bid document for annual rate contract (arc) for hot …gailtenders.in/writereaddata/tender/vol ii of...

GAIL (INDIA) LIMITED (A.GOVT OF INDIA UNDERTAKING)

BID DOCUMENT

FOR

ANNUAL RATE CONTRACT (ARC) FOR HOT TAPPING WORKS INCLUDING SUPPLY OF SPLIT TEES

VOL II OF II – TECHNICAL

(BID DOCUMENT NO.- 110398 A /WGI/GAIL/01-R0) E TENDER NO - 8000006108

OPEN DOMESTIC COMPETITIVE BIDDING

ISSUE DATE: 24.12.2013

ISSUED BY

GAIL ARC PROJECT

MATERIAL REQUISITION FOR SPLIT TEE

CLIENT JOB NO.

TOTAL SHEETS 6

DOCUMENT NO 11 0398A 02 08 06 01

0 18.11.13 ISSUED FOR TENDER MK DD EUR

B 22.10.13 ISSUED FOR CLIENT’S REVIEW MK DD EUR

A 19.10.13 ISSUED FOR IDC MK DD EUR

REV DATE DESCRIPTION PREP CHK APPR

MATERIAL REQUISITION

FOR SPLIT TEE

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11-0398A-02-08-06-01 0

SHEET 2 of 6

TABLE OF CONTENT

1. SCOPE OF SUPPLY 4 2. CONDITION 5 3. REMARKS 5 4. SPECIAL INSTRUCTIONS TO BIDDER 6 5. INFORMATION/ DOCUMENTS/ DRAWINGS TO BE SUBMITTED BY SUCCESSFUL BIDDER 6


FOR SPLIT TEE

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SHEET 3 of 6

LIST OF ATTACHMENTS

S.No. DOCUMENT TITLE DOCUMENT NUMBER No. of Sheets

1.0 SCOPE OF WORK 11-0398A-02-08-02-001 4

2.0 TECHNICAL SPECIFICATION FOR SPLIT TEE 2-09-006 10

3.0 DATA SHEET REDUCED BRANCH SPLIT TEE

WITHOUT LOCK-O-RING FLANGE & GUIDE BARS (48” X 48” X 12”)

11-0398A-02-08-03-001 3

4.0 DATA SHEET REDUCED BRANCH SPLIT TEE

WITHOUT LOCK-O-RING FLANGE & GUIDE BARS ( 36” X 36” X 12”)

11-0398A-02-08-03-002 3

5.0 DATA SHEET REDUCED BRANCH SPLIT TEE WITH LOCK-O-RING FLANGE & GUIDE BARS

( 30” X 30” X 12”) 11-0398A-02-08-03-003 3


( 18” X 18” X 12”) 11-0398A-02-08-03-004 3


( 12” X 12” X 8”) 11-0398A-02-08-03-005 3


( 8” X 8” X 8”) 11-0398A-02-08-03-006 3


( 8” X 8” X 6”) 11-0398A-02-08-03-007 3


( 6” X 6” X 4”) 11-0398A-02-08-03-008 3


( 4” X 4” X 4”) 11-0398A-02-08-03-009 3

12.0 HOT TAPPING PROCEDURE 11-0398A-02-08-02-002 9

13.0 QAP OF SPLIT TEE - 2

14.0 LIST OF TPI - 1


FOR SPLIT TEE

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SHEET 4 of 6

1.0 SCOPE OF SUPPLY 1.1 General This Specification covers the scope of both supply and installation of Split Tee to be used in the GAIL-

ARC Project at various locations in India on M/s Gail’s existing Pipeline. The scope of supply covers the design, manufacture, inspection, testing, and preparation for shipment and documentation requirements of these items in accordance with the requirements of this Requisition.

The Rate-Contract shall be valid for a period of one (01) year from the date of "Fax of Acceptance", and the same may be extended for six (06) months thereafter at the same rates, terms and conditions.

However, separate PO/WO shall be issued during this validity for individual work/item. 1.2 Material Delivery Requirements The finished materials are to be delivered by the Supplier at the nominated delivery point, fixed by the Purchaser/ Purchaser Representative. The Supplier shall be responsible for all handling and transportation between his production plant and the nominated delivery point in accordance with this specification. 1.3 Split tee The type and quantities of Split tees are detailed below:

Item No.

SPLIT TEES QTY (No.)

