GAIL Technical Spec.
Transcript of GAIL Technical Spec.
-
8/18/2019 GAIL Technical Spec.
1/1025
VOLUME – II
PIPELINE ENGINEERING
SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE
0 10.11.2008
DESIGN BASIS/JOB
SPECIFICATION/ STANDARD
SPECIFICATION/STANDARDS/
DRAWINGS/DATASHEET
REV. DATE
-
8/18/2019 GAIL Technical Spec.
2/1025
Page 1 of 7
INDEX Volume – II
PIPELINE ENGINEERING
S.NO.
TITLE REV. SPEC. No. ofPages
JOB SPECIFICATION
1 Engineering Design Basis 0 0001-01-04-03-001 19
2 Piping Material Specification 0 0001-01-05-02-001 68
3Welding Specification forMainline for Transportation of
Gas
0 0001-01-04-02-001 52
4 Welding Specification Chart 0 0001-01-04-02-001-WSC1 01
5 Welding Specification Chart 0 0001-01-04-02-001-WSC2 02
6Specification for Geo Textilebags for Anti-Buoyancy
0 0001-01-04-02-002 06
7Technical Specification for Pre-Commissioning andCommissioning
0 0001-01-04-02-003 15
STANDARD SPECIFICATION – PIPELINES
1Specification for LongitudinalSeam Submerged Arc WeldedLinepipe (Onshore)
0 S-04-02-001 36
2Specification for Helical (Spiral)Seam Submerged Arc WeldedLinepipe (Onshore)
0 S-04-02-002 43
3 Specification for Seamless Pipe 0 S-04-02-003 06
4 Specification of ERW pipe 0 S-04-02-004 34
5Specification of External coating
– 3L PE Coating0 S-04-02-005 34
6Specification of Internal Epoxycoating 0 S-04-02-006 31
7 Specification of Ball Valve 0 S-04-02-007 17
8 Specification of Plug Valve 0 S-04-02-008 14
9Specification of Gas Powered
Valve Actuators0 S-04-02-012 14
10Specification for Seamlessfittings & Flanges, Size up to DN400 mm (16”)
0 S-04-02-013 07
(BIDDING DOCUMENT NO. - 8000000682)
-
8/18/2019 GAIL Technical Spec.
3/1025
Page 2 of 7
11Specification for flanges &Welded Fittings (Size DN 450mm (18") and above
0 S-04-02-014 07
12Specification for Long RadiusBends for Onshore Pipelines
0 S-04-02-015 10
13Specification for Flow Tee (BarTees) for Onshore Pipeline
0 S-04-02-016 12
14 Specification for Scraper Trapsfor Onshore Pipelines
0 S-04-02-017 17
15Specification for Pig Signaler forOnshore Pipelines
0 S-04-02-018 6
16Specification for InsulatingJoints for Onshore Pipelines
0 S-04-02-019 9
17Specification for CasingInsulator and End Seals
0 S-04-02-020 08
18Specification for Field JointCoating (Onshore Pipeline)
0 S-04-02-021 15
19Specification for ConcreteWeight Coating of OnshorePipelines
0 S-04-02-022 15
20Specification for Repair ofPolyethylene Coating
0 S-04-02-023 06
21Specification for Quick OpeningEnd Closure
0 S-04-02-024 08
22Specification for Pipeline RiverCrossings using HDD
0 S-04-02-025 15
23Construction of pipelinescrossing Roads, Rail Roads andMinor Water Crossings
0 S-04-02-026 11
24Major Water Crossing -Conventional Trenching
0 S-04-02-027 15
25Specification for PipelineConstruction (Onshore)
0 S-04-02-028 43
26Specification for HydrostaticTesting of Onshore Pipelines
0 S-04-02-029 22
27Specification for PipelineMarkers
0 S-04-02-030 05
28
Specification for Documentation
for Pipeline Construction 0 S-04-02-031 0929 Specification for Blasting 0 S-04-02-032 11
30Specification for DetailedPipeline Route Survey (Onshore)
0 S-04-02-033 17
31Welding Specification forFabrication of Piping
0 S-04-02-034 32
32Spec. for Instructions to Vendorfor Quality Data Requirement
0 S-04-02-035 10
-
8/18/2019 GAIL Technical Spec.
4/1025
Page 3 of 7
33Spec. for Issue andReconciliation of Material
0 S-04-02-036 09
34Spec. for Pipeline InformationManagement system
0 S-04-02-037 06
STANDARD SPECIFICATION – PIPING
1 Technical Notes for Pipes 0 S-05-02-001 09
2 Technical Notes for Valves 0 S-05-02-002 17
3Technical Notes forButt Welded, Socket Weldedand Screwed Fittings
0 S-05-02-003 07
4Technical Notes for Flanges,Spectacle Blinds and Drip legs
0 S-05-02-004 05
5Technical Notes for Bolts andNuts
0 S-05-02-005 03
6Technical Notes forGaskets
0 S-05-02-006 03
7 Inspection and Test Plan forGaskets
0 S-05-06-001 04
8Standard Specification forFabrication and Erection ofPiping
0 S-05-02-011 16
9Standard Specification of "Non-Destructive Examination ofPiping"
0 S-05-02-012 16
10Specification for Inspection,Flushing and Testing of PipingSystem
0 S-05-02-013 10
11Specification for Shop and FieldPainting
0 S-05-02-014 49
12Standard specification of PMI at
Vendor's works.0 S-14-02-001 07
STANDARD DRAWING – PIPELINES
1Typical Right of Way forPipelines
0 S-04-01-001 02
2Typical Trench Dimensions forPipelines
0 S-04-01-002 01
3 Pipeline Symbols 0 S-04-01-003 014 Topographical Symbols 0 S-04-01-004 01
5Existing pipeline on sleepercrossing
0 S-04-01-005 02
6Pipeline Road/ HighwayUncased Crossing
0 S-04-01-006 01
7 Details of casing vent and drain 0 S-04-01-007 01
8 Casing pipe details 0 S-04-01-008 01
-
8/18/2019 GAIL Technical Spec.
5/1025
Page 4 of 7
9Existing Under Ground PipeCrossing (Type-I)
0 S-04-01-009 02
10Existing Under Ground PipeCrossing (Type-II)
0 S-04-01-010 02
11 Under Ground Cable Crossing 0 S-04-01-011 02
12 Over Head Power Line Crossing S-04-01-012 02
13
Typical trench dimension for two
or more pipelines in commontrench
0 S-04-01-013 01
14 K.M. Post 0 S-04-01-014 03
15 Typical ROU boundary marker 0 S-04-01-015 02
16 Aerial marker 0 S-04-01-016 03
17 Direction marker 0 S-04-01-017 03
18 Pipeline Warning Sign 0 S-04-01-018 03
19Navigable Waterway PipelineCrossing Warning Sign
0 S-04-01-019 02
20Pipeline Road/Highway Cased
Crossing0 S-04-01-020 02
21 Typical Stream Crossings 0 S-04-01-021 02
22 Typical Slope Breakers Details 0 S-04-01-022 03
23Bank Protection Details forwater crossings
0 S-04-01-023 03
24Typical details of railwaycrossings
0 S-04-01-024 03
25Select Backfill for Station
Approach0 S-04-01-026 02
26Slope stabilization in ghat/ hill
areas
0 S-04-01-027 02
27 Soil stabilization in hilly areas 0 S-04-01-028 03
28Typical lined canal casedcrossing detail
0 S-04-01-029 02
29Typical lined canal crossings(Uncased)
0 S-04-01-030 01
30Typical Cross section for ROUpreparation in Hilly areas
0 S-04-01-031 01
STANDARD DRAWING – PIPING
1 Jack Screw for Spectacle Blind 0 S-05-01-001 01
2 Jack Screw for Spacer & Blind 0 S-05-01-002 01
3 Vents & Drains on Lines 1-1/2”& Below
0 S-05-01-003 01
4 Vents & Drains on Lines 2” & Above
0 S-05-01-004 01
5Wells Installations 1-1/2”Diameter Traps
0 S-05-01-005 02
6 Pressure Tapings – PG, PT, PI, 0 S-05-01-006 01
-
8/18/2019 GAIL Technical Spec.
6/1025
Page 5 of 7
PA, PC etc
7Handle Projections for Spacersand Blinds
0 S-05-01-007 01
8T-Strainer Type-1 2"-4" (150#RF, 300# RF and RTJ, 600# RFand RTJ)
0 S-05-01-008 01
9
T-Strainer Type-1 6"-24"
(150# RF, 300# RF and RTJ,600# RF and RTJ)
0 S-05-01-009 01
10 Orientation of Orifice Traps 0 S-05-01-010 01
11 Stub-in Standard 0 S-05-01-011 02
12Welding of pipe with differentthickness
0 S-05-01-012 01
13 Fillet weld details 0 S-05-01-013 01
14Welding details for branchconnections
0 S-05-01-014 01
15
Method of cutting and
dimensions of fieldmanufactured concentricreducers
0 S-05-01-015 01
16 Tolerances for fabrication 0 S-05-01-016 01
17Pipe shoe for hot insulated C.S.pipe, size 2" thru 8", Type-S1(for temp. up to 343°C)
0 S-05-01-017 02
18Pipe shoe for hot insulated C.S.pipe, size 10" thru 30", Type-S2.(for temp. up to 343°C)
0 S-05-01-018 02
19Pipe saddle for bare pipe size14” thru 48” type- S6A 0 S-05-01-019 02
20Pipe shoe for slope line pipe size2" thru 6" type-S9A/9B/9C
0 S-05-01-020 02
21Low support sliding for bare andinsulated pipe size 2" thru 36"type-L1 & L1A
0 S-05-01-021 02
22Low support fixed for bare &insulated pipe size 2" thru 36"type-L3 & L3A.
0 S-05-01-022 01
23
Low support sliding for bare
pipe size 3/4" thru’ 36" type-L5& L5A.
0 S-05-01-023 01
24Low support sliding for bare andinsulated pipe size 2” thru 36”Type-L6
0 S-05-01-024 02
25Low support Fixed/Restrainedfor bare and insulated pipe size2" thru 36", type-L7 & L7A
0 S-05-01-025 03
-
8/18/2019 GAIL Technical Spec.
