Vol

SPECIFICATIONS
FOR
FIELD JOINT COATINGS OF PIPELINE
FOR HDD CROSSING
SPECIFICATION NO. MEC/S/05/62/074
(PROCESS & PIPELINE DESIGN SECTION)

MECON LIMITED
DELHI - 110 092
CONTENTS
Sl.No. Description Page No.
1.0 SCOPE 01 - 01
2.0 REFERENCE DOCUMENTS 01 - 02
3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL 02 - 07
4.0 APPLICATION PROCEDURE 08 - 11
5.0 INSPECTION 11 - 12
6.0 TESTING 12 - 12
7.0 REPAIR OF FIELD JOINT COATING 13 - 13
8.0 REPAIR OF PIPE COATING DEFECTS 14 - 14
9.0 DOCUMENT 14 - 14
PREPARED BY CHECKED BY APPROVED BY

1.0 SCOPE
1.1 General
This specification covers the minimum requirement for application of anti-

corrosion field joints coating on welded pipe section and field tie-in joints
referred to here in after as Joint(s). The contractor shall perform all work in
accordance with this specification, latest pipeline coating practices and to
the full satisfaction of the Owner. The anti-corrosion pipe joint coating shall
be compatible with yard applied, Ultra Violet (UV) radiation protected, 3
layer side extruded polyethylene coating conforming to DIN-30670. The
sleeve width shall be suitable for cut back of 120 ± 20 mm to be left at
both the ends of coated pipes. The job includes supply of all materials
equipment, consumables, labour, supervision, quality control, inspection
repairs.
1.2 Manpower, Material & Equipment
1.2.1 The Contractor shall supply wrap around heat shrinkable sleeves which is
composed of two parts such as adhesive coated wrap around and a
curable modified epoxy primer alongwith applicator pads.
1.2.2 The supply of wrap around heat shrinkable sleeve shall be under
Contractor’s scope.
1.2.3 The Contractor shall provide all skilled/ unskilled personnel required for
execution of this work.
1.2.4 The joint coating operation starting from cleaning and surface preparation
till application of joint coating and wrapping of the pipe joints shall be
performed under the supervision of skilled personnel who are well versed
in the work.
1.2.5 Contractor shall at his own cost provide a fully equipped laboratory and
test facilities with adequate inventory to carry out tests required for
procedure qualification and during regular production, for testing of joint
coating system.
2.0 REFERENCE DOCUMENTS
2.1 Provision of the following documents/ codes shall generally be followed for
standard of specification and workmanship.
a) DIN – 30672 : Corrosion protection tapes and Heat Shrinkable

Sleeves.
D:\Technical Specifications & Standards\Latest\074 - Specification for FPJ Coating for HDD Crossing .doc Page 1 of 14
b) SIS – 055900 : Pictorial surface preparation standard for painting
steel surfaces.
c) SSPC – SP1 : Steel structure painting council – Solvent Cleaning.
2.2 In case of conflict between the requirements of this specification and that
of above referred documents/ codes, the requirements of this
specifications shall govern.
3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL
3.1 General
This scope covers the minimum requirement of materials, equipment

required for installation of field joint coating by wraparound fibre-
reinforcement heat-shrinkable sleeve used for corrosion protection and
sealing of field joints in pipelines that are forced through the soil by
Horizontal Directional Drilling technique. The sleeves shall be suitable for
3LPE/FBE coated pipes operating up to 60°C continuously.
3.1.1 Each Joint Coating System shall consist of :
a) A wraparound heat shrinkable sleeve reinforced with fibre-glass.

The sleeve shall be coated with a higher- shear- strength
thermoplastic hot-melt adhesive.
b) A solvent-free, two component liquid epoxy primer
c) A specifically designed wear cone
d) A clamping belt
3.1.2 Sleeve Backing
The heat shrinkable sleeves shall be manufactured from minimum 1.0 mm

thick radiation cross linked, thermally stabilized, UV -resistant heat-
shrinkable fabric, composed of a fibre glass reinforcement and polyolefin
fibres, embedded in a polyolefin matrix.
3.1.3 Sleeve Adhesive
The inner surface of the sleeves shall be coated with a controlled

thickness of minimum 1mm of adhesive which in combination with the
modified epoxy primer, will bond to and seal to the steel pipe and common
yard applied medium temperature yard coatings.
3.1.4 Epoxy Primer
The Epoxy primer shall be a solvent free, modified two components liquid
epoxy type primer, which is applied to cleaned and dry steel surface.
When the sleeve coatings, comes in contact with the liquid primer during
installation, a strong bond is formed upon full curing of the system.
3.2 Properties of Field Joint Coating Material
The pipe sleeves furnished under this specification shall be tested and
shall meet the requirements specified in the table below:-
3.2.1 Heat-Shrinkable Sleeve Material
Property Test Condition Requirement

Method
Cold Crack ISO 4675 Below 40°C
Chemical ISO 175 168 hrs. immersion on either
resistance 0.1 N
NaCl @ 23°C, 0.1N H2 SO4 @
23°C, 0.1 N NaOH @ 23°C,

Fuel oil @ 23°C. Petroleum jelly
@ 70°C
Followed by test for ISO 3303 23°C 1100 N Min.
bursting strength
Thermal ageing ISO 188 150°C 168 hrs. 1700 N Min.
Followed by test for ISO 3303 23°C

bursting strength
3.2.2 Adhesive material

Method
Softening point ASTM E28 85°C minimum
Peel Strength DIN 30672 23°C. CHS* 200 N/cm minimum

100 mm/ min.
60°C 60 N/ cm
Method
Peel Strength DIN 30672 23°C. CHS* 200 N/cm minimum
After immersion for 4 weeks 100 mm/ min.
at 23°C~NaOH pH12 H2SO4
pH2 ground water solution:-
1.2% H3PO4
1.6% KOH
1.2NaCl
1.0% Fe2O3
Peel Strength after DIN 30672 23°C. CHS* 60 N/cm minimum
conditioning for 30 100 mm/ min.
cycles from -30°C to 60°C
Shear strength ISO 4587 23°C. CHS* 200 N/cm2 minimum

50 mm/ min.
Corrosive effect ASTM D 120°C. No corrosion
2671 16 hrs.
3.2.3 Primer Material
Property Test Method Condition Requirement
Density ASTM D1084 23 +/- 0.50 C Part A: 60+/- 30 Pas

Part A: 2 rpm, spindle #6 Part B: 1.55+/-0.55 Pas
Part B: 20rpm, spindle #3
Mixing ratio By weight 23°C 100:40

By volume 100:60
Shear strength ISO 4587 23°C. CHS* 1000 N/cm2 minimum
50 mm/ min.
* CHS = Cross Head Speed
3.2.4 Functional Properties

Sl. Property Test Method Condition Requirement
No.
a) Impact DIN 30672 23°C. No holidays when tested
resistance Class C at 20 KV
b) Penetration DIN 30672 60°C. Minimum 70% of original
resistance Class C resistance thickness left;
no holidays when tested
at 20 KV
c) Specific coating DIN 30672 23°C. 108 Ohm sq. m minimum;
resistance no oxidation on pipe
surface
d) Cathodic ASTM G42 60°C. 15 mm increase in radius
disbondment 30 days of disbondment max.
resistance
e) Resistance to TEST METHOD- No cut propagation
split 1*
propagation
Sl. Property Test Method Condition Requirement
No.
f) Resistance to TEST METHOD- 50 KN minimum
circumferential 2*
edge loading
g) Resistance to TEST METHOD- 6 KN minimum
local edge 3*
loading (chisel
test)
*Test Methods
3.3 Test Methods
3.3.1 Resistance to split propagation (Test Method -1)
A rectangular piece of 50mm width by 150 mm length shall be cut from the
material as delivered. A 5mm long, clean cut shall be made mid-way in the
piece along once of the long edges perpendicular to this edge. The
sample shall be mounted on a clamp that holds it securely and avoids any
shrinking during testing.
The assembly shall be placed in an air-circulating oven present at 1700C.
After 15 minutes, the sample shall be removed from the oven, allowed to
cool down to room temperature and examined for cut propagation.
This test simulates the unlikely event when the sleeve gets cut during the
installation phase. Sleeves based upon extruded polyelfin show a distinct
tendency to propagate the cut along the total width of the sleeve. Sleeves
suitable for HDD works shall not exhibit this behaviour.
3.3.2 Resistance to circumferential edge loading (Test method -2)
The sleeve shall be installed on a DN 200 three -layer PE coated steel

pipe piece. A thick wall steel ring that fits a DN 200 three-layer PE coated
steel pipe with a tolerance of 0.2+-0.2 mm shall be positioned against the
front edge of the wear cone sleeve and then pushed towards the sleeve
system at a constant speed of 5 mm/ min over a distance of 50 mm. The
forces necessary shall continuously be registered. The minimum required
force shall be less than 50 KN.
During the pushing or pulling operation, any obstacle protruding from the
smooth pipe surface is loaded by the surrounding soil that passes by. This
test simulates the shear forces that are exerted on to the sleeve by rigid
soil type.
3.3.3 Resistance to local edge loading (Chisel test: Test Method -3)
The sleeve shall be installed on a DN 200 three-layer-PE coated steel
pipe piece.
A chisel as depicted in Figure -1 shall be positioned against the front

edge of the wear cone sleeve and, pushed parallel to the pipe surface
towards the sleeve system at a constant speed of 5mm/ min over a
distance of 50 mm. The forces necessary shall continuously be
registered. The minimum required force should not be less than 6 KN.
During the pushing or pulling operation, the pipe may traverse soil area
containing solid particles, such as stones, pebbles or crushed rock. These
particles tend to rip away the pipe coating locally. Any obstacle protruding
from the smooth pipe surface is lifted, leading to soil undercutting. This
test determines the resistance of sleeve against this type of abuse.
I5mm
35mm
View AA
Figure- 1 Chisel
3.4 Qualification for Contractor’s supplied Materials and their
Manufacturer
3.4.1 Prior to procurement of coating materials, Contractor shall furnish the

following information for qualification of the Manufacturer and material:
a. Complete descriptive technical catalogs describing the materials

offered along with samples of corrosion coating materials, its
properties and application instruction as applicable specifically to
the project.
b. Reference list of previous supplies, in last 5 years, of the similar

material or manufacturer shall be notified to Company, whose
approval in writing of all charges shall be obtained before the
materials are manufactured.
3.4.2 Contractor shall ensure that the coating materials supplied by him are
properly packed and clearly marked with the following :-
- Manufacturer’s name
- Material Qualification Certificate Number
- Batch Number
- Date of Manufacturing and date of expiry
3.4.3 Prior to shipment of materials from the Manufacturer’s Works. Contractor

shall furnish the following documents:
a. Test certificate/results as per Manufacturer’s Quality Control

Procedure for each batch of materials complying with the
requirements of relevant sub-clauses of clause no. 3.2 of the this
specification.
b. Specific application instructions with pictorial illustrations.
c. Specific storage and handling instructions.
3.4.4 All documents shall be in English language only.
3.5 Storage of Materials
Material shall be stored in sheltered storage by the Contractor in the

manufacturer’s original packing and away from direct sunlight and in
accordance with manufacturer’s instructions.
4.0 APPLICATION PROCEDURE
4.1 General
a) The application procedure shall be in accordance with

manufacturer’s instruction and the minimum requirements required
below whichever are the most stringent and shall be demonstrated
to and approved by the Owner.
b) Contractor shall provide and maintain mobile facilities which

contains all necessary tools, propane torches, epoxy primer pumps,
silicon rollers, testing instruments, equipment, and spares for
cleaning, coating, repairs, inspection and testing.
c) Contractor shall furnish sufficient number of the following

equipment and the required spares as a minimum for inspection
and testing purpose for each crew :
- Fully automatic full circle adjustable holiday detector with

audio and visual output signal for inspection of coating.
- Portable Tensile Strength Tester
- Digital Thermometer
- Solid state digital thickness gauge for measuring thickness
of joint coating.
4.2 Pipe Surface Preparation
a) The Contractor shall thoroughly clean and dry the joint surface by
power tool cleaning in accordance with SSPC-SP1. The complete
procedure and details of equipment used shall be prepared by the
Contractor for Owner’s approval prior to commencement of joint
coating work.
b) Prior to cleaning operation, Contractor shall visually examine the

joint surface area and shall ensure that all defects, flats and other
damages have been repaired or removed.
c) Where oil, grease or other materials detrimental to the finished

coating is present, it shall be removed with a continuous removal
solvents cleaning system to remove completely all such materials in
accordance with SSPC-SP1.
d) The standard of finish for cleaned pipe surface shall conform to SA

2½ of Swedish Standard SIS-055900 latest edition. The degree of
preparation required to obtain an end product that fulfil the
requirements of this specification may not be sufficiently covered
and is not limited by SIS-055900. Surface of pipe after shot blasting
shall be have an anchor pattern of 50 to 70 microns. This shall be
measured by a suitable instrument such as Elecometer.
e) Piper temperature immediately prior to blasting shall be minimum