1 48’’X48”X12’’ Reduced Branch Extruded Split Tee without Lock-O-ring flange & guide bar, 600#

02

2 36’’X36”X12’’ Reduced Branch Extruded Split Tee without Lock-O-ring flange & guide bar, 600#

02

3 30’’X30”X12’’ Reduced Branch Split Tee with Lock-O-ring flange & guide bar, 600#

02

4 18’’X18”X12’’ Reduced Branch Extruded Split Tee with Lock-O-ring flange & guide bar, 600#

02

5 12’’X12”X 8’’ Reduced Branch Extruded Split Tee with Lock-O-ring flange & guide bar, 600#

02

6 8’’X8”X8’’ Equal Branch Extruded Split Tee with Lock-O-ring flange & guide bar, 600#

04


01


01

9 4’’X4”X4’’ Equal Branch Extruded Split Tee with Lock-O-ring flange & guide bar 600#

04


FOR SPLIT TEE

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SHEET 5 of 6

1.4 LIST OF SPLIT TEE MANUFACTURERS

1) T D WILLIAMSONS 2) TEEMANS LIMITED 3) FURMANITE 4) PIPELINE SERVICES (UK) LTD

Bidders may be either Split Tee manufacturer or may procure the same from above mentioned or any other reputed Split Tee manufacturer. However, in any case, bidder has to submit the Past Track Record (PTR) of split tee manufacturer for approval.

2.0 CONDITION: 2.1 All Split Tee shall be used for Natural Gas/ R-LNG/LPG service. Accordingly, Impact test and hardness tests as per clause 5.5 and 4.5 of technical specification shall be applicable. 2.2 Bidder must submit duly filled up and signed data sheets, compliance statement, Check List and along with his offer. In the absence of this information, Purchaser reserves the right to reject bidder’s offer without any reference to Bidder in this regard. 3.0 REMARKS 3.1 Supplier’s Compliance

Supplier shall submit his bid in full compliance with the requirements of this MR and attachments. Bidder shall include the following statement in his bid: We certify that our bid is fully complying with your enquiry dated �... and referenced ��,

Compliance with this material Requisition in any instance shall not relieve the Vendor of his responsibility to meet the specified performance. 3.2 Compliance with Specification The supplier shall be completely responsible for the design, materials, fabrication, testing, and inspection, preparation for shipment & transfer of above material to nominated delivery point strictly in accordance with the MR & all attachments thereto. 3.3 Supplier’s Scope Supplier’s scope of work includes design, manufacture & Testing and Supply of Split tee as per attached

specification. 3.4 Inspection Supplier shall submit with his bid a list of 3 well known international Third Party inspection Agencies as per enclosed vendor list, which he intends to use for inspection. This agency will issue all relevant certificates as per specification & codes. Inspection shall also be performed by a designated Third Party Inspection agency and/or purchaser a set out & specified in the codes & particular documents forming this MR.


FOR SPLIT TEE

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SHEET 6 of 6

4.0 SPECIAL INSTRUCTIONS TO BIDDERS

4.1 Bidder to note that no correspondence shall be entered into or entertained after the bid submission.

4.2 Bidder shall furnish quotation only in case he can supply material strictly as per this Material Requisition and specification/data sheets forming part of Material Requisition.

4.3 If the offer contains any technical deviations or clarifications or stipulates any technical specifications (even if in line with MR requirements) and does not include complete scope & technical/ performance data required to be submitted with the offer, the offer shall be liable for rejection.

4.4 The submission of prices by the Bidder shall be construed to mean that he has confirmed compliance with all technical specifications of the corresponding item(s).

4.5 Bidder must submit all documents as listed in checklist along with his offer.

4.6 Supplier must note that stage wise inspection for complete fabrication, testing including the raw material inspection to be carried out.

5.0 INFORMATION/ DOCUMENTS/ DRAWINGS TO BE SUBMITTED BY SUCCESSFUL BIDDER

Successful Bidder shall submit 3 copies unless noted otherwise, each of the following: 5.1 Inspection & test reports for all mandatory tests as per the applicable code as well as test reports for any

supplementary tests, in nicely bound volumes. 5.2 Material test certificates (physical property, chemical composition, make, heat treatment report, etc.) as

applicable for items in nicely bound volumes. 5.3 Statutory test certificates, as applicable. 5.4 Filled in Quality Assurance Plan (QAP) for Purchaser's/ Consultant's approval. These QAPs shall be

submitted in four copies with in 15 days from LOI/ FOI. 5.5 WPS & PQR, as required. 5.6 Within two (2) weeks of placement of order, the detailed fabrication drawings for Purchaser's/Consultant's

approval. 5.7 Detailed completion schedule activity wise (Bar Chart), within one week of placement of order. 5.8 Weekly & fortnightly progress reports for all activities including procurement. 5.9 Purchase orders of bought out items soon after placement of order. 5.10 All approved drawings as well as inspection and test reports for Owner's/ Consultants reference/ record

in nicely category-wise bound volumes separately. 5.11 A list of documents to be furnished along with supply. Note: All drawings, instructions, catalogues, etc., shall be in English language and all dimensions shall be metric

units.