7/1025
Page 6 of 7
26Restrained Low support for bareand insulated pipe size 2" thru36", type-L8 & L8A
0 S-05-01-026 01
27 Adjustable low support slidingfor pipe size 2" thru 6" type-L10 & L10A
0 S-05-01-027 01
28
Low support sliding & fixed for
pipe size 3/4" thru 11/2"type-L15.
0 S-05-01-028 02
29Low support stanchion for bare& insulated CS/AS/SS pipetype – L16 and L16A
0 S-05-01-029 01
30 Adjustable low support with 4bolts for pipe size 8" thru 24"type-L17 & L17A.
0 S-05-01-030 02
31 Adjustable low support for bareand insulated pipe size 2" thru
24". type-L18 & L18A
0 S-05-01-031 01
32
Adjustable low support withguide & cross guide for bareand insulated pipe size 2" thru24" type-L19 & L19A.
0 S-05-01-032 02
33Pipe clamp for bare pipe size1/2" thru 24” Type C-1
0 S-05-01-033 01
34U-bolt for bare pipe size 1/2"thru 24" type-C4
0 S-05-01-034 01
35Dummy pipe support for barepipe size 2" thru 24" type B-39
0 S-05-01-035 02
36Dummy pipe support forinsulated pipe size 2" thru 24"type-B40
0 S-05-01-036 02
37 Pipe support brackets type-B42 0 S-05-01-037 01
38Guide support for bare size 1/2"thru 24" type-G1
0 S-05-01-038 01
39Guide support for bare size 1/2"thru 24" type-G2 & G2A
0 S-05-01-039 02
40Cross guide for bare pipe size 2"thru 24" type-G3
0 S-05-01-040 02
41 Cross guide for bare pipe size 2"thru 24" type-G4.
0 S-05-01-041 02
42 Anchor for bare pipe size 2" thru24" type-G5.
0 S-05-01-042 02
43Supporting arrangement forangle & relief valves type-SP2.
0 S-05-01-043 01
44Typical anti vibration support forcontrol valve-SP3.
0 S-05-01-044 01
-
8/18/2019 GAIL Technical Spec.
8/1025
Page 7 of 7
LAYOUT DRAWING & PORTACABIN PLAN
1Layout Sultanpur DispatchTerminal
0 0001-00-10-01-6002 01
2Layout SV-1 (Sultanpur -Neemrana)
0 0001-00-10-01-6003 01
3 Dharuhera CGS & TOP 0 0001-00-10-01-6004 01
4Layout Bhiwadi / Chopanki TOPStation
0 0001-00-10-01-6005 01
5 Layout Bhiwadi CGS 0 0001-00-10-01-6006 01
6 Layout SV-2 & Khushkhera CGS 0 0001-00-10-01-6007 01
7Layout SV-3, Sultanpur -Neemrana
0 0001-00-10-01-6008 01
8 Layout Neemrana CGS & RT 0 0001-00-10-01-6009 01
9Layout Hayatpur TOP (forManesar)
0 0001-00-10-01-6010 01
10 Layout Manesar CGS 0 0001-00-10-01-6011 01
11 Layout Hayatpur PRS 0 0001-00-10-01-6012 0112 Layout SV-1 (Gurgaon Line) 0 0001-00-10-01-6013 01
13 Layout Gurgaon Terminal 0 0001-00-10-01-6014 01
14 Porta-Cabin Layout 0 0001-00-10-01-6015 02
DATASHEETS – LINEPIPE / PIPING
1 Datasheet of Ball Valve 0 0001-01-04-04-BV-001 01
2 Datasheet of Ball Valve 0 0001-01-04-04-BV-002 01
3 Datasheet of Ball Valve 0 0001-01-04-04-BV-003 01
4Datasheet of Scraper Launcher /
Receiver
0 0001-01-04-04-PL/PR-001 01
5 Datasheet of Pig Signaler 0 0001-01-04-04-PSG-001 01
6 Datasheet of IJ 0 0001-01-04-04-IJ-001 01
7Datasheet of Flow Tee (BarredTee) - 18" X 18" , 600#
0 0001-01-04-04-FLT-001 01
8Datasheet of Flow Tee (BarredTee) - 18" X 12" , 600#
0 0001-01-04-04-FLT-002 01
9Datasheet of Flow Tee (BarredTee) - 18" X 8" , 600#
0 0001-01-04-04-FLT-003 01
10Datasheet of Quick Opening EndClosure
0 0001-01-04-04-QOEC-001 01
11Datasheet of Gas Powered Valve
Actuator0 0001-01-04-04-GVA-001 04
12 Datasheet of Plug Valve 0 0001-01-04-04-PV-001 01
13 Datasheet of Plug Valve 0 0001-01-04-04-PV-002 01
14Data Sheets of Gate Valves ofSize below 2”
0 0001-01-05-04-GV-001 03
-
8/18/2019 GAIL Technical Spec.
9/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 1 of 19
Copyright GAIL – All rights reserved
ENGINEERING DESIGN BASIS
(PIPELINE ENGINEERIG)
SPUR LINES OF CHAINSA – JHAJJAR PIPELINE
-
8/18/2019 GAIL Technical Spec.
10/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 2 of 19
Copyright GAIL – All rights reserved
TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 SCOPE
3.0 DESIGN CODES AND STANDARDS
4.0 DESCRIPTION OF FACILITIES
5.0 PIPELINE ROUTE
6.0 DESIGN DATA
7.0 PIPELINE AND ASSOCIATED FACILITIES DESIGN
8.0 OTHER TECHNICAL REQUIREMENTS
ANNEXURE-A LIST OF CODES AND STANDARDS
ENCLOSURES:
1. Schematic Arrangement for Pipeline Facilities Drawing no. 0001-00-03-01-5003.
-
8/18/2019 GAIL Technical Spec.
11/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 3 of 19
Copyright GAIL – All rights reserved
1.0 INTRODUCTION
M/s GAIL (India) Ltd., proposes to lay following Natural Gas spur Pipelines (fromChainsa- Jhajjar pipeline):-
Sl. Pipeline Tap-off Point Size(Inch) X
Length (Km)
1 SultanpurHaryana) toNeemrana(Rajasthan)
Tap-off point atChainage – 70.05 Km inChainsa-Jhajjar line
18” X 85.28
2 Spur Lineto Bhiwadi
Tap-off point at Chainage –31.6 Km in Sultanpur –
Neemrana Line
12” X 9
3 Hayatpur toManesar
Tap-off point atChainage – 61.14 Km inChainsa-Jhajjar line
10” X 5.4
4 Hayatpur toGurgaon
Tap-off point at Chainage –61.14 Km in Chainsa-Jhajjarline
10” X 11
These pipelines are to cater the natural gas requirement of consumers atDharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar and Khandsa/Gurgaon. TheSultanpur-Neemrana pipeline is proposed to pass through Dharuhera andKhushikhera.
The above proposed pipeline shall have laying length as given above and 4 nos. ofSectionalising Valve (SV) stations. The pipeline shall be designed to handle NaturalGas & RLNG.
2.0 SCOPE
This document establishes minimum design parameters and basis for design anddetailed engineering of the Pipeline and Associated facilities covered under thisproject as defined briefly herein below.
3.0 DESIGN CODES AND STANDARDS
Pipelines and terminal facilities envisaged shall be designed and engineered
-
8/18/2019 GAIL Technical Spec.
12/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 4 of 19
Copyright GAIL – All rights reserved
primarily in accordance with the provisions of the latest edition of Code ASME B31.8: Gas Transmission and Distribution Piping Systems and OISD 141: Design andConstruction Requirements for Cross Country Hydrocarbon Pipelines. In addition,requirements, as applicable to gas service of following codes/standards shall becomplied with:
OISD Std. 138 Inspection of Cross Country Pipelines-Onshore
ASME B 31.3 Chemical Plant & Petroleum Refinery Piping
API Std. 1102 Steel Pipeline Crossing Railways & Highways
API Std. 1104 Standard for Welding Pipelines and Related Facilities
ISO 13623 Petroleum & natural gas industries – Pipeline transportationsystems
In addition to above, codes and standards listed in Annexure-A of this document
shall also be referred.
In case of conflict between the requirements of ASME B31.8/OISD 141 and othercodes/Standards referred above, requirement of ASME B 31.8/OISD 141 shallgovern. In case of conflict between requirements of B31.8/OISD 141 and thisdocument, requirements of this document shall govern.
4.0 DESCRIPTION OF FACILITIES
Details of facilities shall be as per P&ID’s, process design basis, data sheets, lineschedule etc covered in the process package. The pipeline facilities envisaged as a
part of Spur Line of Chainsa-Jhajjar Pipeline are described briefly herein below.
4.1 SULTANPUR – NEEMRANA LINE
4.1.1 Despatch cum Receipt Station at Sultanpur and Neemrana
Facilities at Despatch cum Receipt Station at Sultanpur & Neemrana terminals shallconsist of Pig launcher cum receiver complete with associated piping including hook-upwith existing Chainsa-Jhajjar Pipeline at Chainage 70.50 Km in Sultanpur. AdditionallyNeemrana terminal shall have filtering, metering and let down skid (CGS).
4.1.2 SV & TOP at SV-1 (Ch. 16.02 Km), SV-3 (Ch. 62.2)
Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above groundtransition in the above ground section of pipeline. Sectionalizing Valve in Main line.
4.1.3 TOP & CGS at Dharuhera, BhiwadiTap-off with flow tee and valve. Provision for Insulating Joint at the buried/above groundtransition in the above ground section of pipeline. Filtering, metering and let down skidwith associated piping and Instruments.
-
8/18/2019 GAIL Technical Spec.
13/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 5 of 19
Copyright GAIL – All rights reserved
4.1.4 SV-2 , TOP and CGS at KhushkheraTap-off with flow tee and valve. Provision for Insulating Joint at the buried/above groundtransition in the above ground section of pipeline. Sectionalizing Valve in Main line.Filtering, metering and let down skid with associated piping and Instruments.
4.1.5 Bhiwadi/ Chopanki TOP for BhiwadiTap-off with flow tee and valve all underground.
4.2 HAYATPUR – MANESAR LINE
4.2.1 TOP Hayatpur for Manesar LineExtending the existing Tap-off off with valve. Provision for Insulating Joint at theburied/above ground transition in the above ground section of pipeline
4.2.2 TOP & CGS at Manesar
Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above groundtransition in the above ground section of pipeline. Filtering, metering and let down skidwith associated piping and Instruments.