20°C. At no time shall be blast cleaning be performed when the
relative humidity exceeds 85%. Surface temperature must be at
least 3°C above the dew point temperature.
f) The abrasive blast material shall be free of impurities and

inclusions, water and oil. All abrasives shall be removed after blast
by brush or vacuum type cleaner prior to applying joint coating.
The abrasive shall be stored in a dry condition and maintained dry
during use.
g) The compressed air for blasting shall be free of water and oil.
Contractor to verify air cleanliness at the start of the work and every
four hours thereafter. Separators and the traps shall be provided at
the compressor and blasting station. Separators and traps shall be
checked daily for effective moisture and oil removal during coating
operations.
h) The ends of existing line pipe protective coating shall be inspected

and chamfered. Unbonded portions of the coating shall be
removed and then suitably trimmed. Portions where parent coating
is removed shall be thoroughly cleaned as specified.
i) Pipe shall be visually inspected by Contractor immediately after

blast cleaning for surface defects such as slivers, laminations,
leafing, scores, indentation slugs or any other defects considered
injurious to the coating integrity. Such defects shall be reported to
Owner and on permission from Owner, such defects shall be
removed by filling or grinding in such a way as not to “blue” the
steel.
4.3 Procedure
a) The application procedure shall be in accordance with

manufacturers instruction and the minimum requirements specified
below whichever are the most stringent and shall be demonstrated
to and approved by the owner.
b) Applicators for coating application shall be given necessary

instructions and training before start of work by the
CONTRACTOR. To verify and qualify the application procedures,
all coating applied during the qualification test, shall be removed for
destructive testing until the requirements stated in sections
‘Inspection’ and ‘testing’ of this specification are met.
c) Prior to surface cleaning, the surface shall be completely dry. An

effective heating equipment which shall not give rise to deposits
shall be used. Care shall be taken to avoid damage to existing
coating.
d) All pipe joint surfaces shall be thoroughly examined before the

application of the coating in order to ensure that the surfaces are
free of oil, grease, rust, mud, earth or any other foreign matter.
e) Liquid epoxy primer shall be applied on the joints immediately after

the completion of heating operation.
f) The heat shrink sleeve is then wraparound the joint while the primer
is still wet and shall overlap the existing pipe coating by minimum
100 mm on each side.
g) The wraparound sleeve is shrunk on pipe joint with a propane torch

moved back and forth over the surface when heated above 125°C,
the sleeve shall shrink tightly around the substrate on to the wet-
primer. At the time of application of the primer, th pipe surface
temperature shall be at least 60°C at every point. To check this,
approved temperature indicators shall be used . temperature
indicating crayons shall not be used.
h) The wraparound sleeve shall be entirely wrapped around the pipe

positioning the closure patch off to one side of the pipe in 10m or 2
O’clock position, with edge of the undergoing layer facing upward
and an overlap of min. 100 mm.
i) Heat shrinking shall be procedure shall be applied to shrink the

sleeve in such a manner that all entrapped air is removed using
gloved hands and hand rollers. The complete shrinking of entire
sleeves shall be obtained without undue heating of existing pipe
coating and providing due bonding between pipe, sleeve and pipe
coating. A thermochrome paint shall be applied a an closure patch
to indicate that sufficient heat/ temperature has been obtained. The
joint coating shall have wear cone applied over the leading edge of
the sleeve and the clamping belt tightened over it.
j) Application of Wear Cone - The leading edge will be given an extra

wear cone. Start by heating the leading edge area of the main
sleeve to 700C. Wrap the leading edge sleeve over the transition
Mill coating. Ensure that the closure is placed away from the main
sleeve closure Shrink the leading edge sleeve.
k) Application of Metal Belt - The metal belt shall be applied over the
wear cone sleeve. The metal belt will be tightened using the
strapper tool supplied by the manufacturer.
l) Sufficient manpower working on opposite sides of each pipe joint

are required for installation of the sleeve.
m) The installed sleeve shall not be disturbed until the adhesive has
solidified.
5.0 INSPECTION
5.1 For wraparound coating, a visual inspection shall be carried out for the
following :
- Mastic extrusion on either ends of the sleeves shall be examined

- There shall be no sign of punctures or pinholes or bond failure.
The external appearance of the sleeves shall be smooth, free of
dimples, air entrapment or void formation.
- Weld bead profile shall be visible over the sleeves.
- The entire closure patch shall have changed colour uniformly.
5.2 Holiday Inspection
5.2.1 The Holiday Detector used shall be checked and calibrated daily with an
accurate D.C. voltmeter. The detector electrode shall be in direct contact
with the surface of coating to be inspected.
5.2.2 The entire surface of the joint section shall be inspected by means of a full
circle Holiday Detector approved by OWNER set to DC Voltage of at least
25 kV for wraparound sleeves. Inspection of the heat shrink sleeve coating
shall be conducted only after the joint has cooled below + 50°C.
5.2.3 All the coated joints shall be subjected to Holiday Detection test.
5.2.4 An installed sleeve with more than two holiday shall be stripped and a new
one be installed.
6.0 TESTING
a) OWNER reserves the right to test one out of every 30 joint coating
subject to a minimum of 2 joints. CONTRACTOR shall provide all
assistance in removing and testing of field joint coatings. From
each test sleeve, one or more strips of size 25 mm x 200 mm shall
be cut one perpendicular to the pipe axis and slowly peeled off.
This test shall be conducted between either sleeve and metal or
sleeve and mill coating as per direction of Owner/ Engineer-in-
charge.
b) The required peel strength shall be 60 N/cm (min.) at 23°C. The

system shall fail only in the adhesive layer. No failure either in
adhesion to steel or adhesion to backing shall be permitted. The
adhesive layer that remains on the pipe surface shall be free of
voids resulting from air or gas inclusion.
c) If the sleeve taken away for test does not meet the requirement of
clause 6.0 (b), the adjacent two sleeves do not meet the
requirements of clause 6.0 (b) the field joint coating shall be
stopped until OWNER is satisfied with application methods.
d) For the test tensile strength, two parallel incisions spaced 1 CM.
Apart are made right down to the surface of the steel. A further
incision shall then be at right angles to the first angles to the first
two incisions. With the aid of a 1 cm. Wide knife the coating is lifted
over a length of about 2 cm. And clamped into the tensile tester,
where upon a uniform pull is exerted at an angle of 90 degree. The
tensile strength shall be more than a 2500psi.
e) Coating thickness shall be checked by non destructive method for

each field joint.
7.0 REPAIR OF FIELD JOINT COATING
7.1 If a field joint is detected to be unacceptable after inspection and testing

as per clause no. 6.0 of this specification. The CONTRACTOR shall , at
his own cost :
- determine the cause of the faulty results of the coatings.
- mobilise the services of expert of manufactures, if required.
- test to the complete satisfaction of the OWNER, already completed

field joint coatings.
- stop joint coating until remedial measures are taken against the
causes of such failures, to the complete satisfaction of the
OWNER.
7.2 CONTRACTOR shall replace all the joints coating found or expected to be
unacceptable as per clause no. 6.0 of this specification.
7.3 CONTRACTOR shall, at his own cost repair all areas where the coating
has been removed for testing by the OWNER or by the CONTRACTOR
to the complete satisfaction of the OWNER.
7.4 The upright edges of the damaged areas shall be chamfered, in addition
to the steel shall be free from rust, dirt, oil and grease. The coating around
the damaged area shall be roughened. After thorough mixing (in
accordance with the recommendations of the manufacturer) the filler shall
be applied, to sufficient Thickness with the aid of stooping knife, whilst
observing ample overlap hardening. The material will require the approval
of OWNER.
7.5 After the coating work on welded joints and repairs to the coating have
been completed, The coating area as a whole shall be tested with spark-
tester before pull back/ lowering/jacking the pipeline.
7.6 Company shall be entitled to check the coating on buried pipelines or

parts of pipelines with equipment such as the “Pearson meter” and the
resistance meter. If the coating defects are established, the Contractor
shall be responsible for excavation at such points, repairing the coating,
spark testing and backfilling the excavations without extra charge.
8.0 REPAIR OF PIPE COATING DEFECTS
8.1 Any defect or damage in pipe coating observed till incorporation on

permanent works shall be rectified by the Contractor at his risk and cost.
However, for repair of damaged coating observed during taking over of
Owner supplied pipe, if any, shall be paid extra in accordance with the
relevant items of Schedule of Rates.
8.2 Field repair of coated pipes shall be carried out by using same type of
wraparound sleeves used for joint coating.
8.3 The repair procedure shall be same as specified herein above for
application of anti-corrosion field joint coating on welded pipe.
9.0 DOCUMENTATION
9.1 Prior to start the coating works at site Contractor shall furnish following
Owner/ Consultant’s approved documents in addition to that mentioned in
clause no. 3.4 of this specification.
- Procedure for field joint coating & their repair

- Procedure for repair of pipe line coating defects
- Procedure qualification record
- Inspection test plan
- Inspection format
9.2 Final submission of all documents after finish the work shall be as per
relevant specification & SCC enclosed with the tender or as per direction
of Engineer-in-charge.
SPECIFICATION
FOR
PIPELINE CROSSINGS
USING HORIZONTAL DIRECTIONAL
DRILLING METHOD
SPECIFICATION NO. : MEC/S/05/62/75
MECON LIMITED
DELHI - 110 092
\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\75 pipe line crossing using HDD method\Specification for PL CUHDDM 75.doc
MECON LIMITED PROCESS & PIPING TECHNICAL SPECIFICATION
Delhi DESIGN SECTION FOR
PIPELINE CROSSINGS USING
HORIZONTAL DIRECTIONAL
DRILLING METHOD
TECHNICAL SPECIFICATION NO. : MEC/S/05/62/75 REV-0 Page 1 of 11
CONTENTS
1.0 SCOPE 2
2.0 DESIGN AND ENGINEERING 3–6
3.0 CONSTRUCTION 6 – 10
4.0 DOCUMENTATION 10 – 11
PREPARED BY : CHECKED BY : APPROVED BY :
DRILLING METHOD
1.0 SCOPE
1.1 This specification covers the minimum requirements for various activities to be
carried out by the Contractor for the engineering and construction of pipeline
crossing using directional drilling method.
1.2 This specification shall be read in conjunction with the requirements of

specification and other documents included in the CONTRACT between owner
and Contractor.
1.3 Contractor shall, execute the work in compliance with laws, by laws, ordinance
and regulations. Contractor shall provide all services, labour, inclusive of
supervision thereof, supply of all materials (excluding “Owner supplied
Material), equipment , appliances etc..
1.4 Contractor shall take full responsibility for the stability and safety of all
operation and methods involved in the work.
1.5 Contractor shall be deemed to have inspected and examined the work area
and its surroundings and to have satisfied himself as far as practicable with the
surface conditions, hydrological and climatic conditions, the extent and nature
of the work and materials necessary for the completion of the work, and the
means of access to the work area.
1.6 Contractor shall be deemed to have obtained all necessary information with
regard to risks, contingencies and all other circumstances, which may influence
the work.
1.7 Contractor shall, in connection with the work, provide and maintain at his own
costs all lights, guards, fencing, as necessary or directed by Owner or their
representative.
1.8 For the purpose of this specification, the following definitions shall hold.
- The words `Shall’ and `Must’ are mandatory.
- The words `Should, May and Will’ are non mandatory, advisory, or
recommendatory.
1.9 Contractor shall provide free of charge reasonable facilities to Owner’s

personnel to witness all stages of construction.
DRILLING METHOD
2.0 DESIGN AND ENGINEERING
2.1 The limits of each crossing shall be determined by the Contractor on the basis
of crossing profile based on survey drawings, design, equipment, installation
technique and site condition. Contractor shall furnish all engineering design
calculation and crossing drawings etc. to owner for their approval prior to
execution of the work.
2.2 Within the entire limits of crossing, the minimum cover to top of coated pipe
shall be as specified in the Special Conditions of Contract (SCC).
However, wherever the drilled length for a crossing includes the crossings of
obstacles such as roads, railroads, cannals, streams, etc. The following
minimum requirements of cover to the pipe shall be satisfied unless specified
otherwise in the scope of work in SCC.
For Road Crossing : 1.4 m from top of road to top of pipe.
For railroad crossing : 1.7 m from base of Rail to top of pipe.
For canal crossing : 1.5 m from lowest bed level to top of pipe.
In case the pipeline crosses other utilities, viz., other pipelines, sewers, drain
pipes, water mains, telephone conduits and other underground structures, the
pipeline shall be installed with at least 500 mm free clearance from the
obstacle or as specified in the drawing or such greater minimum distance as
may be required by authorities having jurisdiction. Also in all cases, the
minimum covers specified above shall be maintained within the entire limits of
crossing.
2.3 The entry and exit points of the pipeline at ground level shall not come within
the limits of crossing as defined in the crossing drawings.
2.4 Contractor shall carry out calculations for determining the maximum
permissible overburden on pipe, to check that the empty pipeline is safe from
collapse at any point along the drilled crossing section. Contractor shall submit
these calculations to Owner for approval.
DRILLING METHOD
2.5 Pipeline Axis
The plane containing the pipeline route axis shall be perpendicular to the
horizontal plane. There shall be no bending of the pipeline route axis at
depths shall lower than 2 meters below ground level.
2.6 Back-reamed hole and Pipeline Interface
2.6.1 Contractor shall derive combination of:
- Back-reamed hole diameter

- Bentonite density
- Pipeline submerged weight in bentonite (and means to achieve that
weight)
to optimise the crossing design in terms of pipeline stresses and power

requirement
2.6.2 Contractor shall indicated what maximum shear stress in the pipeline coating
will result from his choice of above parameters and other characteristics
described in this section.
2.6.3 Contractor shall furnish all calculations for Onner’s approval. If shear stress in
pipe coating is, in the opinion of Owner, beyond the permissible limits,
Contractor shall revise his choice of parameters to reduce shear stress on pipe
coating to permissible value.
2.7 Contractor shall determine in the minimum allowable elastic bend radius for
pipe from the following consideration:
2.7.1 Maximum Longitudinal Stress During Installation
Total maximum longitudinal stress in the pipeline due to tension and bending
at any location shall not exceed 90% of the SMYS of the pipe material.
Contractor shall, in order to check this requirement, evaluate the maximum

tensile forces to which the pipeline is subjected to at any phase of its
installation during the pulling operation.
DRILLING METHOD
2.7.2. Maximum Equivalent Stress During Final Hydrostatic Test
After installation, the pipeline shall be hydrostatically tested to a minimum test

pressure equal to 1.4 times the design pressure or at a pressure stipulated in
the Special Conditions of Contract whichever is higher. However, during
hydrostatic testing, the combined equivalent stress in the pipeline due to
bending and test pressure shall not exceed 90% of the SMYS of pipe material.
2.7.3 Maximum Equivalent Stress During Service
Permissible values of maximum equivalent stress during services shall be

governed by the requirements of ANSI B 31.8/B 31.4 as applicable. The details
of pipeline operating parameters are provided in the Special Conditions of
Contract.
2.7.4 The minimum allowable radius of curvature for the pipeline shall be the
highest value of the minimum pipeline elastic radius as computed from the
considerations outlined in clause 2.7.1 to 2.7.3 above after correction for
drilling inaccuracies or multiplication by the factor 1.85. whichever results in
the highest permissible value of minimum elastic bend radius.
2.7.5 Contractor shall submit all calculations for Company’s approval alongwith
procedure.
2.8 Pipeline Configuration along the Support String Before Entry Point
2.8.3 Contractor shall determine the required pipeline configuration in order to allow
smooth pull in the crossing entry point and admissible stress in the supported
pipeline string. Pipeline combined stress shall not exceed 95% of the specified
minimum yield strength for line pipe material.
2.8.4 Contractor shall furnish all calculation and specify the number of required
supports, description of the supports, their co-ordinates and capacity in metric
tons.
2.8.5 Contractor shall also furnish a drawing of the launching ramp indicating the
pipeline configuration.
2.8.6 The distance between each roller shall also be specified and justified.
DRILLING METHOD
2.9 Contractor shall, based on result of design and engineering carried out by him,
prepare construction drawings for the crossing and shall submit the same for
Owner’s approval. Construction drawings shall indicate the pipeline profile with
levels furnished at sufficient intervals for proper control during construction.
Other relevant details viz., entry and exit angles, radius of bends, etc. shall
also be indicated. Contractor shall also calculated the total length of pipeline
required as well as the maximum tension required on the pull head of the rig.
2.10 All construction works shall be carried out in accordance with the construction
drawings approved by Owner.
2.11 Before commencement of any field work, Contractor shall furnish for Owner’s
approval all design calculations and construction drawings as stipulated in the
above clauses.
3.0 CONSTRUCTION
Contractor shall comply with all the conditions and requirements issued by
Authorities having jurisdiction in the area where the work is to be performed.
If no public road exists, Contractor shall arrange on his own for access to his
work area at no extra cost to owner.
3.1.0 Installation Procedure
3.1.1 Contractor shall, before commencing any work at site, submit for Owner’s
approval a detailed installation procedure.
3.1.2 The installation procedure as a minimum shall include the following:
a) Project Organisation Chart:

This shall indicate Contractor’s organisational set-up at site and
manpower deployment.
b) Details of fabrication yard and launching areas.
c) Details of Equipment :
Contractor shall furnish the complete list of all equipment to be
deployed for preparation of pipe string and installation of crossing.
Technical characteristics and capacity of each equipment including
instrumentation, monitoring and control equipment shall be furnished in
details.
DRILLING METHOD
d) Pipeline string preparation details (hauling, stringing, welding etc.)
e) Hydrostatic test procedure (pre and post installation)
f) Disposal methodology of bentonite slurry.
g) Method of installation covering all steps of construction, viz. Rig up,

Pilot hole, Back-Reaming, Pulling Down, Backfilling etc.
h) Calculation for maximum pulling force on the rig and recommended

maximum pulling velocity.
i) Time schedule for construction.
3.1.3 The time schedule shall be in accordance with overall time schedule for the
project.
3.1.4 Approval by Owner of the methods used by Contractor shall in no way relieve
Contractor from the sole responsibility for safe and satisfactory installation,
working and operational use of the pipeline crossing.
3.2 Pipe String Preparation
Complete pipe string shall be prepared as a single string for pulling. Welding,
radiographic inspection of joints and joint coating of the string shall be
performed in accordance with the respective applicable specifications included
in the Contract document.
3.3 Pre-testing
3.3.1 Contractor shall hydrostatically pre-test the complete pipe string of each
crossing before installation as per approved procedure for a minimum period of
24 hours.
3.3.2 After pre-testing, joint coating of the welds shall be done as per specification
for specific field joint coating of pipeline for HDD crossing included in the
contract document
3.3.3 The section of the pipeline corresponding to the crossing shall, before
installation, be subjected to hydrostatic test pressure as stipulated in the
Special Conditions of Contract. During the test, Contractor shall check all welds
for leakage. Failure, if any, during the test shall be rectified by the Contractor.
DRILLING METHOD
3.4 Gauging
3.4.1 Before pre and post installation hydrostatic testing, Contractor shall prove the
diameter of the pipeline by passing a gauging pig through the pipeline. The
gauging pig shall have a diameter equal to 95% of the nominal internal
diameter of the pipe. Contractor shall supply and install all temporary scraper
launchers/ receivers and other equipment, piping and materials and
consumables required for the purpose.
3.5 Installation
3.5.1 Installation shall be done in accordance with approval installation procedure.
3.5.2 The lateral offset of the actual exit point of the pilot hole from the calculated
and theoretical exit point shall not exceed half per cent (0.5%) of the length of
the crossing.
3.5.3 The length tolerance shall not exceed one per cent of the crossing length,
subject to the condition that the actual exit point shall not be within the limits
of crossing as defined in the approved drawings.
3.5.4 Back reaming shall be done separately from the pipeline pulling operation. The
size of the back-reamed hole shall be adequate (approximately 1.5 times the
pipeline diameter) to allow enough clearance for a smooth pull-back of the
pipeline.
3.5.5 Contractor shall be responsible for maintaining the drilled hole till such time
the pipeline is pulled in.
3.5.6 During pulling operation, the buoyancy of the pipeline shall be controlled by
suitable approved methods so as to maintain the buoyancy as close as possible
to zero during pull-back in order to reduce friction forces of the pipeline in the
hole.
3.5.7 Bentonite slurry of specified viscosity shall be pumped into the hole,
preventing the wall from collapsing and protecting the pipeline coating.
DRILLING METHOD
3.6 Contractor shall be responsible for the integrity of the corrosion

coating.
3.6.1 Before pull-back operation, megger test shall be done for the entire pipeline
(externally corrosion coated) string made for crossing by HDD method.
3.6.2 After pull-back operation to ensure the integrity of pipeline coating, again
megger test shall be done for the bored string before tied-in to the mainline
pipe. The megger value before & after pulling operation of the pipeline string
shall be nearly same and acceptable to Owner.
3.6.3 However, if, in Owner’s opinion, the integrity of external corrosion coating of
bored pipeline string is not established by above (Clause No. 3.6.1 & 3.6.2),
then further in order to ensure the integrity of coating of the bored pipeline
string, megger test of the coating shall be carried out in accordance with the
following steps:
a) The test must be carried out before the bored pipe is tied-in to the
mainline pipe
b) Measure the natural potential of the bored pipe at both ends.
c) Set up the temporary impressed current system with a digital

multimeter connected to measure the output current. Position the test
electrode anode as far from the bored pipe as interconnecting cable will
allow and no closer than 10 meters.
d) Place the reference electrode at the remote end (opposite to impressed

current system) to monitor the bored pipe potential
e) Impress a current into the bored pipe start at Zero amp. and increase
slowly until the bored pipe potential is depressed to 1.5 V with respect
to the reference electrode.
f) Note the current from the digital multimeter and calculate the current
density.
g) The desirable value of calculated current density should be less than 70

micro ampere per square meter of drilled pipe surface in contact with
the soil.
DRILLING METHOD
3.6.4 If Contractor again fails to establish the integrity of coating of the bored
pipeline string and the same is not acceptable to Owner, the above works shall
not be continued further until the cause analysed and rectified by the
Contractor to the entire satisfaction of Owner.
3.7 Final Hydrostatic Test
3.5.1 The complete crossing section shall be tested after installation. The test
pressure shall be as stipulated in the Special Conditions of Contract. After
temperature stabilisation, pressure shall be retained in the pipeline for a
period of 6 hours and recorded by manothermograph. The hydrostatic testing
shall be carried out in accordance with approved procedures and specification
detailed elsewhere in the document.
3.8 Final Clean up
3.8.1 After completion of construction, Contractor shall clear the site of all balance
material and debris and bentonite slurry. All balance pipe lengths shall be
returned to Owner’s designated stock yard(s). Site/ ROW shall be cleared to
the complete satisfaction of the land owner’s and authorities having
jurisdiction. All such works shall be done at no extra cost to Owner. The Owner
shall be indemnified against any/ all claims arising as a result thereof.
4.0 DOCUMENTATION
4.1 In additional to the documents specified elsewhere in this specification.

Contractor shall submit to the Owner the following documents/ records.
• Copies of the permits obtained from authorities having jurisdiction.

• Records of pre and post installation hydrostatic testing.
• Record of non-destructive testing of welds.
• Clearance certificate from the land owners and authorities having
jurisdiction regarding satisfactory clean-up and restoration of the pipeline
ROW and work sites.
4.2 After completion of construction, Contractor shall prepare and furnish six sets
of copies and two sets of reproducible of `As-built’ for the crossings. As built
drawings shall , as a minimum include the following information
DRILLING METHOD
• True profile of the crossing along the pipeline.

• True profile of the pipeline as installed and the depth of cover to top of
pipe at regular intervals.
• Location of entry and exit point and angles of entry and exit alongwith
lateral offset of exit point from the original pipeline alignment.
• Location and angle of field bends
• Location of pipeline markers.
4.3 All documents shall be in English language.
PROCESS & PIPING DESIGN SECTION
MECON LIMITED
DELHI – 110 092
TECHNICAL SPECIFICATION
FOR
BALL VALVES
SPECIFICATION NO. : MEC/TS/05/62/002, Rev-2
D:\TS\Ball Valves - 002 - TS-R2.doc

BALL VALVES
TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/002 REV-2 Page 1 of 16
CONTENTS
1.0 SCOPE 2
2.0 REFERENCE DOCUMENTS 2
3.0 MATERIALS 3
4.0 DESIGN AND CONSTRUCTION 4
5.0 INSPECTION AND TESTS 9
6.0 EXTENT OF INSPECTION & TESTING 12
7.0 TEST CERTIFICATES 13
8.0 PAINTING, MARKING AND SHIPMENT 13
9.0 SPARES AND ACCESSORIES 14
10.0 DOCUMENTATION 14
11.0 GUARANTEE 16
Revision No. Date Revised by Checked by Approved by
2 08.08.2002 K.P. Singh A.K. Johri Niraj Gupta

K.P. SINGH A.K. JOHRI NIRAJ GUPTA

BALL VALVES
1.0 SCOPE
This specification covers the minimum requirements for design, manufacture

and supply of carbon steel ball valves of size DN 50mm (2”) and above and
ANSI class 150 to 900 to be used in on-shore pipeline systems handling non-
sour hydrocarbons in liquid or gaseous phase, including Liquid Petroleum Gas
(LPG).
This specification does not cover ball valves for sour hydrocarbon (liquid/ gas)
service as defined in NACE standard MR-01-75.
2.1 All valves shall be manufactured and supplied in accordance with the Twenty
Second Edition, January,2002, or the latest edition of American Petroleum
Institute (API) Specification 6D, with additions and modifications as indicated
in the following sections of this specification.
2.2 Reference has also been made in this specification to the latest edition of the
following Codes, Standards and Specifications :
ASME B 16.5 : Pipe flanges and flanged fittings
ASME B 16.25 : Buttwelding ends
ASME B 16.34 : Valves – Flanged, threaded and welding end
ASME B16.47 : Large diameter steel flanges
ASME B 31.3 : Chemical & process plant piping system
ASME B 31.4 : Liquid transportation systems for hydrocarbons and

other liquids
ASME B 31.8 : Gas transmission and distribution piping systems
ASME Sec.VIII/IX : Boiler and pressure vessel code
ASTM A 370 : Standard test methods and definitions for

mechanical testing of steel products
ASTM B 733 : Autocatalytic nickel phosphorous coating on metals

BALL VALVES
API 6FA : Fire test for valves
API 607 : Fire test for soft-seated quarter-turn valves
API 1104 : Welding of pipelines and related facilities
BS:6755 (Part-II) : Testing of valves – Specification for fire type -

testing requirements
MSS-SP-6 : Standard finishes for contact faces of pipe flanges

and connecting-end flanges of valves and fittings
MSS-SP-44 : Steel pipeline flanges
SSPC-VIS-1 : Steel structures painting council-visual standard
2.3 In case of conflict between the requirements of this specification, API 6D

and the Codes, Standards and Specifications referred in clause 2.2 above, the
requirements of this specification shall govern. Order of precedence shall be
as follows :
• Data Sheets
• This Specification
• API 6D Specification
• Other Referred Codes & Standards
• Manufacturer’s Standard
3.0 MATERIALS
3.1 Material for major components of the valves shall be as indicated in Valve Data
Sheet. Other components shall be as per Manufacturer’s standard which will
be subject to approval by Purchaser.
3.2 Carbon steel used for the manufacture of valves shall be fully killed.
3.3 The Carbon Equivalent (CE) of valve end connections which are subject to
further field welding by Purchaser, shall not exceed 0.45% (as calculated by
the following formula) on check analysis for each heat of steel used:
Mn Cr + Mo + V Ni + Cu
CE = C + -------- + ---------------------- + ---------------
6 5 15

BALL VALVES
3.4 Charpy V-Notch test on each heat of base material shall be conducted as per
API 6D, for all pressure containing parts such as body, end flanges and welding
ends as well as bolting material for pressure containing parts. Unless specified
otherwise, the Charpy impact test shall be conducted at 0°C. The Charpy
impact test specimen shall be taken in the direction of principal grain flow and
notched perpendicular to the original surface of plate or forging.
The minimum average absorbed energy per set of three specimens shall
be 27 J with an individual minimum per specimen of 22 J. No specimen shall
exhibit less than 80 percent shear area.
3.5 For all such valves where carbon steel is used as ball material, the ball shall
have 75 micrometer (0.003 inch) thick Electroless Nickel Plating (ENP) as per
ASTM B733 with following classification : SC2, Type II, Class 2. The hardness
of plating shall be minimum 50 RC.
3.6 When specified in Valve Data Sheet, hardness test shall be carried out on each
heat of base material for all pressure containing parts of the valve. A full
thickness cross-section shall be taken for this purpose and the maximum
hardness shall not exceed 248 HV10 based on minimum four measurements
representing the entire thickness.
3.7 All process-wetted parts, metallic and non-metallic, shall be suitable for the fluids
and service specified by the Purchaser. The service gas composition shall be as
given in Annexure-I.
4.0 DESIGN AND CONSTRUCTION
4.1 Valve design shall meet the requirements of API 6D and other referred codes
and shall be suitable for the service conditions indicated in Valve Data Sheet.
The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, shall be
used to design the valve body. Allowable stress requirements shall comply the
provisions of ASME B31.3. In addition, corrosion allowance indicated in Valve
Data Sheet shall be considered in valve design. However, the minimum wall
thickness shall not be less than the minimum requirement of ASME B16.34.
The Manufacturer shall have a valid license to use API 6D monogram for
manufacture of ball valves.
4.2 Valve body shall be either fully welded or bolted. Valve body joints with
threads are not permitted.
4.3 Valves shall be Full Bore (FB) or Reduced Bore (RB) as indicated in Valve Data
Sheet. Full bore valves shall be suitable for the passage of all types of pipeline
scraper and inspection pigs on regular basis without causing damage to either

BALL VALVES
the valve component or the pig. The full bore valve shall provide an
unobstructed profile for pigging operations in either direction. Full bore valves
shall be designed to minimize accumulation of debris in the seat ring region to
ensure that valve movement is not impeded. In case of reduced bore valves,
the nominal valve size indicated in Valve Data Sheet corresponds to the end
connection. Nominal valve size of reduced bore shall be as per Table below:
Nominal Valve Nominal Valve Nominal Valve Nominal Valve

Size (inches)* Size for Reduced Size (inches)* Size for Reduced
Bore (inches)** Bore (inches)**
2 2 24 20
3 2 26 22
4 3 28 24
6 4 30 24
8 6 32 26
10 8 34 28
12 10 36 30
14 10 38 32
16 12 40 34
18 14 42 36
20 16 48 42
22 18
* Nominal valve size corresponds to end connection.
** Nominal valve size corresponds to the minimum bore as listed in

Table-1, API 6D.
4.4 Ball mounting shall be trunnion/ pivot type or as indicated in Valve Data Sheet.
Valve design shall minimize the possibility of debris ingress into the trunnion as
far as practicable.
4.5 Valve seats shall be with primary metal to metal contact. O-rings or other
seals, if used for drip tight sealing, shall be encased in a suitable groove in
such a manner that it can not be removed from seat ring and there is no
extrusion during opening or closing operation at maximum differential
pressure. The seat rings shall be so designed as to ensure sealing at low as
well as high differential pressures. Seat design with PTFE insert is not
acceptable.
4.6 Valves shall have double block and bleed feature to facilitate complete
flushing, draining and venting of the valve body cavity.