GAIL ARC PROJECT

SCOPE OF WORK

CLIENT JOB NO. -

TOTAL SHEETS 4

DOCUMENT NO 11 0398A 02 08 02 001





SCOPE OF WORK

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SHEET 2 of 4

TABLE OF CONTENT

1. BRIEF DESCRIPTION OF WORK 3 2. DETAILED SCOPE 3 3. PREPARATION OF WRITTEN PLANS 4 4. PERSONNEL COMPETENCY AND QUALIFICATION 4 5. FREE ISSUE MATERIAL 4

SCOPE OF WORK

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SHEET 3 of 4

1. BRIEF DISCRIPTION OF WORK

M/s GAIL intends to carry out the hot tapping work on existing above ground and underground pipeline across India.

HOT TAPPING WORK

a) Carry out hot tapping on existing above ground and underground pipeline across India

b) Supply of necessary hot tapping equipment and Installation of hot tap connection by puncturing the run pipe and dismantling as required.

c) Collection and transportation of free issued materials from storage point to work site, providing necessary tools, tackles, machineries etc.

d) Carrying out fabrication, welding, erection, installation of Split Tee as specified in tender.

e) Hot Tapping work shall confirm to ASME B 31.8 and API Recommended Practice 2201.

2. DETAILED SCOPE

Contractor’s scope of work shall include but not limited to the followings

Supply, Installation and commissioning:

a) Supply and Installation of Split Tee as mentioned in Material Requisition (MR)

b) Survey to ascertain the thickness of the parent pipe.

c) Obtaining all permission/ clearance/ permits from owner/ concerned authorities.

d) Supply of all machines, fittings, manpower to complete the Hot Tapping Works including sufficient capacity Hot Tapping equipment, pumps for Hydro testing, NDT equipment etc.

e) Supply of necessary consumables and non-consumables to complete the job in all respect.

f) Preheating as required.

g) Carry out Testing & installation of Split Tee and other works/ Joints as per standard.

h) Carry out Hydrotest and Commissioning of complete works as per Specification and Standard.

i) Following activities including Mobilization & demobilization of hot tapping machine, tools & tackles, Engineer/ Technician/ Welder and boarding and lodging charges of Engineer/ Technician/ Welder are in the scope of the contractor.

2.1 LIST OF SPLIT TEE MANUFACTURERS

1) T D WILLIAMSONS 2) TEEMANS LIMITED 3) FURMANITE 4) PIPELINE SERVICES (UK) LTD

Bidders may be either Split Tee manufacturer or may procure the same from above mentioned or any other reputed Split Tee manufacturer. However, in any case, bidder has to submit the Past Track Record (PTR) of split tee manufacturer for approval.

SCOPE OF WORK

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SHEET 4 of 4

3. PREPARATION OF WRITTEN PLANS:

Prior to conducting welding or hot tapping on piping or equipment in service, a written plan shall be submitted by Contractor for approval which includes at least the following:

a) Connection design, location and carrier thickness

b) Design calculation & drawings of Split Tee, Hot tap procedure etc.

c) Detailed welding procedure (qualified in accordance with the applicable code) documenting heat input, as appropriate.

d) Health, safety, fire protection, emergency response, and other appropriate procedures and instructions, including owner and user requirements.

Additional information when developing a written plan shall be obtained based on MR attached in tender document, relevant codes and standards. API RP 1104 and fundamental ASME code shall address the qualification of welders and the welding procedures to be employed when welding on new and in-service pipelines containing flammable and combustible liquids.

4. PERSONNEL COMPETENCY AND QUALIFICATIONS

Hot tap machine operators and welders must be qualified in accordance with applicable codes and specifications. They should be thoroughly familiar with the welding and hot tap equipment and procedures to be used. Only skilled competent personnel should mount and assemble the hot tapping machine. These skills may be achieved either through on-the-job training or by a formal training program provided by the manufacturer of the hot tapping machine. As noted in previous sections, certain aspects of the job analysis and planning involve participation and approval by both competent and qualified persons.

5. FREE ISSUE MATERIAL

a) Full Bore Ball Valves (600#), of all sizes for all Hot tapping work.

STANDARD SPECIFICATION

STANDARD SPECIFICATION FOR

SPLIT TEE

2-09-006

a trading name of Wood Group Kenny India Pvt. Ltd

0 07.12.12 Issued As Standard MK DD EUR

Rev Date Purpose Prepared

By Checked

By Approved

By

Standard Specification

STANDARD SPECIFICATION FOR SPLIT TEE

Doc No. Rev


2-09-006 00

Page 2 of 10

Abbreviations:

ASME : American Society of Mechanical Engineers.

ASNT : American Society for Non-destructive Testing.

ASTM : American Society for Testing and Materials.

ISO : International Standards Organization.

NDE : Non-destructive Examination.

MSS : Manufacturers Standardization Society.

NPS : Nominal Pipe Size.

UNS : Unified Numbering System.