4.3 HAYATPUR – GURGAON LINE
4.3.1 PRS at Hayatpur Extending the existing Tap-off off with PRS/ valve. Provision for Insulating Joint at theburied/above ground transition in the above ground section of pipeline
4.3.2 SV-1 – Gurgaon Line (Ch. 6.4 Km)Sectionalizing Valve (underground) at Chainage 6.4 Km.
4.3.2 Gurgaon Terminal StationProvision for Insulating Joint at the buried/ above ground transition in the above groundsection of pipeline. Tap-off with Valve and Blind as per P&ID.
4.2 Main Pipeline
Pipeline facilities are schematically indicated in drawing no. 0001-00-03-01-5003.
5.0 PIPELINE ROUTE
5.1 Pipeline Route
Salient features of the surveyed pipeline route as per pipeline route map no. MAS/GAIL/ CGJHPL/08/ RM-01/02/03/04, GAIL/ SKP/ GURGAON/ 2008/ R.M./01 (Rev.-0), and survey report are tabulated herein below:
-
8/18/2019 GAIL Technical Spec.
14/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 6 of 19
Copyright GAIL – All rights reserved
SALIENT FEATURES OF RESPECTIVE PIPELINE ROUTE
Sultanpur –Neemrana
Spur Lineto Bhiwadi
Hayatpur -Manesar
Hayatpur -Gurgaon
Size, OD ( Inch) 18 12 10 10
Length (Km) 85.28 9 5.4 11
Highest elevationabove MSL (m)
Refer SurveyReport
ReferSurveyReport
Refer SurveyReport
Refer SurveyReport
Lowest elevation above
MSL (m)
Refer SurveyReport
ReferSurveyReport
Refer SurveyReport
Refer SurveyReport
No. of River Crossing ,Width > 100 m
0 0 0 0
No. of Road Crossing
(NH/SH)
3/2 0/2 0/0 1/0
No. of Railway
Crossing
3 0 0 0
No. of Canal Crossing 6 0 0 0
5.2 Terrain Details
For Terrain details and Land use pattern refer survey reports prepared by M/s MASCONMSC PVT. Ltd and M/s SKP Projects P. Ltd. attached elsewhere in the bid document.
6.0 DESIGN DATA6.1 Main pipeline shall be designed for conditions as follows:
PIPELINE DESIGN PARAMETER
Description Value
Sultanpur – Neemrana Line 457.2 mm OD
Bhiwadi/ Chopanki Tap-off – Bhiwadi Line 323.9 mm OD
Hayatpur to Manesar 273.1 mm OD
Hayatpur to Gurgaon
PRODUCT – Natural Gas/ RLNG
Design Pressure (Kg/ Cm2g) 99.93
Operating Pressure (Kg/ Cm2g) 60-99
Maximum Design Temperature, 0 Ci. Above Ground Section
ii. Under Ground Section
-29 to 65.0
-29 to 45.0Operating Temperature, 0 C 13 - 25
Economic Design Life, Years 35
Corrosion Allowance 0
Hayatpur to Gurgaon – Design Pressure shall be 49Kg/cm2 g and Design Temp AG/UG (-) 29 to 65 /(-) 29 to 45. Rest other parameter shall be as above.
273.1 mm OD
-
8/18/2019 GAIL Technical Spec.
15/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 7 of 19
Copyright GAIL – All rights reserved
All terminal facilities (equipment and associated piping) shall be designed for designand operating conditions given in the process package.
7.0 PIPELINE AND ASSOCIATED FACILITIES DESIGN
7.1 General
Pipeline and pipeline stations to be installed as a part of this project shall be designedand engineered in accordance with the standards/codes referred in section 3.0 of thisdocument.
7.2 Pipeline
7.2.1 Pipeline shall be designed in accordance with requirements of ASME B 31.8 and OISD141. The pipeline shall withstand all installation, testing and operating condition/ loads.
All necessary calculations shall be carried out to verify structural integrity and stability
of the pipeline for the combined effect of pressure, temperature, bending (elastic),soil/pipe interaction, external loads and other environmental parameters as applicableduring all phases of work from installation to operation. Allowable stress limit shall beas per ASME B 31.8. Such calculations shall include, but are not limited to following:
- Buoyancy control and stability analysis for pipeline section to be installed in areassubjected to flooding/submergence. Unless specified, specific gravity of installationin such area shall be at least 1.2.
- Stress analysis at crossing of major rivers, rail and highway etc.
- Crossing analysis of rivers by HDD if applicable.
- Pipeline expansion and its effect on station piping (above ground/below ground).
7.2.2 Pipeline shall also be checked for adequacy against anticipated earthquake loading andany special measures such as increase in wall thickness/ grade/ select backfill etc. asrequired to ensure safety and integrity of the pipeline system shall be implemented.
7.2.3 Mainline shall be provided with bi-directional pigging facilities suitable for handling alltypes of pigs including intelligent pigs.
7.2.4 Pipeline and its associated facilities shall be designed using the applicable design code
and as modified below.
The pipeline shall be designed to meet the Location Class as defined in ASME B31.8,except as modified below.
-
8/18/2019 GAIL Technical Spec.
16/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 8 of 19
Copyright GAIL – All rights reserved
LocationClass
Type of Facility Design Factor
All Station Piping 0.5
River / Stream Crossings
Drilled / Bored/ Inaccessible / OpenCut
0.6
Others 0.72
HDD 0.5
Cased/Uncased Crossings or ParallelEncroachments on ROW of Hard SurfacedRoads, Public Streets and Highways
0.6
Class – 1
Railway Crossing 0.5
River / Stream Crossings
Drilled / Bored/ Inaccessible / OpenCut
0.5
Others 0.6 HDD 0.5
Cased/Uncased Crossings or ParallelEncroachments on ROW of Hard SurfacedRoads, Public Streets and Highways
0.5
Class – 2
Railway Crossing 0.5
Class – 3 All 0.5
Class – 4 All 0.4
7.3 Station Piping
7.3.1 Station piping to be provided at terminals, intermediate stations, SV stations shall bedesigned in accordance with OISD 141/ASME B 31.8 and utility piping to be provided atthese locations shall be designed in accordance with the provisions of ASME B 31.3.
7.3.2 All piping shall be designed for combined effects of pressure, weight and temperatureduring operating conditions without over stressing the piping, valves or equipment. Allpiping shall be adequately supported, guided or anchored so as to prevent unduevibration, deflection or loads on connected equipment such as filters, meters etc.
7.4 Materials
Pipeline and its appurtenances shall be provided with carbon steel materials suitable forthe intended service, as detailed in subsequent paragraphs
7.4.1 Line pipe for main line
Line pipe shall conform to API 5L and Company specifications. Type of line pipe to beused shall be SEAMLESS/LSAW/ HSAW/EW.
-
8/18/2019 GAIL Technical Spec.
17/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 9 of 19
Copyright GAIL – All rights reserved
Sr.No.
LINE SIZE GRADE Class - I Class - II Class - III Class -IV
1 18”(457.2 mm) X-70,PSL-2
6.5 7.9 9.3 11.7
2 12” (323.9 mm) X-60,PSL-2
6.4 6.4 7.9 9.5
3 10” (273.1 mm) X-60,PSL-2
6.4 6.4 6.4 7.8
7.4.2 Other Materials
All other materials and equipments including scraper traps, flow tees, insulating joints,ball valves, plug valves, globe valves, check valves, pig signallers, flanges and fittingsshall be carbon steel suitable for the service conditions and shall be compatible with theline pipe material.
7.5 External/ Internal corrosion coating
7.5.1 Pipeline to be installed below ground shall be protected against external corrosion by acombination of high integrity externally applied coatings and permanent impressedcathodic protection system. Externally applied coating shall be three layer side extrudedpolyethylene coating.
7.5.2 In addition, pipeline shall be provided with minimum 80 micron thick liquid epoxyinternal coating conforming to ISO 15741/API RP 5L2. Extremities of pipe shall be freefrom coating over a length of 20± 5 mm.
7.5.3 All above ground piping and structures shall be painted to prevent atmosphericcorrosion. Painting of above ground piping and structures shall be as per specifications.Painting shall be suitable for normal corrosive environment/corrosive environment, asapplicable, as defined in Painting Specification No. S-05-02-014 for all stations andterminals.
7.6 Insulating joints
Insulating joints shall be provided to electrically isolate the buried pipeline from aboveground pipeline. Insulating joints shall be monolithic type and shall allow smoothpassage of pigs. Insulating joints shall be installed in above ground portion of thepipeline, immediately after the buried/aboveground transition at the scraper stations.
Wherever pressure/ temperature transmitters are used on cathodically protectivepipeline the same shall be electrically isolated by providing insulating joints/ flanges.
7.7 Pipeline Burial
The pipeline shall be buried normally at a depth of 1.0 meter below natural ground levelexcept river/ rail/ road/ canal/waterways crossing where minimum cover shall be as
-
8/18/2019 GAIL Technical Spec.
18/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 10 of 1
Copyright GAIL – All rights reserved
given below or as per the requirements of statutory/local authorities whichever is morestringent. Increased cover shall be provided at critical locations and crossings.
Sl.Location
Minimum Cover(m)
1.0 Industrial, commercial and residentialarea
1.0
2.0 Rocky terrain 1.0
3.0Minor water crossing/ canal/ drain/nala/ waterways
1.5
4.0 HDD crossing of canals (below bed) 2.5
5.0River crossings for which scour depthis defined (below scour)
1.5
6.0
Other River crossings (Bank width >
50m) (Below Bed)2.5 (For normal soil)1.5 (For rocky strata)
7.0Other River crossings (Bank width <50m) (Below Bed)
1.5
8.0 Cased/uncased road crossing 1.2
9.0 Cased railway crossing 1.7
10.0Drainage, ditches at roads/railwaycrossings
1.2
11.0 Marshy land/Creek area 1.5
Additional soil cover other than specified above shall be provided at locations indicatedby statutory/ local authorities or in areas likely to have an increased risk of impactdamage or third party interference as per agreements between COMPANY andauthorities. In case, any private dwelling, industrial building or place of public assemblyfalls within 15 m of pipeline, additional cover of minimum 300 mm shall be provided overand above the cover indicated in the above table.
