Annexure 3 - Technical Supply Conditions for Pipes

VISAKH MARKETING INSTALLATION RESITEMENT PROJECT BLACK OIL TERMINAL

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TECHNICAL SUPPLY CONDITIONS FOR PIPES

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh




List of Content Page No

1 General 4

2 Testing 4

3 Specification 4

4 IBR Pipes 9

5 Hydrostatic Test 9

6 Marking and Despatch 10

7 Guarantee 11




1 General 1.1 All items and their dimensions, tolerances, chemical compositions physical properties, heat

treatment, hydrotest and other testing and marking requirements shall conform to the latest codes and standard specified in the material requisition (MR). Deviations(s), if any, shall be clearly highlighted in the offer.

1.2 All piping components shall conform to the requirements of ASME B31.3 and relevant referenced Codes, Standards and specifications.

2 Testing 1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material

specification. Test reports shall also be furnished for any supplementary tests as specified in the MR

1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)

shall also be furnished for the items supplied.

3 Specification This specification covers MS pipes (EW/SW) plain / bevel ended intended primarily for piping in storage unit for Petroleum product services, oil drain pipes and fire fighting facilities.

The pipes for petroleum products shall conform to IS 1978 Yst 240: 1982.

The pipes for oil drains shall conform to IS: 1239 (Part 1) Heavy : 2004.

The pipes for steam service (IBR) shall conform to ASTM A106 Gr. B : 1999.

The pipes for fire fighting facilities shall conform to ASTM A106 Gr. B / IS 1239 Heavy : 2004 / IS 3589 Fe410 : 2001.

These pipes shall be Seamless, ERW (Electric Resistance welded) or SAW (Submerged Arc welded) pipes.

3.1 Acceptance of the materials shall be subject to inspection, approval and release by the inspection agency designated by HPCL. Inspection will be carried out as per the scope of inspection detailed in this specification and as per the relevant standard, for which all arrangements/ facilities shall be made by successful tenderer.

3.2 Material and workmanship i. The pipes shall be new and the best of its kind. All pipes and their dimensions,

tolerances, chemical composition, physical properties, heat treatment, hydro test and other testing and marking shall conform to the respective codes indicated against each category of pipes in the schedule of quantities. Deviations if any shall be clearly highlighted in the offer.

ii. All the materials used shall be free from injurious defects and surface defects like

scale, burns, fins, rusts, cracks and deformation etc. The inside surface shall be




free from weld spatter, foreign matter or other obstruction. Reconditioning /repair of pipes by welding is not permitted.

iii. Pipes shall be supplied in standard double random length. Pipes having OD more

than 50mm shall be supplied with bevelled ends and less than 50mm with square ends.

iv. Necessary test certificates shall be submitted to MMCI / HPCL for checking

compliance to specified grade of materials. 3.3 Supplementary technical requirements / Inspection

i. The Steel pipes shall be manufactured by any of the following process

a. Electric welding. b. Helical seam submerged arc welding. c. Longitudinal seam arc welding.

ii. The Steel for the Pipe shall be made by one or more of the following processes:

a. Open Hearth process b. Electric Arc Furnace process c. Basic Oxygen Furnace process

iii. The chemical composition of steel shall be: ASME A106 Gr. B

Chemical Composition (Ladle Analysis), % Max

C Mn S P Ni 0.3 1.06 0.035 0.035 0.4

IS 1239: 2004


C Mn S P 0.2 1.30 0.040 0.040

IS: 1978-1982


C Mn S P 0.22 0.9 0.05 0.04




IS 3589:2001 Fe 410


C Mn S P 0.2 1.3 0.04 0.04

iv. The weld seam of welded pipe shall be heat treated after welding to a minimum temperature of 540 deg. C so that no untempered martensite remains or otherwise processed in such a manner that no untempered martensite remains.

v. All welded pipes should employ only automatic welding. Supplier must confirm the

same. Supplier shall indicate specifically the technique of welding employed. vi. The tenderer shall furnish in his offer, Quality Assurance Plan (QAP). For Inspection

& Test Plan, refer to Indicative Inspection and Test Plan Doc. No. MMCI/STD/IND/ITP/M-001, R-00

vii. The pipes shall not have any circumferential seam joint in a random length.

viii. Pipes in hydrocarbon services shall be of IS 1978 Yst 240 Electric Welded upto and including 14" & IS 1978 Yst 240 SAW with 100% Radiography for sizes 16" & above.

ix. Tolerance on Length, Wall thickness & Diameter of Pipes shall be as follows.

ASME A106 Gr.B: Length:

Nominal Length (m)

Minimum Length (m)

Minimum avg. length for each order Item (m)

Maximum Length (m)

Plain-End Pipe

12 6.7 10.7 13.72

Wall Thickness: Tolerance

(%of specified wall thickness) Size, NB mm Type of Pipe Grade B or Lower

< 50 Seamless 12.5 >50 and 500 Seamless 12.5

Diameter:

Size, mm Tolerance

(w.r.t specified outside diameter)

80 0.4 mm > 80 0.79 mm




IS 1239:2004: Length: The Tolerance on Length of Pipes shall be within 150 mm of the specified Length. Random Lengths: For orders over 150m of any size of the tube, it shall be permissible to supply short random lengths from 2 to 4m provided that the number of such length does not exceed 5% of total number of lengths for sizes below 65 NB and 7.5% of total number of lengths for sizes 65 NB and above.