BALL VALVES
For valves to be used in liquid service, the body cavity over-pressure shall be
prevented by self relieving seat rings/assemblies. A pressure relief hole in the
ball is not permitted. Self relieving seat rings shall relieve at a body cavity
differential pressure not exceeding 50% of the valve class rating pressure.
4.7 When specified in Valve Data Sheet, valves shall be designed to withstand a
sustained internal vacuum of at least 1 (one) milli-bar in both open and closed
positions.
4.8 Full Bore Valves of nominal size 200mm(8”) & above and Reduced Bore Valves
of nominal size 250mm(10”) & above shall have provision for secondary
sealant injection under full line pressure for seat and stem seals. Sealant
injection points shall be provided with a needle valve accommodating a grease
fitting. Location and arrangement of sealant points shall be as per Figure-1
(Annexure-II).
4.9 Valves shall be provided with vent and drain connections. Location and
arrangement of vents and drains alongwith provision of valves shall be as per
Figure-1 (Annexure-II).
4.10 Valve design shall ensure repair of gland packing under full line pressure.
4.11 a) Valve ends shall be either flanged or butt welded or one end flanged and one
end butt welded as indicated in Valve Data Sheet. Flanges of the flanged end
cast/ forged body valves shall be integrally cast/forged with the body of valve.
Face-to-face/ end-to-end dimensions shall conform to API 6D.
b) Flanged end shall have dimensions as per ASME B16.5 for valve sizes upto DN
600mm (24 inches) excluding DN 550mm (22 inches) and as per MSS-SP-44
for valve sizes DN 550mm (22 inches) & for DN 650mm (26 inches) and above.
Flange face shall be either raised face or ring joint type as indicated in Valve
Data Sheet. Flange face finish shall be serrated or smooth as indicated in Valve
Data Sheet. Smooth finish when specified shall be 125 to 200 AARH.
c) Butt weld end preparation shall be as per ASME B16.25. The thickness of the
pipe to which the valve has to be welded shall be as indicated in Valve Data
Sheet. Valves shall be without transition pups. In case significant difference
exists between thickness of welding ends of valve and connecting pipe, the
welding ends of valve shall have bevel preparation as per ASME B31.4 or ASME
B31.8, as applicable.

BALL VALVES
4.12 Design of weld end valves shall be such that during field welding operation,
the soft seals are not liable to be damaged.
4.13 Valves shall be provided with ball position indicator and stops of rugged
construction at the fully open and fully closed positions.
4.14 Full Bore Valves of nominal size ≥ 200mm(8”) and Reduced Bore Valves of
nominal size ≥ 250mm(10”) shall be equipped with support foot and lifting
lugs. Tapped holes and eye bolts shall not be used for lifting lugs. Height of
support foot shall be kept minimum.
4.15 When indicated in Material Requisition, valves shall have locking devices to
lock the valve either in full open (LO) or full close (LC) positions. Locking
devices shall be permanently attached to the valve operator and shall not
interfere with operation of the valve.
4.16 Valves shall be of fire resistant design as per API 607/BS:6755 (Part-II)/API
6FA, as indicated in Valve Data Sheet.
4.17 Valves shall be provided with anti-static devices to ensure electrical continuity
between stem / ball and valve body. Valve design shall be such as to avoid
bimetallic corrosion between carbon steel and high alloy steel components.
Suitable insulation shall be provided as required.
4.18 Valves shall be suitable for either buried or above ground installation as
indicated in Valve Data Sheet.
4.19 When stem extension requirement is indicated in Valve Data Sheet, the valves
shall have the following provisions :
a) Valves provided with stem extension shall have water proof outer casing.
Length of stem extension shall be as indicated in Valve Data Sheet. The length
indicated corresponds to the distance between centreline of the valve opening
and centreline of the rim of the hand wheel on a vertical shaft or centreline of
the hand wheel on a horizontal shaft.
b) Vent and drain connections and sealant injection lines shall be terminated
adjacent to the valve operator by means of suitable piping anchored to the
valve body. Pipe used shall be API 5L Gr. B/ ASTM A 106 Gr. B, with Sch. 160.
Fittings shall be ASTM A 105/ ASTM 234 Gr. WPB, Socket Welded, ANSI class
6000.

BALL VALVES
c) Stem extension and stem housing design shall be such that the complete
assembly will form a rigid unit giving a positive drive under all conditions with
no possibility of free movement between valve body, stem extension or its
operator.
d) Outer casing of stem extension shall have 3/8” or ½” NPT plugs at the top and
bottom, for draining and filling with oil to prevent internal corrosion.
4.20 Operating Devices
a) Valves shall have a power actuator or manual operator as indicated in Valve

Data Sheet. In case of manual operator, valve sizes < DN 100mm (4 inches)
shall be wrench operated and valve sizes ≥ DN 150mm (6 inches) shall be gear
operated. Valve design shall be such that damage due to malfunctioning of
the operator or its controls will only occur in the operator gear train or power
cylinder and that damaged parts can be replaced without the valve cover being
removed.
b) The power actuator shall be in accordance with the Purchaser specification

issued for the purpose and as indicated in Valve and Actuator Data Sheet.
Operating time shall be as indicated in Valve Data Sheet. Valve operating time
shall correspond to full close to full open/full open to full close under maximum
differential pressure corresponding to the valve rating. For actuated valves, the
actuator torque output shall be 1.50 times the break torque required to
operate the ball valve under the maximum differential pressure corresponding
to the valve class rating.
c) For manual operator of all valves, the diameter of the hand wheel or the
length of operating wrench shall conform to API 6D requirements and be such
that under maximum differential pressure, the total force required to operate
the valve does not exceed 350 N. Manufacturer shall also indicate the number
of turns of hand wheel (in case of gear operators) required for operating the
valve from full open to full close position.
d) Direction of operation of hand wheel or wrench shall be in clock-wise direction

while closing the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self locking provision and shall be
fully encased, in water proof/ splash proof/ dust proof/ weather proof
enclosure and shall be filled with suitable grease.

BALL VALVES
f) Operating devices shall be designed for easy operation of the valve under
maximum differential pressure corresponding to the valve rating.
4.21 All welds shall be made by welders and welding procedures qualified in
accordance with the provisions of ASME Section IX. The procedure qualification
shall include impact test and hardness test and shall meet the requirements of
clauses 3.4 and 3.6 of this specification, respectively.
4.22 All welds shall be stress relieved in accordance with ASME Section VIII.
4.23 Repair by welding is not permitted for fabricated and forged body valves.
However repair by welding as per ASME B16.34 is permitted for cast body
valves. Repair shall be carried out before any heat treatment of casting is
done. Repair welding procedure qualification shall include impact test and
hardness test and shall meet the requirements of clauses 3.4 & 3.6 of this
specification, respectively.
4.24 The tolerance on internal diameter and out of roundness at the ends for
welded end valves shall be as per applicable connected pipe specification as
indicated in Valve Data Sheet.
4.25 Valve stem shall be capable of withstanding the maximum operating torque
required to operate the valve against the maximum differential pressure
corresponding to applicable class rating. The combined stress shall not exceed
the maximum allowable stresses specified in ASME Section VIII, Division I. In
case of power actuated valves, the valve stem shall be capable of withstanding
maximum output of the power actuator.
5.0 INSPECTION AND TESTS
5.1 The Manufacturer shall perform all inspection and tests as per the
requirements of this specification and the relevant codes, prior to shipment, at
his works. Such inspection and tests shall be, but not limited to, the following:
5.1.1 All valves shall be visually inspected.
5.1.2 Dimensional check on all valves shall be carried out as per the Purchaser
approved drawings.
5.1.3 Chemical composition and mechanical properties shall be checked as per

relevant material standards and this specification, for each heat of steel used.

BALL VALVES
5.1.4 a) Non-destructive examination of individual valve material and components

consisting of, but not limited to castings, forgings, plate and assembly welds
shall be carried out by the Manufacturer.
b) Body castings of all valve shall be radiographically examined on 100% of the

surface of critical areas as per ASME B16.34. Procedure and acceptance
criteria shall be as per ASME B16.34. The extent of radiography shall be as
follows:
ANSI class 150 - All sizes - Nil
ANSI class 300 - < DN 400mm (16”) - Nil

> DN 450mm (18”) - 100%
ANSI class 600 - All sizes - 100%

and above
All castings shall be wet magnetic particle inspected 100% of the internal
surfaces. Method and acceptance shall comply with ASME B.16.34.
c) All valves, with body fabricated from plates made or by forgings, shall be
ultrasonically examined in accordance with the procedure and acceptance
standard of Annexure E of ASME B16.34. All forgings shall be wet magnetic
particle inspected 100% of the internal surfaces. Method and acceptance shall
comply with ASME B 16.34
d) Bodies and bonnets made by welded assembly of segments of castings,

forgings, plates or combinations thereof shall be examined, as applicable, by
methods of clause 5.1.4 b) for cast components or clause 5.1.4 c) for forged
components and plates.
5.1.5 Full inspection by radiography shall be carried out on all welds of pressure
containing parts. Acceptance criteria shall be as per ASME B 31.4 or ASME
B31.8, as applicable, and API 1104.
5.1.6 Welds which in Purchaser’s opinion cannot be inspected by radiographic

methods, shall be checked by ultrasonic or magnetic particle methods and
acceptance criteria shall be as per ASME Section VIII, Division 1, Appendix 12
and Appendix 6, respectively.

BALL VALVES
5.1.7 a) All finished wrought weld ends subject to welding in field shall be 100%
ultrasonically tested for lamination type defects for a distance of 50mm from
the end. Laminations shall not be acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100%
radiographically examined and acceptance criteria shall be as per ASME
B16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrant or
wet magnetic particle methods. All defects longer than 6.35 mm are rejected,
as are defects between 6.35 mm and 1.59mm that are separated by a distance
less than 50 times their greatest length. Rejectable defects must be removed.
Weld repair of bevel surface is not permitted.
5.1.8 All valves shall be tested in compliance with the requirements of API 6D.
During pressure testing, valves shall not have sealant lines and other cavities
filled with sealant, grease or other foreign material. The drain, vent and
sealant lines shall be either included in the hydrostatic shell test or tested
independently. No leakage is permissible during hydrostatic testing. The body
cavity self relieving feature meeting the requirements of clause 5.6 of this
specification shall also be checked.
5.1.9 A supplementary air seat test as per API 6D shall be carried out for all valves.
A bubble tight seal is required without the use of any sealant. No leakage is
allowed. Test pressure shall be held for at least 15 minutes.
5.1.10 Manufacturer who intends bidding, must submit at bid stage, certificate and
report for successful fire type-tests for valves in accordance with API-607/
BS:6755 (Part-II)/ API 6FA, as applicable in Valve Data Sheet.
Failure to comply with this requirement shall be a cause of rejection of the

offer.
5.1.11 Valves shall be subjected to Operational Torque Test as per supplementary

test requirement of API 6D under hydraulic pressure equal to maximum
differential pressure corresponding to the valve rating.
For manually operated valves, it shall be established that the force required to
operate the valve does not exceed the requirements stated in clause 4.20(c) of
this specification.

BALL VALVES
5.1.12 Power actuated valves shall be tested after assembly of the valve and actuator at
the valve Manufacturer’s works. At least five open-close-open cycles without
internal pressure and five open-close-open cycles with maximum differential
pressure shall be performed on the valve actuator assembly. The time for full
open to full close shall be recorded during testing.
If required, the actuator shall be adjusted to ensure that the opening and closing
times are within the limits stated in Actuator Data Sheet issued for the purpose.
Hand operator provided on the actuator shall also be checked after the cyclic
testing, for satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five(5)
valves of the same size, rating and the actuator model/ type. In case the tests do
not meet the requirements, retesting / rejection of the lot shall be decided by
Purchaser’s Inspector.
5.1.13 When indicated in Valve Data Sheet, valves shall be subjected to anti-static
testing as per supplementary test requirement of API 6D.
5.2 Purchaser reserves the right to perform stage-wise inspection and witness tests
as indicated in clause 5.1 above at Manufacturer’s works prior to shipment.
Manufacturer shall give reasonable access and facilities required for inspection to
the Purchaser’s Inspector.
Purchaser reserves the right to require additional testing at any time to confirm or
further investigate a suspected fault. The cost incurred shall be to Manufacturer’s
account.
In no case shall any action of Purchaser or his Inspector relieve the Manufacturer
of his responsibility for material, design, quality or operation of valves.
Inspection and tests performed/ witnessed by the Purchaser’s Inspector shall in

no way relieve the Manufacturer’s obligation to perform the required inspection
and tests.
6.0 EXTENT OF INSPECTION & TESTING
6.1 Purchaser’s Inspector shall perform inspection and witness tests on all valves or
as indicated in the Quality Assurance Plan (QAP) attached with this specification.
6.2 The hydrostatic testing and cyclic opening and closing of the valves with the
operator shall be witnessed by Purchaser’s Inspector.

BALL VALVES
7.0 TEST CERTIFICATES
7.1 Manufacturer shall submit the following certificates :
a) Mill test certificates relevant to the chemical analysis and mechanical

properties of the materials used for valve construction as per the relevant
standards.
b) Test certificates on hydrostatic and pneumatic tests complete with records of

timing and pressure of each test.
c) Test reports on radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 5.1.11 and 5.1.12 of

this specification.
e) All other test reports and certificates as required by API 6D and this
specification.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only
those valves which have been certified by Purchaser’s Inspector shall be
despatched from Manufacturer’s works.
8.0 PAINTING, MARKING & SHIPMENT
8.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and
applied with sufficient coats of corrosion resistant paint. Surface preparation
shall be carried out by shot blasting to SP-6 in accordance with “Steel
Structures Painting Council – Visual Standard SSPC-VIS-1”. For valves to be
installed underground, when indicated in Valve Data Sheet, the external
surfaces of the buried portion of valves shall be painted with three coats of
suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns.
8.2 Manufacturer shall indicate the type of corrosion resistant paint used, in the
drawings submitted for approval.
8.3 All valves shall be marked as per API 6D. The units of marking shall be metric
except Nominal Diameter which shall be in inches. Marking shall be done by
die-stamping on the bonnet or on the housing. However, for buried valves the
marking shall be done on the above ground portion of the stem housing only.