7.8 Marshy Areas / Areas Prone to Flooding
Wherever marshy areas/areas prone to flooding are encountered along the pipelineroute, pipeline shall be provided with anti buoyancy measures viz. continuous concretecoating/ Geotextile gravel filled bags. Unless specified otherwise in AFC drawings,specific gravity of installation in such areas shall be at least 1.2.
7.9 Pipeline in common ROW
The location of new underground pipeline, when running parallel to an existingunderground pipeline in same ROU/ROW shall be laid at minimum clear distance of 5.0m from the existing underground pipeline. This distance may be reduced to 3.0 m after
-
8/18/2019 GAIL Technical Spec.
19/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 11 of 1
Copyright GAIL – All rights reserved
assessment of construction methodology which do not result in unsafe conditionsduring construction.
7.10 Backfilling
In normal cross-country areas, the pipeline trench shall be backfilled with excavatedsoil. Select rockfill/ slope breakers shall be provided in the trench in steep areas (slopegenerally 10% and more) to prevent erosion. In case of rivers/water bodies prone toscour and erosion, the safety cover shall be provided below the predicted scour level. Inaddition to the cover, anti buoyancy measures (concrete coating) shall be provided atriver crossings.
Contractor shall keep top 150 mm of excavated top soft soil (free of gravels) aside,which shall be back filled in the end as top layer.
Select backfill shall be provided at approaches to terminal up to transition point (belowground/above ground) inside terminal.
Select back fill shall also be provided as applicable for areas prone to seismic activity.Recommendation of Seismic Analysis Report should be considered for such specialbackfill.
Pipeline route shall be examined to establish any drainage requirement in hilly terrain.In case required, the drainage shall be designed to prevent trench flooding duringconstruction and protect the integrity of the installed pipeline following completion of allconstruction activities.
In rocky areas, the trench bottom shall have sand/soft soil padding of 150 mm. Afterlaying of pipeline, sand/soft soil padding shall be placed around and on top of the pipe
so that thickness of compacted padding on top of pipe corrosion coating shall be atleast 150 mm.
Disposal of debris and surplus material to designated disposal areas or designatedplace(s), as the case may be and as directed by Engineer-in-charge shall be carried out.
8.0 OTHER TECHNICAL REQUIREMENTS
8.1 Scraper Stations
Scraper traps shall be provided at the Despatch terminals (Sultanpur) and Receiver
Terminal at Neemrana. The scraper traps shall be bi-directional capable of handlingintelligent pigs and other cleaning pigs. The launching and receiving barrels shall bedesigned in accordance with the requirements of ASME B 31.8 and its end closure shallbe designed and fabricated according to ASME Section VIII, Div.1. Adequatearrangements for launching, retraction, handling and lifting of cleaning andinstrumented pigs shall be provided at the scraper stations. Traps shall be accessibleby walkway/road for movement of equipment, pigs etc. These stations shall be providedwith access road from the nearest metalled road.
-
8/18/2019 GAIL Technical Spec.
20/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 12 of 1
Copyright GAIL – All rights reserved
Corrosion resistant coating shall be provided on the pipeline up to a minimum length of500 mm after it comes aboveground / before it gets buried underground at terminalsand scraper stations.
The diameter of barrel of the launcher cum receiver shall be three nominal sizes largerthan the pipeline nominal size. Center line elevation of scraper trap shall be at suitableheight from grade level. Suitable arrangements shall be provided for handling & liftingof pigs.
The piping system at the terminals and intermediate stations shall be designed to havesufficient flexibility to prevent pressure and thermal expansion or contraction fromcausing excessive stresses on the connected equipment. The piping shall bedesigned/fabricated as defined in clause 8.3.
As far as possible, pipeline expansion shall be absorbed by allowing the scraper traps tomove on supports. Installation of anchor block in the under ground pipeline is not
permitted. If required adequate length of trench in approaches to stations shall beprovided with a select backfill to ensure flexibility.
8.2 Sectionalising Valve Stations
Sectionalising valve station shall be provided along pipeline route for isolating sectionsof pipeline as per ASME B 31.8 for:
- Limiting the hazard and damage from accidental discharge from pipeline system.
- Facilitating maintenance of pipeline system and
- Complying with the requirements of applicable codes.
The location of sectionalizing valves are indicated in PFD. The requirements ofapplicable codes taking consideration of terrain features, requirement of safety andoperation etc. to be taken in to account while providing Sectionalizing Valves.Sectionalizing valve on the main pipeline shall be ball valves of full bore type, to allowsmooth passage of cleaning and intelligent pigs.
All valves installed at Intermediate facilities, block valve stations, scraper stations andpipeline sectionalizing valve stations shall be gas actuated/ hand operated and with buttwelding ends. Sectionalizing and Station block valves shall be installed buried andprovided with a stem extension in such a way that the center line of rim of the handwheel on a horizontal shaft or center of actuator is at approximately 1.0 m above the
finished ground level. Valve surface shall be provided with corrosion protection coating. Valve body vent and drain lines shall be extended and terminated above ground.
The valve stations shall be located at a readily accessible location such as near road andshall be provided with an access road from the nearest all weather metalled road. Thefacilities within valve station shall be secured by a chain link fence enclosure with gate.The location of valve station shall be clear of overhead power lines.
The provisions of remote operated feature shall be as per the operation and control
-
8/18/2019 GAIL Technical Spec.
21/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 13 of 1
Copyright GAIL – All rights reserved
philosophy to be adopted for the project. At locations, where valve stations arecombined with CP/Repeater stations, the safe distance and statutory clearance as perstandard shall be followed.
8.3 Piping
8.3.1 General
This section describes the design requirements of piping applicable for Despatchstation, intermediate pigging stations, sectionalizing valve stations and receiving station.
All piping and equipment shall be designed as per ASME B 31.8. All piping materialsshall be as per Piping Material Specification (PMS).
Utility piping to be provided shall be designed in accordance with the provisions of
ASME B 31.3.Design shall provide consideration for all loadings like weight, temperature etc.,significantly affecting the pipe material stresses in addition to fluid pressure.
8.3.2 Piping flexibility/stress analysis
All piping shall be designed for thermal expansion under start up, operating and shutdown conditions without over stressing the piping, valves or equipment. Provisions forexpansion shall normally be made with bends and offsets.
All piping shall be adequately supported, guided or anchored so as to prevent unduevibration, deflection or loads on connected equipments. Equipments/ valves requiring
periodical maintenance shall be supported in such a way that the valves and equipmentcan be removed with minimum temporary pipe supports.
8.3.3 Piping layout
Piping will be located above-ground wherever possible within the terminals. Piping shall be designed considering skin temperature of piping material under empty
conditions as 65ºC or design temperature of pipeline whichever is higher.
Piping stress analysis shall be carried out to determine allowable pipe movement andsupport requirements wherever felt necessary.
Buried piping inside the terminal area will have a minimum depth of cover of 1.2 m. Where buried pipes come out of the ground, the underground coating on the pipe will
continue for a distance of 500 mm above ground. Platforms, crossovers shall be provided for ease of operation and maintenance. Platform for filters shall be provided for maintenance/ operational access. Painting above ground piping and structures shall be as per specifications enclosed in
the Bid package.
8.4 Welding
-
8/18/2019 GAIL Technical Spec.
22/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 14 of 1
Copyright GAIL – All rights reserved
Welding shall be carried out in accordance with API 1104, specification for welding andwelding charts. Butt welds shall be 100 % radio graphed / automatic UT for automaticwelding, as applicable for all pipelines.
For gas service all butt welds for process piping shall be 100% radiographed and forutility piping NDT requirements shall be as per specification no. S-05-02-12.
8.5 Hydrostatic Testing
After installation, the entire pipeline system shall be hydrotested with inhibited water.The water shall tested, as applicable prior to using for hydrotesting. The minimumhydrostatic pressure in any section shall be as per ASME B 31.8 for gaseoushydrocarbon pipelines. The maximum hydrostatic test pressure at any location of thepipeline shall not exceed the pressure required to produce a hoop stress equal to 95%of SMYS of the pipe material based on minimum wall thickness in the test section. Thetest duration shall be minimum 24 hours. Hydrostatic testing of terminals shall becarried out separately. Terminals as well as other intermediate facilities shall be tested
at 1.4 times the design pressure. The test duration shall be 6 hours. Mainline valvesshall be installed after successful completion of hydrotesting.
8.6 Dewatering and swabbing
Dewatering, swabbing and pre-commissioning operations shall be carried out afterhydrotesting and prior to commissioning of the pipeline as per Project specifications.For gaseous hydrocarbon pipeline the line shall be dried. Swabbing shall be carried outprior to installation of Sectionalizing valves. After swabbing operation the pipelinesections shall be dried as per relevant specification enclosed with the tender.
8.7 Crossings
8.7.1 Water Crossings
All water crossing shall be installed by open cut. The requirement of HDD at any watercrossing shall be finalized during detailed engineering.
Wherever there is an evidence of bank erosion, the banks shall be protected by usinggravel and boulders filled embankment mattresses of galvanized iron wire to be laidover the backfilled, compacted and graded banks.
8.7.2 Rail Crossing
Pipeline at rail crossings shall be provided with casing pipe. The size of Casing pipe
shall be – 609.6 mm O.D. (24”), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW (unlessadvised otherwise by concerned authorities) and shall be installed by boring/ jacking/HDD/ ramming. The rail crossing shall comply with the requirements of API 1102 andIndian Railway Authorities. The crossing angle shall be as close to 90º as possible. Itshould be noted that the extent of casing pipe generally specified by Railways is 14.0 mbeyond centerline of the outermost tracks on either side or 0.6 meter beyond the ROUlimits of Railways on either side, whichever is more. Carrier pipe shall be electricallyinsulated from the casing pipe and casing ends shall be sealed using durable,
-
8/18/2019 GAIL Technical Spec.
23/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 15 of 1
Copyright GAIL – All rights reserved
electrically non-conducting materials. The crossing drawing shall be subject to approvalof concerned Railway Authorities prior to implementation.
