3210-8210-sp-0007 rev a2.pdf

PARADIP REFINERY PROJECT PROJECT SPECIFICATION A

SPECIFICATION FOR LINEPIPE MATERIALS

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CONTENTS

1.0 INTRODUCTION .................................................................................. 3 1.1 Scope................................................................................................... 3 1.2 Pipelines Description ......................................................................... 3 2.0 REFERENCES, CODES AND STANDARDS ...................................... 4 2.1 Project Specific Documents .............................................................. 4 2.2 Codes and Standards......................................................................... 4 2.3 Abbreviations...................................................................................... 5 3.0 SPECIFICATION.................................................................................. 6 3.1 Manufacturing Process ...................................................................... 6 3.2 Mechanical Properties........................................................................ 6 3.3 Inspection/ Acceptance Criteria ........................................................ 6 3.4 Line Pipe Steel Grade......................................................................... 6 3.5 Line Pipe Diameters ........................................................................... 7 3.6 Line Pipe Wall Thickness................................................................... 7 3.7 Pipe Straightness ............................................................................... 7 3.8 Outside Diameter ................................................................................ 7 3.9 Inside Diameter ................................................................................... 7 3.10 Out-of-Roundness .............................................................................. 8 3.11 Pipe Lengths ....................................................................................... 8 3.12 Surface Finish ..................................................................................... 8 3.13 Induction Bends.................................................................................. 8 3.14 Service Environment .......................................................................... 8 3.15 Operating Temperature ...................................................................... 8 3.16 Chemical Properties ........................................................................... 9 4.0 QUALITY ASSURANCE .................................................................... 10 4.1 Measuring Devices ........................................................................... 10 4.2 Certification....................................................................................... 10 4.3 Quality System.................................................................................. 10 4.4 Marking and Surface Treatment ...................................................... 10 4.5 Handling ............................................................................................ 10 4.6 Storage .............................................................................................. 10 4.7 Delivery.............................................................................................. 10 4.8 Content of the Quality Plan.............................................................. 11 UPDATED SECTIONS 1.2 Pipeline Description, Lengths of Product Pipelines removed. Other changes are highlighted in yellow



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1.0 INTRODUCTION

1.1 Scope This document details the requirements of the line pipe material to be used for the proposed pipelines for the Indian Oil Corporation Ltd (IOCL) Paradip Refinery project.

1.2 Pipelines Description 1.2.1 Product Pipelines

The Product Pipelines comprise one (1) Crude Oil pipeline connecting the South Loading Jetty to the Refinery; three (3) Utility Pipelines and eleven (11) Product Pipelines connecting the Refinery to the South Loading Jetty; and four (4) Product Pipelines connecting the Refinery to the Marketing Terminal.

1.2.2 Raw water Pipeline

The Raw Water pipeline will run from the Cuttack pumping and terminate at the raw water reservoirs at Paradip Refinery. The surveyed distance of the pipeline is 92.8km.



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2.0 REFERENCES, CODES AND STANDARDS

2.1 Project Specific Documents 3210-8210-RP-0039 Pipeline Sizing Report

3210-8210-RP-0017 Raw Water Pipeline Mechanical Design Report

3210-8210-RP-0007 Product & Crude Oil Pipelines Basic Engineering Data Report

3210-8210-RP-0040 Product Pipeline Pipe Wall Thickness Report

3210-8210-RP-0015 Product Pipeline Hyd & Surge Analysis Design Report

3210-8960-TN-0001 Material and Procurement Management Requirements

2.2 Codes and Standards API 5L Specification for Line pipe

ASTM A333 Seamless and Welded Steel Pipe for Low Temperature Service

NACE RP 0472 Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments

NACE MR 0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments

ISO 11126-7 Preparation of steel substrates before application of paints and related products. Specifications for non-metallic blast-cleaning abrasives

ISO 11126-10 Preparation of steel substrates before application of paints and related products - Specifications for non-metallic blast-cleaning abrasives

ASTM E353 Standard Test Methods for Chemical Analysis of Stainless, Heat-Resisting, Maraging, and Other Similar Chromium-Nickel-Iron Alloys

ASTM A751 Methods, practices and definitions for chemical analysis of steel products.