BALL VALVES
8.4 Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by
a coat of grease or other suitable material. All valves shall be provided with
suitable protectors, for flange faces, securely attached to the valves. Bevel
ends shall be protected with metallic or high impact plastic bevel protectors.
8.5 All sealant lines and other cavities of the valve shall be filled with sealant
before shipment.
8.6 Packaging and shipping instructions shall be as per API 6D.
8.7 On packages, following shall be marked legibly with suitable marking ink :
a) Order Number
b) Manufacturer’s Name
c) Valve Size and Rating
d) Tag Number
e) Serial Number
9.0 SPARES & ACCESSORIES
9.1 Manufacturer shall furnish list of recommended spares and accessories for
valves required during start-up and commissioning.
9.2 Manufacturer shall furnish list of recommended spares and accessories

required for two years of normal operation and maintenance of valves.
9.3 Manufacturer shall quote for spares & accessories as per Material Requisition.
10.0 DOCUMENTATION
10.1 At the time of bidding, Manufacturer shall submit the following documents :
a) General arrangement/assembly drawings showing all features and relative

positions and sizes of vents, drains, gear operator / actuator, painting, coating
and other external parts together with overall dimensions.

BALL VALVES
b) Sectional drawing showing major parts with reference numbers and material
specification. In particular, a blow-up drawing of ball-seat assembly shall be
furnished complying the requirement of clause 4.5 of this specification.
c) Reference list of similar ball valves manufactured and supplied in last five
years indicating all relevant details including project, year, client, location, size,
rating, service etc.
d) Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for power actuated valves.
e) Descriptive technical catalogues of the Manufacturer.
f) Installation, Operational and Maintenance Manual.
g) Copy of valid API 6D certificate, wherever applicable.
h) Details of support foot, including dimensions and distance from valve centre
line to bottom of support foot.
i) Quality Assurance Plan enclosed with this tender duly signed, stamped and
accepted.
IMPORTANT
The drawings to be submitted alongwith the bid shall be in total

compliance with the requirement of technical specification and data
sheets of the valves with no exception & deviation.
10.2 Within two weeks of placement of order, the Manufacturer shall submit six
copies of, but not limited to, the following drawings, documents and
specifications for Purchaser’s final approval :
a) Detailed sectional arrangement drawings showing all parts with reference

numbers and material specifications as referred to in clause 10.1 above.
b) Assembly drawings with overall dimensions and features. Drawing shall also
indicate the number of turns of hand wheel (in case of gear operators)
required for operating the valve from full open to full close position and the
painting scheme. Complete dimensional details of support foot (where
applicable) shall be indicated in these drawings as referred to in clause 10.1
above.
c) Welding, heat treatment and testing procedures.
d) Details of corrosion resistant paint to be applied on the valves.

BALL VALVES
Manufacture of valves shall commence only after approval of the above

documents. Once the approval has been given by Purchaser, any changes in
design, material and method of Manufacture shall be notified to Purchaser
whose approval in writing of all changes shall be obtained before the valve is
manufactured.
10.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser
one reproducible and six copies of the approved drawings, documents and
specifications as listed in clause 10.2 above.
10.4 Prior to shipment, Manufacturer shall submit one reproducible and six copies of
the following:
a) Test certificates as per clause 7.0 of this specification.

b) Manual for installation, erection, maintenance and operation instructions,
including a list of recommended spares for the valves.
11.0 GUARANTEE
11.1 Manufacturer shall guarantee that the materials and machining of valves and
fittings comply with the requirements in this specification and in the Purchase
Order.
11.2 Manufacturer is bound to replace or repair all valve parts which should result
defective due to inadequate engineering or to the quality of materials and
machining.
11.3 If valve defect or malfunctioning cannot be eliminated, Manufacturer shall

replace the valve without delay,
11.4 Any defect occurring during the period of Guarantee shall be attended to by
making all necessary modifications and repair of defective parts free of charge
to the Purchaser as per the relevant clause of the bid document.
11.5 All expenses shall be to Manufacturer’s account.

MECON LIMITED
DELHI – 110 092
FOR
CHECK VALVES
D:\old data\FATEH\MP Region\Kailaras\Tender RFQ\Check Valve\Check Valves - 004 - TS-R2.doc

CHECK VALVES
CONTENTS
1.0 SCOPE 2
2.0 REFERENCE DOCUMENTS 2
3.0 MATERIALS 2
4.0 DESIGN AND CONSTRUCTION 3
5.0 INSPECTION AND TESTS 4
6.0 TEST CERTIFICATES 5
7.0 PAINTING, MARKING AND SHIPMENT 6
8.0 SPARES AND ACCESSORIES 6
9.0 DOCUMENTATION 6
10.0 GUARANTEE 7

CHECK VALVES
1.0 SCOPE
This specification covers the minimum requirements for design, manufacture

and supply of carbon steel check valves of size DN 50mm (2”) and above and
ANSI class 150, 300 and 600 , for use in onshore pipeline systems handling
non-sour hydrocarbons in liquid phase or gaseous phase including Liquefied
Petroleum Gas (LPG).
2.1 All valves shall be manufactured and supplied in accordance with the latest
edition of American Petroleum Institute (API) Specification 6D or 594 or British
Standard BS:1868, with additions and modifications as indicated in the
following sections of this specification.
For Contractual purpose, the edition in force at the time of floating of the
enquiry shall be termed as “latest edition”.
3.0 MATERIALS
3.1 Material for major components of the valves shall be as indicated in Valve Data
Sheet. Other components shall be as per Manufacturer’s standards which will
be subject to approval by Purchaser.
3.2 Carbon steel used for the manufacture of valves shall be fully killed.
3.3 The Carbon Equivalent (CE) of valve end connections which are subject to
further field welding by Purchaser, shall not exceed 0.45% (as calculated by
the following formula) on check analysis for each heat of steel used :
CE = C + -------- + ---------------------- + ---------------
6 5 15
3.4 Charpy V-Notch test on each heat of base material shall be conducted as per
API 6D, clause 7.5, for all pressure containing parts such as body, end flanges
and welding ends as well as bolting material for pressure containing parts.
Unless specified otherwise, the Charpy impact test shall be conducted at 0°C.
The Charpy impact test specimen shall be taken in the direction of principal
grain flow and notched perpendicular to the original surface of plate or forging.
The minimum average absorbed energy per set of three specimens shall
be 27 J with an individual minimum per specimen of 22 J. No specimen shall
exhibit less than 80 percent shear area.

CHECK VALVES
3.5 All process – wetted parts, metallic and non-metallic, shall be suitable for the
fluids and service specified by the Purchaser.
4.1 Following types of check valves, meeting the requirements of applicable

standards (refer clause 2.1 of this specification) are acceptable :
a) Swing check valve

b) Dual plate check valve
c) Axial flow (Nozzle) check valve
Valve design shall be suitable for the service conditions indicated in Valve Data
Sheet. Corrosion allowance indicated in Valve Data Sheet shall be considered in
valve design.
4.2 In case of swing check valves, the disc hinge shall be mounted on the valve
body and shall not be attached to the valve body cover. Valve body cover joint
shall be of bolted design. Screwed covers shall not be used.
4.3 Valves shall be provided with non-renewable integral type seats as indicated in
Valve Data Sheet. Non-renewable seats shall be of a design which does not
required renewal over the design life of the valve.
4.4 Valves shall be provided with drain connection as per the Manufacturer’s
standard. Drain tapping shall be provided in a position suitable to completely
drain the valve with valve in horizontal position.
4.5 Valve ends shall be either flanged or butt welded or one end flanged and one
end butt welded as indicated in Valve Data Sheet. Flanged end shall have
dimensions as per ASME B16.5 for sizes upto DN 400mm (16”). Flanges of the
flanged end cast body valves shall be integrally cast with the body of the
valve.
4.6 Butt weld end preparation shall be as per ANSI B16.25. The thickness of the
pipe to which the valve has to be welded shall be as indicated in Valve Data
Sheet. Valves shall be without transition pups. In case difference exists
between thickness of valve neck end and connecting pipe, the bevel end of
valve shall be prepared as per ANSI B31.8 or ANSI B31.4, as applicable.
4.7 Valves of size DN 200mm (8”) and above shall be equipped with lifting lugs.
Tapped holes and eye bolts shall not be used for lifting lugs.

CHECK VALVES
4.8 An arrow indicating the direction of flow shall be embossed or cast on the body
of all valves.
4.9 All welds shall be made by welders and welding procedures qualified in
accordance with the provisions of ASME Section IX. The welding and repair
welding procedure qualification shall include impact test and shall meet the
requirements of clause 3.4 of this specification.
4.10 Repair by welding is permitted for cast body valves subject to written approval
by Purchaser and shall be carried out as per ANSI B16.34. Repair shall be
carried out before any heat treatment of casting is done.
5.1 The Manufacturer shall perform all inspection and tests as per the requirements
of this specification and the relevant codes, prior to shipment at his works. Such
inspection and tests shall be, but not limited to, the following :
5.1.1 All valves shall be visually inspected.
5.1.2 Dimensional check on all valves shall be carried out as per the Purchaser
approved drawings.
5.1.3 Chemical compositions and mechanical properties shall be checked as per

relevant material standards and this specification, for each heat of steel used.
5.1.4 a) Where applicable, the body castings of valves shall be radiographically

examined on 100% of the surface of critical areas as per ANSI B16.34.
Procedure and acceptance criteria shall be as per ANSI B16.34.
b) Where applicable, valve body made by forging and plate components

shall be ultrasonically examined in accordance with procedure and
acceptance standard of Annexure E of ANSI B16.34.
c) The extent of radiography/ ultrasonic examination shall be as follows :
ANSI class 150 - All sizes - Nil
ANSI class 300 - < DN 400mm (16”) - Nil

> DN 450mm (18”) - 100%
ANSI class 600 - All sizes - 100%

CHECK VALVES
5.1.5 All valves shall be tested in compliance with the requirements of applicable
standard (refer clause 2.0).
5.2 Purchaser reserves the right to perform stage-wise inspection and witness tests
as indicated in clause 5.1 above at Manufacturer’s works prior to shipment.
Manufacturer shall give reasonable access and facilities required for inspection to
the Purchaser’s Inspector.
Purchaser reserves the right to require additional testing at any time to confirm
or further investigate a suspected fault. The cost incurred shall be to
Manufacturer’s account.
In no case shall any action of Purchaser or its Inspector relieve the Manufacturer
of his responsibility for material, design, quality or operation of valves.
Inspection and tests performed/ witnessed by the Purchaser’s Inspector shall in

no way relieve the Manufacturer’s obligation to perform the required inspection
and tests.
Manufacturer shall submit the following certificates :
a) Mill test certificates relevant to the chemical analysis and mechanical

properties of the materials used for the valve construction as per the
relevant standards.
b) Hydrostatic test certificates complete with records of timing and pressure

of each test.
c) Test reports of radiograph and ultrasonic inspection, as applicable.
d) All other test reports and certificates as required by applicable standard

and this specification.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only
those valves which have been certified by Purchaser’s Inspector shall be
despatched from Manufacturer’s works.

CHECK VALVES
7.0 PAINTING, MARKING AND SHIPMENT
7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and
applied with sufficient coats of corrosion resistant paint. Surface preparation
shall be carried out by shot blasting to SP-6 in accordance with “Steel Structures
Painting Council – Visual Standard SSPC-VIS-1”.
7.2 All valves shall be marked as per applicable standard. The units of marking shall
be metric except nominal diameter which shall be in inches.
7.3 Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by
a coat of grease or other suitable material. All valves shall be provided with
suitable protectors for flange faces, securely attached to the valves.
7.4 Packaging and shipping instructions shall be as per applicable standard.
7.5 On packages, the following shall be marked legibly with suitable marking ink:
a) Order Number
b) Manufacturer’s Name
c) Valve Size and Rating
d) Tag Number
8.0 SPARES AND ACCESSORIES
8.1 Manufacturer shall recommend and quote separately the spares for valves
required for commissioning and two years of normal operation.
9.0 DOCUMENTATION
9.1 At the time of bidding, Manufacturer shall submit the following documents :
a) General arrangement drawings showing all features together with overall

dimensions and actual valve bore size.
b) Sectional drawing showing major parts with reference numbers and

material specification.

CHECK VALVES
c) Details of corrosion resistant paint proposed to be applied.
d) Reference list of similar supplies of check valves, including project, year,

client, location, size, rating, services, etc. shall be furnished by the
Manufacturer for the last three years. (The valves shall be proven
for service indicated in Valve Data Sheet).
9.2 Within three weeks of placement of order, the Manufacturer shall submit four
copies of, but not limited to, the following drawings, documents and
specifications for Purchaser’s approval.
a) Detailed sectional drawings showing all parts with reference numbers and
material specification.
b) Assembly drawings indicating overall dimensions, features and painting

scheme.
Once the approval has been given by Purchaser, any changes in design, material
and method of manufacture shall be notified to Purchaser whose approval in
writing of all changes shall be obtained before the valve is manufactured.
9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser
one reproducible and six copies of all approved drawings, documents and
specifications as listed in clause 9.2 above.
9.4 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and
six copies of the following :
a) Test certificates as listed in clause 6.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions,

including a list of recommended spares for the valves.
10.0 GUARANTEE
10.1 Manufacturer shall guarantee that the materials and machining of valves and
fittings comply with the requirements in this specification and in the Purchase
Order.

CHECK VALVES
10.2 Manufacturer is bound to replace or repair all valve parts which should result
defective due to inadequate engineering or to the quality of materials and
machining.
10.3 If valve defect or malfunctioning cannot be eliminated, Manufacturer shall

replace the valve without delay,
10.4 Any defect occurring during the period of Guarantee shall be attended to by
making all necessary modifications and repair of defective parts free of charge
to the Purchaser as per the relevant clause of the bid document.
10.5 All expenses shall be to Manufacturer’s account.