8.7.3 Road Crossing
Road crossings shall comply with the requirements of API 1102 and the requirements ofthe concerned road authorities. Unless otherwise required by concerned Authorities,casing pipe shall not be used. However at national highway road crossings pipeline shallbe provided with casing pipe, which shall extend min. 600 mm beyond Road ROW oneither side. The casing pipe shall be installed by trenchless method like ramming/boring/ jacking/ HDD /Micro Tunelling. Provision of casing at locations other thannational highways shall be decided based on type of road crossing and as perrequirements of local authorities if necessary. The casing pipe shall be 609.6 mm O.D.(24”), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW. The crossing angle shall be as closeto 90º as possible. Casing insulators and end seals shall be provided to ensure electricalisolation of carrier pipe and casing pipe.
8.7.4 Existing Pipeline Crossing
The specific requirements of Owner/operator of existing pipeline shall generally befollowed. The minimum clearance between the lines shall be 300 mm unless specifiedotherwise.
8.8 Valves
8.8.1 Application of various types of valves shall be as follows:
Valve type Typical application
Globe Throttling
Ball On/off, Isolation (on main line)
Plug On/off, Isolation (in the terminals)
Check Uni-directional flow
All pipeline valves shall comply with the requirements of API 6D/ relevant PMS. Ballvalves shall have primary metal seated design. In order to minimise potential leak sources, valves used in mainline shall be with butt-weld ends. Valve installed within the
terminal to isolate the mainline/ pipeline shall also be provided with butt welding ends.However terminal valves shall be flanged ends. Flanges may be used where frequentaccess or removal of equipment is required.
Wherever underground valves are provided, valves shall be provided with a stemextension in such a way that the centreline of the rim of the hand wheel on a horizontalshaft or centre of power actuator as approximately 1.0 m above the finished groundlevel.
Minimum size of any tapping from the underground pipeline shall be 2" NB and shall be
-
8/18/2019 GAIL Technical Spec.
24/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 16 of 1
Copyright GAIL – All rights reserved
provided with an isolation ball valve located at a minimum distance from the pipeline.
8.9 Branch Connections
All branch connections or side tap on the piggable lines wherever the branch linediameter is approx. 40% or more of the main line size, shall be provided with flow tees
to enable smooth passage of all types of pigs. Flow tees for this purpose shall have aninternal pipe housed in a tee.
8.10 Pipeline Bends
In order to accommodate changes in vertical and horizontal alignment in piggablesection of pipeline, elastic bends/cold field bends/hot formed long radius bends shall beused. Miter bends shall not be used for change in direction. Necessary design/calculation for arriving Minimum Elastic Bend Radius shall be worked out by Contractorand shall be ratified by GAIL. Minimum bend radius shall be as follows:
Minimum Bend Radius
Pipeline DetailsCold FieldBend Radius
Hot FormedLR BendRadius
18”, X-70, PSL-2(thk. 6.5/7.9/9.3mm)
R=27 D R=6D
12”, X-60, (thk.6.4/7.9/9.5 mm)
R=18 D R=6D
10”, X-60, (thk.6.4/ 7.8 mm)
R=18 D R=6D
8.11 Pig Signallers
8.11.1 Pig signallers shall be installed as a minimum at the following locations at eachLauncher/ Receiver:
- On Pig launcher cum receiver
- One location on the line
8.11.2 Pig signaller shall be bi-directional type with trigger mechanism, suitable formaintenance with pipeline under operating pressure.
8.12 Specifications All procurement of materials shall be as per Piping Material Specification (PMS) andspecifications indicated in PMS.
ANNEXURE - A LIST OF CODES AND STANDARDS
In addition to the codes/standards mentioned in para 3.0, the latest edition of the below listedequivalent codes and standards shall also be used for design of proposed pipeline. The listingincludes, but is not limited to, the following:
-
8/18/2019 GAIL Technical Spec.
25/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 17 of 1
Copyright GAIL – All rights reserved
1. Line Pipes
API 5L Specification for Line pipe
API 5L1 Recommended Practice for Railroad Transportationof Line pipe
API 5LWRecommended Practice for Transportation of Linepipe on Barges & Marine Vessels
2. Valves
API 6D Specification for pipeline valves (Steel Gate, Plug,Ball and Check Valves)
API 602 Compact Steel Gate Valves-Flanged, Threaded,Welding & Extended Body ends.
ASTM A694 Forgings, Carbon & Alloy steel for Pipe Flanges,Fittings, Valves & parts for High PressureTransmission Service.
MSS-SP-6 Finishes for Contact Faces of connecting EndFlanges of Ferrous Valves and Fittings.
MSS-SP-25 Standard Marking System for Valves, Fittings &Unions
BS 5351 Steel Ball Valves for the Petroleum, Petrochemicaland Allied Industries
3. Flanges & Fittings
MSS-SP-44 Steel Pipeline Flanges
ANSI B16.5 Pipe Flanges and Flanged Fittings
ANSI 16.20 Ring-joint Gaskets & Grooves for Steel PipeFlanges
ASTM A105 Forgings, Carbon Steel for Piping Components
ASTM A193 Carbon & Alloy Steel Bolts & Studs for HighTemperature Service
API 601 Standard for Metallic Gaskets for Raised-Face PipeFlanges & Flanged Connections
ANSI B16.9 Factory Made Wrought Steel Butt Welding Fittings
ANSI B16.11 Forged Fittings, Socket Welded & Threaded
ANSI B16.26 Butt Welding Ends ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy
Steel for Moderate and Elevated Temperatures
ASTM A694 Forgings, Carbon & Alloy Steel for Pipe Flanges,Fittings, Valves & Parts for High PressureTransmission Service.
MSS-SP-75 Specification for High Test Wrought Butt WeldingFittings
-
8/18/2019 GAIL Technical Spec.
26/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 18 of 1
Copyright GAIL – All rights reserved
MSS-SP-97 Integrally Reinforced Forced Branch Outley Fittings – Socket Welding, Threaded and Butt WeldingEnds.
PFI-ES-24 Pipe Bending Methods, Tolerances, Processes &Material Requirements
4. Testing & Welding
ANSI/AWS D1.1 Structural Steel Welding
API 1104Standard for Welding Pipelines and Related
Facilities
AWS A3.0 Welding Terms and Definitions
AWS A5.1 Welding Electrodes
AWS A5.5 Specification for Low Alloy Steel Covered ArcWelding Electrodes
ASTM E165 Liquid Dye Penetrant Inspection of Pipeline Welds
ASTM A370 Standard Methods and Definitions for MechanicalTesting of Steel Products.
ASTM E18 Standard Hardness Test for Metals
ASTM E23 Standard for Impact Test for Metals
ASTM E84 Standard Test Method for Micro-hardness of Metals
ASTM E92 Standard Test Method for Vickers Hardness ofMetallic Materials
ASTM E110 Standard Test Method Indentation Hardness forMetallic Materials by Portable Hardness Testers
ASTM E709 Standard Guides for Magnetic Particle Examination
MSS-SP-53 Quality Standard for Steel Casting & Forging-Magnetic Particle Method
MSS-SP-54 Quality Standard for Steel Casting & Forging-Radiographic Examination
MSS-SP-55 Quality Standard for Steel Castings & Forgings- Visual Method.
5. Surface Preparation, Painting and Coating
SIS-05-59 Pictorial Surface Preparation Standards for PaintingSteel Surfaces
SSPC-SP-01 Solvent Cleaning
SSPC-SP-03 Power Tool Cleaning
-
8/18/2019 GAIL Technical Spec.
27/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
ENGINEERING DESIGN BASIS
PIPELINE ENGINEERING 0001-01-04-03-001Page 19 of 1
Copyright GAIL – All rights reserved
SSPC-SP-05 Joint Surface Preparation Standard: White Metal BlastCleaning
SSPC-SP10 Structural Steel Painting Council – Joint Surface
NACE No.2 Preparation Standard - Near-White Metal Blast
CleaningSSPC-PA-02 Measurement of Dry Paint Thickness and Magnetic
Gauges
ASTM E12 Measurement of Pipeline Dry Film Coating Thickness
ASTM-G6 Abrasion Resistance of Pipeline Coating
ASTM G8 Cathodic Disbonding of Pipeline Coatings
NACE-RP-0274 High Voltage Electrical Inspection of Pipeline Coatings Prior toInstallation
IEC 454 – 2 Specification for Pressure-Sensitive Adhesive Tapes forElectrical Purposes
CSA Z245.20-02 External Fusion Bond Epoxy Coating for SteelPipe
6. Safety Systems
IP Model Code of Safe Practice in the Petroleum Industry parts 3, 6 and 9.
-
8/18/2019 GAIL Technical Spec.
28/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 1 of 68
PIPING MATERIAL SPECIFICATION
SPUR LINES OF CHAINSA – JHAJJAR PIPELINE
-
8/18/2019 GAIL Technical Spec.
29/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 2 of 68
CONTENTS
SL NO. DESCRIPTION
1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 MATERIAL SPECIFICATIONS
4.0 CLASS DESIGNATION CODES
5.0 PIPELINE
6.0 PIPING
7.0 FITTINGS
8.0 BENDS
9.0 FLANGES
10.0 GASKETS
11.0 BOLTING
12.0 THREAD SERALANT
13.0 VALVES
14.0 QUICK OPENING END CLOSURE
15.0 HYDROTESTING VENT AND DRAINS
16.0 PIPELINE SPECIALITY ITEMS
TABLE - 1 PIPE WALL THICKNESS DETAILS FOR MAINLINE SPUR LINE
TABLE - 2 PRESSURE/TEMP & OTHERS DESIGN CONDITIONS FOR VARIOUS PIPING CLASSES
ANNEXURE-
A,B,C,D,E,F,G,H,I
MATERIAL SPECIFICATIONS FOR PIPING CLASSES
ANNEXURE-1 LIST OF ATTACHMENTS
-
8/18/2019 GAIL Technical Spec.
30/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 3 of 68
1.0 SCOPE
1.1 It is propose to install a Natural gas pipe lines from Sultanpur – Neemrana, Bhiwadi / Chopanki
TOP to Bhiwadi, Hayatpur – Manesar and Hayatpur - Gurgaon in Haryana / Rajasthan states to
initially cater the demand of consumers in Dharuhera, Bhiwadi, Khushkhera, Neemrana,
Manesar, Khandsa and Gurgaon regions. The proposed Natural gas pipeline shall be of 457
mm (18”) OD, approximately 85.28 km long; 323.9 mm (12”) OD, approximately 9 km long and
273.1 mm (10”) OD, approximately 16.40 km.
