEST CERTIFICATE CERTIFICATE

R P W

R W W

PER LOT

ASTM A 370 / GTS / PTS

35 / 28 JOULE

SUPPLIER T.C.

P

W

PROCESS CARD

100% W R

IMPACT TEST (-20oC) CHEM. TEST PHY. TEST VISUAL IMPACT TEST (-20oC) TRANSFER OF HEAT NO.

100%

DIMENSIONS

100%

APPVD. DRG

APPVD. DRG

INSPECTION REPORT

TRANSFER OF HEAT NO. DIMENSIONS RADIOGRAPHY VISUAL

100% 100% 100% 100%

APPVD. DRG APPVD. DRG ASME / ANSI B 16.34 / API 6D ASME / ANSI B 16.34

APPVD. DRG APPVD. DRG ASME / ANSI B 16.34 / API 6D ASME / ANSI B 16.34

INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT

W W W W

R/W R W-1 sample per size per lot R/W R/W R/W R/W

CHEMICAL PHYSICAL DIMENSIONS IMPACT TEST (-20oC) HEAT TREATMENT

PER LOT PER LOT 10%

A 320 GR. L7 & 194 GR. 7 A 320 GR. L7 & 194 GR. 7

A 320 GR. L7 & A 194 GR. 7 A 320 GR. L7 & A 194 GR. 7

SUPPLIER T.C. SUPPLIER T.C.

R P P

R W W

PER LOT

ASTM A 370 / A 194 GR 7

AS PER TENDER DOC.

SUPPLIER T.C.

P

W

100%

ASTM A 370

AS PER CODE

HEAT TREATMENT REPORT

P

W

Approved By

w

Reviewed and Approved By

Page 2 of 2

QAP No. : 05/28/23JT/M-008 Date : Prepared : Approved :

QUALITY ASSURANCE PLAN BALL VALVE

Rev. 0 Check :

Gujarat State Petronet Ltd. COMPONENT & OPERATIONS

SR. No. 4 4.1 4.2 4.3 4.4 4.5

ACTIVITIES

QUANTAM OF CHECK

AS PER API 598

VISUAL DIMENSIONS HYD. BODY TEST HYD. SEAT TEST AIR SEAT TEST DOUBLE BLOCK & BLEED TEST PERFORMANCE TEST FIRE SAFE TEST ANTI SAFE TEST LEAK TEST

INSPECTION VENDOR

TPI

P P P P P

100% W 100% W 100% W 100% W 100% W

SURFACE PREPARATION

APPVD. DRG / TENDER DOC. APPVD. DRG . / API 6D APPVD. DRG . / API 6D APPVD. DRG / TENDER DOC.

MSS-SP-55/API 1104 APPVD. DRG APPVD. DRG . / API 6D APPVD. DRG . / API 6D APPVD. DRG

100%

APPVD. DRG / TENDER DOC.

APPVD. DRG

TEST REPORT

P

100% W

100% TYPE TEST 100% 100%

API 598 API 6FA BS 5351 API 598

API 598 API 6FA BS 5351 API 598

TEST REPORT TYPE TEST CERTIFICATE TEST REPORT TEST REPORT

P P P P

100% W W 100% W 100% W

100%

DATA SHEET

DATA SHEET

INSPECTION REPORT

P

DATA SHEET

DATA SHEET

PAINT INSP REPORT

P

DATA SHEET

DATA SHEET

PAINT INSP REPORT

P

… AS PER SPEC. / APPVD. DRG. AS PER APPVD. DRG. / TENDER DOC.

MSS-SP-55 AS PER SPEC. / APPVD. DRG. AS PER APPVD. DRG. / TENDER DOC.

… COMPLIANCE CERTIFICATE

P P

100% W, 100% R 100% W, 100% R 100% W, 100% R W H

COMPLIANCE CERTIFICATE

P

W

W - WITNESS,

H - HOLD

5.3

FINAL COAT

5.4 6

VISUAL REVIEW

6.1

MARKING / TAG DETAILS

100%

LEGENDS :

P - PERFORM,

R - REVIEW,

Notes ;1 2 3 4 5 6

FORMET OF RECORD

100% 100% 100% 100% 100%

MEASUREMENT OF DFT MEASUREMENT OF DFT 100% 100%

NOTE :

ACCEPTANC NORMS

INSPECTION REPORT INSPECTION REPORT TEST REPORT TEST REPORT TEST REPORT

PAINTING

5.1 5.2

REFERENCE DOCUMENTS

FINAL INSPECTION

4.5 4.6 4.7 4.8 4.9 5

MECON Limited

AS PER DATA SHEET

FINAL DOCUMENTS

PRIMER COAT

TPIA - THIRD PARTY INSPECTION AGENCY

1. VENDOR SHALL SUBMIT WPS AND PQR FOR APPROVAL. 2. REFERENCE DOCUMENTS AND ACCEPTANCE NORMS FOR ABOVE ACTIVITY WILL BE AS PER PTS / GTS.

The Above Testing and acceptable criteria are minimum requirement, however, equipment supplier shall ensure and that the product also comply to the additional requirements as per Technical specifications and data sheets. The supplier shall submit their own details QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA. Supplier shall submit Calibration certificates of all Instruments/Equipments to be used for Inspection and Testing to TPIA with relavent procedures and update standards for TPIA review / Approval. TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above. TPIA along with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / Drawings etc. submitted by supplier. Contractor shall in coordination with Supplier / Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilities Owner/Owner's representative and TPIA to organise Inspection.

Prepared By

Approved By

Reviewed and Approved By

Pages 1 of 2 QAP NO : 05/28/23JT/M-009

QUALITY ASSURANCE PLAN CHECK VALVE

Date

:

Prepared by

:

Rev. Checked by

Approved by : MECON LIMITED

Gujarat State Petronet Ltd. Sl. No.

COMPONENTS & OPERATIONS

ACTIVITIES CHEM. TEST

1.1

1.2

BODY & COVER

DISC & SEATRING

2.1

2.3 3

HARD FACING BROUGHTOUT ITEM

4.1

ASTM A 350 LF2 & Tender doc.

FORMET RECORD FOUNDRY T.C. FOUNDRY T.C.

INSPECTION R

Rev.

PER HEAT

ASTM A 350 LF2 & Tender doc.

ASTM A 350 LF2 & Tender doc.

P

W

VISUAL IMPACT TEST (-200c) RADIOGRAPHY MPT

100%

MESS-SP-55/API 1104

MESS-SP-55/API 1104

INSPECTION REPORT

P

W

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

P

W

3 Sample < 6", 100%> 8" 100%

INSPECTION REPORT INSPECTION REPORT SUPPLIER T.C.

Rev. W

PER HEAT

ASME B 16.34 -DOA 182 F 316 + STELLITED & Tender doc. A 182 F 316 + STELLITED & Tender doc.

P P

CHEM. TEST

ASME B 16.34 -DOA 182 F 316 + STELLITED & Tender doc. A 182 F 316 + STELLITED & Tender doc.

P

Rev.

P

W

P

W

SUPPLIER T.C.

PHY. TEST

PER HEAT

VISUAL

100%

MSS-SP-55/API 1104

MSS-SP-55/API 1104

PER HEAT

AS PER TENDER

35 / 28 JOULE

INSPECTION REPORT

P

W

100% 3 Sample < 6", 100%> 8"

ASEM B 16.34 ASME B 16.34

ASEM B 16.34 ASME B 16.34

INSPECTION REPORT INSPECTION REPORT

P P

W R

TRANSFER OF HEAT NO.

100%

ANSI B 16.34

ANSI B 16.34

INSPECTION REPORT

W

R/W

DIMENSIONS

100%

AS PER APPROVED DRAWING

AS PER APPROVED DRAWING

INSPECTION REPORT

H

R W-1 sample per size per lot

BODY & BONNET

DISC & SEATRING

4

ASTM A 350 LF2 & Tender doc.

ACCEPTANCE NORMS

INTERMEDIATE AUDIT

2.2

3.1

PER HEAT

REFERENCE DOCUMENTS

PHY. TEST

IMPACT TEST (-200c) MPT RADIOGRAPHY 2

QUANTAM OFCHECK

FASTNERS

TRANSFER OF HEAT NO. HARDNESS & D.P.

100%

ANSI B 16.34

ANSI B 16.34

INSPECTION REPORT

P

R/W

1005

ANSI B 16.34

ANSI B 16.34

INSPECTION REPORT

W

R/W

CHEMICAL

PER LOT

A 320 GR. L7 & A 194 GR. 7

A 320 GR. L7 & A 194 GR. 7

R

R

PHYSICAL DIMENSIONS IMPACT TEST (-200c)

PER LOT 10%

A 320 GR. L7 & A 194 GR. 7 AS PER APPROVED DRAWING

A 320 GR. L7 & A 194 GR. 7 AS PER APPROVED DRAWING

INSPECTION REPORT INSPECTION REPORT

R P

W W

PER LOT

ASTM A 370 / A 194 GR 7

AS PER TENDER DOC.

INSPECTION REPORT

P

W

VISUAL DIMENSIONS HYD.BODY TEST HIGH PRESSURE CLOSER TEST BACKSEATTEST PERFORMANCETEST

100% 100% 100% 100%

MSS-SP-55/API 1104 APPVD. DRG. AND TS APPVD. DRG. AND TS APPVD. DRG. AND TS APPVD. DRG. AND TS API 598 API 598

MSS-SP-55/API 1104 APPVD. DRG. AND TS APPVD. DRG. AND TS APPVD. DRG. AND TS APPVD. DRG. AND TS API 598 API 598

INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT

P P P P

100% W W W W

INSPECTION REPORT

P

W

INSPECTION REPORT

P

SUPPLIER T.C.

FINAL INSPECTION

AS PER API 598/B.S.6755 PART1/API 6D

Prepared By

100% 100%

Approved By

Reviewed and Approved By

Pages 2 of 2 QAP NO : 05/28/23JT/M-009

QUALITY ASSURANCE PLAN CHECK VALVE

Date

:

Prepared by

:

Rev. Checked by

Approved by : MECON LIMITED

Gujarat State Petronet Ltd. COMPONENTS & Sl. No. OPERATIONS PAINTING 5 5.1 5.2 5.3 5.4 6

AS PER DATA SHEET FIANAL DOCUMENTS

6.1

ACTIVITIES

QUANTAM OFCHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

FORMET RECORD

INSPECTION

SURFACE PREPARATION PRIMER COAT FINAL CAOT VISUAL

100%

DATA SHEET

DATA SHEET

INSPECTION REPORT

P

10%w, 100%

MEASUREMENT OF DFT MEASUREMENT OF DFT 10%

P P P

10%w, 100% 10%w, 100% W

100%

DATA SHEET DATA SHEET MSS-SP-55 AS PER SPEC./ APPVD. DRG./ ANSI B 16.34

PAINT. INST. REPORT PAINT. INST. REPORT -

REVIEW

DATA SHEET DATA SHEET AS PER SPEC./ APPVD. DRG./ ANSI B 16.34

COMPLIANCE CERTIFICATE

R

R

COMPLIANCE CERT,

P

W

MARKING / TAG DETAILS R = REVIEW;

100%

AS PER APPR. DRG/ TENDER DOC. AS PER APPR. DRG/ TENDER DOC.

LEGEND : P = PERFORM; W = WITNESS; H = HOLD; TPIA = THIRD PARTY INSPECTION Notes:1 The above Testing and acceptance criteria are minimum requriements, however, equipment supplier shall ensure and that the product also com;y to the additional requirements as per Technical Specifications and data sheets. 2 The supplier shall submit their own detailed QAP prepared on the basis of the aboe for approval of Owner/Owner's representative and TPIA. 3 Supplier shall submit Calibration certificates of all instruments/Equipments to be used for inspection and Testing to TPIA with relevent procedures and updated standards for TPIA review/Approval. 4 TPIA will have Right to inspect minimum 10% of all manufacturing activities on each day or as specified above. 5 TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/drawigs etc. submitted by suppler. 6 Contractor shall in coordination with Supplier/Sib vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitaate Owner/Owner's representative and TPIA to organise inspection.

Prepared By

Approved By

Reviewed and Approved By

Page 1 of 2

QUALITY ASSURANCE PLAN PRESSURE SAFETY VALVE Gujarat State Petronet Ltd. SN. 1

INSPECTION AND TESTING

RT 3 first Casts Each Piece

ASME V, Art.2 100%: Each type/size/rating 100%: BW Eends

PT 3 first Casts Each Piece

ASME V, Art.6 - ASTM E-165 100%: Each type/size/rating 100%: BW Eends

MT

Mechanical properties Low temperate certificate ( if applicable ) Forgings PT

Alternative for PT Reffered API / ASTM Each heat and product Reffered API / ASTM on samples taken from mill ASTM A-370

ASME V, Art.6 100% presure retanings parts

MT on presure retanings parts Chemical Analysis Mechanical properties Low temperate certificate ( if applicable ) 3

ACCEPTANCE CRITERIA AND CERTIFICATE

Rev. 0 Check :

MECON Limited Sub Vendor

Supplier/TPIA

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

P

100% W

Remarks

Cast

Chemical Analysis

2

PROCEDURE

QAP No. : 05/28/23JT/M-010 Date : Prepared : Approved :

ASME VIII-1, App.7 ASME B 31.3 (1990), table 341.3.2 A, Severe cyclic cond. ASME VIII-1, App.8 and 7

subject to approval Reffered API / ASTM Reffered API / ASTM Reffered API / ASTM with impact test ASME VIII-1, App.8 ASME VIII-1, App.6

ASME V, Art.7 100% presure retanings parts Reffered API / ASTM Each heat and product Reffered API / ASTM on samples taken from mill ASTM A-370

Reffered API / ASTM Reffered API / ASTM Reffered API / ASTM with impact test

Bolting PT each batch HT each heat treatment batch Chemical Analysis Mechanical properties Low temperate certificate ( if applicable )

Prepared BY

ASME V, Art.6 after final machining reffered ASTM

ASME VIII-1, App.8

Reffered API / ASTM Each heat and product Reffered API / ASTM on samples taken from mill ASTM A-370

Reffered API / ASTM

reffered ASTM

Reffered API / ASTM certificate EN 10204/3.2 Reffered API / ASTM with impact test

Approved BY

Reviewed and Approved BY

Page 2 of 2

QUALITY ASSURANCE PLAN PRESSURE SAFETY VALVE Gujarat State Petronet Ltd. SN.