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TABLE OF CONTENTS Sl.No. Description

1.0 SCOPE 3

2.0 REFERENCE DOCUMENTS 3

3.0 MANUFACTURER'S QUALIFICATION 3

4.0 MATERIALS 4

5.0 DESIGN AND CONSTRUCTION REQUIREMENTS 4

6.0 INSPECTION AND TESTS 5

7.0 TEST CERTIFICATES 5

8.0 PAINTING, MARKING AND SHIPMENT 7

9.0 WARRANTY 7

10.0 DOCUMENTATION 7

ATTACHMENT 10



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1.0 SCOPE

This specification covers the basic requirements for the design, manufacture and supply of carbon steel split tees as hot tap material to be installed in pipeline system for handling hydrocarbons in liquid or gaseous phase.

2.0 REFERENCE DOCUMENTS 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: Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols.

b) ASME B 31.8: Gas Transmission and Distribution Piping System

c) ASME B 16.9: Factory made wrought steel butt-welding fittings.

d) ASME B 16.25: But Welding Ends

e) ASME Sec. VIII: Boiler & Pressure Vessels Code-Rules for the construction of Pressure vessels.

f) ASME Sec. IX : Boiler & Pressure Vessel Code-Welding & Brazing Qualifications.

g) ASTM A 370: Mechanical Testing of Steel Products

h) MSS-SP-53 : Quality Standard for Steel Castings and Forgings for Valves, Flanges and fittings and other Piping components and - Magnetic Particle Examination Method.

i) MSS-SP-75: Specification for High Test Wrought Butt Welding Fittings

j) API 1104: Specification for Welding Pipeline and Related Facilities

K) SSPC-VIS-1: STEEL STRUCTURES PAINTING COUNCIL

i) API 2201: Safe Hot Tapping practices in the Petroleum & Petrochemical Industries

2.2 In case of conflict between the requirements of this specification and any code, Standard and

Specification referred in Clause 2.1 above. Order of precedence shall be as follows: • Data Sheets • This Specification • Other Referred Codes & Standards • Manufacturer’s Standard.



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3.0 MANUFACTURER'S QUALIFICATION Manufacturer who intends bidding for fittings must possess the records of a successful proof test, in accordance with the provisions of ASME B16.9/ MSS-SP-75. These records shall be submitted at the time of bidding when specified in data sheet. 4.0 MATERIALS 4.1 The basic materials required for manufacturing of split tees have been indicated in the data sheet. Other

additional materials required for manufacturing split tees shall be as per manufacturer's standard suitable for the service conditions indicated in data sheet and shall be subjected to approval by Purchaser.

4.2 Fully killed Carbon steel shall be used in the manufacture of split tees. 4.3 Each heat of steel used for the manufacture of pressure containing parts of the flow tees shall have

carbon equivalent (CE) not greater than 0.45 calculated from the check analysis in accordance with the following formula.

CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15 Carbon content on check analysis shall not exceed 0.22%.

4.4 When specified in Data sheet, Charpy V-notch test shall be conducted for each heat of steel used in

manufacture of split tee. Test shall conform to the provisions of ASTM A-370 and at a temperature of 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 the plate or forging. The average impact energy values of three full sized specimens shall be 27 joules, unless indicated otherwise in the data sheets:

Minimum impact energy value of any one specimen of the three specimens analysed shall not be less than 80% of the average impact energy specified. No specimen shall exhibit less than 80% shear. When Low Temperature Carbon Steel (LCTS) materials are specified in Datasheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with.

4.5 When specified in the data sheet, hardness test shall be carried out as per ASTM A 370 for each heat of

steel used. A full thickness cross section shall be taken for this purpose and the maximum hardness of base metal, weld metal and HAZ of all pressure containing parts shall not exceed 248 HV10, unless otherwise specified.

5.0 DESIGN AND CONSTRUCTION REQUIREMENTS 5.1 Split tees shall be designed and manufactured in accordance with the provisions of codes and standards

referred in Section 2.0 of this specification. Design factor and corrosion allowance indicated in data sheet shall be taken into account for design of split-tees.

5.2 Split tees shall meet following requirements as minimum:

a) Sleeves shall be designed to meet pressure & reinforce requirements of ASME Codes. b) Fittings shall be manufactured with controlled carbon equivalent for its welding in harsh out side environments. c) Split tee shall be of full branch or reducing branch & meet the requirement for fittings with hot tap machine.

5.3 Butt weld ends shall be beveled as per MSS-SP-75/ B16.25.



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5.4 Split tees shall be manufactured by hot drawn, full branch/ reduced branch opening, snug-fitting sleeve or fabricated full size nipple, branch outlet welded to snug-fittings sleeve.

5.5 All welds shall be made by welders and welding procedures qualified in accordance with ASME Section-

IX. The welding procedure qualification test shall include charpy impact test and hardness test and shall meet the requirements of clause 4.4 and 4.5 of this specification respectively.