The scope shall include piping and tap-off points at various locations of Chainsa–Jhajjar spur pipeline, that is for Bhiwadi, Gurgaon, Manesar, dispatch terminals, Sectionalising Valve stations,
Tap-off terminals, receiving terminals, Spur line and various CGS’s.
This document covers minimum requirements for various piping materials necessary for the design
of the piping/ pipeline and metering skid facilities coming under the project. This specification shall
be read in conjunction with various Codes and Standards of latest edition, as applicable.
2.0 CODES AND STANDARDS
2.1 Pipeline and pipeline terminal facilities envisaged as part of this project shall be designed and
engineered primarily in accordance with the provisions of the latest edition of the following codes:
(i) ASME B31.8 - Gas Transmissions and Distribution for pressure Piping
System
(ii) ASME B31.3 - Chemical Plant and Petroleum Refinery Piping
(iii) OISD Standard 141 - Design and Construction Requirements for Cross CountryHydrocarbon Pipelines.
2.2 All codes, standards and specifications referred herein shall be the latest edition of such documents.
2.3 For sake of brevity the initials of the society to which the codes are referred may be omitted in the
specifications, for example, B16.5 is a code referring to ASME; A106 is a code referring to ASTM.
2.4 In addition, GAIL specifications and standards for various piping and pipeline materials shall also be applicable.
3.0 MATERIAL SPECIFICATIONS
Individual piping class has been generally designed to cover a set of service operating within pressure-temperature consideration as per ASME B16.5/ B16.34 or part of it. Deviations of material
from class specifications may occur due to specific design conditions and/ or availability. These
deviations are permissible if they equal or better the individual class requirements and shall be
subjected to approval on case-to-case basis.
All materials shall conform to detailed specifications / data sheets for items as applicable.
4.0 CLASS DESIGNATION CODE
The piping class designation shall generally consist of three digits made up of a letter, number,letter e.g. A1A, A3A, A4A, B1A, D1A, E1A, etc. as follows:
First letter indicates ASME Class rating e.g.
-
8/18/2019 GAIL Technical Spec.
31/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 4 of 68
A – Class 150
B – Class 300
D – Class 600
E – Class 900
The middle number indicates differences in the specifications within the same class rating and
material.
The last letter indicates type of material. E.g. A – Carbon steel.
5.0 PIPELINE
5.1 Line pipe material grade and wall thickness details are indicated in Table-I.
6.0 PIPES
6.1 Carbon steel pipe shall be made by open hearth, electric furnace or basic oxygen process only. The
steel used shall be fully killed and made with fine grain structure. The grade and wall thickness of
various sizes of pipes shall be as per piping material specification for the applicable class.
6.2 Pipe dimensions shall be in accordance with ASME B 36.10 for carbon steel ASTM standard pipes;
& API 5L for carbon steel API 5L grade pipes.
6.3 All pipe threads shall conform to American Standard taper as per ASME B1.20.1 NPT, unless
otherwise specified.
6.4 For butt weld end, bevel shall be in accordance with API specification 5L or ASME B 16.25 asapplicable.
7.0 FITTINGS
7.1 Fully killed carbon steel shall be used in the manufacture of fittings. The fitting shall have carbonequivalent not exceeding 0.45, based on check analysis.
7.2 Threaded joints, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT.
7.3 Dimensions of socket welded/ screwed fittings shall conform to ASME B 16.11. Swage shall be as per BS 3799.
7.4 Dimensions of steel butt welded fittings shall be as per ASME B 16.9.
7.5 Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its thickness.
7.6 Butt welding ends shall conform to API specification 5L or ASME B 16.25 as applicable. In case ofdifference in thickness of matching ends, requirements of ASME B 31.8 shall apply.
7.7 Integrally reinforced forged branch fittings such as Sockolet, Weldolet etc. shall be as per MSS-SP-97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturer’s standard.
7.8 Fittings thickness tolerances shall match pipe thickness tolerance.
8.0 BENDS
-
8/18/2019 GAIL Technical Spec.
32/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 5 of 68
8.1 Unless otherwise specified for process piping, elbow of radius R = 1.5 D shall only be used.
Minimum Bend Radius D = Specified Outside Diameter
8.2 In order to accommodate changes in vertical and horizontal alignment in piggable section of pipeline, Elastic bends/ Cold field bends/ Hot formed long radius bends shall be used. Long Radius
Bend shall be used only when indicated in the drawing.
8.3 Miters shall not be used.
9.0 FLANGES
9.1 Pressure Temperature rating of flanges shall conform to B16.5 / MSS-SP44/ B16.47 Series A, asapplicable.
9.2 Dimensions of flanges shall be in accordance with B16.5/ MSS-5P44/ B16.47 Series A, as
applicable.
9.3 Neck of weld neck (WN) flanges shall suit pipe bore and thickness.
9.4 Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness.
9.5 Threads for screwed flanges, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT.
9.6 Sizes for blind flanges shall be indicated by nominal pipe size.
9.7 Unless specified otherwise in Piping Material Specification the flange face finish shall be as perASME B16.5.
9.8 Butt welding ends of WN flanges shall conform to ASME B 16.25.
9.9 Spectacle blind/ spacer & blinds shall be in accordance with ASME B16.48/ manufacturer’sstandard.
9.10 Two jack screws, 1800 apart shall be provided in spectacle blind or spacer & blind assemblies as per
GAIL standards.
10.0 GASKETS
10.1 Spiral wound metallic gasket with compressed asbestos filler shall conform to ASME B16.20/ API
601. All spiral wound gaskets shall be provided with stainless steel centering ring.
10.2 Spiral wound gasket shall be self-aligning type.
11.0 BOLTING & THREADS
11.1 Nuts for stud bolts shall be American Standard Hexagon Heavy Series and double chamfered.
11.2 Dimension and tolerances for stud bolts and nuts shall be as per ASME B18.2.1 and 18.2.2 with fullthreading to ASME B 1.1 Class 2A thread for bolts and Class 2B for nuts. Diameter and length of
stud bolts shall be as per ASME B 16.5/ ASME B16.47 with full threading.
11.3 Threads for nuts shall be as per ASME B 1.1
Nuts for stud bolts dia ¼“ to 1” : UNC-2B
-
8/18/2019 GAIL Technical Spec.
33/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 6 of 68
Nuts for stud bolts dia 1⅛ %” to 3¼ : 8UN-2B
11.4 Threads for stud bolts shall be as per ASME B 1.1, as follows:
Stud bolts dia ¼“ to 1” : UNC-2A
Stud bolts dia 1⅛ %” to 3¼ : 8UN-2A
11.5 Threads for threaded pipe, fitting, flanges and valve shall be in accordance with B1.20.1 taper
threads, unless specified otherwise.
11.6 Heads of jack screws shall be heavy hexagonal type. Jack screw end shall be rounded. Stud bolts
shall be fully threaded with two hexagonal nuts.
12.0 THREAD SEALANT
12.1 Threaded joints shall be made with 1” wide PTFE jointing tape.
13.0 VALVES
13.1 Valve ends shall be as per valve data sheets for various piping class.
13.2 Sectionalizing valves, Block valves and other isolation valves installed on the main pipeline shall be ball valves with butt welding ends. All inline isolation valves on the mainline (pipeline) shall be
full bore valves to allow smooth passage of cleaning as well as intelligent pigs.
13.3 All buried valves shall be provided with stem extension, sealant, vent/drain and shall have buttwelded ends as per relevant specification/ data sheet.
13.4 Flange dimensions and face finish of flanged end valves shall conform to clause 9.0 of thisspecification.
13.5 Butt welding ends of Butt Welded valves shall conform to ASME B 16.25.
13.6 Face to face and end to end dimensions shall conform to applicable standards.
13.7 Valves shall conform to following standards unless specified otherwise in piping materialspecification for various piping class.
Flanged/ Socket Welded end valves (1½” and below)
Design STD. for Process lines
Gate Valves : API 602Globe Valves : BS 5352
Ball Valves : BS 5351
Plug Valves : BS 5353
Flanged/ Butt Welded end valves (2” and above)
Design STD. for Process Lines
Gate Valves : API 6DGlobe Valves : BS 1873
Check Valves : API 6D
-
8/18/2019 GAIL Technical Spec.
34/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 7 of 68
Ball Valves : API 6DPlug Valves : API 6D
13.8 All manual operated valves shall be provided with wrench I hand wheel or gear operator as
specified here in below.
13.8.1 Gate Valves
For ANSI class 150 and 300 : Hand wheel operated for size ≤12” NB.
Gear operated for size ≥14” NB.
For ANSI class 600 : Hand wheel operated for size ≤ 10” NB.
Gear operated for size ≥ 12” NB
13.8.2 Globe Valves
For ANSI class 150, 300, 600 and 900 - Hand Wheel operated for all size
13.8.3 Ball valves & Plug Valves
For all ANSI class : Wrench operated for size ≤ 4” NB.
Gear operated for size ≥
6” NB.
13.8.4 Gas Actuated Valves
Gas actuated valves shall be as per P & IDs. The actuator shall have provision for remote operation
as per P & IDs. All gas actuated valves shall have additional provision of hand wheel operation.
14.0 QUICK OPENING END CLOSURE
Quick opening end closure to be installed on scraper traps shall be designed in accordance with
Section VIII of ASME Boiler and Pressure Vessel Code and equipped with safety locking devicesin compliance with Section VIII, division 1. UG-35.2 of ASME Boiler and Pressure Vessel Code.
15.0 HYDROTESTING VENTS AND DRAINS
In terminal piping, high point vents and low point drains required for the purpose of hydrotestingshall be of size 0.75”. These vents & drains shall consist of gate valves with blind flange assembly.
16.0 PIPELINE SPECIATLITY ITEMS
Pipeline specialty items viz, scraper traps, Barred tees, insulating joints, LR bends etc. shall be as
per specifications attached elsewhere.
-
8/18/2019 GAIL Technical Spec.