INSPECTION AND TESTING

4

BW ends

5

Welds & weld repairs

6 7 8 9

each piece each piece

QAP No. : 05/28/23JT/M-010 Date : Prepared : Approved :

ACCEPTANCE CRITERIA AND CERTIFICATE 100% RT ASME V, Art.2 ASME B 31.3 (1990table 341.3.2 A, Severe cylic cond. 100% RT ASME V, Art.2 ASME B 31.3 (1990table 341.3.2 A, Severe cylic cond. ASME V, Art.9 Reffered ANSI dimensions API 598 / ASTM A-530 and data sheet API 598 / ASTM A-530 API 598 / ASTM A-530 and data sheet API 598 / ASTM A-530 Three Openings and Closing at Atmospheric and API 598 / ASTM A-530 Maximum Dififrential Presure Manufacturer’s Approved procedure BS 5351/5146 Manufacturer’s Approved procedure BS 5351 API 6FA / API 607 / BS 5146 / OCMA API 6FA / API 607 / BS 5146 / OCMA

Rev. 0 Check :

MECON Limited

PROCEDURE

Visual and Dimensional Tests each piece Hydrostatic test (shell & Nozzle) each piece Air Seat Test each piece Functional Tests each piece 10 Antistatic tests each piece 11 Anti Blow Out Tests each piece 12 Fire Safe Tested ( Certificates of previously conducted tests shall be 13 Painting as per approval procedure 14 Packing and identification Marking as per approval procedure Legend RT: Radiographic Test PT: Liquid Penetrant test HT: Heat Treatment P: Performed R: Review W: Witness TPI: Third Party inspection agency MT: Magnetic particle test

as per approval procedure as per approval procedure

Sub Vendor

Supplier/TPIA

P

100% W

P P

100% W 100% W

P

100% W

P P

100% W 100% W

-

-

P P

100% W 100% W

Remarks

VT: Visual Test

Note : 1 The above testing and acceptance criteria are minimum requirements, however, equ supplier shall ensure and that the product also comply to the additional requirements as per technical specifications and data sheets. 2 Supplier shall submit their own detailed QAP prepared on the basis of the above for approval of owner/owner's representative. 3 Supplier shall submit Caliberatio certificates of all instruments/equipments to be used for inspection and testing to TPIA with relevant procedures and updated standards for TPIA review/approval. 4 TPIA will have right to inspect minimum 10% of all manufacturing activities on each day or as specified above. 5 TPIA along with Owner/Owner's Representative shall review/ approve all the documents related to QAP/Quality Manuals/Drawings etc. submitted by supplier. 6 TPIA shall also review the Test certificates submitted by the Actuator manufacturer. 7 Contractor shall in coordination with Supplier/Sub Vendor shall issue detailed Production and Inspection Schedule indicating the dates and the locations to Facilitate Owner/Owner's Representative and TPIA to organise Inspection.

Prepared BY

Approved BY

Reviewed and Approved BY

QUALITY ASSURANCE PLAN 3 LPE COATING OF LINEPIPE

QAP NO Date Prepared by Approved by

:05/21/JT/3LPE Coating : : Checked by :

INSTRUMENTS

INSPECTION MANUF.

Rev.

MECON LIMITED Sl. No. ACTIVITY

TEST FREQUENCY

ACCEPTANCE CRITERIA

DOCUMENTAION

REFERENCE DOCUMENT

REMARKS TPIA

A.

PRIOR TO REGULAR PRODUCTION

1

Quality control test plan

Before production

-

-

TS/Approved Procedure

-

H

R

2

repair procedure

-

-

-

TS/Approved Procedure

-

H

R

3

Handling, Storage & transportation of bare and coated pipes procedure

-

-

TS/Approved Procedure

-

H

R

4

Raw material acceptance, review of test cetificates for Epoxy, Adhesive, PE

Each Batch certificate

Raw material manufacturer's test certificates.

Raw Material Cl. no. 4.1 & 4.2 of TS No.- MEC/S/05/62/014 manufacturer's test certificates.

VISUAL INSPECTION FOR MARKING

R

R

5

Test of raw material (Epoxy, adhesive & PE)

Each batch

As per material test certificate & Cl. no. 4.3(a,b&c) of TS No. MEC/S/05/62/014

Test report

-

H

W

6

Storage

All Materials

Manufacturer Recommendation

STOCK REGISTER Approved procedure

-

H

M

7

Bare pipe receipt at mill, handling & storage etc.

Each pipe

As per TS No. MEC/S/05/62/014

PACKING LIST & Test report

VISUAL

H

M

8

PROCEDURE QUALIFICATION TESTS:- BEFORE START OF REGULAR PRODUCTION 5 PIPES TO BE COATED (4 PIPES FULLY COATED WITH 3LPE AND ONE PIPE COATED PARTLY WITH EPOXY & PARTLY WITH EPOXY & ADHESIVE).

8.1

Bare pipe stacking & handling in yard/plant

8.2

Each pipe

TS No. MEC/S/05/62/014

TS No. MEC/S/05/62/014 & approved procedure

PE sheet over sand row Teflon STOCK REGISTER TS No. MEC/S/05/62/014 & approved procedure padded hooks

VISUAL

H

M

Bare pipes receiving surface defect, Bevel Each pipe damage, Grease/ oil on surface

No defects, damages, Data sheet oil/grease on pipe surface etc.

TS No. MEC/S/05/62/014

Visual solvent cleaning for pipes with oil grease

H

W

8.3

repair of Bare pipes defects

pipes removed for defects

As per API 5L & pipe Specification

Approved procedure

Bevel cutting m/c, Jacks etc.

H

W

8.4

Pre heating

All pipes

65 - 850C

Cl. no. 8.4 of TS & approved procedure

LPG Burner, contact thermometer

H

R/W

8.5

DOUBLE SHOT BLASTING

Data sheet

8.5.1

Ambientemp., Relative humidity, Dew point & Elapsed time

Each pipe

RH should be less than 85% Data sheet (IF RH> 85% no shot blasting).

TS No.MEC/S/05/62/014 and approved procedure. thermo hygrometer, Dew point apparatus

H

R/W

8.5.2

phosphoric Acid treatment

Each pipe

pH = 1-2, Pipe temp prior to Data sheet phosphoric acid treatment = 45750C or as manuf. Recommendation.

Cl. No. 8..6.2 of TS approved procedure

PH paper, contact thermometer

H

R/W

8.5.3

DM water wash

Each pipe

pH = 6.0-7.0, pipe surface should be dried

Data sheet

TS No. MEC/S/05/62/014

PH paper

H

R/W

8.5.4

Cleaniness

Each pipe

SA 2½

Data sheet

Cl no.8.7 of TS and approved procedure

ISO - 8501-1

H

R/W

8.5.5

Degree cf dust

Each pipe

Rating 2 or Class 2

Data sheet

Cl no.8.7 of TS and approved procedure

ISO - 8502-3

H

R/W

8.5.6

Surface roughness

Each pipe

50 - 70 µm (Rz)

Data sheet

Cl no.8.7 of TS and approved procedure

Surface Profile gauge, Hand held 30X magnifying glass

H

R/W

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE

Padmala - Godhra Pipeline of GSPL

Page 1 of 5

QUALITY ASSURANCE PLAN 3 LPE COATING OF LINEPIPE

QAP NO Date Prepared by Approved by

:05/21/JT/3LPE Coating : : Checked by :

Rev.

MECON LIMITED Sl. No. ACTIVITY

TEST FREQUENCY

8.5.7

Bare pipe temp.

8.5.8

Bare pipe temp. after Epoxy application by Every pipe by online pyrometer IR thermometer recording

9

Every pipe

ACCEPTANCE CRITERIA

DOCUMENTAION Test report

0

180-230 C or as per manuf. Recommendation

190-230 0C or as per manufacturer recommendation

TS No. MEC/S/05/62/014 & approved procedure

INSPECTION MANUF. contact thermometer H

TPIA R/W

TS No. MEC/S/05/62/014

IR Optical pyrometer

H

R/W

H

W

H

W

H

W

REFERENCE DOCUMENT

INSTRUMENTS

REMARKS

TEST ON COATED PIPES PARTLY WITH EPOXY AND PARTLY WITH EPOXY & ADHESIVE LAYERS

9.1

Epoxy layer thickness

One pipe at 3,6,9,12 positions

180µm min.

Test report

9.2

Adhesive Layer thk.

One pipe at 3,6,9,12 positions

200µm min.

Test report

9.3

Degree of cure

One pipe(one sample)

Test report

9.4

Adhesion test (St. Andrews cross Method) One pipe

∆Tg = +3, -20C % cure = 95% min. Rating -1-3

Sl. No. 3 of amendment-1 to TS & as per approved Coating thk. gauge procedure Sl. No. 3 of amendment-1 to TS & as per approved Coating thk. gauge procedure Cl. no. 7.5.1.(a) of TS DSC Machine

Test report

Cl. no. 7.5.1.(e) of TS

Utility knife

H

W

10 10.1

TEST ON COATED PIPES WITH ALL THREE LAYERS heat ageing, Light ageing, Coating (each batch test certificate resistivity typical value will be issued by manufacture)

Melt rate shall not deviate by more than 35% of original value and Coate resistivity shall be 10 8 ohm-m2 minimum

Test report

DIN 30670

-

R

R

10.2

Bond strength test at ends & middle

Three pipe

@ 20+50C = 8 Kg/Cm 0 @65+5 C = 5 KG/Cm

Test report

Cl. no. 7.5.2.(a) of TS & approved procedure

H

W

10.3

Degree of cure

One pipe (One sample)

Test report

Cl. no. 7.5.2.(e) of TS & approved procedure

Peel test M/C by dynamometer (type2) DSC Machine

H

W

10.4 10.5

Impact strength Indentation test

Test report Test report

Cl. no. 7.5.2.(b) of TS & approved procedure Cl. no. 7.5.2.(c) of TS & approved procedure

H H

W W

10.6

Elongation at failure

Test report

Cl. no. 7.5.2 (d) of TS & approved procedure

H

W

10.7

Cathodic Disbondment test

Three PE coated pipes only (5 samles from each pipe) Two samples for 30 days at 60 0 + 30C, one sample for 48 hrs. at 600 + 30C

ASTM G-42 & sl. No. 01 of amendment-1 of TS No. CD, test assembly MEC/S/05/62/014

H

W

10.8

Holiday test at 25 kv

All pipes

Cl. no. 7.5.2(f) of TS & approved procedure

Holiday detector

H

W

10.9

Over all Coating Thickness

All pipes

Coating thk. gauge

H

W

10.10 Air entrapment at 30X magnification

All pipes

Test report

Cl. No. 7.5.2.(g) of TS & Sl. No. 03 of ammendment-1 to TS no. MEC/S/05/62/014 Cl. no. 7.5.2.(h) of TS No. MEC/S/05/62/014

30X magnification hand-held microscope

H

W

10.11 Visual inspection

All pipes

Test report

TS no. MEC/S/05/62/014

Visual

H

W

10.12 Cut back length

All pipes

Test report

Sl. No. 04 of ammendment-1 to TS no. MEC/S/05/62/014

steel Scale

H

W

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE

∆Tg = 3, -20C % cure = 95% min. Three pipe 7 Joules/mm Twp sample for both temp. from 0.2 max. at 23+ 20C 4 pipes 0.3 max. at 70+ 20C 300% min.

Test report ECR = 15 mm max. (for 30 days) - at 60 0C+ 30C 0 7 mm max. (for 48 hrs. at 60 C + 30C Test report Max. + 30C One holiday surface area < 0.01 sq.mtrs. (repair as per approved Procedure) 3.2mm on Body (S-v) Test report Polyethylene and adhesive layers shall have not more than 10% of the observed area. No defect (Blisters, pinholes scratches, wrinklee etc.) 110 mm, (+)20, (-) 0 mm

Padmala - Godhra Pipeline of GSPL

Impact tester Controlled temp, bath, Dial Gauge, weight Tensile M/C

Page 2 of 5

QUALITY ASSURANCE PLAN 3 LPE COATING OF LINEPIPE

QAP NO Date Prepared by Approved by

:05/21/JT/3LPE Coating : : Checked by :

INSTRUMENTS

INSPECTION MANUF.

Rev.

MECON LIMITED Sl. No. ACTIVITY B 1 2

TEST FREQUENCY

REGULAR PRODUCTION BARE PIPES AT INLET Bare pipe stacking & handling in Each pipe yard/plant Bare pipes receiving surface defect, Bevel Each pipe damage, Grease/ oil on surface

ACCEPTANCE CRITERIA

DOCUMENTAION

REFERENCE DOCUMENT

PE sheet over sand row Teflon STOCK REGISTER TS no. MEC/S/05/62/014 & approved procedure padded hooks No defects, damages, Data sheet TS no. MEC/S/05/62/014 & approved procedure oil/grease on pipe surface etc.

3

repair of Bare pipes defects

pipes removed for defects

4

recording of pipe parameters and tick off against mill packing list. Pre heating

Each pipe All pipes

As per API 5L & pipe Specification Clear visibility OF STENCIL MARKING 0 65 - 85 C

C. 1

DOUBLE SHOT BLASTING Ambient temp., relative humidity, Dew point and Elapsed time.

Start of every shift thereafter every 1 hr.

2

phosphoric Acid treatment

Each pipe

3

DM water wash

Each pipe

4

Cleaniness

5

REMARKS TPIA

VISUAL

H

M

Visual solvent cleaning for pipes with oil Bevel cutting m/c, Jacks etc. Visual & white paint

H

M

H

W

H

M

-

API 5L & pipe specification

Test report

Mill packing list

Data sheet

Cl. no. 8.4 of TS & approved procedure

LPG Burner, contact thermometer

H

R/W

RH should be less than 85% (If Data sheet RH> 85% no shot blasting).

TS no. MEC/S/05/62/014

Thermo hygrometer, Dew point apparatus

H

R/W

Cl. no. 8.6 of TS & approved procedure

PH paper, contact thermometer

H

R/W

TS no. MEC/S/05/62/014

PH paper

H

R/W

Each pipe

pH = 1-2, Pipe temp prior to Data sheet phosphoric acid treatment = 450 75 C or as per manuf. Recommendation. pH = 6.0-7.0, pipe surface Data sheet should be dried SA 2½ Data sheet

H

R/W

Degree of dust

Each pipe

Rating 2 or Class 2

Data sheet

H

R/W

6

Surface roughness

Each pipe & one in 50 pipes by press-o-film

50 - 70 µm (Rz)

Data sheet

H

R/W

D. 1

COATING APPLICATION Bare pipe temp.

H

R/W

H

R/W

H

R/W

H

R/W

H

M

5

180 - 230 0C or as per powder Data sheet manufacturer recom. Bare pipe temp. after Epoxy application by Every pipe by online pyrometer. 190-230 0C or as per powder IR thermometer Recording every one hour. manufacturer recommendation

TS No. MEC/S/05/62/014 & approved procedure

contact thermometer

TS No. MEC/S/05/62/014 & approved procedure

IR Optical phrometer

3

Adhesive film temperature.

Every hour.

200 - 240 0C or as per manufacturer recom.

Test report

TS no. MEC/S/05/62/014

4

PE film temperature.

Every hour.

Test report

TS no. MEC/S/05/62/014

5

Recording of batch no.'s of Epoxy, Adhesive Polyethylene ON LINE INSPECTION & TESTING Epoxy layer thickness

Every hour.

220-270 0C or as per manufacturer's recommendation. As per standard data

Test report

Manufacturer's test certificate

Optical pyrometer/digital thermometer Optical pyrometer/digital thermometer visual

2

E. 1

Every pipe

Cl. no. 8.7 of TS no. MEC/S/05/62/014 & approved ISO - 8501-1 procedure Cl. no. 8.7 of TS no. MEC/S/05/62/014 & approved ISO - 8502-3 procedure Cl. no. 8.7 of TS & approved procedure Surface Profile gauge, Hand held 30X

Every shift at 3,6,9,12 positions

2

Holiday test at 25 kv

All pipes

3

Over all Coating Thickness

All pipes

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE

Epoxy thk. - 0.18mm min. Test report Adhs. Thk. - 0.20mm min. Max. one holiday surface area Test report < 0.01 sq. mtrs. (repair as per approved procedure) 3.2mm on Body (S-v) Test report

Cl. no. 10.3 of TS & approved procedure

Coating thk. Gauge.

R/W H

Cl. no. 10.4 of TS & approved procedure

Holiday detector

Sl. no. 03 of ammendment-1 to TS no. MEC/S/05/62/014

Coating thickness gauge

R/W

H

Padmala - Godhra Pipeline of GSPL

W H

Page 3 of 5

QUALITY ASSURANCE PLAN 3 LPE COATING OF LINEPIPE

QAP NO Date Prepared by Approved by

:05/21/JT/3LPE Coating : : Checked by :

INSTRUMENTS

INSPECTION MANUF.