5.6 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.

6.0 INSPECTION AND TESTS 6.1 The manufacturer shall perform all inspections 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:

6.1.1 All split tees shall be visually inspected. 6.1.2 Dimensional checks shall be carried out as per the approved drawing. 6.1.3 Chemical composition and Mechanical properties shall be checked as per MSSSP-75 and this specification for each heat of steel used. 6.1.4 Non destructive examination of individual split tees shall be performed as given

below: a) 100% inspection by radiography shall be carried out on all pressure containing welds on fittings. Acceptance limits shall be as per API 1104.

b) Welds which in Purchaser's Representative's opinion cannot 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.

c) All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a distance of 50mm from the end. Any lamination larger than 6.35mm shall not be acceptable.

d) All forgings shall be wet magnetic particle examined on 100% of the forged surfaces. Method and acceptance shall comply with MSS-SP-53.

6.2 Purchaser's Representative shall also perform stage wise inspection and witness tests as indicated in

clause 6.1 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 Purchaser's Representative shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests.

7.0 TEST CERTIFICATES 7.1 Manufacturer shall submit following certificates to Purchaser's Representative:

a) Test certificates relevant to the chemical analysis and mechanical properties of the materials used for construction as per this specification and relevant standards.

b) Test reports on radiographic and ultrasonic inspection and wet magnetic particle examination.



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c) Certificates for each split tee stating that it is capable of withstanding without leakage for a test duration of 15 minutes and test pressure which results in a hoop stress equivalent to 95% of the specified minimum yield strength.

d) Test reports on heat treatment carried out.

8.0 PAINTING, MARKING AND SHIPMENT 8.1 Split tees entire surface shall be thoroughly cleaned, freed from rust and greaseand applied with sufficient

coats of corrosion resistant paint, after all the required tests have been performed and accepted by Purchaser's Representative. The surface preparation shall be carried out by shot blasting to SP 6 in accordance with "Steel Structures Painting Council - Visual Standard -SSPC-VIS-1"

. 8.2 Manufacturer shall indicate the type & recommended coats of corrosion resistant paint used, in the

drawing submitted for approval. 8.3 Split tees shall be marked with indelible paint with the following data:

a) Manufacturer's Name b) Nominal diameter in mm D1 x D2 c) End thickness in mm T1 x T2 e) Material

8.4 Split tees shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for weld ends.

9.0 WARRANTY

Purchaser will be reimbursed by Manufacturer for any Split tee furnished to this specification which fails under field hydrostatic testing and if such failure or non-performance is caused by a defect in the Split tees which is outside the acceptance limits of this specification. The reimbursement cost shall include cost of Split tee, labour and equipment rental for finding, excavating, cutting, and installation of replaced Split tee in position.

10.0 DOCUMENTATION 10.1 At the time of bidding, bidder shall submit the following documents: -

a) General arrangement drawing of split tees with overall dimensions and cross sectional drawings.

b) Reference list of previous supplies of split tees of similar specification

With relevant details viz Project, Year of supply, Client, size, Rating and service for the last five years. c) Clause wise list of deviation from this specification, if any. d) Records of successful proof test for tees qualifying the range of sizes

quoted. e) Brief description of the manufacturing, heat treatment and quality control facilities of the

manufacturer’s work. f) 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.



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a) Fabrication drawings and relevant calculations for pressure containing parts.

b) Calculation for fittings thickness. c) Method of manufacture, welding procedure and heat treatment details. d) Quality control Manual. Once the approval has been given by Purchaser, any change in design, material method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the Split tees are manufactured.

10.3 Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies of

the approved drawings, documents and specification as stated in clause 10.3 of this specification. 10.4 Prior to shipment, Manufacturer shall submit one reproducible and six copies of

test certificates as listed in clause 7.0 of this specification. 10.5 All documents shall be in English Language.



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ATTACHMENT



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GAIL ARC PROJECT

DATA SHEET FOR REDUCED BRANCH EXTRUDED SPLIT TEE WITHOUT LOCK-O-RING FLANGE & GUIDE BARS (48” X 48” X 12”)

CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 001





DATA SHEET REDUCED BRANCH EXTRUDED SPLIT TEE WITHOUT LOCK-O-RING FLANGE & GUIDE

BARS (48” X 48”X 12”)

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SHEET 2 of 3

S.No DESIGN DATA

1 Types of Fitting 48’’X48”X12’’ Reduced Branch Extruded Split Tee without Lock-O-ring flange & guide bar

2 ANSI Rating 600#

3 Design Code ASME B 31.8, MSS-SP-75 / ASME B 16.9

4 Design Pressure 98 bar

5 Design Temperature(degree centigrade) 0 to 65

6 Corrosion Allowance (mm) 0.5

7 Design Factor 0.5

8 Flange Facing RF

9 Flange finish 125 AARH

10 Field test Pressure 147 bar

11

Existing Pipeline Details(on which hot tapping to be conducted )