ISO 10474 Steel and Steel Products - Inspection Documents First Edition

ISO 10012 Measurement management systems - Requirements for measurement processes and measuring equipment

ISO 10005 Quality management systems - Guidelines for quality plans

ISO 9001 Quality management systems - Requirements



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2.3 Abbreviations IOCL Indian Oil Corporation Ltd.

SAW Submerged Arc Welding

ERW Electric Resistance Welding

SMLS Seamless

OD Outer side diameter

ID Internal diameter

D Diameter



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3.0 SPECIFICATION

3.1 Manufacturing Process All pipe shall be manufactured in accordance to API 5L and should be either seamless or welded as defined in section 3.5. The pipe shall be limited to the product specification levels and grades limitations specified in APL 5L Table1.

Only the following processes shall be acceptable. All LPG pipelines shall be PSL2 with the base material and testing as stated ASTM A333.

3.1.1 Seamless Pipe (SMLS)

The seamless process is a process of hot working steel to form a tubular product without a welded seam.

3.1.2 Electric Welded Pipe (ERW)

Electric welding a longitudinal seam by electric-resistance or electric-induction welding.

• PSL1 or PSL2 for Product pipelines

3.1.3 Longitudinal Seam Submerged-Arc Welded Pipe (SAW)

Pipe that has one longitudinal seam produced by the automatic submerged-arc welding process.

For the Raw-water pipeline spiral welded SAW is acceptable.

• PSL1 or PSL2 for Crude and Product pipelines

• PSL1 or PSL2 for Raw-water pipeline

3.2 Mechanical Properties All pipe shall have minimum mechanical properties in accordance to API 5L.

For LPG pipelines (excluding vapour return) shall have the minimum mechanical properties be in accordance to Grade 3, ASTM A333.

3.3 Inspection/ Acceptance Criteria All pipe should be inspected in accordance to API 5L.

For LPG pipelines (excluding vapour return) impact testing shall be in accordance to ASTM A333.

3.4 Line Pipe Steel Grade The grades of the pipe range from Grade B though to X52. Reference datasheets 3210-8210-DS-0007 and 3210-8210-DS-0023.

For LPG pipelines (excluding vapour return) the line pipe grade shall be Grade 3, ASTM A333.



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3.5 Line Pipe Diameters The diameters and grades for each pipeline are stated in datasheets 3210-8210-DS-0007 and 3210-8210-DS-0023.

Line pipe shall be and manufactured using one of the following processes.

• Longitudinal Submerged Arc Welding (SAW) process ≥ 14”.

• Electric Resistance Welding (ERW) process from 10” to 14”

• Seamless (SMLS) for 2” to 8”

o Exception: LPG will be SMLS up to 12”

3.6 Line Pipe Wall Thickness The wall thickness of the pipe is stated datasheets 3210-8210-DS-0007 and 3210-8210-DS-0023.

The tolerance on the nominal wall thickness shall be:

Seamless -10% +15%

Longitudinally welded pipe -10% +10%

3.7 Pipe Straightness All pipe shall be checked for straightness. Deviations from a straight line shall not exceed 1.5 mm/m or 12mm total over the full length whichever is smaller.

3.8 Outside Diameter The outside diameter of the pipe body, as measured by a circumference tape, shall not deviate by more than ±0.5% of the nominal diameter.

3.9 Inside Diameter The inside diameter shall be checked over a distance of 100mm from each end face. The maximum permitted variation from the nominal internal diameter shall be as follows.

Designation Tolerance on nominal ID Pipe ≤ 219.1 mm OD ± 1 mm Pipe > 219.1 mm OD ± 1.5 mm

Table1 – Tolerance on nominal ID



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3.10 Out-of-Roundness The pipe out-of-roundness shall be determined at three locations equidistant along the pipe body.