Rev.

MECON LIMITED Sl. No. ACTIVITY

TEST FREQUENCY

F. 1

OFF LINE TESTS Impact test. (30 Impacts) at 30mm intervals.

Two pipes per shift.

2

Resistance to peel test at cut back ends.

One in 50 pipes.

3

Resistance to indentation test (Two samples for each temp.)

Two pipes per shift.

4

Air entrapment at 30X magnification

One sample per shift

DOCUMENTAION

7J/mm Impact energy (No holiday shall be observed at 25KV at impact area.) Peel strength at 20 + 50C 8.0Kg/cm min. Peel strength at 60 + 50C 5Kg/cm min.

REFERENCE DOCUMENT

Cl. no. 10.5 of TS & approved procedure

Impact test instrument

Cl. no. 10.6 & amendment-1 to TS no. MEC/S/05/62/014

Peel test Machine, chisel etc.

Cl. no. 10.7 of TS & as per approved procedure

Indentation bath heater, dial gauge, thermostate 30X magnification hand-held microscope

Test report

Test report Test report

At 23+20C = 0.2mm At 70+20C=0.3mm

Cl. no. 10.8 of TS. Polyethylene and adhesive layers shall have no more than 10% of the observed area. Test report ∆Tg = 3, -20C % cure = 95% min. Test report Test report

5

Degree of cure

6

Adhesion test (St. Andrews cross Method) Once per shift

7

Cathodic Disbondment test

G. 1

FINAL INSPECTION Cut back length at ends.

2

Marking on caoted pipes external color band

H. 1 2 I. 1

HANDLING & STORAGE Repair of Coating followed by holiday detection at 25 KV Peel test on repari area RECOMMENDATION Handling

Each pipes

No damages on coated pipes. STOCK REGISTER TS no. MEC/S/05/62/014 Support bed, min. 2 nos. support on trailor & securing by three wire rope covered with nylon rubber tubing

2

Storage

Each pipes

Proper stacking on sand rows covered with PE sheets with stack separator.

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE

Once per shift

ACCEPTANCE CRITERIA

Cl. no. 10.9 of TS

DSC M/C

Cl. no. 10.10 of TS

Utility knife

REMARKS TPIA

H

W

H

W

H

W

H

W

H H

W W

Every batch no. of epoxy powder.

Max. Disbondment radius 7 mm (At 650C + 30C for 48 hours.

Test report

Cl. no. 10.11 of TS & approved procedure

Test vessel D.C. votage supplier electrodes etc.

H

W

Each pipes

110 mm, (+)20, (-) 0 mm

Test report

Cl. no. 9.2.11 & sl. no. 04 of amendment-1 to TS no. MEC/S/05/62/014

Measuring tape, scale etc. and visual

W

M

Each pipes

Proper information on coated As per TS No. surface (ME side) I.e. as MEC/S/05/62/014 follows. (1 mtr. From end PROJECT ……PIPE DIA… WALL THK…. PIPE NO… LENGTH…HEAT NO…….. COATING No….COLOUR BAND, ANY OTHER INFORMATION CONSIDERED RELEVANT BY COMPANY

Spray gun, stencil paper etc.

H

M

All coating repair

All repairs as per approved procedure As per manufacturer's

Test report

Cl. no. 12.0 of TS no. MEC/S/05/62/014

H

W

Test report

TS no. MEC/S/05/62/014

H

W

Crane with teflon padded hooks, trailor with rubber padded beds etc.

H

R/W

--do--

H

R/W

One in 25 pipes

STOCK REGISTER TS no. MEC/S/05/62/014

Padmala - Godhra Pipeline of GSPL

Heating torch. Chisel, scale etc. Spring balance

Page 4 of 5

QUALITY ASSURANCE PLAN 3 LPE COATING OF LINEPIPE

QAP NO Date Prepared by Approved by

:05/21/JT/3LPE Coating : : Checked by :

INSTRUMENTS

INSPECTION MANUF.

Rev.

MECON LIMITED Sl. No. ACTIVITY

TEST FREQUENCY

J. 1

CALIBRATION OF EQUIPMENT Digital thermometer

Every month.

2

Thickness gauge.

3

ACCEPTANCE CRITERIA

DOCUMENTAION

REFERENCE DOCUMENT

REMARKS TPIA

Test report

Ref. Thermometers, water/ oil bath etc.

H

R/W

Every month.

Add or subtract the observed value w.r.t. reference measurement. ----di---

Test report

H

R/W

Roughness gauge

Every month.

----di---

Test report

ref. Thickness foils, steel Standard roughness

H

R/W

4

Holiday detector

Every month.

By spark gap method

Test report

H

W

5

Hygrometer

Once in four month

By spark gap method

Test report

H

W

6 D meter Every time before use By standard thickness block Test report Raw Material Combination to be used During Production as per ANNEXURE - 1 of TS no. MEC/S/05/62/014 LEGEND : W = WITNESS; H = HOLD; M = MONITORING; R = REVIEW OF DOCUMENTS; R/M = RANDOM CHECK; A = APPROVED; TPIA = THIRD PARTY INSPECTION AGENCY Notes:1 2 3 4 5 6

Spark gap assmbly/ Calibrated meter

The above Testing and acceptance criteria are minimum requriements, however, equipment supplier shall ensure and that the product also comly to the additional requirements as per Technical Specifications and data sheets. The supplier shall submit their own detailed QAP prepared on the basis of the aboe for approval of Owner/Owner's representative and TPIA. Supplier shall submit Calibration certificates of all instruments/Equipments to be used for inspection and Testing to TPIA with relevent procedures and updated standards for TPIA review/Approval. TPIA will have Right to inspect minimum 10% of all manufacturing activities on each day or as specified above. TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/drawigs etc. submitted by suppler. Contractor shall in coordination with Supplier/Sib vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitaate Owner/Owner's representative and TPIA to organise inspection.

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPE

Padmala - Godhra Pipeline of GSPL

Page 5 of 5

QAP NO Date

QUALITY ASSURANCE PLAN 3 LPP COATING OF LINEPIPE

Prepared by Approved by

: 05/21/JT/3LPP Coating : Checked by :

Rev.

:

MECON LIMITED Sl. No. ACTIVITY A. 1 2 3 4

5

6 7 8 8.1 8.2

8.3 8.4

TEST FREQUENCY

PRIOR TO REGULAR PRODUCTION Quality control test plan Before production repair procedure Handling, Storage & transportation of bare and coated pipes procedure Raw material acceptance review of test Each Batch certificate cetificates for Epoxy, Adhesive, Poly propy,ene & repair product. Test of raw material Each batch (Epoxy, adhesive & Poly propylene & repair product) Storage All Materials

ACCEPTANCE CRITERIA

DOCUMENTAION

REFERENCE DOCUMENT

INSTRUMENTS

INSPECTION MANUF.

REMARKS TPIA

-

-

TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure

-

H H H

R R R

Raw material manufacturer's test certificates.

Raw Material manufacturer's test certificates. Test report

TS no. MEC/S/05/21/014B

R

R

Cl. No. 4 of TS MEC/S/05/21/014B

VISUAL INSPECTION FOR MARKING -

H

W

TS/ Approved Procedure

-

H

M

As per manufacturer recommednation & TS NO. MEC/5/05/62/014B Manufacturer Recommendation STOCK REGISTER

Bare pipe receipt at mill, handling & Each pipe As per TS PACKING LIST & Test TS/ Approved Procedure VISUAL H M storage etc. report PROCEDURE QUALIFICATION TESTS:- BEFORE START OF REGULAR PRODUCTION 5 PIPES TO BE COATED (4 PIPES FULLY COATED WITH 3LPE AND HDPE, ONE PIPE COATED PARTLY WITH EPOXY & PARTLY WITH EPOXY & ADHESIVE). Each pipe As per Cl. No.10 of TS TS/ Approved Procedure VISUAL H M Bare pipe stacking & handling in yard/plant Bare pipes receiving Each pipe No defects, damages, oil/grease Data sheet TS/ Approved Procedure Visual solvent H W surface defect, Bevel damage, Grease/ oil on pipe surface etc. cleaning for pipes on surface with oil grease repair of Bare pipes defects pipes removed for defects As per API 5L & pipe API 5L/ Pipe Specficiation Bevel cutting m/c, H W Specification Jacks etc. Pre heating All pipes Data sheet TS/ Approved Procedure LPG Burner, contact H R/W 65 - 850C thermometer

8.5 DOUBLE SHOT BLASTING 8.5.1 Ambientcemp., Relative humidity, Dew point & Elapsed time

Each pipe

8.5.2 Phosphoric Acid treatment

Each pipe

8.5.3 DM water wash

Each pipe

8.5.4 Cleaniness 8.5.5 Degree of dust 8.5.6 Surface roughness

Each pipe Each pipe Each pipe

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP

Ambient temp shall be max. 350C & less than 100C. RH should be less than 85% (IF RH> 85% no shot blasting). pH = 1-2, Pipe temp prior to phosphoric acid treatment = 450 75 C or as manuf. Recommendation. pH = 6.0-7.0, pipe surface should be dried SA 2½ Rating 2 or Class 2 50 - 70 µm (Rz)

Data sheet

TS/ Approved Procedure

Thermo hygrometer, Dew point apparatus

H

R/W

Data sheet

TS/ Approved Procedure

PH paper, contact thermometer

H

R/W

Data sheet

TS/ Approved Procedure

PH paper

H

R/W

Data sheet Data sheet Data sheet

TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure

ISO - 8501-1 ISO - 8502-3 Surface Profile gauge, Hand held 30X magnifying glass

H H H

R/W R/W R/W

Padmala - Godhra Pipeline of GSPL

Page 1 of 5

QAP NO Date

QUALITY ASSURANCE PLAN 3 LPP COATING OF LINEPIPE

Prepared by Approved by

: 05/21/JT/3LPP Coating : Checked by :

Rev.

:

MECON LIMITED Sl. No. ACTIVITY

TEST FREQUENCY

ACCEPTANCE CRITERIA

DOCUMENTAION

0

185 - 210 C for liquid epoxy coat Test report 0 130-200 C for powder epoxy coat or as per manuf. Recommendation 8.5.8 Bare pipe temp. after Epoxy application by Every pipe by online 190-2300C or as per IR thermometer pyrometer recording powdermanufacturer recommendation 9 TEST ON COATED PIPES PARTLY WITH EPOXY AND PARTLY WITH EPOXY & ADHESIVE LAYERS 9.1 Epoxy layer thickness One pipe at 3,6,9,12 0.18 mm min. Test report positions 9.2 Adhesive Layer thk. One pipe at 3,6,9,12 0.20 mm min. Test report positions 0 9.3 Degree of cure One pipe(one sample) Test report △ Tg = +3, -2 C % cure = 95% min. 9.4 Adhesion test Two locations Rating -1-3 Test report 9.5 Electrical Porosity at 25 KV One pipe No defects Test report

8.5.7 Bare pipe temp.

Every pipe

REFERENCE DOCUMENT

INSTRUMENTS

REMARKS

TS/ Approved Procedure

INSPECTION MANUF. contact thermometer H

TS/ Approved Procedure

IR Optical phrometer

H

M

TS/ approved procedure

Coating thk. gauge

H

W

TS/ approved procedure

Coating thk. gauge

H

W

TS/ Approved Procedure

DSC Machine

H

W

TS/ Approved Procedure TS/ Approved Procedure

Utility knife DC Holiday detector

H H

W W

Hydraulic, press/ binding manfa. Etc. Microscope knife etc.

H

W

H

W

TPIA R/W

9.6

2.50 Flexibility test

One pipe ( 3 Specimens)

No Cracking

Test report

TS/ Approved Procedure

9.7

Cross section & Interface porosity test

One pipe ( 3 Specimens)

Rating - 1-4

Test report

TS/ Approved Procedure

Larger than 390% 3.2 mm

Test report Test report

ASTM D 638/ NF A - 49-74 TS/ Approved Procedure

Magnatic/ electromagnatic type over lap measuring instrument

R H

R W

110 mm , + 20 mm no defects > 15 Nm / mm > 60 0 > 500 N/ 50 mm 50+5 C 0 > 400 N/50 mm 90+5 C 0 < 0.1 mm at 25 C 0 <0.3 mm at 100 C No holiday, no crack, no surface defect < 15 mm after 60 days < 7 mm after 48 hrs. 8 2 > 10 ohm x m CL. No.5.3.4 (d) of TS 10% thickness △Tg = +3, -2% cure - 95% min.

Test report Test report Test report Test report Test report

TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure r

Steel tape DC holiday Pile Hammer

H H H H H

W W W W W

Test report

TS/ Approved Procedure

H

W

Test report

TS/ Approved Procedure

H

W

Test report

TS/ ASTM G8

H

W

Test report Test report Test report Test report

TS/ NFA 49-711 Cl . No.7.5.2 (d) of TS Cl. No. 7.5.2 (h) of TS Cl. No. 7.5.2 (i) of TS

H H H H

W W W W

10 TEST ON COATED PIPES WITH ALL THREE LAYERS 10.1 U.V. Aging Each pipe 10.2 Overall Thickness Each pipe

10.3 10.4 10.5 10.6 10.7

Cut back Electrical Porosity at 25 KV Impact Test Rockwell Hardness Resistance to peeling

Each pipe Each pipe Three pipe Each pipe Each pipe

10.8 Indentation

All pipes

10.9 Bendability

Each pipe

10.10 Cathodic disbonding

Three samples

10.11 10.12 10.13 10.14

Each pipe Two pipes Each pipe One pipe

Coating Specific Resistivity Elongation at Break Air entrapment Digree of cure

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP

Padmala - Godhra Pipeline of GSPL

Dynometer

Bending Machine

As Per TS As per TS 30x microscopr DSC Machine

Page 2 of 5

QAP NO Date

QUALITY ASSURANCE PLAN 3 LPP COATING OF LINEPIPE

Prepared by Approved by

: 05/21/JT/3LPP Coating : Checked by :

Rev.

:

MECON LIMITED Sl. No. ACTIVITY B 1 2

TEST FREQUENCY

REGULAR PRODUCTION BARE PIPES AT INLET Bare pipe stacking & handling in Each pipe yard/plant Bare pipes receiving surface defect, Bevel Each pipe damage, Grease/ oil on surface

3

Repair of Bare pipes defects

4

Recording of pipe parameters and tick off Each pipe against mill packing list. Pre heating All pipes

5

pipes removed for defects

ACCEPTANCE CRITERIA

DOCUMENTAION

-

REFERENCE DOCUMENT

INSTRUMENTS

INSPECTION MANUF.

REMARKS TPIA

TS/ Approved Procedure

VISUAL

H

M

No defects, damages, oil/grease Data sheet on pipe surface etc.

TS/ Approved Procedure

H

M

As per API 5L & pipe Specification Clear visibility OF STENCIL MARKING 65 - 850C

-

TS/ Approved Procedure

H

W

Test report

Mill packing list

Visual solvent cleaning for pipes with oil Bevel cutting m/c, Jacks etc. Visual & white paint

H

M

Data sheet

TS/ Approved Procedure

LPG Burner, contact thermometer

H

W

C. 1

DOUBLE SHOT BLASTING STATION. Ambient temp., relative humidity, Dew point and Elapsed time.

Start of every shift thereafter RH should be less than 85% (IF Data sheet every 1 hr. RH> 85% no shot blasting).