MECON LIMITED
DELHI - 110 092
FOR
GLOBE VALVES
D:\old data\FATEH\MP Region\Kailaras\Tender RFQ\Globe Valve\TS - Globe Valve.doc

DELHI DESIGN SECTION
TITLE GLOBE VALVE SPECIFICATION NO. PAGE 1 OF 11
MEC/TS/05/62/005 REVISION 0
CONTENTS
1.0 GENERAL 2
2.0 DOCUMENTATION 3
3.0 DESIGN & CONSTRUCTION 4
4.0 OPERATION 6
5.0 INSPECTION & TESTING 7
6.0 RADIOGRAPHY OF CAST VALVES 8
7.0 IBR CERTIFICATION 9
8.0 QUALITY ASSURANCE PLAN (QAP) 9
9.0 MARKING 10
10.0 DESPATCH 11
GURDEEP SINGH A.K. SARKAR A.K. JOHRI

TITLE GLOBE VALVES SPECIFICATION NO. PAGE 2 OF 11
1.0 GENERAL
1.1 Vendor shall supply valves along with auxiliaries, if any, such as gear operator,
bypasses, drains, etc., specified in the valve specification sheets and this
specification.
1.2 Vendor shall quote in strict accordance with the valve Data / Specification
sheets, technical specification and enclosures to this specification. Deviations
to the Specification / Data sheets, if any, shall be indicated as per clause 2.0.
1.3 All codes and standards for manufacturing, testing, inspection etc., shall be of
latest editions.
1.4 Associated Gas Composition
As per Annexure-I
1.5 Materials
1.5.1 Material for major components of the valves shall be as indicated in Valve Data
Sheet. However, Manufacturer shall confirm that valve trim material is suitable
for Natural Gas with composition/ quality as given in clause 1.4. Other
components shall be as per Manufacturer's standards which will be subject to
approval by Purchaser.
1.5.2 Carbon steel used for the manufacture of valves shall be fully killed.
Carbon equivalent (CE) of valve end connections which are subject to further
field welding , as calculated by the following formula, shall not exceed 0.45 on
check analysis for each heat of steel used.
CE = C + -------- + ---------------------- + ---------------
6 5 15

2.0 DOCUMENTATION
2.1 Vendor shall submit with the offer the following :
2.1.1 Manufacturer’s complete descriptive and illustrative Catalogue/ Literature.
2.1.2 Detailed dimensioned general arrangement and cross-sectional drawings with

Parts/ material lists, weight etc., for valves to manufacturer’s standard.
2.1.3 Drawings for valves with accessories like gear operator, extension bonnet,
extended stems with stands bypass, etc., giving major salient dimensions.
2.1.4 One copy of the valve technical specification and data sheets signed as
“ACCEPTED” by the manufacturer with all deviations marked clearly.
2.1.5 If the valve is regretted or has no deviation, the manufacturer shall write
clearly on valve specification sheets as “REGRET” or “NO DEVIATION”.
2.1.6 If there is any deviation in the specification, the same shall be listed clause
wise. Even clauses which are acceptable shall be categorically confirmed as
“ACCEPTED”.
2.1.7 On failure to submit document as specified in clauses 2.1.1 to 2.1.6 above, the
offer is likely to be rejected.
2.2 Vendor shall submit for approval the drawings mentioned in item no 2.1.2 &
2.1.3 after placement of order and before start of manufacture. No other
drawing shall be submitted for approval.
2.2.1 Test reports shall be supplied for all mandatory tests as per the applicable
code. Test reports shall also be furnished for any supplementary tests as
specified in clause 3.11 to 3.16.
2.2.2 Material test certificates (Physical property, chemical composition & heat
treatment report) of the pressure containing parts shall be furnished for the
valves supplied. Material test certificates for the other parts shall also be
furnished for verification during inspection.

3.1 Valves shall be designed, manufactured, tested, inspected and marked as per
the manufacturing standards design codes and standards (Latest editions)
indicated in the respective valve specification sheets. Any conflict between the
the technical specifiction, specification sheets and referred standard codes shall
be brought to the notice of the purchaser for clarifications, but generally
technical specification, data sheets shall govern. No deviation to specification/
standard shall be permitted through vendor drawings approval. Approval of
drawings shall be valid only for design features.
3.2 Bonnet extension wherever specification the valve sheet to BS : 6364 shall be
for “Non Cold Box Application” unless otherwise specified in the requisition.
Even if not called for in valve sheet, valves indicated as ‘CRYO’ shall be
supplied with bonnet extension.
3.3 For heavy valves provisions shall be available for lifting by way of lugs, eye
bolts and such standard devices.
3.4 All flanged valves shall have flanges integral (except forged valves) with the
valve body. Flange finish shall be as per valve specification sheet.
3.5 For all weld end valves with bevel end as per ANSI B16. 25.
The contour of bevel shall be as follows :
Material Wall Thickness Weld Contour
Carbon steel upto 22 mm figure 2 type A

(Except low temp. > 22 mm figure 3 type A
carbon steel )
Alloy steel, upto 10 mm figure 4
Stainless steel & > 10 mm to 25 mm figure 5 type A
low temp. carbon steel > 25 mm figure 6 type A
3.6 If an overlay weld-deposit is used for the body seat ring and seating surface,
the seat ring base material shall be at least equal to the corrosion resistance of
the material of the shell.

3.7 Valve body/ bonnet shall be forged/ cast as specified. Forging is acceptable in
place of casting but not vice-versa.
3.8 Material of construction of yoke shall be minimum equivalent to body/ bonnet

material.
3.9 Stem shall be forged or machined from forged / rolled bar. No casting is
permitted, .
3.10 Stelliting / hard facing by deposition shall be minimum 1.6 mm. Renewable
seat ring may be seal welded.
3.11 As a pre qualification low temperature carbon steel, (LTCS), 3 ½ Ni steel

(CRYO) & austenitic stainless (CRYO) valves shall be subjected to cryogenic
test as per BS 6364 and test shall be witnessed and certified by third party
inspection agency like Lloyds, B.V., DNV or EIL. For INDIAN vendors,
inspection agency shall be MECON only. The vendor has to submit test
certificate for prototype valves along with the offer. Prototype test carried on a
particular size, rating and design will qualify valves of sizes equal to and below
the particular size of the same rating and design.
Cryogenic testing as per BS 6364 shall be carried out at temperature (-45 °C),
(-100 °C) & (-196 °C ) for “LTCS”, 3 ½ Ni steel (CRYO) & austenitic stainless
steel “CRYO” valves respectively.
3.12 Repair welding procedure for austenitic stainless steel valves in ‘CRYO’ service
shall have to be qualified for impact test as per ANSI B31.3. Minimum
acceptable impact energy shall be 20J or lateral expansion of 0.38 mm at temp
of -196 Deg C
3.13 Wherever impact test of SS studs/ nuts is called for in the data sheet, the
impact value shall be 27J at the intended service temperature specified in the
data sheets.
3.14 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall
have to be conducted as per following :
- ASTM A 262 practice “B” with acceptance criteria of “60 Mills/ Year (Max.)” –
For all materials forged, rolled, wrought and casting.

OR
- ASTM A 262 practice “E” with acceptance criteria of “No cracks as observed
form 20X magnification” – For all materials other than castings. “Microscopic
structure to be observed form 250X magnification” in addition.
3.15 When specifically asked for in MR for high temperature application of some
grades of austenitic stainless steel (eg. SS309, 310, 316, 316H etc.) ASTM A
262 practice “C” with acceptance criteria of “15 Mils/ Year – (Max.)” shall have
to be conducted.
3.16 For the IGC test as described in 3.14 & 3.15 two sets of samples shall be
drawn from each solution annealing lot, one set corresponding to highest
carbon content and other set corresponding to highest pressure rating
3.17 Spiral wound bonnet gasket are to be provided with inner/ outer ring except
when encapsulated gaskets type body- bonnet joints are employed. Outer ring
may be avoided in case of Non- circular spiral wound gasket used in 150#
valve provided the outermost layer of spiral touches the bolts ascertaining the
centering.
4.0 OPERATION
4.1 Generally the valves are hand wheel of lever operated. Gear operation shall be
provided as under :
Class Size Requiring

Gear Operator
900 # 6” and Larger

For sizes lower than these ranges, hand wheel shall be provided.
4.2 Gear operator shall be totally enclosed bevel gear in grease case with grease
nipples/ plugs with position indicators for open / close position.

4.3 Where gear operator is not called for as per clause 4.1 but vendor
recommends a gear operator, he shall highlight such case/s and quote
separate prices for the valve and gear operator.
4.4 Gear operator shall be so designed to operate effectively with the differential
pressure across the closed vale equal to the cold non-shock pressure rating.
4.5 Hand wheel diameter shall not exceed 750 mm and lever length shall not
exceed 500 mm. on both sides. Effort to operate shall not exceed 35 kgs at
hand wheel periphery. However failing to meet the above requirements vendor
shall offer gear operated valve and quote as per clause 4.3.
5.0 INSPECTION AND TESTING
5.1 Every valve shall be subjected to all the mandatory tests and checks called in
the respective codes/ data sheet.
5.2 Every valve, its components and auxiliaries be subjected to all the mandatory
tests and checks called in the respective codes, data sheets etc. by the
manufacturer.
5.3 Though the extent of inspection by purchaser or his authorised representative

shall be as under, however exact extent with hold points shall be decided by
MECON and recorded in the form of inspection plan.
FORGED VALVES :
1) Visual and dimensional inspection.
2) Review of material test certificates.
3) Any mandatory or supplementary test.
4) Hydrostatic test on 10% valves selected on random basis.
5) Strip check as applicable for valves

CAST STEEL VALVES :
1) Visual and dimensional inspection.

2) Review of material test certificates.
3) Review of radiographs/ radiographic reports of any other NDT
tests wherever applicable as per data sheet.
4) Any mandatory or supplementary test.
5) Hydrostatic test. 100% for body, 10% other test.
6) Strip check as applicable for valves.
5.4 In case of motor operated or actuator operated valves, functional/operational

checks as per the requirements of the specifications shall be made on each
valve.
6.0 RADIOGRAPHY OF CAST VALVES
6.1 Valves under critical, very highly critical, lethal and toxic services shall be
radiographed as specified in respective data sheets When specifically not
mentioned in individual data sheet, valve casting shall undergo radiographic
examination as specified hereunder :
...........................................................................................................
Material Rating Size Range Radiography
...........................................................................................................
All 150 # 24” And Below Nil
150 # 26” And Above 100%
300 # 16” And Below Nil
300 # 18” And Above 100%
600 # All Sizes 100%
& Above
...........................................................................................................
6.2 Radiography procedure, areas of casting to be radiographed shall be a per ANSI

B-16.34 and acceptance criteria shall be as per ANSI B-16.34 Annexure-B.
However for areas of casting to be radio-graphed for types of valve not covered
in ANSI B-16.34, vendor shall enclose details of areas to be radiographed in line
with ANSI B-16.34.
6.3 Random radiography wherever specified in individual data sheets, the sampling
shall be per size of the quantity ordered for each foundry.

6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be
done by X-Ray/ Gamma-Ray to get the required sensitivity.
6.5 Over and above the stipulation laid down in clauses 6.1, 6.2, 6.3 & 6.4, all valve
castings shall only be procured among the foundries after obtaining approval
from Client / Consultant.
7.0 IBR CERTIFICATION
7.1 For valves described “IBR” valves shall be in accordance with the latest IBR
(Indian Boiler Regulation) including the requirements specified in the
specification.
7.2 SW/ BW end carbon steel valves under IBR< the chemical composition shall
conform to the following :
Carbon (Max) : 0.25%

Others (S,P, Mn) : As per IBR regulations
7.3 For valves described “IBR” test certificate in form III-C shall be furnished,
signed by IBR inspection authority or an approved representative.
7.4 All “IBR” valves shall be painted red in body-bonnet/ body cover joint.
8.0 QUALITY ASSURANCE PLAN (QAP)
8.1 Procurement of Bought out Materials
All critical materials such as casting, forging, pressure holding parts, electrical
and instrument accessories, etc. shall be purchased by the Vendor from GAIL/
MECON approved suppliers meeting Qualification Criteria stipulated if any.
Vendor shall submit a list of bought out materials and sub-vendors for these
bought out materials for MECON approval within 2 weeks from Telefax/ Letter
of Intent.
8.2 Calibration Records
Vendor shall use only calibrated measuring and test instruments and maintain
calibration records. Vendor shall furnish records of calibration of measuring and
test instruments including re calibration records to concerned Inspection
Authority.

8.3 Quality Records
Vendor shall maintain quality records as per approved procedures. Inspection

Reports & Test Record. Copies shall be furnished to Inspection Authority.
8.4 Final Documentation
8.4.1 Final drawings/ documents consisting of technical data manual/ mechanical

catalogue is a compilation of “as built” certified, drawings and data,
manufacturing and test records, installation, operating and maintenance
instructions. For drawings where Purchaser’s approval is required, the final
certified drawings shall be included. Final documents shall be legible
photocopies in A4, A3 or A2 size only. The purchase requisition shall also form
a part of the final documentation.
8.4.2 Final documentation shall be bound in Hard board folder(s) of size 265 mm x
315 mm (10½” x 12½”) and shall not be more than 90 mm thickness.
9.0 MARKING
9.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-
SP-25 or the standard referred in specification sheet as applicable. Vendors
name, valve rating, material designation, nominal size, direction of flow (if any)
etc. shall be integral on the body.
9.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no,
securely attached on the valve body.
9.3 Paint or Ink for marking shall not contain any harmful metal or metal salts
such as zinc, lead or copper which causes corrosive attack on heating.
9.4 Carbon steel valves shall be painted with coats of red oxide zinc chromate
primer or single coat of aluminum paint. Forged valves supplied chemically
blackened (phosphated) is also acceptable.
9.5 All alloy steel high temp valves shall be painted with heat resistant silicone
paint suitable for intended temperature.

9.6 All 3 ½ Ni Steel / LTCS valves shall be painted with one coat of inorganic zinc
silicate coating.
10.0 DESPATCH
10.1 Valves shall be dry, clean and free from moisture, dirt and loose foreign
materials of any kind.
10.2 Valves shall be protected from rust, corrosion and any mechanical damage
during transportation, shipment and storage.
10.3 Rust preventive on machined surfaces to be welded shall be easily removable

with a petroleum solvent or not harmful to welding.
10.4 Each end of valves shall be protected with the following materials :
Flange face : Wood, Metal or Plastic cover

Bevelled end : Wood, Metal or Plastic cover
SW & Scrd. End : Plastic cap
10.5 End protectors to be used on flange faces shall be attached by at least three
bolts or wiring through bolt holes and shall not be smaller than the outside
diameter of the flange. However plastic caps for SW & SCRD. End valves shall
be press fit type.
10.6 End protectors to be used on beveled end shall be securely and tightly
attached.
10.7 For special service valves additional requirement of despatch shall be

prescribed in data sheet.