35/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 8 of 68
TABLE -1
C l a s s -
I V 1 1 . 7
9 . 5
7 . 8
6 . 4
C l a s s
– I I I
9 . 3
7 . 9
6 . 4
6 . 4
C l a
s s
– I I
7 . 9 6 . 4 6 . 4 6 . 4 W
. T . ( m m )
C l a s s
– I
6 . 5
6 . 4
6 . 4
6 . 4
M E T H O D O F
M A N U F A C T U R E
L S A W , H S A W ,
S E A M L E S S , E W
S E A M L E S S , E W
S E A M L E S S , E W
S E A M L E S S , E W
M A T E R I A L
( A P I 5 L )
X – 7 0 , P S L - 2
X – 6 0 , P S L - 2
X – 6 0 , P S L - 2
X – 6 0 , P S L - 2
T P I P E
D I A
( I N C H )
1 8
1 2
1 0
1 0
S E C T I O N
L I N E P I P E
S u l t a n p u r – N i m
r a n a P i p e l i n e
B h i w a d i / C h o p a
n k i T O P – B h i w a d i S p u r L i n e
S p u r l i n e H a y a t p u r - M a n e s a r
S p u r L i n e H a y a
t p u r - G u r g a o n
S l . N o .
1 .
2 .
3 .
3 .
-
8/18/2019 GAIL Technical Spec.
36/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 9 of 68
TABLE – 2
Design ConditionClass Service
Pressure
(Kg/cm2 )
Temp.
(0 C)
C.A. (mm) Pipe
Material
Design
Code
D1A Hydrocarbon
Gas
99.93 65 1.5 API 5L X –
52/ ASTM
A 106 GR-
B / Gr.B
(Charpy) /
Gr. B PSL-
2 as
applicable
ASME B
31.8 /
OISD –
141
B1A Hydrocarbon
Gas
49.0 65 1.5 ASTM A
106 GR- B
/ Gr.B
(Charpy) /
Gr. B PSL-
2 as
applicable
ASME B
31.8 /
OISD –
141/ 226
A1A Hydrocarbon
Gas
19 65 1.5 ASTM A
106 GR- B
/ Gr.B
(Charpy) /
Gr. B PSL-
2 as
applicable
ASME B
31.8 /
OISD –
141 / 226
A3A Utilities 10.5 65 1.5 IS-1239
(BLACK)
ASME B
31.3
J2A Potable Water 10.5 65 0 IS-1239
(Galv)
ASME B
31.3
A93A Fire Water 18.9 65 1.5 IS-1239(Black)/
IS-3589
GR 410 as
applicable
ASME B31.3
CORROSION ALLOWANCE : Above mentioned corrosion allowance is only for station piping.
No corrosion allowance is considered in linepipe.
-
8/18/2019 GAIL Technical Spec.
37/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 10 of 68
ANNEXURE A
PIPING MATERIAL SPECIFICATION
(A1A - CLASS 150#)
-
8/18/2019 GAIL Technical Spec.
38/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 11 of 68
PIPING CLASS : A1A, 150 #
BASE MATERIAL : CARBON STEEL
CORROSION ALLOWANCE : 1.5 MM
SPECIAL REQUIREMENT : NON IBR
TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS
SERVICE : NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHAL-
HYDROCARBONS, AMMONIA, STEAM & GAS CONDENSATE (NON- IBR), UTILITIES (WATER, INST,
AIR, NITROGEN, CARBON DIOXIDE) AND LUBE OIL BEFORE THE FILTER.
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:
RADIOGRAPHY : ALL BUTT WELDS - 100%
MPI : SOCKET WELDS - 100%
3. PIPING DESIGN AS PER ASME B 31.8 & OISD 226.
4. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.
5. ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE
CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE
BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED.
6. FOR VALVES, REFER RESPECTIVE VALVE DATA SHEETS. FOR HANDLE PROJECTION REFERSTD. DRG-S-05-01-007.
7. SPECIAL NOTES
ITEM SIZE DESCRIPTION
MAINTENANCE
JOINTSALL
FLANGED TO BE KEPT MINIMUM
1.5” & BELOW SW COUPLINGPIPE JOINTS
2.0” & ABOVE BUTT WELDED
DRAINS ON LINES ≤1.5” REFER GAIL STD.S-05-01-003
ON LINES ≥2.0” AS PER P&ID OR 0.75” REFER STD.S-05-01-004
ON LINES ≤1.5” REFER GAIL STD – S-05-01-003VENTS
ON LINES ≥2.0” AS PER P&ID OR 0.75” REFER STD.S-05-01-004
TEMP. CONN 1.5” FLANGED, INSTALLATION AS PER GAIL STD – S-05-01-005.
PRESS. CONN 0.75” SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.S-05-01-006
-
8/18/2019 GAIL Technical Spec.
39/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 12 of 68
72 72
70 70
68 68
66 66
64 6462 62
60 60
58 58
56 56
54 54
52 52
50 50
48 48
46 46
44 44
42 42
40 40
38 38
36 3634 34
32 32
30 30
28 28
26 26
24 24
22 22
20 20
18 18
16 16
14 14
12 12
10 T 108.0 T T 8.0
6.0 T T T 6.0
5.0 5.0
4.0 T T T T 4.0
3.5 3.5
3.0 T T T W W 3.0
2.5 2.5
2.0 T T T W W W 2.0
1.5 T T S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S 1.0
0.75 T T T S S S S S S 0.75
0.5 T T T T S S S S S S 0.5
B R A N C H
P I P E
( S I Z E I N
I N C H E S )
0 . 5 0 0
0 . 7 5 0
1 . 0 0 0
1 . 2 5 0
1 . 5 0 0
2 . 0 0 0
2 . 5 0 0
3 . 0 0 0
3 . 5 0 0
4 . 0 0 0
5 . 0 0 0
6 . 0 0 0
8 . 0 0 0
1 0 . 0 0
B R A N C H P
I P E
( S I Z E I N
I N C H E S )
RUN PIPE (SIZES IN INCH) – A1A
-
8/18/2019 GAIL Technical Spec.
40/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 13 of 68
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Item Type
Lower
Size
(Inch)
Upper
Size
(Inch)
Sch./
Thk
Dim.
STDMaterial Description
Pipe Group (A1A)
PIPE 00.500 00.750 S160 B 36.10 ASTMA 106 GR.B PE, SEAMLESS
PIPE 01.000 01.500 XS B 36.10 ASTMA 106 GR.B PE, SEAMLESS
PIPE 02.000 02.000 XS B 36.10 ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE 03.000 03.000 STD B 36.10 ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE 04.000 04.000 STD B 36.10 ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE 06.000 06.000 STD B 36.10 ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE 8.000 14.000 6.4 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 16.000 18.000 6.4 API 5L API 5L GR.B PSL2 BE, SAW
PIPE 20.000 20.000 7.1 API 5L API 5L GR.B PSL2 BE, SAW
NIPPLE 00.500 00.750 M B 36.10 ASTMA 106 GR.B PBE, SEAMLESS
NIPPLE 01.000 01.500 M B 36.10 ASTMA 106 GR.B PBE, SEAMLESS
Flange Group (A1A)
FLNG.WN 00.500 01.500 M B-16.5 ASTM A 105 150, RF/125AARH
FLNG.WN 02.000 24.000 M B-16.5 ASTM A 105 (CHARPY) 150, RF/125AARH
FLNG.BLIND 00.500 01.500 B-16.5 ASTM A 105 150, RF/125AARH
PLNG.BLIND 02.000 24.000 B-16.5 ASTM A105 (CHARPY} 150, RF/125AARH
FLNG.FIG8 00.500 01.500 B-16.48 ASTM A 105 150, RF/125AARH
-
8/18/2019 GAIL Technical Spec.
41/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 14 of 68
FLNG.FIG8 02.000 08.000 B-16.48 ASTM A105 (CHARPY) 150, RF/125AARH
SPCR &BLIND 10.000 24.000 B-16.48 ASTM A105 (CHARPY) 150, RF/125AARH
Fitting Group (A1A)
ELBOW.90 00.500 0..750 B-16.11 ASTM A 105 SW, 6000
ELBOW.90 01.000 1.500 B-16.11 ASTM A 105 SW, 3000
ELBOW.90 02.000 24.000 B-16.9 ASTM A 234,GR. WPB
(CHARPY)
BW, 1.5D
ELBOW.45 00.500 00.750 B-16.11 ASTM A 105 SW, 6000
ELBOW.45 01.000 01.500 B-16.11 ASTMA 105 SW, 3000
ELBOW.45 02.000 24.000 M B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW, 1.5D
T.EQUAL 00.500 00.750 B 16.11 ASTM A 105 SW, 6000
T.EQUAL 01.000 01.500 B 16.11 ASTM A 105 SW, 3000
T.EQUAL 02.000 24.000 M B-16.9 ASTM A234,GR.WPB
(CHARPY)
BW
T.RED 00.500 00.750 B-16.11 ASTM A 105 SW, 6000
T.RED 01.000 01.500 B-16.11 ASTMA 105 SW, 3000
T.RED 02.000 24.000 M, M B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
REDUC.CONC 02.000 24.000 M,M B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
REDUC.ECC 02.000 24.000 M,M B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
SWAGE.CONC 00.500 03.000 M,M BS-3799 ASTM A 105 (CHARPY) PBE
SWAGE.ECC 00.500 03.000 M,M BS-3799 ASTM A 105 (CHARPY) PBE
CAP 00.500 00.750 B-16.11 ASTMA 105 SCRF, 6000
CAP 01.000 01.500 B-16.11 ASTMA 105 SCRF, 3000
CAP 02.000 24.000 M B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
CPLNG.FULL 00.500 00.750 B-16.11 ASTM A 105 SW, 6000
CPLNG.FULL 01.000 01.500 B-16.11 ASTM A 105 SW, 3000
CPLNG-HALF 00.500 00.750 B-16.11 ASTM A 105 SW, 6000
CPLNG.HALF 01.000 01.500 B-16.11 ASTM A 105 SW, 3000
-
8/18/2019 GAIL Technical Spec.