TS/ Approved Procedure

Thermo hygrometer, Dew point apparatus

H

M

2

Phosphoric Acid treatment

Each pipe

Data sheet

TS/ Approved Procedure

PH paper, contact thermometer

H

R/W

3

DM water wash

Data sheet

TS/ Approved Procedure

PH paper

H

R/W

4 5 6

Cleaniness Degree of dust Surface roughness

Data sheet Data sheet Data sheet

TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure

ISO - 8501-1 ISO - 8502-3 Surface Profile gauge, Hand held 30X

H H

R/W R/W

H

R/W

D. 1

COATING APPLICATION Bare pipe temp. before epoxy application Every pipe

H

R/W

H

R/W

H

R/W

H

R/W

H

R/W

2

pH = 1-2, Pipe temp prior to phosphoric acid treatment = 450 75 C or as manuf. Recommendation. Each pipe pH = 6.0-7.0, pipe surface should be dried Each pipe SA 2½ Each pipe Rating 2 or Class 2 4 per shift on each of the first 50 - 70 µm (Rz) 25 pipes

3

Bare pipe temp. after Epoxy application by Every pipe by online IR thermometer pyrometer. Recording every one hour. Adhesive film temperature. Every hour.

4

PE film temperature.

Every hour.

5

Recording of batch no.'s of Epoxy, adhesive & polyethylene

Every batch

0

210 - 220 C or as per powder manufacturer recom. 185-2100C or as per powder manufacturer recommendation

Test report

contact thermometer TS/ As per Approved Procedure

-

IR Optical phrometer TS/ Approved Procedure

0

180 - 230 C or as per manufacturer recom.

Test report TS/ Approved Procedure

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP

0

240-260 C or as per manufacturer's recommendation. As per standard data

Test report TS/ Approved Procedure Test report Manufacturer's test ceritificate

Padmala - Godhra Pipeline of GSPL

Optical pyrometer/digital thermometer Optical pyrometer/digital thermometer visual

Page 3 of 5

QAP NO Date

QUALITY ASSURANCE PLAN 3 LPP COATING OF LINEPIPE

Prepared by Approved by

: 05/21/JT/3LPP Coating : Checked by :

Rev.

:

MECON LIMITED Sl. No. ACTIVITY E. 1

ON LINE INSPECTION & TESTING Epoxy & adhesive thickness

TEST FREQUENCY

ACCEPTANCE CRITERIA

DOCUMENTAION

Epoxy thk. - 0.18mm min. Test report Adhs. Thk. - 0.20mm min. Max. one holiday surface area < Test report 0.01 sq. mtrs.

REFERENCE DOCUMENT

2

Holiday test at 25 kv

Every shift at 3,6,9,12 positions All pipes

3

Over all Coating Thickness

All pipes

3.2mm on Body

Test report

Cut back OFF LINE TESTS Epoxy layer thickness

All pipes

110 mm, + 20 mm

Test report

TS/ Approved Procedure TS/ Approved Procedure

0.18 mm min.

Test report

TS/ As per approved procedure

INSTRUMENTS

2.0

Adhesive Layer thk.

3.0

Degree of cure

One pipe at 3,6,9,12 positions One pipe at 3,6,9,12 positions One pipes (one sample)

4.0 5.0 6.0 7.0

Adhesion test Impact Strength Rockwell Hardness Strength

3 pipes 1 pershift 1 pershift 1 pershift

8.0

Rockwall Hardness

9.0

Resistance to peeling

1 pipe per shift, one test per 50 pipes 1 test per shiftbut 5 test minimum 1 test per shiftbut 5 test minimum

10.0 Indentation G. 1

FINAL INSPECTION Cut back length at ends.

2

Marking on caoted pipes external color band

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP

REMARKS TPIA

Coating thk. Gauge. TS/ Approved Procedure

H

W

H

W

H H

W W

H

W

H

W

H H H H H

W W W W W

Holiday detector TS/ Approved Procedure

4 F. 1.0

INSPECTION MANUF.

Coating thickness gauge Steel Scale Coatng thk. gauge Coatng thk. gauge

0.20 mm min. 0 △Tg = +3, - 2 C % cure = 95% min. Rating - 1-3 15 Nm/ mm thick. > 60 0 500 N/ 50mm, 50+ 5 C 0 400 N/ 50mm, 90+ 5 C

Test report

TS/ As per approved procedure DSC Machine

Test report Test report Test report Test report Test report

TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure TS/ Approved Procedure

> 60

Test report

TS/ Approved Procedure

H

W

> 750 N/ 50 mm

Test report

TS/ Approved Procedure

H

W

< 0.1 mm at 250C 0 < 0.3 mm at 100 C

Test report

TS/ Approved Procedure

H

W

Each pipes

110 mm, + 20 mm

Test report

TS/ Approved Procedure

H

W

Each pipes

STOCK REGISTER Proper information on coated surface (ME side) I.e. as follows. (1 mtr. From end PROJECT ……PIPE DIA… WALL THK…. PIPE NO… LENGTH…HEAT NO…….. COATING No….COLOUR BAND, ANY OTHER INFORMATION CONSIDERED RELEVANT BY COMPANY

H

W

TS/ Approved Procedure

Padmala - Godhra Pipeline of GSPL

Utility knife -

Measuring tape, scale etc. and visual

Page 4 of 5

QAP NO Date

QUALITY ASSURANCE PLAN 3 LPP COATING OF LINEPIPE

Prepared by Approved by

: 05/21/JT/3LPP Coating : Checked by :

Rev.

:

MECON LIMITED Sl. No. ACTIVITY

TEST FREQUENCY

2

HANDLING & STORAGE Repair of Coating followed by holiday detection at 25 KV Peel test on repari area

One in 25 pipes

I. 1

RECOMMENDATION Handling

Each pipes

2

Storage

Each pipes

J. 1

CALIBRATION OF EQUIPMENT Digital thermometer

Every month.

2

Thickness gauge.

3 4

H. 1

5

All coating repair

ACCEPTANCE CRITERIA

All repairs as per approved procedure As per manufacturer's recommendation

DOCUMENTAION

REFERENCE DOCUMENT

Test report

TS

Test report

TS

No damages on coated pipes. STOCK REGISTER Support bed, min. 2 nos. support on trailor & securing by three wire rope covered with nylon rubber tubing Proper stacking on sand rows STOCK REGISTER covered with PE sheets with stack separator.

Heating torch. Chisel, scale etc. Spring balance

INSPECTION MANUF.

REMARKS TPIA

H

R/W

H

R/W

TS

Crane with teflon padded hooks, trailor with rubber padded beds etc.

H

R/W

TS

--do--

H

R/W

Test report

Calibration procedure

Ref. Thermometers, water/ oil bath etc.

H

R/W

Every month.

Add or subtract the observed value w.r.t. reference measurement. ----di---

Test report

Calibration procedure

H

R/W

Roughness gauge

Every month.

----di---

Test report

Calibration procedure

Ref. Thickness foils, steel Standard roughness

H

R/W

Holiday detector

Every month.

By spark gap method

Test report

Calibration procedure

Spark gap assmbly/ Calibrated meter

H

Hygrometer

Once in four month

By spark gap method

Test report

Calibration procedure

6 D meter Every time before use By standard thickness block Test report Calibration procedure Raw Material Combination to be used During Production as per ANNEXURE - 1 As per TS No. MEC/S/05/21/014B LEGEND : W = WITNESS; H = HOLD; M = MONITORING; R = REVIEW OF DOCUMENTS; R/M = RANDOM CHECK; A = APPROVED; TPIA = THIRD PARTY INSPECTION Notes:1 2 3 4 5 6

INSTRUMENTS

W

H

W W

The above Testing and acceptance criteria are minimum requriements, however, equipment supplier shall ensure and that the product also com;y to the additional requirements as per Technical Specifications and data sheets. The supplier shall submit their own detailed QAP prepared on the basis of the aboe for approval of Owner/Owner's representative and TPIA. Supplier shall submit Calibration certificates of all instruments/Equipments to be used for inspection and Testing to TPIA with relevent procedures and updated standards for TPIA review/Approval. TPIA will have Right to inspect minimum 10% of all manufacturing activities on each day or as specified above. TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/drawigs etc. submitted by suppler. Contractor shall in coordination with Supplier/Sib vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitaate Owner/Owner's representative and TPIA to organise inspection.

T Roy/Desktop/r gspl/QAP 3LPE Coating of Linepipe3LPP

Padmala - Godhra Pipeline of GSPL

Page 5 of 5

APPENDIX-IV LIST OF APPROVED VENDORS FOR BOUGHT OUT ITEMS

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Man Industries (P) Ltd

1

M/s Khartstzk Tube Works

4

LSAW Line Pipes with EUROPIPE three layer external PE/PP and internal Mannesmannröhrencoating Werke

7

TENARIS (TECHINT)

8

THYSSEN STAHLUNION GMBH

9

Corus International Projects

10

Vallouarec Industries

11

12

Man House, 15, PU-3, AB Road, Indore-452008 and Anjar,Kutch Gujarat

9, paton Str, Khartsyzsk, Donestk Region, 86703, Ukraine Formerstrasse, 49 40878 Ratingen Germany Wiesenstrasse 36 45473 Mülheim a.d. Ruhr GERMANY Cantonment Road, 200 # 04-01 Southpoint 089763 Singapore SINGAPORE P.O.Box. No.101048 40001 Dusseldorf Germany Hampton House, 20, Albert Embankment London SE1 7TJ, United King dom 130 Rue De Silly, BP 415, 92103 Boulogne- Bilancourt, Cedex France

0731-559070-73

Fax No

Qualified for Size

0731-57891-92

Up to 30"

11-26170691

Up to 30"

022-22490 8020

Up to 30"

00 380 6257 71032

00380 6257 45695

Up to 56"

+ 49 21 02 85 70

+ 49 21 02 85 72 85 Up to 30"

+ 49 208 458 01

+ 49 208 458 19 99 Up to 30"

+ 65 224 90 77

+ 65 222 40 90

Up to 30"

+492119670

+492119675398

Up to 30"

+442079758393/ +442079758370

+442079758406

Up to 30"

+33 1 49093500

+33 1 49093705

Up to 30"

HSAW Lines pipe with three layer external PE/PP and internal coating HSAW Line Pipe,Vendor shall be confirmed during the Pre-bid meeting.

13

Hyundai corporation

226, 1-G-A, Sinmunno Jongho GV, Seoul, 110786, Korea

14

Seah Steel Corporation

10 Bongnae-Dong 1, Joong-Gu, Seoul South Korea

15

Umran Steel

85/5, 80040 Salipazan Istanbul, Turkey

16

Phone No

Saw Pipes Limited Jindal Centre 011-26188360-74 12, Bikhaji Cama place New Delhi – 110 066 Trade World, "B" Wing, Gr. Floor, Welspun Gujarat Stahl Kamla Mill compound, Senapati 022-5650 3000 Rohren Ltd bapat marg, Lower parel, MUMBAI 400 013

3

6

Address

Saw Pipes Limited

2

5

Name of the vendor

ERW Line Pipes

82-2-390-1114

82-2-390-1693

Av. Gasto Vidigal Neto, 475 Cidade Comfab Industrial S.A. Nova 12414-020 Pindamonhangabasp, Brazil

17

ILVA SpA

Viale certosa, 249 Milano, Italy

18

HU Steel Corpoation

South Korea

19

Surya Roshni Limited

Prakash Nagar, Bahdurgarh, Haryana - 124 507 Email : [email protected]

20

Welspun Gujarat Stahl Anjar, Kutchh, Gujarat Rohren Ltd

01276-241 540, 241 296/97

01276-241 886

upto 12" size,

02836-573428/29

2856-247070

upto 12" size,

Contractor shall ensure that each line pipe manfacturer shall have valid API 5L license and in case of firm order the license should be valid till complete execution of supplies 21

Vendor list .xls

3LPE Pipe Coating

PSL Holdings Ltd

386, Veer Savarkar Marg, Prabhadevi, Mumbai- 400 025

(022) 4307023, 4309058

(022) 430 7365, 430 5335

page 1 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

22

Ishwardas Aggarwal & Sons (Trader)

23

M.J. Patel & Company(Trader)

116, P.D. Mello Road, Near Carnace Bridge, MUMBAI - 400 009

24

Apex Tubes Pvt. Ltd. Apex Tubes Pvt. Ltd. 1/6-B, Asaf Ali Road (Manufacturer & Trader) New Delhi – 110 002

25

Steel Tubes (India)

Station Piping (Trader) (Seamless Pipes) Trader

526/36, Maulana Azad Road, Floor, Gulalwadi Circle, MUMBAI - 400 004

Phone No

Fax No

+91 22 342 2566

+91 22 342 3782

-

-

2nd

+91 22 389 5908 +91 22 381 2564

+9122 3895906

Nagardas Kanji Shah (Trader)

176, Magazine Street, Darukhana, Mazgaon, Mumbai- 400 010

(022) 3721066/ 3724157, 3781031

(022) 3781032

27

Jyoti Industries

P.B.No. 3081, 276/278, Samuel Street, 2nd Floor, Vadgadi, Mumbai400 003

(022) 3435091/92, 3451530

(022) 3421391

28

The Bengal Mill Stores Supply Co (Trader)

205, Magnanial Chambers, Baburao Bobde Marg, Iron Market, Mumbai400 009

(022) 3430105, 3430107, 3434918, 3442864

(022) 3414763

29

Radiant Engineering Co.

M-2, Sundaram, Sion Circle, Mumbai- (022) 409 2016, 4096036 400 022

(022) 4094822

30

Tianjin Pipe corporation

PO Box 17537, Jebel Ali Free Zone, Dubai, U.A.E

97148833899

31

Mitsubihsi

33

Seamless Pipe Manfacturer

97148833799

Trub chomutov TENARIS

34

Valcvony

35

Vallurorec Maneshman Tubes Barzil

36

Virgo Engineers Ltd,Pune

Virgo Engineers,J/517, MIDC 020-2747 4481 Bhosari,Pune – 411 026 Oswal Industries Limited 404, Sakar-III Oswal Industries Ltd 079-30947636 Opp. Old High Court Ahmedabad – 390 014 Plot no. R-241, TTC Industrial Area Steel Strong Valves (P) MIDC,Rabale, New Bombay-400 Ltd. 701 Flow Chem Industries 10, Navdurga Indl. Estate Flow Chem Industries Opp. Forge Blower 79-220 4773 Naroda Road Ahmedabad – 25

37

38

39

Qualified for Size

011-3236408

26

32

020-2747 0772

079-27540839

Upto 24" class 600

Up to 12" class 600

Up to 12" class 600 of split body type

79-220 1401

Up to 12" class 600

Micro Finish Valves

B.D.K. Engineering (I) Ltd. Gokul road Hubli 580 030

Up to 12" class 600

41

Hawa Valves (India) Pvt. Ltd

4, Karmabhumi Industrial Estate, Opp. Ajit Mill Police chowky, Rakhial Road, Ahemdabad

Up to 8" class 600

42

L&T /Audco Valves

Chennai

Upto 24" 600#

43

Cooper Cameron No.2, Gul Circle, Jurong Industrial Valves (Singapore) Pte. Estate, Singapore - 629560 Ltd.