SPECIFICATION
FOR
SCRAPPER TRAP
SPECIFICATION NO. : MEC/S/05/62/007, Rev-1
MECON LIMITED
DELHI - 110 092
D:\Technical Specifications & Standards\007 - Scrapper Trap - TS.doc

MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF RANCHI DESIGN SECTION SCRAPPER TRAP
NEW DELHI
CONTENTS
Sl.No. Description
1.0 SCOPE
3.0 MATERIALS
8.0 GUARANTEE
9.0 SPARES
10.0 DOCUMENTATION

NEW DELHI
1.0 SCOPE
This specification covers the basic requirements for design, manufacture, inspection,
testing & supply of scrapper launching & receiving traps to be installed in pipeline
system transporting non-sour hydrocarbons in liquid or gaseous phase including
Liquefied Petroleum Gas (LPG). This specification does not cover scraper launching &
receiving trap for sour hydrocarbons (liquid/ gas) services as defined in NACE Std. MR-
01-75.
2.1 Reference has also been made in this specification to the latest edition of the following
codes, standards and specifications :
a) ASME B 31.4 : Pipeline Transportation System for Liquid

Hydrocarbons and Other Liquids
b) ASME B 31.8 : Gas Transmission and Distribution Piping System
c) ASME B 16.5 : Steel Pipe Flanges and Flanges Fittings
d) ASME B16.9 : Factory made Wrought Steel Butt Welding Fittings
e) ASME B 16.11 : Forged Steel Fittings, Socket-Welding and

Threaded
f) ASME B 16.25 : Butt-Welding Ends
g) ASTM A370 : Mechanical testing of steel products
h) ASME Sec-VIII and IX : Boiler and Pressure Vessels Codes.
i) API 1104 : Specification for Welding Pipeline and

Related Facilities
j) MSS-SP-44 : Specification for High Test Wrought Welding

Fittings.
k) MSS-SP-75 : Specification for High Test Wrought Welding

Fittings
l) MSS-SP-97 : Integrally Reinforced Forged Branch Outlet Fittings

Socket Welding Threaded and Butt Welding Ends

NEW DELHI
m) SSPC-VIS-1 : Steel Structure Painting Council
In case of conflict between the requirements of this specification and the requirements
of above referred documents, the requirements of this specification shall govern.
3.0 MATERIALS
3.1 Materials and thicknesses of main components used in manufacture of traps shall be
indicated by Manufacturer and shall be suitable for service conditions indicated in the
data sheets and annexures. These shall be subject to approval by purchaser. The steel
used shall have a minimum SMYS of 35,000 psi.
3.2 Fully killed carbon steel shall be used.
3.3 Material of the ends to be field welded by purchaser shall have carbon equivalent less
than or equal to 0.45 based on check analysis, for each heat of steel, calculated
according to the following formula.
CE = C + -------- + --------------------- + ---------------
6 5 15
3.4 For Scraper Traps, specified to be used for Gas service or High Vapour Pressure (HVP)
liquid service, Charpy V-notch test shall be conducted at 0°C for each heat of steel used
in the manufacture of pressure containing parts of the traps. Test procedure shall
conform to ASTM A-370. The Charpy V-notch test specimens shall be taken in the
direction of principal grain flow and notched perpendicular to the original surface of the
plate or forging. The minimum average absorbed impact energy values of three full sized
specimens shall be as under, unless otherwise indicated in the Data sheets :-
Diameter Base Metal Weld Metal and HAZ

(inches) (Joules) (Joules)
For all size 27 27
The minimum impact energy value of any one specimen of the three specimens
analysed as above, shall not be less than 80% of the above mentioned average values.
For scrapper Traps, specified to be used for other hydrocarbon service, the Charpy V-
notch test requirements as stated above are not applicable.

NEW DELHI
3.5 For Scraper Traps, specified to be used for Gas service or High Vapour Pressure (HVP)
liquid service, hardness test shall be carried out as per ASTM A370 for each heat of steel
used. A full thickness cross section shall be taken for this purpose and the maximum
hardness of the base material, weld metal and heat affected zone (HAZ) of all the
pressure containing parts shall not exceed 248 HV10. The maximum difference in
hardness of Base metal, Weld metal and Heat affected zone (HAZ) of pressure
containing parts of the traps shall be less than 80 points Vicker’s HV10.
For scrapper Traps, specified to be used for other hydrocarbon service, the hardness test
requirements as stated above are not applicable.
4.1 The cylindrical portion of the trap shall be designed as per design code and design factor
indicated in the data sheets. Quick end closure shall be designed as per sec. ASME Sec.
VIII, Div. 1 for design conditions indicated in data sheets. A corrosion allowance of 3
mm shall be considered in design of the traps. Quality of welding shall be such that weld
efficiency factor of 1.0 is achieved.
4.2 The trap shall be capable of handling instrumented pigs, model like Linalog 360 of AMF
Tuboscope or British gas magnetic inspection vehicle or equivalent and scraper pigs as
specified in scraper Trap data sheet.
4.3 The trap body and neck, diameter has been indicated in the data sheet. Trap length to
suit the purpose and thickness to meet the class rating shall be suggested by the
manufacturer and approved by the purchaser. Circumferential weld on scraper tarp
body and neck shall not be permitted.
4.4 Concentric or eccentric reducer, as indicated in data sheets, used in the manufacture of
traps shall conform to MSS-SP-75.
4.5 Vents and drains shall be provided on each trap. The trap shall be provided with a
suitable slope and the drain location shall be such that complete drainage of the trap is
possible. Sizes for vent and drain shall be as indicated in data sheet.
4.6 All branch connections shall be made by weldolets/ nippolet or by extrusions as indicated
in the data sheet. All weldolets shall confirm to MSS-SP-97 and nippolets shall be
manufacturer’s standard. The extruded opening shall be adequately heat treated and
stress relieved.
4.7 End connections of traps shall be flanged or butt welded as indicated in data sheet.
a) Flanged ends, if specified shall have dimension as per ASME B16.5 for sizes upto
24" NB (excluding 22 NB) and as per ASME B16.47 / MSS-SP-44 for sizes 22 NB
and 26 NB and above. Flanges shall be as indicated in data sheets.

NEW DELHI
b) Butt weld ends if specified shall have ends prepared as per ASME B16.25.
However, end preparation for butt welding ends having unequal thicknesses with
respect, to connecting pipe shall be as per ASME B31.4/ ASME B31.8 as
applicable.
c) The location & orientation of all nozzle connections shall be submitted for
purchaser's approval before manufacturing.
4.8 The quick opening end closure shall be of clamp ring or band lock type or equivalent
design. The closure shall also consist of a safety relief system allowing the opening only
when there is no pressure in the trap. Screwed type or plug-in type of end closures are
not acceptable. End closure shall be hand operated and operable by one operator. End
closures of size 24" and above shall be fitted with worm gear operator for the opening of
the closure.
Hinge of the closure shall be so designed that the weight of the end closure is fully
supported with out sagging.
4.9 Receiving traps shall be provided with a pig indicator in the middle of the neck and the
indicator shall conform to the specification issued for the purpose. Pig indicator shall be
suitable for bi-directional operation and shall have visual flag and manual reset. The
same shall also have provision for remote indication. REFER SPECIFICATION No.
MEC/S/05/62/48 and Pig Signaller Data Sheet.
4.10 Suitable handling system for inserting and retracting the scraper and instrumented pigs
from the trap shall be provided with each trap. Handling system shall consist of a
fabricated structural steel framework comprising a bench fitted with a purpose-designed
cradle for the pig. A pusher/ puller mechanism operated by a cable system employing a
hand cranked winch shall be mounted on the bench framework for inserting/ retracting
the pig from the trap. The bench frame should be suitable for bolting to the floor. All
parts of the handling system in contact with each other shall be of the anti spark type.
4.11 Fabricated steel supports, minimum two numbers at suitable spacing shall be provided
with traps for mounting on concrete blocks. These supports will not be subjected to
pipeline achorage forces. The material of support shall be compatible with trap material
for welding purposes. All welds shall be examined by magnetic particle method.
4.12 Completed assembly shall be stress relieved as per the provisions of the design codes.
4.13 All welds shall be made by welders and welding procedures qualified in accordance with
the provisions of ASME Sec. IX. The procedure qualification shall include impact test and
hardness test when required as per clause 3.4 & 3.5 of this specification and shall meet
the requirements as specified therein.

NEW DELHI
4.14 Repair by welding on parent metal is not allowed. Repair of welds shall be carried out
only after specific approval by purchaser's representative for each repair. The repair
welding shall be carried out by the welders and welding procedures duly qualified as per
ASME Section IX and records for each repair shall be maintained. The repair welding
procedure qualification shall include impact test and hardness test when required as per
clause 3.4 & 3.5 of this specification and shall meet the requirements as specified
therein.
4.15 The traps shall be equipped with a half internal removable filtering basket consisting of a
punched plate with a least five rows of drain holes.
4.16 The filtering basket shall slide on guides on wheels and in all cases the material of the
parts being in contact with each other shall be of the anti spark type.
4.17 The tolerance on internal diameter and out of roundness at the ends for the welding
end of the neck (at the end where connecting pipeline will be welded) shall be as per
applicable connected pipe specification as indicated in the data sheet.
5.1 The manufacturer shall perform all inspections and test as per the requirements of this
specification and the relevant codes prior to shipment at his works. Such inspections and
tests shall be, but not limited to the following :-
5.1.1 All trap shall be visually inspected.
5.1.2 Chemical composition and mechanical properties including hardness shall be checked for
each heat of steel used.
5.1.3 Dimensional check shall be carried out as per the approved drawings.
5.1.4 Hydrostatic test shall be conducted for all scraper traps complete in all respects including
mounting of pig indicators at a pressure equal to 1.5 times the design pressure. The test
pressure shall be held for a minimum period of one hour.
5.1.5 All butt welds shall be 100% radiographically inspected. Procedure and acceptance
criteria shall be as per API 1104.
5.1.6 Ultrasonic or magnetic particle inspection shall be carried out on all welds which in
Purchaser's Representative's opinion can not be radiographically inspected. Procedure
and acceptance criteria shall be as per ASME Sec. VIII, Appendix-U and VI respectively.

NEW DELHI
5.1.7 All finished wrought weld shall be 100% ultrasonically inspected for lamination type
defects for a distance of 50mm from the end. Any lamination larger than 6.35 mm shall
not be acceptable.
5.1.8 All forgings shall be wet magnetic particle examined on 100% of the forged surfaces.
Method and acceptance shall comply with MSS-SP-53.
5.1.9 A minimum of two closing and opening cycles shall be performed and correct operation
of both quick opening closure and safety system shall be ascertained.
5.2 Purchaser's Representative reserves the right to perform stage wise inspection and
witness tests including hydrostatic test, as indicated in specification at manufacturer’s
works prior to shipment. Manufacturer shall give reasonable notice of time & shall
provide without charge reasonable access and facilities required for inspection, to the
purchaser's representative.
Inspection and tests performed / witnessed by Purchaser's Representative shall in no

way relieve the Manufacturer's obligation of specific integrity of the scraper traps.
Manufacturer's equipment shall be subject to examination and approval by purchaser to

ensure proper fabrication and testing of traps.
Manufacturer shall furnish the following certificates
a) Test certificates relevant to the chemical and Mechanical properties including

Hardness of the materials used for manufacture of trap as per relevant standards
and this specification.
b) Hydrostatic test certificates.
c) Test reports on radiography, ultrasonic inspection and magnetic particle

examination.
d) Test reports on heat treatment carried out, if any.
The certificate shall be considered valid only when signed by purchaser’s representative.

NEW DELHI
7.1 After all inspection and test required have been carried out, all external surfaces shall be
thoroughly cleaned to remove grease, dust and rust. Surface preparation shall be carried
out by shot blasting to SP-6 in accordance with "Steel Structures Painting Council Visual
Standard - SSPC-VIS-1". Machined parts shall be coated with anti-rust removable paint
and non machined parts shall be applied with two coats of protective paint.
Manufactures shall indicate the type of paint used in the drawings submitted for
approval.
7.2 Marking shall be done on a stainless steel plate and affixed to the body by means of
corrosion resistant fasteners. Marking shall include the following :-
a) Manufacturer's Name
b) Trap/ Neck Diameter, Thickness
c) Material
d) ASME Class Rating
e) Tag Number
f) Design Pressure
g) Design Temperature
h) Test Pressure
i) Design Factor
j) Year of Manufacture
k) Empty weight of the trap assembly.
7.3 Before shipment, traps shall be properly packed against damage during
transportation. All machined surface subject to corrosion during transit shall be well
protected by coat of grease or other suitable material. All traps shall be provided with
suitable protectors, for flange faces, securely attached to the traps. Bevel ends shall
be protected with metallic or high impact plastic bevel protectors.
7.4 Only those traps, which have been inspected and certified by the purchaser’s
inspector shall be supplied.
8.0 GUARANTEE
8.1 Manufacturer shall guarantee that the trap alongwith accessories is in compliance with
the requirements of this specification for materials and workmanship. Manufacturer shall
replace or repair all parts which should result defective due to inadequate design or the
workmanship. In case the defect can not be eliminated, Manufacturer shall replace the
trap without any delay. Any defect occurring within the time period specified elsewhere
shall be repaired making all necessary modifications and repair of defective parts free of
charge to the purchaser.

NEW DELHI
9.0 SPARES
9.1 Manufacturer shall furnish list of recommended spares and accessories for Scrapper
Traps required during start up and commissioning. As a minimum, the commissioning
spares shall include 200% extra consumable spares viz. gaskets/ o-rings/ seals etc. for
each trap. Cost of such spares shall be included by the Manufacturer in the item rates
indicated in Purchase Requisition.
9.2 Manufacturer shall furnish separately a list of recommended spares and accessories
required for two years of normal operation and maintenance of Scraper Traps.
10.0 DOCUMENTATION
10.1 Manufacturer shall furnish at the time of bidding, the following documents:-
a) General arrangement drawing of scraper trap, pig signallers, quick opening end
closure with overall dimensions.
b) Clause wise list of deviations from this specification, if any listed at one place in
the document.
c) Reference list of similar supplies for the past five years including project, client
year of supply & contact person.
d) Quality Assurance Plan (QAP) enclosed with this tender duly signed, stamped
and accepted.
10.2 Within two weeks of placement of order, the manufacturer shall submit four copies of,
but not limited to, the following drawings, documents and specifications for approval.
a) Calculations according to the relevant codes for the body including branch
connections and quick end closures.
b) Trap assembly and sectional drawings showing all parts with materials and
dimensions.
c) Support Assembly Drawing.
d) Arrangement & details of foundation bolts for pig handling and lifting system,
where applicable.
e) Welding procedure and method of manufacture.

NEW DELHI
Once the above said documents have been approved by the Purchaser, any changes in
design, material and method of manufacturer shall be notified to the Purchaser, whose
approval in writing of all changes shall be obtained before the traps are manufactured.
10.3 Within four weeks from the approval date Manufacturer shall submit one reproducible
and six copies of all approved drawings, documents and specification as listed in clause
10.2 of this specification.
10.4 Prior to shipment, the manufacturer shall submit one reproducible and six copies of the
following :
a) Test certificate as listed in clause 6.0 of this specification.
b) Manual for installation, erection instructions, maintenance and operations

instruction.
10.5 All documents shall be in English Language.