(Note-8)

Outside Diameter: 48’’NB

Thickness: 25mm

Material: API 5L Gr X70

12 Connecting Branch Pipeline Details

(Note-8)


Thickness: 10.3mm

Material: API 5L Gr X65

13 Type of Valve to be used on the branch (Free Issue)

Full Bore Ball Valve as per API 6D

14 Product handled Natural gas

15 Sleeve, OD-dia A (mm) @

16 Sleeve, thickness-T1 (mm) @

17 Sleeve, Length-L(mm) @

18 Branch, Thickness-T2(mm) @

19 Fitting Height (Center line to run pipe to flange top )-H (mm)

@

20 Flange OD- dia C @

21 Split Tee, Weight(Kg) @

DATA SHEET REDUCED BRANCH EXTRUDED SPLIT TEE WITHOUT LOCK-O-RING FLANGE & GUIDE

BARS (48” X 48”X 12”)

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SHEET 3 of 3

Material requirement

SL.No Part Description Specified Material Offered Material By Bidder

1 Full Encirclement Sleeve –Top Portion

MSS-SP-75,Gr WPHY-70 / ASME B 16.9 @

2 Full Encirclement Sleeve –Bottom Portion


3 Branch MSS-SP-75,Gr WPHY-65 / ASME B 16.9 @

4 Lock-O-Ring Flange Not Required @

5 Lock-O-Ring Assembly with Guide Bars

Not Required @

6 Lock-O-Ring / Retaining Device

Not Required @

Notes: @ Bidder to indicate

1) Split Tee shall be manufactured, tested, and supplied in accordance with spec. 2-09-006

2) The Fitting shall be capable of withstanding field hydrostatic test Pressure indicated above or 90% SMYS of fittings material which ever is more.

3) Fitting thickness shall be calculated based on pressure corresponding to ANSI 600# and considering design code, design factor and corrosion allowance indicated above. Calculation in this respect shall be submitted by vendor for review/ approval of purchaser/ consultant.

4) Requirement of impact test and hardness as per Spec. 2-09-006 shall be applicable for fitting and flange material.

5) Deleted

6) Deleted

7) Deleted

8) Actual pipe material details and wall thickness shall be confirmed from site by Hot Tap Vendor/Contractor.

9) Vendor shall submit ITP & QAP for approval within two weeks from date of order.

GAIL ARC PROJECT

DATA SHEET FOR REDUCED BRANCH EXTRUDED SPLIT TEE WITHOUT LOCK-O-RING FLANGE & GUIDE BARS (36” X 36” X 12”)

CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 002





DATA SHEET FOR REDUCED BRANCH EXTRUDED SPLIT TEE

WITHOUT LOCK-O-RING FLANGE & GUIDE BARS (36” X 36”X 12”)

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SHEET 2 of 3

S.No DESIGN DATA

1 Types of Fitting 36’’X36”X12’’ Reduced Branch Extruded Split tee without Lock-O-ring flange & guide bar

2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11


(Note-8)


Thickness: 19.1mm

Material: API 5L GrX70


(Note-8)


Thickness: 10.3mm










@



DATA SHEET FOR REDUCED BRANCH EXTRUDED SPLIT TEE

WITHOUT LOCK-O-RING FLANGE & GUIDE BARS (36” X 36”X 12”)

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SHEET 3 of 3








4 Lock-O-Ring Flange Not Required @


Not Required @


Not Required @





4) Requirement of impact test and hardness as per Spec. 2-09-006, shall be applicable for fitting and flange material.

5) Deleted

6) Deleted

7) Deleted



GAIL ARC PROJECT

DATA SHEET FOR REDUCED BRANCH EXTRUDED SPLIT TEE WITH LOCK-O-RING FLANGE & GUIDE BARS (30” X 30” X 12”)

CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 003





DATA SHEET FOR REDUCED BRANCH EXTRUDED SPLIT TEE WITH LOCK-O-RING FLANGE & GUIDE BARS (30” X 30”X 12”)

Document No. Rev

11-0398A-02-08-03-003 0

SHEET 2 of 3

S.No DESIGN DATA

1 Types of Fitting 30’’X30”X12’’ Reduced Branch Extruded Split Tee with Lock-O-ring flange & guide bar

2 ANSI Rating 600#

3 Design Code ASME B 31.8, MSS-SP-75 / ASME B16.9




7 Design Factor 0.5

8 Flange Facing RF



11


(Note-8)


Thickness: 19.1mm



(Note-8)


Thickness: 10.3mm










@




Document No. Rev

11-0398A-02-08-03-003 0

SHEET 3 of 3








4 Lock-O-Ring Flange Manufacturer Standard @


Carbon Steel @


Manufacturer Standard @






5) Flow through lock-O-ring assembly with guide bars shall allow full flow into branch line and shall allow pigs to cross the opening smooth & unobstructed in the main pipeline.