44

BÖHMER BALL VALVES

45

MSA

40

BALL VALVES

Vendor list .xls

Address 39, Latif House, 3rd floor,Sant Tukaram Road, Iron Market, MUMBAI-400 009

0065 865 2887 Mobile 0065 9783 7381

0065 861 7109

Gedulderweg, 95 45549 Sprockhövel GERMANY

+ 49 2324 7001 0

+ 49 2324 7001 79 Up to 30" class 600

Hlucinska, 41 747 22 Dolni Benesov CZECH REPUBLIC

+ 420 553 881 111

+ 420 553 651 236

Up to 30" class 600

Up to 30" class 600

page 2 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

46

47

48

49

BALL VALVES

50

VIAR VALVOLE

51

BREDA ENERGIA SESTO INDUSTRIA FLOW CONTROL TECHNOLOGIES (TYCO Flow Control)

52

53

55

M/s BIFI Gas Over Oil Actuators

PC Intertecnik M/s Bettis

57

58

59

60

Globe Valve

63

64

Fax No

Qualified for Size

Oststrasse, 17 77694 Kehl GERMANY

+ 49 78 51 86 80

+ 49 78 51 86 813

Daimlerstrasse 4-7 89555 Steinheim GERMANY

+ 49 73 29 950 0

+ 49 73 29 950 161 Up to 30" class 600

+ 33 - 495 055 050

+ 33 495 055 070

+39 049 919 96 11

+39 049 912 54 55 Up to 30" class 600

+ 39 0331 99 29 85

+ 39 0331 99 29 92 Up to 30" class 600

279-305, Bvd D. Casanova 13309 Marseille FRANCE Via Campolongo, 97 35020 Due Carrare PD ITALY Via L. Cadorna, 6 21041 Albizzate VA ITALY Viale Sarca, 336 20126 Milano ITALY 23, deuxième avenue 13743 Vitrolles FRANCE

Up to 30" class 600

Up to 30" class 600

+ 39 02 64 47 71

+ 39 02 64 47 75 42 Up to 30" class 600

+ 33 442 10 36 00 + 91 11 647 14 69

+ 33 442 10 36 36 G39 India + 91 11 646 15 50

Up to 30" class 600

Italy

M/s Rotork fluid Sytem Italy

56

62

Phone No

Viale G Borri, 42 21053 Castellanza VA + 39 0331 334 111 + 39 0331 675 830 Up to 30" class 600 ITALY Contractor shall ensure that each valve manfacturer shall have valid API 6D license and in case of firm order the license shall be valid till complete execution of supplies.

55

61

Address

PETROLVALVES

54

Vendor list .xls

Name of the vendor

RMA Maschinen- und Armaturenbau Faulhaber & Truttenbach SCHUCK ARMATUREN (ex BORSIG) SUD ROBINETTERIE INDUSTRIE (SRI) TORMENE GAS TECHNOLOGY (VALVITALIA)

Germany

Belgium Flow Chem Industries 10, Navdurga Indl. Estate Flow Chem Industries Opp. Forge Blower 079 2204773/3623 Naroda Road Ahmedabad – 25 101, samrudhi, Sattar Taluka Socitey, Opp old high court Shreeraj Industries lane,Ahemdabad Plot no. R-241, TTC Industrial Area Steel Strong Valves (P) MIDC,Rabale, New Bombay-400 Ltd. 701 Ornate Valves Pvt. Ltd. Ornate Valves Pvt. Ltd., 104, Eric House Mumbai 16th Road Chembur, Mumbai- 400 071 B.D.K. Engineering (I) Ltd. Gokul road Micro Finish Valves Hubli 580 030 L&T /Audco Valves Chennai Oswal Industries Limited 404, Sakar-III Oswal Industries Ltd 079-30947636 Opp. Old High Court Ahmedabad – 390 014 D-115/116 Ghatkopar Industrial Estate Niton Valve Industries L.B.S. Marg 022-500 8315 Pvt. Ltd. Ghatkopar (West) MUMBAI - 400 086

Up to 12" class 600

Up to 8" class 600 Up to 12" class 600 split body type

Up to 12" class 600

Up to 12" class 600 Up to 12" class 600

079-27540839

Up to 12" class 600

022 5007654

Up to 12" class 600

page 3 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

65

Econo Valves Pvt. Ltd.

66

L&T/ Audco Valves

Chennai

67

Steel Strong Valves (P) Ltd.

68

Oswal Industries Ltd

69

Micro Finish Valves

70

Check/ NonReturn Valves

Flow Chem Industries

Plot no. R-241, TTC Industrial Area MIDC,Rabale, New Bombay-400 701 Oswal Industries Limited 404, Sakar-III Opp. Old High Court Ahmedabad – 390 014 B.D.K. Engineering (I) Ltd. Gokul road Hubli 580 030 Flow Chem Industries 10, Navdurga Indl. Estate Opp. Forge Blower Naroda Road Ahmedabad – 25 Ornate Valves Pvt. Ltd. 104, Eric House 16th Road Chembur, Mumbai- 400 071 Arpita Enterprise 1201, GIDC Estate Phase IV Vithal Udyog Nagar Anand – 388 112 D-115/116 Ghatkopar Industrial Estate L.B.S. Marg Ghatkopar (West) MUMBAI - 400 086 147, Karapakkam Village, CHENNAI - 600 096

Phone No

Fax No

Qualified for Size

044-6251829 / 6254371 044-6257501

022-27699489/90

022-27695537

Spring Loaded Type Upto 12” x 600# of split body type

079-30947636

079-27540839

Up to 12" 600# (Lift Type ,Wafer Type & Swing Type)

0836-331 499/ 333 930

Up to 12" 600#

079-220 4773/3623

Up to 12" 600# (Lift Type ,Wafer Type & Swing Type)

022-556 6432/7231

Up to 12" 600# (Lift & Swing Type)

02692-36187

Upto 8" 600#(Wafer Type)

71

Ornate Valves Pvt. Ltd., Mumbai

72

Arpita Enterprise

73

Niton Valve Industries Pvt. Ltd.

74

FMC Sanmar Ltd.

75

Protego Equipments Pvt. Ltd. ,

Navi Mumbai

Larsen & Toubro

32, Sivaji Marg, Post Box No.6223, 011-5931302 Near Moti Nagar, NEW DELHI

011-5438624

77

SEBIM Valves India Pvt. Ltd.

908, Ansal Bhawan, 16, Kasturba Ghandhi Marg, New Delhi-110 00

011-331 2110, 331 8360

011-371 2155

78

RMG Regal + Messtech GmbH, Germany

Germany

79

ZUNT ITALIANA

Via Grinetta, 22- Seriate, 24068 Bergamo, ITALY

39 035 303 982

39 035 303 969

Alfa Engineering, S.r.l

Via Leonardo da Vinci, 17/19, 41030 Bastiglia (Modena), Italy

39059904611

39059815156

81

PROCHIND

Via Mantova, 10, 21053 Muggio ( Milano), ITALY

39 039 795 599

39 039 214 4426

82

NUOVA GIUNGAS srl

(059) 558390 (r.a.)

(059) 570633

83

DYLAN België

+32 3 488 48 00

+32 3 488 48 80

Up to 30" class 600 fittings and Flow Tee

+32 3 820 58 80

+32 3 828 96 22

Up to 30" class 600 fittings and Flow Tee

+49 201 818 01

+49 201 818 2822

Up to 30" class 600 fittings and Flow Tee

76

Pressure Relief Valve

80

Insulating Joints

84

85

Vendor list .xls

Address 197 SIDCO Industrial Area Ambattur CHENNAI - 600 098

F.B.F. FERROSTAAL (MAN Group)

Via Prampolini,30-41043 Formigine (Modena) ITALY Lerenveld 20 2547 Lint BELGIUM Dynamicalaan 4-8 2610 Antwerpen BELGIUM Hohenzollernstrasse 24 45128 Essen GERMANY

022-5008315

022-5007654 / 5007436

044-492-5455

044-492-6114

Up to 12" 600# (Lift & Swing Type)

page 4 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Name of the vendor

86

INTERFORGE

87

KÜRVERS Piping

88

MEREK Engineering

89

PETROFIT

90

PHOCEENNE (Groupe Genoyer)

91

VAN LEEUWEN BUIZEN

92

MS Fittings Mfg. Co. Pvt. Ltd, Kolkatta

93

Vendor list .xls

Item

Pipe Fittings (Elbows, Ferrous Alloy Forging Tee, Reducers) (P) Ltd.

Address

Große Straße 14 27356 Rotenburg GERMANY Mark S. Clarkelaan 13 a Haven No. M 512 4761 RK Zevenbergen THE NETHERLANDS Premier estate Leys Road Brockmoor Brierley Hill DY5 3UT West Midlands UNITED KINGDOM Unit 3 Rowan Court Crystal Drive Smethwick B66 1RB West Midlands UNITED KINGDOM Ten Bergstraat 4 2830 WIllebroek BELGIUM Schaarbeeklei 189 1800 Vilvoorde BELGIUM M.S.FITTINGS MFG.CO.(P)LTD. H.O. 17-WESTERN STREET, KOLKATA-13

Phone No

Fax No

+49 4261 4081

+49 4261 3090

Up to 30" class 600 fittings and Flow Tee

+31 168 33 43 44

+31 168 33 43 49

Up to 30" class 600 fittings and Flow Tee

+44 121 544 9938

+44 121 544 9132

Up to 30" class 600 fittings and Flow Tee

0121 544 9938

0121 544 9132

Up to 30" class 600 fittings and Flow Tee

+32 3 860 73 70

+32 3 860 73 71

Up to 30" class 600 fittings and Flow Tee

+32 2 255 40 00

+32 2 253 20 92

Up to 30" class 600 fittings and Flow Tee

033- 2362902, 2362903

033-2252103

Upto 24 " class 600

Ferro Tubes & Forging Industries C1/129, GIDC Estate, Vaghodia, 02668-62479 Baroda-391760

upto 12"

94

Pipe Fit Engineers

496/1, GIDC Industrial Estate, Makarpura, Baorda-390010 [email protected]

0265-2636 547/545

95

Teekay Tube

315/317, Navratan 69, P D Mello Road Near Carnac Bridge,MUMBAI - 400 009

+91 22 342 3382-83, +91 22 343 7716, (022) 349162 3445477, 3446975

96

Steward & Lloyds

Atrul Manai (1st floor) 27 whites Road Cehnnai-600014

044 8523375

97

ALLIACE FITTINGS & FORGINGS INC. Alliance Fittings and 022-2788 1134 / 022-2778 1333 / 1916 Forgings, Navi Mumbai A-468/469, T.T.C. Industrial Area, 5590 2273 Mahahpe, Navi Mumbai – 400 701

98

Swastik Lloyds Engineering Pvt. Ltd. Mumbai

99

Tube Products Incorporate.,Baroda

100

Steel Tubes (India)

101

Eften Engineering Pvt. D1, Sipcot Industrial Park, 04111-256284, Ltd. Irungattukottai-602105, Tamilnadu 256714

102

Sawan Engineers

Swastik LIoyds Engineering Pvt Ltd. 58,Islampura street , MumbaI-400 004 748/8, GIDC Indl. Estate Makarpura BARODA - 390 010 [email protected] 526/36, Maulana Azad Road, IInd Floor, (Gulalwadi Circle) , Mumbai400 004

201, Palace Plaza, Lalbaug Road, Near Kashivishwanath Temple, Baroda - 390 001 Email : [email protected]

Qualified for Size

0265-2636 546

upto 24" size, 600#

Up to 24" class 600

044 8522877

Up to 12" class 600

022-3860222/23

022-7402779

Up to 12" class 600

0265-5545 211/214

0265-2831 031

Upto 36 " class 600

(022) 3895908 / 3822821

(022) 3895906

Upto 24 " class 600

0411-256714

Up to 8" class 600

0265-243 3003 / 553 0265-243 5196 8308

Up to 18" class 600

page 5 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

104

105

106

MS Fittings Mfg. Co. Pvt. Ltd, Kolkatta

Tube Products Incorporate.,Baroda

109

Choudhary Hammer Works

108

Pipe Fit Engineers

110

Punjab Steel Works

111

TD WILLIAMSON LTD.

112

FORAIN S.r.l.

113

Skelton Hall

114

GD ENGINEERING

116

Vendor list .xls

Flanges

108

115

Address

111, DLF Industrial Estate 14th Ferrous Alloy Forging Mile Stone Mathura Road (P) Ltd. FARIDABAD - 121 003 Parvati Chambers, Opp. Apsara Sanghvi Forging & Cinema, Pratapnagar Road, Engineering Ltd Baroda - 390 004 201, Palace Plaza, Lalbaug Road, Near Kashivishwanath Temple, Sawan Engineers Baroda - 390 001 Email : [email protected] Kanjur Village Road ECHJAY Forgings Ltd. Kunjan Marg east MUMBAI - 400 042

103

107

Name of the vendor

EQUIP ENGINEERS Scraper Traps(Pig INDIA PVT. LTD. Launchers & Receivers) GEA Energy System (India) Ltd.

Phone No

--

Fax No

--

Qualified for Size

Up to 24" class 600

0265-258 0644/1658 0265 258 1126

Up to 12" class 600 Flanges Only.

0265-243 3003 / 3096008

0265-243 5196

Up to 18" class 600

+91 22 578 2461 +91 22 578 2830

+91 22 578 4962

Up to 24" class 600

033- 2362902, 2362903

033-2252103

Up to 24" class 600

0265-5545 211/214

0265-2831 031

Upto 36 " class 600

+91 120 474 4921

+91 120 479 2897

Up to 24" class 600

0265-2636 547/545

0265-2636 546

upto 24" size, 600#

+91 11 513 0960

+91 11 513 7432

Up to 24" class 600

+44793524971

+44793643969

+39028467345

+39028465325

44(0)114243 1332

44(0)114 244 9579

Nottinghamshire S82 PY ENGLAND

+441909482323

+441909477902

120,Maker chamber, V-221, Nariman point, Mumbai-2

(022)20443635, 2042473

(022)2845910

443, Anna Salai, Teynampet, CHENNAI - 600 018

+9144-433-5958 +9144-4334940

+9144-43605 9144-434-3374

M.S.FITTINGS MFG.CO.(P)LTD. H.O. 17-WESTERN STREET, KOLKATA-13 748/8, GIDC Indl. Estate Makarpura BARODA - 390 010 [email protected] PO Box 20, Near Hapur Road Opp. Power House GHAZIABAD 496/1, GIDC Industrial Estate, Makarpura, Baorda-390010 [email protected] 38B, Mayapuri, Indl.Area Phase-I NEW DELHI - 110 064 Faraday Road, Dorcan Way, Swindon Wittshire SN3 5HF ENGLAND Via G. Boeri, 11 20141, Milano, ITALY 70, Carwood Road Sheffield S4 7SD England

117

Gastech USA

Gastech Engineering Pvt. Ltd., B20, 1st Floor, Lajpat Naagr-II, New 011 251721141 Delhi-110024

118

Fouress India Pvt. Ltd

Fouress Engineeing(India) Ltd., Mahalaxmi Chambers, 22 Bhulabhai Desai Road, Mumbai – 400 026

022-24964400

022-24937544

page 6 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

Address

Phone No

119

GD ENGINEERING

Nottinghamshire S82 PY ENGLAND

120

Phoceene, France

9/11,rue de Lisboone, Z.l.,B.P.61,F+33(0) 442 794 821 13742 Vitrolles, France

Quick Opening Closures and Pig Signallers

+441909482323

Fax No

+441909477902

+33(0) 442 794 079

Walkerville Industrial Estate INTERNATIONAL PIPELINE PRODUCTS Catterick Garrison North Yorkshire +441748834577 DL9 4RR,ENGLAND LTD.

+441748834121

122

RMA MASCHINENUND ARMATURENBAU KEHL FAULHABER & TRUTTENBACH KG

Oststrasse, 17 77694 KEHL/RHEIN , GERMANY

+4978518680

+49785186813

123

Tata Projects Ltd.