The out-of-roundness (i.e. the difference between the major and minor outside diameter) measured at the same plane over four axes at 45° intervals shall not exceed 1% of the nominal outside diameter.

3.11 Pipe Lengths Pipe shall be supplied in the following lengths:

• A minimum of 95% of pipes shall be between 11 and 12.2m in length.

• No pipe shall be less than 8m in length.

• No pipe shall be greater than 12.5m in length.

3.12 Surface Finish All internal and external surfaces shall be supplied free of scale, oxide film, oil, grease and lacquers (except for paint marking characters)

Abrasive for blast cleaning shall be fused aluminium oxide in accordance with ISO 11126-7, or garnet in accordance with ISO 11126-10. Abrasive shall not be recycled.

3.13 Induction Bends The Linepipe should be suitable for induction bending to a radius of 3D.

3.14 Service Environment The service environment shall not include sour conditions as stated in NACE RP 0472 or NACE MR 0103.

3.15 Operating Temperature The maximum design temperature for the line pipe shall be 65°C the minimum will be -5°C.

Expectation for LPG pipelines (excluding the vapour return pipeline) maximum design temperature for the line pipe shall be 0°C the minimum will be -45°C.



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3.16 Chemical Properties Chemical analysis shall be determined in accordance with ASTM E353 or ASTM A751.

Carbon equivalent shall not be greater the 0.65% as calculated from API 5L.

For LPG pipelines (excluding vapour return) the line pipe chemical properties shall be to ASTM A333.



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4.0 QUALITY ASSURANCE

4.1 Measuring Devices The Manufacturer/Supplier shall control measuring devices within requirements of ISO 10012.

4.2 Certification Inspection certificates in accordance with ISO 10474 type 3.1B or ISO 10474 type 3.2 shall be supplied. The Manufacturer/Supplier shall provide a listing of all pipes supplied detailing for each pipe the unique pipe number, heat treatment, test number, certificate number, length and weight. This data shall also be supplied on a computer disc. This shall be compatible with the Material Control software, reference 3210-8960-TN-0001, with the data being in a suitable format for integration into a Geographical Information System (GIS).

4.3 Quality System The Manufacturer/Supplier should maintain and operate a quality assurance system in accordance with ISO 9001.

4.4 Marking and Surface Treatment Marking of test pressure, sizes and weights should be in metric units.

The paint used for stencilling shall be free of halogens, metal ions and other elements which may be detrimental to the pipe surface.

Paint markings should be executed in black, block capitals with a minimum height of 25mm.

4.5 Handling During manufacture, storage and transportation, the pipes shall not be in contact with loose carbon steel (e.g. swarf, fillings, etc.). Nylon slings or rubber-coated hooks/supports etc. shall be used for all handling operations.

4.6 Storage The pipe shall be segregated from other materials during storage.

4.7 Delivery The transportation of pipe shall be as specified in the following:

1. API RP 5LW for marine transportation;



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2. API RP 5L1 for railroad transportation.

Pipe shall not travel as deck cargo.

4.8 Content of the Quality Plan The format and issue of the quality plan shall be consistent with the documented control element of the Manufacturer’s quality system.

The quality plan shall be prepared in accordance with ISO 10005 and shall include the following:

1. Identification of the product and contract to which the plan is to be applied.

2. Reference to API Spec 5LC and this Specification.

3. Location of steel making and pipe production.

4. Identification of the individuals responsible for controlling the activities defined in the plan.

5. Identification of the individuals with the authority to interface directly with the purchaser.

6. Identification of all subcontractors.

7. The quality plans of all subcontractors.

8. All sequenced activities for the product required and references to the quality system procedures and work instructions which will be applied to these activities.

9. Copies of all the quality system procedures and work instructions covering production, test and inspection, special processes, control of non-conforming product, handling, storage, packing, preservation, and delivery.

10. Test and inspection frequency and acceptance criteria including the upper and lower process control limits where statistical process control is employed.

11. The location of each inspection and test point in the process sequence.

12. Points where the purchaser has established witnessing or verification requirements.