SPECIFICATION
FOR
INSULATING JOINTS
MECON LIMITED
DELHI - 110 092
D:\TS\Insulating Joints - 09 - TS.doc

REGD. OFF RANCHI DESIGN SECTION INSULATING JOINTS
NEW DELHI
CONTENTS
Sl.No. Description
1.0 SCOPE
3.0 MATERIALS
4.0 DESIGN & CONSTRUCTION REQUIREMENTS
8.0 GUARANTEE
9.0 DOCUMENTATION

NEW DELHI
1.0 SCOPE
This specification cover the basic requirements for design manufacture, testing
and supply of carbon steel insulating joints to be installed in onshore pipeline
systems handling hydrocarbons in liquid or gaseous phase including Liquified
Petroleum Gas (LPG).
2.1 Reference has been made in this specification to the latest edition of, the
following Codes, Standards and Specifications.
a) ASME B 31.8 Gas Transmission & Distribution piping

System
b) ASME B 31.4 Liquid transportation systems for

hydrocarbons, LPG, Anhydrous Ammonia and
Alcohols
c) ASTM A 370 Mechanical testing of Steel Product
d) ANSI B 16.25 Butt Welding Ends
e) ASME Section Boiler & pressure Vessel Code viii & ix
f) API 1104 Standard for welding pipelines and Related

facilities.
g) SSPC-VIS-1 Steel Structures painting Council Visual

Standard.
h) MSS-SP-53 Quality standard for steel castings and

forgings for valves flanges and fittings and
other piping components - magnetic particle
examination method.
i) MSS-SP-75 Specification for high test wrought welding

fittings.

NEW DELHI
j) NACE RP 0286 The electrical isolation of cathodically

protected pipelines.
2.2 In case of conflict between the requirements of this specification and any code,
Standard or Specification referred to in this Specification, the requirements of
this specification shall govern.
3.0 MATERIALS
3.1 Material for the pressure containing parts of the insulating joints shall be as
indicated in the data sheets. Material for pups shall be equivalent or superior to
the material of connecting pipeline which is indicated in the data sheets. Other
part shall be as per manufacturer's standard suitable for the service condition
indicated in Insulating Joint Data Sheets and shall be subject to approval by
purchaser.
3.2 Insulating joints which are subject to field welding by purchaser, shall have
carbon equivalent (CE) not exceeding 0.45 based on check analysis for each heat
of steel calculated according to the following formula :
CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15
3.3 When specified in the IJ Data Sheet, charpy V-notch test shall be conducted on
each heat of base material, weld metal and heat affected zone of all pressure
containing parts such as body, welding ends in accordance with the impact test
provisions of ASTM A 370 at a temperature of 0° C. The charpy impact test
specimens shall be taken in the direction of principal grain flow and notched
perpendicular to the original surface of the plate of forging. Average impact
energy value of three full sized specimens shall be 27 joules. Minimum impact
energy value of any one specimen shall not be less than 80% of the average
impact energy specified. No specimen shall exhibit less than 80% shear area.
3.4 Carbon steel used for the manufacture shall be fully killed
3.5 When specified in data sheet, hardness test shall be carried out as per ASTM
A370 for each heat of steel used. The maximum hardness of base metal, weld
metal and heat affected zone of all pressure parts shall be 248 HV10, unless
specified otherwise.

NEW DELHI
3.6 Insulation material shall be minimum 20 mm thick and shall comply section 5,
NACE RP 0286.
4.0 DESIGN & CONSTRUCTION REQUIREMENTS
4.1 Mechanical
4.1.1 Insulating joints shall be of integral type fabricated by welding and with pups on
either side as shown in data sheet. A corrosion allowance as indicated in data
sheet shall be considered in design. Bolted and threaded joints are not
acceptable.
4.1.2 All materials used for the manufacture of the insulating joint shall be in
accordance with clause 3.0 of this Specification.
4.1.3 Insulating joints shall be designed using the design principles of ASME Section-
VIII Div. 1. The design shall be checked for the following two cases :
Case-I : Design Pressure (as per Data Sheet) + Axial Force (F)
The Axial force shall be calculated as under :
F = 0.1 x S x A
Where
S = SMYS of connected pipe (refer Data Sheet)

A = Metal cross-sectional area of connected pipe.
The allowable stress in this case shall be less than or equal to 0.5 x SMYS of
insulating joint material.
Case-II : Hydrostatic Test Pressure
The allowable stress in this case shall be less than or equal to 90% of SMYS of
insulating joint material.
All design parameters shall be as per Insulating Joint Data Sheet. Detailed
calculations shall be submitted for Purchaser approval.

NEW DELHI
4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to
1 millibar.
4.1.5 The joint between pipe pup pieces and main forging shall be full penetration butt
weld type. Weld design shall be such as resulting in a weld joint factor of 1.0.
4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparation
for butt welding ends having unequal thickness with respect to connecting pipe,
shall be as per ASME B31.4/ B31.8 as applicable.
4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW
pipes, shall be removed for a distance of at least 50mm from each end.
4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. The
internal bore shall be same as that of connecting pipe including its tolerances.
4.1.9 The insulating joint shall be formed by sandwiching and locking in positions the
insulating material in a bell and spigot type of joint. The joint shall be assembled
in such a way that its various components are firmly locked in position and the
completed joint is capable of withstanding stresses due to designed operating
conditions and field hydrostatic testing.
4.1.10 Insulating joints shall be suitable for aboveground or underground installations

as indicated in the data sheets.
4.1.11 All welds shall be made by welders and welding procedures qualified in
accordance with the provisions ASME section IX. The procedure qualification
shall include impact test and hardness test and shall meet the requirements of
clause 3.3, 3.5 of this specification.
4.1.12 Repair welding on parent metal is not allowed. Repair of welds shall be carried
out only after specific approval by purchaser's representative for each repair.
The repair welding shall be carried out by welders and welding procedures duly
qualified as per ASME section IX and records for each repair shall be maintained.
4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm from
the nominal internal diameter.

NEW DELHI
4.1.14 Out of roundness measured at the root face of the welding ends shall not be
more than 0.5% of the specified inside diameter.
4.2 Electrical
4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kilo
Volts.
4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either side
of the insulating joint for connecting 10 mm2 and 50 mm2 cables for
measurement/ shorting purposes. Cleats shall be attached to the insulating joint
by welding.
5.1 The manufacture, shall perform all inspection and tests as per the requirements
of this specification and the relevant codes, prior to shipment at his works. Such
inspection and tests shall be, but not limited to the following:
5.1.1 All insulating joints shall be visually inspected.
5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings.
5.1.3 Chemical composition and mechanical properties including hardness shall be

checked as per relevant material standards and this specification, for each heat
of steel used.
5.1.4 Non-destructive inspection of insulating joints shall be carried out as given

below:
a) 100% radiography shall be carried out on all butt & repair welds of
pressure containing parts. Acceptance limits shall be as per API 1104.
Welds which in purchaser's Representative opinion can not be inspected

by radiographic methods,shall be checked by ultrasonic or magnetic
particle methods. Acceptance criteria shall be as per ASME Section VIII
Appendix-12 and Appendix-6 respectively.

NEW DELHI
b) All finished weld ends shall be 100% ultrasonically tested for lamination
type defects for a distance of 5Omm from the ends. Any lamination
larger than 6.35 mm shall not be acceptable.
c) All forgings shall be wet magnetic particle inspected on 100% of forged

surfaces. Method and acceptance shall comply MSS-SP-53.
d) All fillet weld of thickness < 6mm shall be examined 100% by magnetic
particle inspection and ≥ 6mm shall be examined 100% by UT.
Accetpance criteria for MPI & UT shall be as per ASME Sec.VIII Appendix-
6 & Appendix-12 respectively.
5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data

sheet. The test duration shall be of 15 minutes.
5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for
10 minutes. The tightness shall be checked by immersion or with a frothing
agent. No leakage will be accepted.
5.1.7 Dielectric Test
a) Insulation resistance of each insulating joint shall be atleast 25 mega-

ohms when checked with 500-1000 V DC.
b) Insulating joint before and after the hydrostatic test, shall be tested for
dielectric integrity for one minute at 5000 V A.C., 50 cycles and the
leakage current before and after hydrostatic test shall be equal. Testing
time voltage and leakage shall be recorded and certified. No repair shall
be permitted to the insulating joints failed in the above mentioned tests.
5.2 Purchaser reserves the right to perform stagewise inspection and witness test as
indicated in Para 5.1 at Manufacturer's works prior to shipment. Manufacturer
shall give reasonable notice of time and shall provide without charge reasonable
access and facilities required for inspection to the purchaser's Representative .
Inspection and tests performed/witnessed by the Purchaser's Representative

shall in no way relieve the Manufacturer's obligation to perform the required
inspection and test.

NEW DELHI
6.1 Manufacturer shall submit following certificates to Purchaser's Representative.
a) Test certificates relevant to the chemical analysis and mechanical

properties including hardness of the materials used for construction of
insulating joint as per this specification and relevant standards.
b) Test reports on non-destructive testing.
c) Test certificates for hydrostatic and air tests.
d) Test certificate for electrical test.
e) Test report on vacuum test.
7.0 PAINTING, MARKING AND SHIPMENT.
7.1 Insulating joint surface shall be thoroughly cleaned, freed from rust and grease
and applied with sufficient coats of corrosion resistant paint. Surface preparation
shall be carried out by shot blasting to SP-6 in accordance with "steel structures
painting council - Visual standard SSPC-VIS-l.". External surfaces of burried
insulating joints shall be painted with three coats of suitable coal tar epoxy resin
with a minimum dry film thickness of 300 microns.
Manufacturer shall indicate the type of corrosion resistant paint used, in the
drawings submitted for approval.
7.2 Insulating joints shall be marked with indelible paint with the following data:-
a. Manufacturer's name
b. Suitable for inch nominal diameter pipeline
c. End thickness in mm
d. Material
e. Design Pressure/ Hydrostatic Test Pressure

NEW DELHI
f. ANSI Class Rating

g. Tag No.
h. Year of Manufacture
7.3 Insulating joints shall be suitably protected to avoid any damage during transit.
Metallic bevel protectors shall be provided to weld ends.
7.4 Only those insulating joints which have been inspected and certified by
Purchaser shall be shipped.
8.0 GUARANTEE
8.1 The manufacturer shall guarantee that the materials used comply with the
requirements of this specification.
8.2 Manufacturer shall replace or repair insulating joints found defective due to
inadequate engineering or quality of material.
8.3 Manufacturer shall replace the insulating joint without delay if the defect or
malfunctioning can not be eliminated.
8.4 Any defects occurring within 12 months from the date of installation or within 30
months from the date of despatch, whichever is earlier, shall be repaired making
all necessary modifications and repair of defective parts free of charge to the
purchaser.
9.0 DOCUMENTATION
9.1 All documents shall be in English Language.
9.2 At the time of bidding, Bidder shall submit the following documents:-
a) General arrangement drawing along with cross sectional view, overall

dimensions and details of insulating meterials recommended.
b) Reference lists of previous supplies of insulating joint of similar

specification.

NEW DELHI
c) Clausewise list of deviation from this specification, if any.
9.3 Within three weeks of placement of order, the Manufacturer shall submit four
copies of but not limited to the following drawings, documents and specifications
for approval.
a) Fabrication drawings and relevant calculations for pressure containing

parts.
b) Welding procedure and method of manufacture for all phases of

manufacture.
c) Quality Assurance Plan (QAP)
Once the approval has been given by purchaser any changes in design, material
and method of manufacture shall be notified to the Purchaser whose approval in
writing of all changes shall be obtained before the insulting joint are
manufactured.
9.4 Within four weeks from the approval date Manufacturer shall submit one
reproducible and six copies of the approved drawings, documents and
specifications as listed in 9.3 of this specification.
9.5 Prior to shipment, the manufacturer shall submit one reproducible and six copies
of the test certificates as listed in Clause 6.0 of this specification.

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SPECIFICATIONS

SPECIFICATION NO. MEC/S/05/62/074

(PROCESS & PIPELINE DESIGN SECTION)

Sl.No. Description Page No.

2.0 REFERENCE DOCUMENTS 01 - 02

3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL 02 - 07

4.0 APPLICATION PROCEDURE 08 - 11

7.0 REPAIR OF FIELD JOINT COATING 13 - 13

8.0 REPAIR OF PIPE COATING DEFECTS 14 - 14

PREPARED BY CHECKED BY APPROVED BY

This specification covers the minimum requirement for application of anti-

1.2 Manpower, Material & Equipment

2.0 REFERENCE DOCUMENTS

a) DIN – 30672 : Corrosion protection tapes and Heat Shrinkable

c) SSPC – SP1 : Steel structure painting council – Solvent Cleaning.

3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL

This scope covers the minimum requirement of materials, equipment

3.1.1 Each Joint Coating System shall consist of :

a) A wraparound heat shrinkable sleeve reinforced with fibre-glass.

b) A solvent-free, two component liquid epoxy primer

c) A specifically designed wear cone

3.1.2 Sleeve Backing

The heat shrinkable sleeves shall be manufactured from minimum 1.0 mm

The inner surface of the sleeves shall be coated with a controlled

3.1.4 Epoxy Primer

3.2 Properties of Field Joint Coating Material

3.2.1 Heat-Shrinkable Sleeve Material

Property Test Condition Requirement

NaCl @ 23°C, 0.1N H2 SO4 @

23°C, 0.1 N NaOH @ 23°C,

Followed by test for ISO 3303 23°C

3.2.2 Adhesive material

Property Test Condition Requirement

Peel Strength DIN 30672 23°C. CHS* 200 N/cm minimum

Shear strength ISO 4587 23°C. CHS* 200 N/cm2 minimum

3.2.3 Primer Material

Property Test Method Condition Requirement

Density ASTM D1084 23 +/- 0.50 C Part A: 60+/- 30 Pas

Mixing ratio By weight 23°C 100:40

* CHS = Cross Head Speed

3.2.4 Functional Properties

3.3 Test Methods

3.3.1 Resistance to split propagation (Test Method -1)

The assembly shall be placed in an air-circulating oven present at 1700C.

3.3.2 Resistance to circumferential edge loading (Test method -2)

The sleeve shall be installed on a DN 200 three -layer PE coated steel

A chisel as depicted in Figure -1 shall be positioned against the front

3.4.1 Prior to procurement of coating materials, Contractor shall furnish the

a. Complete descriptive technical catalogs describing the materials

b. Reference list of previous supplies, in last 5 years, of the similar

- Material Qualification Certificate Number

- Date of Manufacturing and date of expiry

3.4.3 Prior to shipment of materials from the Manufacturer’s Works. Contractor

a. Test certificate/results as per Manufacturer’s Quality Control

3.4.4 All documents shall be in English language only.

3.5 Storage of Materials

Material shall be stored in sheltered storage by the Contractor in the

a) The application procedure shall be in accordance with

b) Contractor shall provide and maintain mobile facilities which

c) Contractor shall furnish sufficient number of the following

- Fully automatic full circle adjustable holiday detector with

4.2 Pipe Surface Preparation

b) Prior to cleaning operation, Contractor shall visually examine the