22, Sarvodaya Society,Nizampura ,Baroda-390002

0265-2392863

0265-2785952

124

Indian Register of Shipping

125

Bax counsel Inspection Bureau Pvt. Ltd.

02226591526,26590236

022-26591526

022-6956300

022-6956309

044-24320335

044-24328186

121

303, Madhava, Bandra Kurla Complex, Bandra (E), Mumbai-

400051 The Leela Galleria ,5th Floor,Andheri-Kurla Road,Andheri (East),Mumbai-400059

126

Bureau Veritas

127

Germanischer Lloyd Salai,Teyanampet,Chennai 600018

Qualified for Size

304-305, Anna

128

Velosi Certification Services, Mumbai ABS Industrial

129

Third Party Inspection Verification Agency Ltd.,Mumbai

Velosi Certification Services (I) Pvt. Ltd., 212,ShivKrupa Commercial Centre, 022-5376770 Off Gokhale Road,Navpada Thane (W) 400 602 404,Mayuresh Chambers, Sector11,CBD Belapur(E), Navi

022-27578780/1/2

022-5426777

022-27578784/5

Mumbai -400614

130

Certification Engineers International Ltd.

131

Dalal Mott MacDonald

132

International Certification Systems

133

M/s Intertek Testing 401, Everest House, 4th Floor, 6Services (Inida) Pvt. SUREN ROAD, Andheri (E), Mumbai-400093 Limited

134

TUV India Pvt Ltd ( 0265 235 0920, 235 0265 235 0900 RC Dutt Road, Baroda - 390 005 0930 TUV NORD Group) E mail : [email protected]

135

Rites Ltd.

136

SGS

EIL Bhavan, 5th Floor, 1 ,Bhikaji 011Cama Place,New Delhi -110066 26167539,26102121 501, Sakar -II ,Ellisbridge,

Ahmedabad-380006 E-7 ,Chand Society, Juhu Road, Juhu, Mumbai-4000049

011-26101418

079-6575550

079-6575558

022-26245747

022-26248167

022 26934848

T15, Third Floor, National Plaza,

Churchgate Station Bldg., 2nd 022-22012523 Floor, M.K.Road, MUMBAI SGS India Pvt. Ltd, SGS House, 4B ,A.S.Marg, Vikhroli(W), Mumbai- 022-25798421 to 28

022-22084155

022-25798431to 33

400083

Vendor list .xls

page 7 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Corrosion Control Services(B) Pvt. Ltd.,Mumbai

137

138

Name of the vendor

Cathodic Protection Sub-Contractor

Raychem RPG Limited Corrtech International Pvt. Ltd., Ahmedabad

139

Address

Phone No

Fax No

Qualified for Size

022405, Arun Chambers, Tardeo 23524593,566270 022-24934570 Road, Mumbai -400034 10 709/710, Tolstoy House, Tolstoy Marg, New Delhi - 110 001

22, Dhara Centre ,Vijay Cross 079079-6431615 Road, Navrangpura, 6563443,6568639 Ahmedabad- 380009

CATHODIC PROTECTION SYSTEM MATERIALS M/s CANARA ELECTRIC CONTROLS MUMBAI

140

141

Transformer Rectifier Unit [TRU] AC Input DC M/s CIMCON Output, & CPPSM SOFTWARE SERVICES INC.,AHMEDABAD

142

M/s TITANOR COMPONENTS,GOA

143

M/s ELTECH, NETHERLANDS

MMO ANODES 144

M/s ORANZIO DE NORA,USA

145

M/s CORPRO TECHNOLOGIES, SINGAPORE

146

M/s METAL FOUNDERS MUMBAI

147

M/s SHAKTI ENTERPRISES AHMEDABAD

148

M/s PROTECH ALLOY ANODES KARAIKUDI

SACRIFICIAL ANODES

Vendor list .xls

149

M/s SCIENTIFIC METAL ENGINEERS KARAIKUDI

150

M/s CORPEN ANODES

149

M/s ELECTROPROTECTION SERVICES

page 8 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

150

Name of the vendor

Address

Phone No

Fax No

Qualified for Size

M/s HARCO USA

151

M/s MC MILLER USA

REFERENCE COPPER SULPHATE ELECTRODES 152

M/s BORIN USA

153

M/s ELECTROCHEMICAL DEVICES USA

154

PIN BRAZING

155

THERMITWELD

M/s. Safetrack

M/s. Erico Europa

155

M/s DEHN GmbH

156

M/s CITEL

157

M/s MC MILLER

SURGE DIVERTORS 158

M/s CONTROL TECHNOLOGY

159

M/s DAIRYLAND ELECTRICAL INDUSTRIES

160

M/s INTERNATIONAL CORROSION CONTROL Inc.

161

M/s KIRK ENGINEERING

162

M/s INTERNATIONAL CORROSION CONTROL Inc.

163

Vendor list .xls

POLARIZATION CELLS / M/s ELK ENGINEERING AC DECOUPLING ASSOCIATES Inc, DEVICE

164

M/s RUSTROL

165

M/s DAIRYLAND ELECTRICAL INDUSTRIES

page 9 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

166

167

E R PROBE

169

M/s. BASCO

170

M/s. ALFA

171

M/s. R M A

172

M/s. NUOVAGIUNGAS

173

M/s. ZUNT

INSULATION MONO BLOCKS

M/s. PPELINE ENGINEERING & SUPPLY CO.

176

M/s. TUBE TURN TECHNOLOGIES

177

M/s. KEROTEST MFG.

178

M/s.INTERNATION CORROSION CONTROL Inc.

179

M/s. PIPELINE SEAL & INSULATORS Inc.

Cold Applied Tapes

Qualified for Size

Denso GmbH

P.O.Box 15 01 20 * D-51344 Leverkusen, Germany

+49 214 2602-0

+49 214 2602-318

Raychem

181 182

Stud Bolts with Nut

Multi Thread Fasteners., Multi Thread Fasteners, 885/B GIDC Makarpura, Baroda Baroda – 390010 Darukhanwala Mumbai

184

Precision Engineeris , Baorda

Baroda

185

Raychem RPG Limited

709/710, Tolstoy House, Tolstoy Marg, New Delhi - 110 001

186

Fax No

M/s. PHOCENNE

175

183

Phone No

M/s CORRTEST

M/s ROSE CORROSION, U.K

180

Address

M/s METAL SAMPLES

168

174

Vendor list .xls

Name of the vendor

Heat Shrinkable Sleeves Canussa (Bhotika Brothers- Indian Represntative)

0265-2647310

Bhotika Brothers, 59, R.N.Arcade,1st Floor, Lokhandwala 022-6331458/9 Complex, Andheri West ,Mumbai400053

0265-2642821

022-6362253

page 10 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

Address

187

No 20, First Street, Vedhachala Agni Heavy Engineering Industries Nagar, Kodambakkam, ChennaiLtd 600 024

188

Krunal Enginering Works

189

Master Fire Fighters Ltd Amcon Technologies

190

Fire Fighting

191

K.V. Fire Chemicals(I) Pvt. Ltd. Mumbai

192

Extinct Fire Engineers Pvt. Ltd., Mumbai

193

Safety Equipment Corpn

194

Dectronics

Krunal compound, Gala No 1, Ganesh Nagar, Old Belapur Road, Near Indian Aluminium Cop, Vitawa, Kalwa (E), Thane- 400 0605 The Nest, 6th Road, Santacruz East, Mumbai- 400 055 6, Saru Sadan, St. Anthony Street, Kalina, Santacruz (E), Mumbai-400 029 K.V. Fire Chemicals (I) Pvt. Ltd. Kamala Nivas, 2nd Floor Plot No. 32, Lane – D Sector 8 Vashi, Navi Mumbai 400 703 Extinct Fire Engineers Pvt. Ltd. 3, A.V. Punjab Soc., Opp. Sony Mony J.P. Road, Andheri (W) Mumbai – 400 053 105, Popatlal Chambers, 4th Clive Cross Road, Dana Binder, Masjid, Mumbai- 400 009

Phone No

Fax No

(044) 4812420, 4728713, 4817463, 4819692, 4725106

(044) 4830885, 4838020

(022) 6161166, 6106617

(022) 6106618

(022) 6193401/3283

(022) 6193402

Qualified for Size

022-2782 0827, 2782 3901

022-267 70272

(022) 3719564, 3773240

(022) 3725884

Dectronics Corporation 4655 Old Ironsides Dr., Suite 100 Santa Clara, CA 95054, USA

Gas and Fire Detection M/s Detection Instruments India Pvt System Ltd +91-22-2857-5089/ 2857-557

General Monitors

196

Empire Industrial Equipment

Empire House, 414, Senapati 011-6012333, Bapat Marg, Lower Parel, Mumbai6012334 400 013

197

Protego Equipments Pvt. Ltd. ,

Navi Mumbai

MARVC:Mekaster International Pvt. Ltd

908, Ansal Bhawan, 16, Kasturba 011Gandhi Marg, New Delhi- 110 001 3318360,3319233

011-3712155

199

AMAL. UK: AOYP Engineering Co. Pvt. Ltd

Sanjay Building No 3, Gala No. 22/22, Mittal Industrial Estate, Andheri Kurla Road, Andheri(E), Mumbai- 400 059

022-8504162

200

Westech

5636 Burbank Cres, SE, Calgary, Alberta, Canda T2H 1Z6

201

Finolex Cables

405, BMC House, N-1, Connaught Place, NEW DELHI - 110 001

202

RPG Cables Limited

198

Flame Arrestors

OFC

Vendor list .xls

Amar Hill, Saki Vihar Road Powai, Bombay 400-072, India

195

203

Himachal Futuristic Communications Ltd.

204

Sterlite Industries (I) Ltd.

0228503819,8504770

011-6012332

+91 11 335 3160 +91 11 335 3103

12th Floor +91 11 331 2880 Hindustan Times House +91 11 331 9653 18-20 Kasturba Gandhi Marg +91 11 371 5504 NEW DELHI - 110 001 International Division 286, Udyog Vihar Phase-II , GURGAON - +91 124 634 0744 122 016 +91 124 634 2469 HARYANA OFC Division 604-607, Tolstoy +91 11 335 1393 House Tolstoy Marg NEW DELHI +91 11 3736941 110 001

+91 11 331 3235

+91 124 634 0743

+91 11 335 5768

page 11 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

205

Jain Irrigation System Ltd, Jalgaon

206

Parixit Induatries Limited, Ahmedabad HDPE Duct for OFC

209 210

Phone No

Upto 50 mm Diameter

Upto 50 mm Diameter

507, International Trade Tower, (011) 646 6293 Nehru Place, NEW DELHI - 110 019 1214, Hemkunt Tower, Nehru (011) 646 2451 Powerica Limited Place, NEW DELHI - 110 019 AMF D.G. Set Supplier Bhaskar Power Project B-137, Sector - 2, NOIDA - 201 301 (0118) 452 1355 Ltd. UTTAR PRADESH Sudhir Engg. Co.

a-43, Phase II (Extension), NOIDA (0118) 456 3156 201 305 UTTAR PRADESH

Jakson Engineers Ltd.

212

Contronics Switchgear A-30, Sector - 58, NOIDA - 201 (I) Pvt. Ltd. 301, UTTAR PRADESH

213

Elpro Engineering

Plot No. 4458, Y-95, 8th Street, Anna Nagar, CHENNAI - 600 040

214

RYB Switchgears Pvt. Ltd.

C-543, 2nd Floor, Saraswati Vihar, (011) 701 2329 / 701 DELHI - 110 034 0097

215

Trident Switchgears

Mata Bhavan, C-49, Jangpura Extension, NEW DELHI - 110 014

217

Qualified for Size

Upto 50 mm Diameter

5841648

211

216

Fax No

0257-250011

Pennwalt Agru Plastics Ltd. Plot No. 272 A Pennwalt Agru Plastics Savli GIDC 02667-64436-38 Village Manjusar- 391 775, Baroda Ltd, Baroda

207

208

Address

Jain Irrigation System Ltd. Jain Plastic Park P.O. Box 72 Jalgaon - 425 001 Parixit Industries Ltd. Plot No. 4912, Phase IV GIDC Vatva Ahmedabad – 382 445

MileStones Main/Secondary & UPS Switchgears Pvt. Ltd. Distribution Board Vidhyut control (I) Pvt. Ltd. Electronic Instrumentation & Control

218

(0118) 458 3472

(044) 628 1214

(011) 431 3946

D-92/8, Okhla Industrial Area, Phase-I, NEW DELHI - 110 020 D-12, Sector - 17, Kavi Nagar Industrial Area, GHAZIABAD - 201 301, UTTAR PRADESH Plot No. 436, Phase-II, G.I.D.C. Estate, Vatva, AHMEDABAD - 382 445, GUJARAT

(011)681 5500 / 681 5501

222, Okhla Industrial Estate, NEW DELHI - 110 020

(011) 684 7154 / 682 9063

(0120)470 1223 / 470 0112 (079) 583 0505 / 583 1665

219

Sawti Switchegear, Ahemdabad Larsen & Toubro Ltd.

220 221 222

Control & Switchgear Co. Ltd.

223

Universal Cables Ltd., M.P

224

Cord Cables Industries

231

NICCO Corporation Ltd. , Baroda Cable Corporation of India Ltd. KEI Industrie Ltd. Grandlay R.P.G. Cable Ltd. Chandresh Cables, Ahmedabad Finolex Cable

232

Polycab Wire Pvt. Ltd.

233

INCAB

225 226 227 228 229 230

Vendor list .xls

Power Cables

Power Cable

Power Cable

page 12 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

234 235 236 237

Flameproof Lighting Fixtures, FLP, J.Box/FLP Switch Socket

Name of the vendor

238

Flex pro Electricals Pvt. Ltd, Navsari

239

CEAG

240

Crompton Greaves Ltd.

241 242 243 244

Lighting Fixtures

245 246 247 248

Solar Light (TATA BP)

249

Relays

253

Emmerson Network Power Management

254

Gutor Electronics Ltd.

255

Emerson Pressure Transmitter

Switzer Delta Pressure Switch

SOR United Electric

266

ITT-Barton

267

CCS

268

ICA

270 271

Vendor list .xls

H. Guru Pressure & Temperature A.N. Instrument Gauge Wika

263

269

B-14/1, G.I.D.C. Electronics Zone, 079-232 21636 / Sector - 25, GANDHINAGAR - 382 22531 044, GUJARAT

Tata Honey Well Ltd

262

265

0281-258 5532

Invensys India/emerson Process

258

264

206, Kalptaru Complex, Indira Circle, Rajkot

Yokogawa Blue Star

256

261

Flameproof & Explosion Proof Electrical Equipment

OMRON

U.P.S.

260

Qualified for Size

A-14, navjivan Soc., Dahej bypass 91-98244-75574 Saroj Urja Services Co road B-2, Lalita Co-op Hou.Soc. Isanpur 91-98254-11692 Solartech System raod, Ahmedabad Jay marketing, Sukrut Apt., HJ 91-98251-62853 Khodiyar Enterprise Doshi Hospital Road, Rajkot

Hi-REL Controls Ltd.

252

259

Fax No

OEN Fuji Electric Company Limited

251

257

Phone No

Philips Bajaj Electrical Ltd. GE KESELEC Schneider Electric

Hitech Industrial Corp.

250

Address

Baliga Lighting Equipments Pvt. Ltd. Sudhir Switch Gears Pvt. Ltd. Flame Proof Control Gears Pvt. Ltd. Flame Proof Equipment Pvt. Ltd.