6) Lock-O- ring flange assembly with guide bars shall be TDW make or equivalent. Vendor shall indicate the name of manufacture for the same.

7) For Typical arrangement of Split Tee with Lock-O-ring Flange & Guide Bar Assembly Refer specification no. 2-09-006



GAIL (India) Limited


CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 004






Document No. Rev

11-0398A-02-08-03-004 0

SHEET 2 of 3

S.No DESIGN DATA


2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11


(Note-8)


Thickness: 14.3mm



(Note-8)


Thickness: 10.3mm










@




Document No. Rev

11-0398A-02-08-03-004 0

SHEET 3 of 3










Carbon Steel @













GAIL ARC PROJECT


CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 005






Document No. Rev

11-0398A-02-08-03-005 0

SHEET 2 of 3

S.No DESIGN DATA

1 Types of Fitting 12’’X12”X 8’’ Reduced Branch Extruded Split Tee with Lock O- ring flange & guide bar

2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11 Existing Pipeline Details(on which hot tapping to be conducted )


Thickness: 10.3mm




Thickness: 7.9mm










@




Document No. Rev

11-0398A-02-08-03-005 0

SHEET 3 of 3










Carbon Steel @













GAIL ARC PROJECT

DATA SHEET FOR EQUAL BRANCH EXTRUDED SPLIT TEE WITH LOCK-O-RING FLANGE & GUIDE BARS (8” X 8” X 8”)

CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 006





DATA SHEET FOR EQUAL BRANCH EXTRUDED SPLIT TEE WITH

LOCK-O-RING FLANGE & GUIDE BARS (8” X 8”X 8”)

Document No. Rev

11-0398A-02-08-03-006 0

SHEET 2 of 3

S.No DESIGN DATA

1 Types of Fitting 8’’X8”X8’’ Equal Branch Extruded Split Tee

with Lock-O-ring flange & guide bar

2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11


(Note-8)


Thickness: 7.9mm



(Note-8)


Thickness: 7.9mm










@





Document No. Rev

11-0398A-02-08-03-006 0

SHEET 3 of 3










Carbon Steel @













GAIL ARC PROJECT


CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 007






Document No. Rev

11-0398A-02-08-03-007 0

SHEET 2 of 3

S.No DESIGN DATA


2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11

Existing Pipeline Details (on which hot tapping to be conducted )

(Note-8)


Thickness: 7.9mm



(Note-8)


Thickness: 6.4mm










@




Document No. Rev

11-0398A-02-08-03-007 0

SHEET 3 of 3


SL.No Part Description Specified Material Offered Material

By Bidder








Carbon Steel @







4) Requirement of impact test and hardness as per Spec. 2-09-006, RO shall be applicable for fitting and flange material.

5) Flow through lock-O-ring assembly with guide bars shall allow full flow into branch line and shall allow pigs to cross the opening smooth and unobstructed in the main pipeline.

6) Lock-O-ring flange assembly with guide bars shall be TDW make or equivalent. Vendor shall indicate the name of manufacture for the same.

7) For Typical arrangement of Split Tee with Lock-O-Ring Flange & Guide Bar Assembly Refer specification no. 2-09-006



GAIL ARC PROJECT


CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 008






Document No. Rev

11-0398A-02-08-03-008 0

SHEET 2 of 3

S.No DESIGN DATA


2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11


(Note-8)


Thickness: 6.4mm



(Note-8)


Thickness: 6.4mm



Full Bore Ball Valve,as per API 6D







@




Document No. Rev

11-0398A-02-08-03-008 0

SHEET 3 of 3



By Bidder






4 Lock – O Ring Flange Manufacturer Standard @

5 Lock –O-Ring Assembly with Guide Bars

Carbon Steel @










7) For Typical arrangement of Split Tee with Lock-O-Ring Flange & Guide Bar Assembly Refer specification no. 2-09-006



GAIL ARC PROJECT

DATA SHEET FOR EQUAL BRANCH EXTRUDED SPLIT TEE WITH LOCK-O-RING FLANGE & GUIDE BARS (4” X 4” X 4)

CLIENT JOB NO.