Wall Thickness:

Type of Pipe Tolerance (%of specified wall thickness) 1. Welded tubes

Heavy + Not limited - 10 %

IS: 1978 - 1982:

Length:

Type of Pipe Shortest length in entire shipment

(m)

Minimum average length in entire shipment (m)

1. Threaded & Coupled Double random length 6.7 10.7

2. Plain end pipes Double random length 4.3 10.7

Wall Thickness:

Type of Pipe Pipe Size (OD, mm) Tolerance (%)

Seamless & welded pipes 73 & smaller +20.0, -12.5 88.9 +18.0, -12.5

Welded pipes 101.6 to 457.2 +15.0, -12.5 508.0 & above +17.5, -10.0

Diameter: The outside Diameter tolerances shall be as follows

Size of Pipe Tolerance

48.3 mm OD and Less + 0.40 mm, -0.80 mm 60.3 and above + 1 %




IS 3589:2001 Length:

Steel tubes shall be supplied in double random length of 7 m to 14 m. The permissible variations shall be +10 mm for length upto and including 6 m.

Thickness : The thickness shall not apply to weld area. The maximum height of the weld bead on the internal surface of the pipe shall not exceed 60 % of the wall thickness. The tolerance of the specified wall thickness shall be as follows

ERW Pipes 10 % SAW Pipes +20 % -12.5%

Diameter: Tolerance on outer diameter shall be 0.75% for all dia pipes.

x. No material shall be despatched before MMCI / HPCL confers the acceptance after

the inspection.

xi. All pipes are to be inspected before application of varnish coating.

xii. The straightness shall be randomly checked for straightness and deviation from a straight line shall not exceed 0.2% of the length.

xiii. The pipes cleared by inspection agency shall be stamped with the identification

mark of the inspection agency and marked in accordance with the code of manufacture.

ASME A106 Gr.B Pipes

The identification and marking method for A106 Gr. B pipes shall conform to ASTM A106 - 1999 IS 1239:2004 Tubes Each tube shall be marked with Manufacturers name/ Trademark, IS (Specification) Number, BIS Standard mark (if any) and Class. The different classes of tubes shall be distinguished by colour bands given hereunder.

Heavy tubes Red

IS: 1978-1982 The Pipes shall be marked with Manufacturers name/ Trademark, ISI monogram, Nominal Size (OD), Weight in Kg per m, Grade, Process of manufacture, Type of steel, Heat treatment, Hydrostatic test pressure (preceded by word TESTED) and Length.




IS 3589 :2001

Each pipe shall be marked with Manufacturers name or trade mark, outside diameter and specified wall thickness and pipe designation.

xiv. The inspection shall in no way relieve the supplier of his responsibility as per the contract and shall in no way be binding on MMCI / HPCL.

3.4 The pipes shall be cleaned and degreased before despatch. The pipes for petroleum products shall

be provided with external protective varnish coating suitable for use in petroleum products. Rust preventive coating used on machined surfaces to be welded shall be easily removable and shall not be harmful to welding.

Both the ends of the pipes supplied shall be protected with the following materials wherever necessary:

Plain ends - plastic caps Bevelled ends wood, metal or plastic cover

3.5 Product catalogues giving details of manufacturing ranges and specifications shall be included in the offer.

4 IBR Pipes 4.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form IIIA,

duly approved and countersigned by IBR authority/local authority empowered by the Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

4.2 For carbon steel pipes under IBR the chemical composition shall conform to the following: Carbon (max.) : 0.25 % Others (S, P, Mn) : As prescribed in IBR regulation. The chemical composition as indicated in this clause is not applicable for pipes other than

IBR services.

5 Hydrostatic Test 5.1 All pipes shall be hydrostatically tested. 5.2 The mill test pressure shall be as follows:




5.2.1 Seamless, E.R.W. & Spiral Welded: a) Carbon Steel

Material Std. Test Pressure Std. ASTM A106 Gr.B ASTM A530

5.2.2 Carbon Steel Pipes to IS Standards:

Material Std. Test Pressure Std. IS 1239 IS 1239 IS 3589 IS 3589 IS 1978 IS 1978

6 Marking and Despatch 6.1 All pipes shall be marked in accordance with the applicable codes, standards and

specifications. In addition the purchase order number, the item code & special conditions like IBR shall also be marked.

6.2 Pipes under IBR shall be painted in red strips longitudinally throughout the length for easy

identification. 6.3 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc,

lead or copper which cause corrosive attack on heating. 6.4 Pipes shall be dry, clean and free from moisture, dirt loose foreign materials of any kind. 6.5 Pipes shall be protected from rust, corrosion and mechanical damage during transportation,

shipment and storage. 6.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a

petroleum solvent and the same shall not be harmful to welding. 6.7 Both ends of the pipes shall be protected with the following materials:

Plain end : Plastic cap Bevel end : Wood, Metal or Plastic cover Thread end : Metal or Plastic threaded cap

6.8 End protectors to be used on bevelled ends shall be securely and tightly attached with belt or

wire. 6.9 Steel end protectors to be used on galvanised pipes shall be galvanised




7 Guarantee The supplies shall be fully guaranteed against any manufacturing defect/ poor workmanship/ inferior design or quality for a period of 12 months from the date of commissioning or 18 months from the date of last delivery whichever is earlier. Defects observed during this period shall be rectified or the defective items replaced by the tenderer at his cost.

Annexure 3 - Technical Supply Conditions for Pipes

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