42/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 15 of 68
CPLNG.LH 00.500 00.750 B-16.11 ASTM A 105 SW, 6000
CPLNG.LH 01.000 01.500 B-16.11 ASTM A 105 SW,3000
CPLNG.RED 00.500 00.750 B-16.11 ASTM A 105 SW, 6000
CPLNG.RED 01.000 01.500 B-16.11 ASTM A 105 SW, 3000
O’let Group (A1A)
SOCKOLET 00.500 0.750 MSS-SP97
ASTM A 105 SW, 6000
SOCKOLET 01.000 01.500 MSS-
SP97
ASTM A 105 SW, 3000
WELDOLET 02.000 10.000 M,
XXS
MSS-
SP97
ASTMA 105 (CHARPY) BW
Valves Group (A1A)
VLV.GATE 00.500 01.500 API-602 BODY-ASTM A
105, TRIM-STELLITED,
STEM13%CR. STEEL
SW,800, 3000,B-
16.11
VLV.GLOBE 00.500 01.500 BS-5352 BODY-ASTM A
105,TRIM-STELLITED,STEM13%CR STEEL
SW,800, 3000,B-
16.11
VLV.CHECK 00.500 01.500 BS-5352 BODY-ASTMA
105,TRIM-STELLITED
SW,800, 3000, B-
16.11
Bolt Group (A1A)
BOLT.STUD 00.500 24.000 B18.2 BOLT: 193 GR.B7,NUT:
A194 GR. 2H
Gasket Group (A1A)
GASKET 00.500 24.000 B16.20-
ANSI B
16.5
SP,WND, SS316+CAF SPIRAL, 150
-
8/18/2019 GAIL Technical Spec.
43/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 16 of 68
ANNEXURE B
PIPING MATERIAL SPECIFICATION
(A3A - CLASS 150#)
-
8/18/2019 GAIL Technical Spec.
44/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 17 of 68
PIPING CLASS : A3A, 150 #
BASE MATERIAL : CARBON STEEL
CORROSION ALLOWANCE : 1.5 MM
SPECIAL REQUIREMENT : NON IBR
TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS
SERVICE : NON CORROSIVE UTILITIES (ABOVE GROUND) – COOLING WATER, INERT GAS,
INSTRUMENT AIR, CONDENSATE
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT REQUIREMENT AS PER GAIL STANDARD S-05-02-012
3. FOR VALVES REFER VALVE DATA SHEET
SPECIAL NOTES
ITEM SIZE DESCRIPTION
MAINTENANCE
JOINTSALL
FLANGED TO BE KEPT MINIMUM
1.5” & BELOW SW COUPLING 3000 #PIPE JOINTS
2.0” & ABOVE BUTT WELDED
DRAINS ON LINES ≤1.5” REFER GAIL STD.S-05-01-003
ON LINES ≥2.0” AS PER P&ID OR 0.75” S-05-01-004
ON LINES ≤1.5” REFER GAIL STD S-05-01-003VENTS
ON LINES ≥2.0” AS PER P&ID OR 0.75”, S-05-01-004
TEMP. CONN 1.5” FLANGED, INSTALLATION AS PER GAIL STD.
S-05-01-005
PRESS. CONN 0.75 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.S-05-01-006
-
8/18/2019 GAIL Technical Spec.
45/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 18 of 68
72 72
70 70
68 68
66 66
64 64
62 62
60 60
58 58
56 5654 54
52 52
50 50
48 48
46 46
44 44
42 42
40 40
38 38
36 36
34 34
32 32
30 30
28 28
26 26
24 24
22 22
20 20
18 18
16 16
14 14
12 12
10 10
8.0 8.0
6.0 T 6.0
5.0 5.0
4.0 T P 4.03.5 3.5
3.0 T P P 3.0
2.5 2.5
2.0 T P P P 2.0
1.5 T T H H H 1.5
1.25 1.25
1.0 T T H H H H 1.0
0.75 T T T H H H H 0.75
0.5 T T T T H H H H 0.5
B R A N C H
P I P E
( S I Z E
I N
I N C H E S )
0 . 5 0 0
0 . 7 5 0
1 . 0 0 0
1 . 2 5 0
1 . 5 0 0
2 . 0 0 0
2 . 5 0 0
3 . 0 0 0
3 . 5 0 0
4 . 0 0 0
5 . 0 0 0
6 . 0 0 0
B R A N C H P
I P E
( S I Z E
I N
I N C H E S )
(A3A)
-
8/18/2019 GAIL Technical Spec.
46/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 19 of 68
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Item Type
Lower
Size
(Inch)
Upper
Size
(Inch)
Sch./
Thk
Dim.
STDMaterial Description
Pipe Group (A3A)
PIPE 00.500 1.50 HVY IS-1239-
I
IS-1239 (BLACK) PE, C. WELDED
PIPE 02.000 06.000 HVY IS-1239-
I
IS-1239 (BLACK) PE, C. WELDED
NIPPLE 00.500 01.50 HVY IS-1239-I
IS-1239 (BLACK) PE, C. WELDED
Flange Group (A3A)
FLNG.SW 00.500 01.500 M B-16.5 ASTM A 105 150,
RF/125AARH
FLNG.SO 02.000 06.000 B-16.5 ASTM A 105 (CHARPY) 150,
RF/125AARH
FLNG.BLIND 00.500 01.500 B-16.5 ASTM A 105 150,
RF/125AARH
FLNG.BLIND 2.00 6.00 B-16.5 ASTM A105 (CHARPY} 150,
RF/125AARH
FLNG.FIG8 00.500 01.500 B-16.48 ASTM A 105 150,
RF/125AARH
FLNG.FIG8 02.000 06.000 B-16.5 ASTM A105 (CHARPY) 150,
RF/125AARH
Fitting Group (A3A)
ELBOW.90 00.500 01.500 B-16.11 ASTM A 105 SW,3000
ELBOW.90 02.00 06.00 STD B-16.9 ASTM A 234 GR. WPB
(CHARPY)
BW, 1.5D
ELBOW.45 00.500 01.50 B-16.11 ASTM A 105 SW, 3000
ELBOW.45 02.000 06.000 STD B-16.9 ASTM A 234 GR. WPB
(CHARPY)
BW, 1.5D
T.EQUAL 00.500 01.50 B 16.11 ASTM A 105 SW, 3000
-
8/18/2019 GAIL Technical Spec.
47/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 20 of 68
T.EQUAL 02.00 06.00 STD B 16.11 ASTM A 234 GR. WPB
(CHARPY)
BW
T.RED 00.500 01.500 B-16.11 ASTM A 105 SW, 3000
T.RED 02.000 06.00 STD B-16.9 ASTM A 234 GR. WPB
(CHARPY)
BW
REDUC.CONC 02.000 06.000 STD,STD B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
REDUC.ECC 02.000 06.000 STD,STD B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
SWAGE.CONC 00.500 03.000 STD,STD BS-3799 ASTM A 105 (CHARPY) PBE
SWAGE.ECC 00.500 03.000 STD,STD BS-3799 ASTM A 105 (CHARPY) PBE
CAP 00.500 01.50 B-16.11 ASTMA 105 SCRF, 3000
CAP 02.000 06.00 STD B-16.9 ASTM A234,GR. WPB
(CHARPY)
BW
CPLNG.FULL 00.500 01.50 B-16.11 ASTM A 105 SW, 3000
CPLNG-HALF 00.500 01.50 B-16.11 ASTM A 105 SW, 3000
CPLNG.LH 00.500 01.50 B-16.11 ASTM A 105 SW, 3000
CPLNG.RED 00.500 01.50 B-16.11 ASTM A 105 SW, 3000
UNION 0.50 01.500 BS-3799 ASTM A 105 SW, 3000
Valves Group (A3A)
VLV.GATE 00.250 01.500 API-602 BODY-ASTM A
105, TRIM-STELLITED,
STEM13%CR. STEEL
SW,800, 3000,B-
16.11
VLV.GATE 02.00 24.00 API-600 BODY-ASTM A
216, WCB, TRIM-STELLITED, STEM13%CR.
STEEL
FLGD, 150, B
16.5,RF/125AARH
VLV.GLOBE 00.25 01.500 BS-5352 BODY-ASTM A
105,TRIM-STELLITED,
STEM13%CR STEEL
SW,800, 3000,B-
16.11
VLV.GLOBE 02.00 16.00 BS-1873 BODY-ASTM A
216, WCB, TRIM-
STELLITED, STEM13%CR.
STEEL
FLGD, 150, B
16.5,
RF/125AARH
VLV.CHECK 00.250 01.500 BS-5352 BODY-ASTMA
105,TRIM-STELLITED
SW,800, 3000, B-
16.11
VLV.CHECK 02.00 24.00 BS 1868 BODY-ASTM A 216, GR.
WCB, TRIM 13% CR.
SREEEL
FLGD, 150, B
16.5,
RF/125AARH
-
8/18/2019 GAIL Technical Spec.
48/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 21 of 68
VLV.BALL 00.500 16.00 BS-5351 BODY-ASTM A
105,A 216 GR. WCB TRIM-
BODY SEAT - RPTFE
FLGD, 150, , B
16.5,
RF/125AARH
VLV.BTRFLY 03.500 24.00 BS-5155 BODY-ASTM A 216 GR.,
WCB, TRIM- 13% CR.
STEEL
WAFL, 150, B-
16.5
WAF/125AARH
Bolt Group (A3A)
BOLT.STUD 00.500 6.000 B18.2 BOLT: A 307, GR. B, NUT:A 563 GR.B
Gasket Group (A3A)
GASKET 00.500 6.000 B16.21-ANSI B
16.5
IS-2712- GR.-W/3 RING, 150, 2 MM
TRAP/ STRAINER GROUP (A3A)
TRP 00.500 1.50 MANF’S
STD
B:A105, T:13%CR, S:SS304 FLGD,
THRMDNMC,
150, RF/125AARH
TRP 01.500 6.000 MANUF
STD
B:A285GR.C; INT: SS304 CONETYPE, 150,
FF/125 AARH
TRP 00.500 1.500 MANUF
STD
B:A105; INT: SS304 SW, Y-TYPE, 800
TRP 02.00 6.000 M MANUF
STD
B:A234GR. WPB; INT:
SS304
BW, T - TYPE
-
8/18/2019 GAIL Technical Spec.
49/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 22 of 68
ANNEXURE C
PIPING MATERIAL SPECIFICATION
(B1A - CLASS 300#)
-
8/18/2019 GAIL Technical Spec.
50/1025
SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI
PIPING MATERIAL SPECIFICATION
0001-01-05-02-001Page 23 of 68
PIPING CLASS : (B1A), 300 #
BASE MATERIAL : CARBON STEEL
CORROSION ALLOWANCE : 1.5 MM
SPECIAL REQUIREME