Instrumentation Panel

Rittal Pyrotech Controls Enclotek

page 13 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

Address

Phone No

Fax No

Qualified for Size

Patson Transformers Pvt. Ltd. , Ahmedabad

272

Transformer Voltamp Transformers Pvt. Ltd., Ahmedabad

273

274 275 276 277 278

Instrument Fittings Swagelock including manifold,needle valve Parkar etc. Impulse Tubing Diesel Engine

Cummins Kirloskar KEC

279

JYOTI

280 281

Sandvik

Generator

NGEF

282

Stamford

283

CGL B.C.H

284 285 286

Switch Socket and Plugs

Baliga CGL

287

MDS

288

L&T

289

CGL

290 291 292 293

Siemens Moulded case corcuit Breaker, Switch, Fuse GE Bharti Cutller & and Contractor Hammer Schneider Electric

294

CSC

295

Indocoil

296

GM Koppa

297 298

CT/PT

Silkana

299

Siemens

300

AE

301

Pragati

302

L&T

303 304

Push Button

307

GE Kaycee

305 306

Siemens

Selector Switch

Kaycee

Instrumentation Signal Polycab Assiocates cables Control Cable MTL India Pvt Ltd

308

A-223 Ansal Chambers-1 3, Bhikaji Cama Place. New Delhi

011-26715408/6180

011-26716181

Isolating Barrier P&F

309

SITOP

310

24 V DC Power Supply PHEONIX

311

312

Vendor list .xls

RTD

ALTOP

page 14 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

313

Alarm Annunciator

Name of the vendor

Address

Phone No

Fax No

Qualified for Size

IIC

Masibus

314

Power Indicator 315

Yokogawa

24/3,Pantra palya, Mysore Road Bangalore-560039 India

080-26742855

08026742551/26744015

316

MTL India Pvt Ltd

A-223 Ansal Chambers-1 3, Bhikaji Cama Place. New Delhi

011-26715408/6180

011-26716181

Signal Repeater P&F

317 318 319

Indication Lamp

L&T

320

Control Switch Gear

321

Electromac Commet

322 323

Cable Glands

Baliga Flameproff control gear

324 325

Lugs

Dowells

326

Terminal Blocks

Elemex

327

MDS

328

Indo Asian

329

Lighting MCB DB

clipsal

330

Datar

331

Havels

332

Standard

333

Voltas

334

Air Conditioner

Carrier

335

LG

336

Amtrex Hitachi

337

MDS

338

Vendor list .xls

Concord

MCB

Datar

339

Havells

340

Indo- Asian

page 15 of 16

Doc. No : GSPL/Vendor/2006

GUJARAT STATE PETRONET LTD. Gas Grid Pipeline

Rev. No. : 07 Date

: 16 NOV 2006

LIST OF RECOMMENDED VENDORS Sr.

Item

Name of the vendor

341 342

Essar Construction Ltd.

343

344

HDD Contractor 345

Horizontal Drilling International (France)

347

COE Drilling Australia PTY Ltd. (Australia)

348

350

Phone No

Fax No

Qualified for Size

Intellegent Pigging Contractor

Essar House, PO 7945, Mahalaxi, Mumbai -400 034

Rosen Euro BV, Netherland M/s PII, U.K NGKS, Russia TDW Williams, India

351

022-2495 4324

Mersing Construction and Engineering Sdn Bhd., Selangor (Malaysia) Herrenknecht (Asia) Ltd. (Thailand)

346

349

Address

PLN Construction Pvt. Ltd. (India) Cherington Asia (India) Pvt. Ltd.

Only for Calliper Pigging

Additional Contractor may also be approved by Owner based on the qualification and shall be confirmed during Pre-bid meeting. IP contractor shall ensure that tool calibration is done in presence of TPIA EIL, New Delhi

352 353 354 355 356

Valdel, Bangalore Flour Daniel Engineering Consultant P.L. Enginnering, Germany Worley, Perth

357

Bechtel

358

Asian Paints (i) Ltd

359

Berger Paints Ltd. Goodlass Nerolac Paints ltd Shalimar paints Ltd Coromandal paints & Chemical Ltd. Bombay Paints ltd

360 361 362 363

Paint

Note : 1) The details of Vendors indicated in this list are based on the information available with GSPL, Contractor shall verify capabilities of each vendor for producing the required quantity with. Owner does not Gurantee any responsibility on the performance of the Vendor, it is the contractor reponsiblity to verify the correct status of vendor and quality control of each parties and also to expedite the material in time. 2) Contractor shall submit the details of each of the party before placement of order. 3) For any item, if the vendor names are not available, it is the reponsiblity of the contractor to submit the credentials of at least three parties for GSPL approval

Vendor list .xls

page 16 of 16

APPENDIX-V AMENDMENT TO PIPELINE STANDARD AND SPECIFICATION

AMENDMENT TO PIPELINE STANDARD AND TECHNICAL SPECIFICATIONS SCOPE This document covers modification / addition to various standard specification and pipeline standards enclosed with the bid package. The standard specification stands modified to an extent defined in this amendment. Unless modified by this amendment the requirement of the applicable standard specification shall govern. CONTENTS 1)

Standard Specification No. MEC/S/05/62/01 (Specification for Mainline Construction (Onshore))

2)

Specification No. MEC/S/05/62/02A (Welding of Onshore Cross-Country Pipeline)

3)

Specification No. MEC/S/05/62/03A (Hydro-testing)

4)

Specification No. MEC/S/05/62/06 (Terminal Piping, Fabrication and Erection)

5)

Specification No. MEC/S/05/62/11 (FLUSHING AND TESTING)

6)

Specification no. MEC/TS/05/62/025 Rev.1 (Technical specification for seamless fittings and flanges upto 400 mm (16”) NB)

7)

Specification no.: MEC/S/05/62/61 Rev-1 (Specification for Pre Commissioning / Commissioning)

8)

Specification no. MEC/S/05/62/70 (Caliper Pigging)

9)

Standard Specification No. MEC/S/05/62/75 (Specification for pipeline crossings using horizontal directional drilling method)

10)

Specification No. MEC/TS/05/21/012D, R-0 (Technical Specification for Linepipe)

11)

Specification No. MEC/S/05/62/014, Polyethylene Coating Of Linepipes )

D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc

R-2

(Specification

for

3-Layer

Page 1 of 10

1)

Standard Specification No. MEC/S/05/62/01 (Specification for Mainline Construction (Onshore)) 1.

Refer Clause No. 9.1.8 i.e. related to lowering in trench “The maximum section which should be lowered in a stretch shall be limited to 1.6 km maximum length”. Other details remain unaltered.

2)

Specification No. MEC/S/05/62/02A (Welding of Onshore CrossCountry Pipeline) Refer Clause No. 12.5 “Non-Destructive Examination” Following to be noted : i) ii) iii) iv) v)

Standards of acceptability shall be strictly as per API 1104. Any requirement over and above, this mentioned anywhere in this specification shall not be applicable for this project. Ultrasonic inspection is must for repair & tie-in joints. Welding qualification, testing and acceptance criteria shall be as per API 1104. Re-repair of joints shall be permitted as per API 1104 provided all procedure is followed as stipulated in API 1104. Gamma-ray radiography may be used for tie-in joint provided slow film like D4 radiography film is used by contractor for better sensitivity.

Special points w.r.t. Welding i)

For mainline welding following LINCON Electrode to be used. Root – E6010 Filler & Hot Pass – E7010

ii)

Electrode Qualification Test (EQT) for every batch is required.

iii)

Mainline welding shall be downhill. Tie-in & Root shall be uphill welding. Rest shall be downhill.

All other points of the specification remains unchanged. 3)

Specification No. MEC/S/05/62/03 A (Hydro-testing) a)

Refer Page No.: 4 of 17, Clause No. 5.1 shall be read as “The duration of hydrostatic test shall be minimum of 24 hrs. after stabilization and the test pressure shall be 1.5 x Design pressure (95 bar) and as indicated in Clause 5.2”.

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Page 2 of 10

b)

Refer Page No.: 4 of 17, Clause No. 6.0, Add the following at the end of Para. “PV reorder with chart for hydro-test and calibration certificate” not older than one month shall be provided by the contractor.

c)

Refer Page No.: 4 of 17, Clause No. 5.2, shall be read as “The maximum base pressure shall not be higher than one resulting in a hoop stress corresponding to 95% of SMYS of pipe material based on the minimum wall thickness in the test section & minimum test pressure shall not be lower than the one resulting in a hoop stress corresponding to 85% of SMYS of pipe material based on the minimum wall thickness in the test section”.

d)

Refer Page No.: Page No. 4 of 17, Clause No. 6.0 equipment and instrumentation. Fill pump capacity shall be such that pig travel speed is approx. 2 km/hr.

e)

Refer Page No.: 9 of 17, Clause No. 7.8, The line “In order the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e. 1.06)” shall be replaced by the line “In order the above ratio is acceptable, it shall not differ from 1 by more than 2% (i.e. 1.02)”.

f)

Refer Page No.: 9 of 17, Clause No. 7.8, “V1/Vp exceeds 1.06” shall be replaced by “V1/Vp exceeds 1.02”.

g)

Refer Page No.: 9 of 17, Clause No. 7.9, Replace Para 1 by following : “After the section has been pressurized and the air volume test has given acceptable results the test pressure shall be held for 24 hours for strength test at specified test pressure maintained by periodically make-up and bleed off after stabilization. After temperature and pressure has stabilized, the injection pump shall be disconnected and all connections at the test heads shall be checked for leakage. The pressure recorders shall then be started with the charts in a real time orientation for continuous recording throughout the test”.

h)

Refer Page No.: 11 of 17, Clause No. 9.1, shall be read as: “Contractor shall de-pressurise the line at the rate of 5 kg/cm2 per minute upto 2 kg/cm2 and shall dewater the tested line as per the following requirement after test acceptance. The dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed air. The detailed dewatering procedure shall be developed by the contractor in such as a way as to provide adequate control to pigs during dewatering. Pigs and equipment required for dewatering the line shall be furnished by contractor and shall be approved in advance by the company. Four cup pigs shall first be passed through the line to displace the water. Foam pigs shall then be passed in order to complete the line dewatering. Contractor shall use a number of foam pigs, each in different colors / numbered for this purpose. The line shall be considered dewatered when a negligible amount of water is flushed out by the last foam pig and approval is given by the company.

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4)

Specification No. MEC/S/05/62/06 (Terminal Piping, Fabrication and Erection) Following changes shall be considered:i) ii)

5)

Gamma ray shall be used for Terminal Pipe welding provided slow film like D4 film is used. Acceptability Criteria shall be only as per API-1104

Specification No. MEC/S/05/62/11 (FLUSHING AND TESTING) Refer page no. 8 of 9.

6)

(1)

Clause no. 4.4.1, Para no. 6, the last line shall be read as “Test period shall be maintained for minimum 6 (six) hours”.

(2)

Refer page no. 9 of 9 clause no. 4.5, para 3 shall be read as “After testing is completed the test blinds shall be removed and equipment/ piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests and leakage test at design pressure i.e. 95 bar by N2 to be carried out by the contractor for complete loop/ circuit including equipments (except rotary equipments).

Specification no. MEC/TS/05/62/025 Rev.1 (Technical specification for seamless fittings and flanges upto 400 mm (16”) NB) (1)

Refer Para 1.0 i.e. SCOPE of above specification

-

“Seamless fittings 400 mm (16”) NB and smaller, such as tees, elbows, reducers and caps”. The above line shall be read as: “Seamless fittings 200 mm (8”) NB and smaller, such as tees, elbows, reducers and caps”. Further for 300 mm (12”) NB and 250 mm (10”) NB – fittings shall be of welded construction.

(2)

Refer Para 4.3 : The same should be read as under: “Unless specified otherwise, Charpy V – notch test shall be conducted for each heat of steel, in accordance with the impact test provision of ASTM A370 at ( - ) 20 °C. The average impact energy values of three full sized specimens shall be 35 Joules and minimum should not be less than 28 Joules for any of the specimens.

7)

Specification no.: MEC/S/05/62/61 Rev-1 (Specification for Pre Commissioning / Commissioning) Following amendment / additional requirements shall be applicable:a)

Refer page no. 2 of 8, clause no. 2.0 para no. 3, shall be read as “The contractor shall be responsible for demonstrating the successful

D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc

Page 4 of 10

completion of all the activities i.e. flushing of terminal piping, dewatering, swabbing, drying inertisation and commissioning of the pipeline. All necessary work to perform the job successfully including necessary modifications required shall be the responsibility of the contractor”. b)

Refer page no. 3 of 8, clause no. 3.0, new para to be added

Drying - Drying the entire pipeline to required degree of the dryness as specified. c) 4.3.3

Refer page no. 6 of 8, following new clause 4.3.3 and 4.3.4 to be added DRYING The pipeline shall be finally dried with appropriate drying method such as vacuum drying, drying with super dry air etc. to the required dryness.

4.3.3.1

Vacuum Drying

4.3.3.2

General During the vacuum drying method, the residual water in the pipeline left after the swabbing operation shall be removed by reducing the internal pressure of the pipeline phase wise. The vacuum drying operation shall commence as soon as possible after the swabbing operation is completed. Contractor shall submit the detailed drying procedure for company’s approval.

4.3.3.3

Operational Requirements The vacuum drying operation consists of three phases i.e. evacuation, evaporation and the final drying by reduction of the pressure. During the entire operation, dew point, vapor temperature and pressure shall be record.

4.3.3.4

Acceptance Criteria Finally when the pipeline pressure has been lowered to the specified vapor corresponding to the required dew point i.e. (-) 20°C at atmospheric pressure, the pipeline shall be locked in and pressure shall be monitored during the soak period of a minimum of 12 hrs. If pressure increases during this phase, it indicates a further boil-off. The dew point at the inlet and outlet ends; each individual consumer points and sectionalising valve stations shall be

D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc

Page 5 of 10

monitored to ensure that the required dew point is achieved throughout the pipeline system. The process shall be repeated until no significant pressure increase are measured. The dew points at the inlet and outlet ends and each individual consumer points shall be measured to ensure that the required dew point is achieved throughout the pipeline system. 4.3.4

Super Dry Air Method

4.3.4.1

General The air drying operation shall remove the residual water in the pipeline left behind after swabbing by means of absorption of the water into super dry air blown through the pipeline. Contractor shall specify the procedure and duration of the air drying method, which shall be approved by company. The air drying operation shall commence as soon as possible after the swabbing operation is completed.

4.3.4.2

Operational Requirement The inlet air shall be oil free dry and have dew point below the required dew point in the pipeline.

4.3.4.3

Acceptance Criteria When the pipeline is dried using super dry air, contractor shall dry the pipeline to a dew point of (-) 20 0C, at atmospheric pressure.

8)

Specification no. MEC/S/05/62/70 (Caliper Pigging) a)

Refer Page No. 5 of 9, Clause No. 8, The new para added “Prior calibration with dent pipe to be done at site in presence of owner / consultant.

b)

Refer Page no. 8 of 9, the following new clause 15.0 to be added. 15.0

Acceptance criteria.

i) ii) iii)

For dents = 5% of O. D. Ovality = 5% of I. D. Location Accuracy = Actual + 3.0 m = Circumferential : + 12° Final report shall be submitted within 30 days

iv)

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9)

Standard Specification No. MEC/S/05/62/75 (Specification for pipeline crossings using horizontal directional drilling method) 1.

Refer Clause No. 2.2 – Following minimum requirements of minimum cover to the pipe shall be satisfied unless specified otherwise in the scope of work in SCC. For Road crossing: 1.5 m from top of road to top of pipe. For Rail Road crossing: 1.8 m from base of rail to top of pipe For Canal crossing:

For river / streams:

i)

2.5 m from lowest bed in case of lined crossing.

ii)

2.5 m from scour depth in case of unlined crossing.

2.5 m from scour depth.

Above cover requirements shall be considered for this project instead of covers mentioned under this clause in specification. Other details mentioned in this clause remain unchanged. 2.

Refer Clause 3.3.1 of pre-testing. It shall be read as “Contractor shall hydrostatically pretest the complete pipe string at 95% of SMYS before installation as per approved procedure for a minimum period of 24 hrs.

3.

Refer clause No. 3.7, Final Hydrostatic Test “After temperature stabilization, pressure shall be retained in the pipeline for a period of 6 hrs. and recorded by manothermograph”. The above line shall be read as under. “After temperature stabilization pressure shall be retained in the pipeline for a period of 24 hrs. and recorded by manothermograph”. Other details remain unchanged.

10)

Amendment to Technical Specification for Linepipe NO.: MEC/TS/05/21/012D, R-0. MECON TS No. MEC/TS/05/21/012D, R-0 on Linepipe shall be read in conjunction with following ammendments

Clause 5.0 : Process of Manufacture and Material Line Pipe shall be manufactured by ERW Process only and the steel coils to be procured from following steel suppliers. --

M/s POSCO, Korea M/s Azovastal, Ukraine

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----

M/s ILVA, Itly M/s ISPAT, India up to 10.3mm thickness M/s Essar Steel, Hazira

In case bidder propose steel manufacturer other than above for supply of HR Coils to be used in manufacturing of quoted line pipes, bidder should submit documentary evidence confirming supplier past track record of at least tonnage equivalent to present bid quantity confirming to API 5L Gr. X 65 and above grade steel. GSPL reserve the right to accept /reject the proposed steel supplier if they don’t have past experience. Clause 5.1.3.3.2 : PSL 2 Electric Welded Pipe Electric welding shall be performed with a minimum welder frequency of 250 kHz.The system shall have an integrated control in which following data, as a minimum shall be monitored. • Time • Welding Speed • Current & Voltage • Welding Temperature • Heat Treatment Temperature Clause 6.2.5.2 : Charpy Impact Tests for PSL 2 Charpy V-notch impact test in accordance with SR5 ( Appendix - F) shall also be performed at (-)20 degree C for regular production and at (-)25 degree C. for First Day Production. Impact testing to be done at – 20, -25 degree and 0 degree at Base Metal, Fusion line, Fusion line+2mm and Fusion line + 4 mm and acceptance criteria for standard size sample as per ASTM A 370 is as follows Grade X-65

Test Temp

Base Metal And Weld

-20°/-25° C

Base Metal And Weld

0° C

Minimum Average Value ( for 3 specimen )

Minimum Value

35 J

28 J

100 J

80 J

Single

Clause 7.3 : Wall Thickness The tolerances on specified wall thickness shall be (+) 10% and (-) 0% on pipe body as well as on weld. Clause 7.5 : Length The length of pipe upto 10.5 m shall also be acceptable for sampling pipes. D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc

Page 8 of 10

Clause 9.4.3 : Test Pressure The test pressure of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS and test pressure shall be determined in accordance with Appendix–K of API-5L. Burst Test : ( New ) One pipe for entire campaign (lowest thickness ) shall be subjected to burst test and burst pressure shall be noted. Burst pressure shall be more than 130% of minimum yield strength. Cyclic Hydro Test : ( New ) Cyclic Hydro Test has to be carried out 1 in every 500 pipes including 1 pipe in the “ First Day Production Test” as detailed below : • The pipe to be pressurized upto 50% of the Hydro test pressure and hold pressure for one hour. • Drop the pressure to static head plus one bar. • Pressurise again to 75% of the Hydro test pressure and hold the pressure for one hour. • Drop the pressure to static head plus one bar. • Pressurise again to 100% of the Hydro test pressure and hold the pressure for 6 hours and recorder shall be used to monitor the TIME V/S PRESSURE throughout the Test duration of 24 hours. Clause 9.8.3 : Non-Destructive Inspection For UT and MPI , one qualified inspector of Level-III shall be available at pipe mill for overall supervision of UT and MPI. Clause 9.8.3.3 : Lamination Det ection Either coiled strip area shall be 100% ultrasonically tested or pipe body shall be 100% ultrasonically tested for lamination detection. Clause 9.8.4 : Radiological Inspection – Weld Seams Spot random radiographic examination of weld seam to the extent of 0.5% shall be carried out at pipe mill for the ordered quantity. Clause 9.8.5.2 Standards.

: Ultrasonic and Electromagnetic Inspection Reference

The primary reference sensitivity level shall be adjusted on the following reference reflectors for UT inspection: Lamination Detection - FBH 1.6 mm Defect Detection Welds - Notch N5 APPENDIX – F SR 6 : Drop Weight Tear Testing ( DWTT ) On Welded Pipe DWTT shall be carried out in accordance with the requirement of SR 6.2 through SR 6.8 Two transverse specimens shall be taken from one length of pipe from each lot of 100 pipes per heat. D:\old data\Vijyant\GSPL\Tender\Const\Latest Amendment to TS.doc

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The test shall be conducted at(-)20 degree C. At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or more for the specified test temperature. All applicable supplementary requirement for PSL – 2 are mandatory.

11.)

Amendment to Technical Specification No.:MEC/S/05/62/014, R-2 (Specification for 3-Layer Polyethylene coating Of Linepipes)

Sl. No.

Cl. No

7.5.2 .e O1

(CD Test)

02

8.13 (Chemical Pre-treatment)

03

9.2.2 (Coating Thickness)

Modified Clause CD test for 48 hrs – One test shall be conducted at manufacturer’s In house lab. CD test for 30 days – Two numbers test shall be conducted, one test at manufacture’s In house lab and another test in an independent lab. of national/international recognition. Chemical Pre-treatment solution is not applicable

with

Chromate

The minimum coating thickness on weld seam shall be 3.2 mm and minimum coating thickness on body shall also be 3.2 mm. The thickness for the epoxy shall be 180 microns , adhesive 200 microns and balance shall be polyethylene.

04

9.2.11 (Cut Back)

Cut back length shall be 110 mm (+)20, (-) 0 mm from pipe ends.

05

10.5.b (Bond Strength Test)

The frequency of test for cut back portions shall be one pipe in every fifty (50) pipes coated. Majority of the peeled off area on the pipe shall show presence of adhesive to be removed.

06

Coating system/ Material Pre qualification

Contractor shall propose coating system(s) indicating specific grade of epoxy,adhesive and polyethylene manufactured by any of he material Manufactures indicated in Technical Specification and submit the details as per Table 1.

07

Design Temperature

Maximum Design Temp. for 3 LPE coating system shall be + 60° C.

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APPENDIX-VI SCHEME SHOWING DEMARCATION OF M/L AND TERMINAL

APPENDIX-VII THIRD PARTY AGENCY

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED APPENDIX

THIRD PARTY INSPECTION AGENCY (TPIA)

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Gujarat State Petronet Ltd.

Volume-IB of V

MECON LIMITED

TABLE OF CONTENTS 1.

INTRODUCTION

2.

SCOPE

3.

COORDINATION WITH TPIA

4.

ELECTRICAL

5.

FIELD INSTRUMENTS

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

1.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

INTRODUCTION Owner has decided that the Independent Third Party Inspection Agency (TPIA) shall witness, review and certify all quality related activities pertaining to Supply of Materials and Construction. The TPIA shall ensure that all quality related requirements during manufacturing/construction are followed as per Owner/Owner’s representative specifications and approved Documents. The extent of TPIA involvement as indicated in tender shall be binding on the contractor and no activity shall be accepted if not approved/certified by TPIA. This chapter also indicates general quality control requirements for various activities pertaining to Gas Pipeline Projects.

2.

SCOPE TPIA, as appointed and paid by the Owner, shall be involved in all inspection and testing related activities for Mechanical, Electrical, Civil and Instrumentation system. The extent of TPIA involvement is indicated in the various Quality Control Sheets attached with the tender document and also shall be as per final approved QA/QC procedures or as per codes and standards, wherever applicable. For items/construction activities for which, Quality Control Tables are not attached, contractor shall require to submit the Quality Control Sheets and Quality manual and shall obtain Approval of Owners/Owner’s representative. Prior to start of any activity pertaining to supply of material or carrying out construction at site. Owner/Owner’s representative shall get the documents reviewed by the TPIA. The various Hold points/TPIA involvement as mentioned in various QC sheets are indicative minimum, however, actual involvement shall be decided by Owner/Owner’s Representative during review of documents, and contractor shall be bound by the same. As indicated in various QC tables, TPIA shall witness minimum 10% of the activities pertaining to manufacture on each day or as indicated in final approved documents. TPIA involvement in various construction activities at site/Workshop of the contractor/Sub vender of the contractor shall be as per the approved construction procedures prepared by the contractor and approved by the Owner/Owner’s representative. Contractor shall also submit the calibration certificates of all the equipment/Instruments, which are part of manufacturing/Inspection & Testing for TPIA review. TPIA shall also Check/witness the necessary calibration of such equipment/Instruments during visit to contractor’s works. TPIA representative deputed at Construction site will apart from the construction activities, shall also be involved in certification of all supply material received at site. Contractor shall not be allowed to use such material in construction activities, which is not certified by the TPIA. Contractor shall have to carryout all necessary inspections and testing which are

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

indicated in Approved documents and shall have to provide all necessary latest Tools & Tackles, measuring Instruments and facilities, which are required by the TPIA/ Owner/Owner’s representative and all necessary assistance to carry out Inspection/Testing at Contractor’s cost. Owner/Owner's representative shall have a right to inspect any activities 3.

COORDINATION WITH TPIA Contractor on award of the Contract/LOI shall submit the detail procurement and construction schedules within fifteen (15) days to Owner/Owner’s representative for their approval. The detail item wise Construction/Manufacturing schedule indicating dates and location of manufacturer works shall be submitted by the Contractor within seven (7) days from the date of issue of their internal Indent /Purchase order to sub vendor. Contractor shall inform in writing seven (7) days in advance to inform the Owner/Owner’s representative for Inspection Notice/Call. All coordination among Owner/Owner’s representative/TPIA and Contractor’s/ Vendor’s works shall be the responsibility of Contractor. In case the Contractor fails to honor its inspection calls/notice, contractor has to reimburse all costs incurred by the Owner/Owner representative toward TPIA at actual. Inspection of site construction activities shall be coordinated on daily basis and adequate notice shall be given to Owner/Owner’s representative to mobilize TPIA, this shall be as per site conditions and requirements.

3.1.

Mechanical The Minimum requirements are indicated in the Quality Control Tables attached and as detailed above.

3.2.

Civil In addition to as indicated above, all procured items required for civil works should satisfy the following conditions:

•

It should be of reputed make having proven record of being successfully used in similar works earlier and as per approval by Owner’s Representative.

•

All materials shall be of standard quality and shall be procured from renowned sources / manufacturers approved by Owner/ Owner’s representative.

•

All tests of the materials as specified by the relevant BIS codes should be carried out by the contractor in an approved laboratory and the test reports should be duly authenticated by the laboratory and should be submitted to TPIA for his approval. If so desired by Owner/ Owner’s representative, tests shall be conducted in his presence or in presence of his authorized nominee.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IB of V

MECON LIMITED

•

Quality and acceptance of materials not covered under general technical specifications shall be governed by relevant BIS codes. In case BIS codes are not available for particular material other codes i.e. BS/DIN/ API/ASTM shall be considered.

•

The Contractor shall submit manufacturer’s test reports on quality and suitability of any material procured from them and their recommendations on storages/ application/ workmanship etc. for the intended use. Submission of manufacturer’s test reports does not restrict Owner/ Owner’s representative from asking fresh test results from an approved laboratory of the actual materials supplied even from an approved manufacturer.

4.

ELECTRICAL •

Contractor shall furnish the QAP for Panels, DG Sets, Cables, UPS for Owner’s review.

•

QA Plan will commence at the instigation of the requisition and follow through to equipment acceptance thus ensuring total conformity to the specifications.

•

Type test certificates of similar equipment shall be provided.

•

Routine tests shall be carried out on the panels, DG sets, Cables, UPS, Flame proof equipment and other items as per I.S.S.

•

Owner/Owner’s Representative reserves the right to witness routine acceptance tests at the manufacturer works as indicated in QAP & ISS.

•

Owner/Owner’s Representative will witness the routine tests on Panels, DG sets, UPS at the manufacturer works prior to dispatch, to prove compliance with specifications.

•

Owner/Owner’s Representative shall carry out the inspection of the erection and witness the testing & commissioning of the equipment at site and approve the test certificates.

5.

FIELD INSTRUMENTS •

Contractor shall furnish the quality assurance procedure for field instruments and cables for review of Owner/ Owner’s representative.

•

QAP will commence at the instigation of the requisition and follows through to equipment acceptance. Thus ensuring total conformity to the specifications.

•

Type test certificates of similar equipment shall be provided.

•

Owner/Owner’s Representative shall carryout the inspection of erection of the equipment and witness the testing and commissioning and approve the certificates.

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APPENDIX-VIII LIST OF MINIMUM NOS OF CONSTRUCTION EQUIPMENT TO BE DEPLOYED

LIST OF MINIMUM NOS. OF CONSTRUCTION EQUIPMENT TO BE DEPLOYED Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Note: 1. 2. 3. 4.

Equipment Description Grader Dozer D7/ D6 Or, Equivalent Excavator/ Back-Hoe (≥ Hitachi 100 or equivalent) JCB Or, Excavator/ Back-Hoe (≥ Hitachi 60 or equivalent) Side Boom/ Pipe Layer Or, Equivalent Hydra-( 8-10 MT) Tyre Mounted Crane (20 MT) Diesel Welding Machine/ Welding Rectifier DG Set 120 kVA + Stabilizer Automatic Bevelling Machine Internal Clamp ND 10” External Clamp ND 10” Internal X-ray Unit (Complete) External X-ray Unit (Complete) Manual UT Gamma Ray Unit (Complete) Radiography Film Viewer Sand Blasting Unit (Complete) Air Compressor (Minimum 300 CFM) Air Compressor (Minimum 600 CFM) Holiday Detector Dewatering Pump Water Filling Pump of Adequate Capacity Dosing Pump of Adequate Capacity Pressurization Pump – Motorised ( Adequate capacity ) Complete hydrotesting kit (dead weight tester, pressure instrument, temperature inst. etc.) Pipe Bending Machine Horizontal Augur Boring Machine HDD Machine with adequate pipe pulling capacity > 10T minimum alongwith complete accessories/ equipment Rock Breaking m/c with Excavator Mono Drill Crawler Mounted / Hand Drill (Pneumatic) with Compressor Pneumatic Drill (Tractor Mounted for Blasting) with Compressor Pipe Trailers of adequate size Concrete mixture Gruniting Machine Pipe Locator

Qty. (Nos.) 2 2 8 2 4 16 1 20 As required 2 2 4 1 1 As required 1 2 4 4 1 2 10 2 1 2 1 1 As required As required 1 As required As required 3 6 1 1

Bidder is required to mobilize the above minimum equipments in good working condition and suitable to lay this 12” diameter pipeline. Bidder is required to augment the above list with additional numbers of equipments as per actual requirement and instruction of Engineer-In-Charge without any additional financial implication to client. Bidder shall replace any defective / damaged equipments promptly to complete the work without any time & cost implication to the client / owner. After completion of certain activities, in case equipments are not required the same can be demobilized with prior approval of Engineer-In-Charge. Any other equipment required for completion of pipeline laying and associated works but not specifically mentioned above here, shall be deployed by Contractor without any additional cost.