TOTAL SHEETS

3

DOCUMENT NO 11 0398A 02 08 03 009







Document No. Rev

11-0398A-02-08-03-009 0

SHEET 2 of 3

S.No DESIGN DATA

1 Types of Fitting 4’’X4”X4’’ Equal Branch Extruded Split Tee

with Lock-O-ring flange & guide bar

2 ANSI Rating 600#





7 Design Factor 0.5

8 Flange Facing RF



11


(Note-8)


Thickness: 6.4mm



(Note-8)


Thickness: 6.4mm










@





Document No. Rev

11-0398A-02-08-03-009 0

SHEET 3 of 3



By Bidder








Carbon Steel @













GAIL ARC PROJECT




REV. DATE DESCRIPTION PREP CHKD APPD

PROCEDURE FOR HOT TAPPING

CLIENT JOB NO. -

TOTAL SHEETS 09

DOCUMENT NO 11 398A 02 08 02 002


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 2 OF 9

CONTENTS

1 SCOPE ............................................................................................................................................................... 3

2 DEFINITIONS ....................................................................................... ERROR! BOOKMARK NOT DEFINED.

3 WORK PROCEDURE ……………………………………………………………………………. .. 4

4 PIPELINE CONDITIONS ................................................................................................................................... 5

5 SAFETY PROCEDURE AND CHECK LIST ..................................................................................................... 5

6 NON DESTRUCTIVE TESTING ........................................................................................................................ 6

7 CHECK LIST IN ADDITION TO PRE-EXECUTION & EXECUTION CHECK LIST ......................................... 7

8 RESPONSIBILITY MATRIX .............................................................................................................................. 8

9 WELDING RECOMMENDATIONS FOR FULL ENCIRCLEMENT FITTINGS ...8


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 3 OF 9

1 SCOPE

1.1 It should be borne in mind that Hot Tapping will be done on in-service pipeline which contains considerable quantity of hydrocarbons and hence any deviation from the established procedure or committing any inadvertent mistake will result in serious consequences of product leak, fire or explosion, which could be disastrous. It is absolutely essential that all those concerned with the operation shall rigidly follow established procedure, be alert & vigilant all the time & ensure safety of personnel, property & environment around.

Following things are to be taken care for design of hot tapping:-

• Safety

• Condition of the pipe under consideration

• Configuration of the connection

• Code / statutory requirements

• Operating conditions

• Technical capabilities of the tapping equipment under operating condition

• Welding

• Environment/pollution aspect

1.2 The safety plan shall include:-

• Access to site for personnel & equipment

• Roles of dedicated personnel and their responsibilities on site

• Monitoring of operating conditions

• Foreseeable hazards and contingency actions

• Communication on site

• Warning system

• Means of escape

• Fire fighting equipment and personnel

• Safety equipment and personnel

• Safety equipment and services

• First aid facilities

• Emergency procedures shall also be specifically addressed, either in the safety plan or in a separate document.

2 DELETED


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 4 OF 9

3 WORK PROCEDURE

3.1 Procedure shall be prepared for all aspects of the physical work:-

• Site preparation

• Pipe preparation

• Welding

• NDT

• Hot Tapping

3.2 Pipe preparation:-

• Coating removal

• Surface cleaning & visual inspection

• Ovality check with callipers/check reports

• Area to be welded

• Internal consideration

3.3 Welding & inspection of in-service pipeline:-

Approved welding procedure specification (WPS) shall be used and qualification in accordance with API 1104. Approved procedure qualification record (PQR) shall be used to weld the joints.

3.4 Consumable:-

Electrode shall confirm to AWS A 5.1/5.5/AWS Class E6010/E8010 electrodes shall be used for the welding as specified in WPS/PQR.

3.5 Welding inspection

a) During welding:-

Visual inspection for discontinuities such as cracking, porosity, proper slag removal

DPT of the root run

b) After welding:-

MPT of the welds

NDT personnel shall be qualified to ASNT recommended practice for non-destructive testing. Only level II or level III personnel shall be used for interpretation of the test results.


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 5 OF 9

4 PIPELINE CONDITIONS:

4.1 Initial inspection of the pipeline before welding

Job Description

Verify the atmosphere in the immediate area of the work is free of any and all flammable, explosive and toxic vapors. Flammable gases to be detected through calibrated hand held gas detectors.

The area shall be continually monitored for vapours

If required, demagnetization shall be carried out and arrangements will be made in advance

Communication facility needs to be available at site

Personnel at site should not wear 100% nylon, polyester clothing. It is preferable to use cotton clothes

Appropriate personnel protective equipment-safety hats, safety shoes, gloves, goggles, welding hood etc. should be used

Identify the desired location of the tapping fitting. Clean the pipe in the area to be inspected to bare metal by mechanical and/or chemical means contaminates (using GQ-4 grinding machine with stringer brush) to remove all coating, dirt, and contaminates. necessary precautions needs to taken not to remove the parent metal during cleaning

Mark the area to be inspected. This area shall extend beyond the projected ends of the tapping fitting by at least 4” in both directions

Ultrasonically examine this area to determine the actual wall thickness and the soundness of the pipe. Ultrasonic examination to be witnessed by TPIA & owner

Confirm the operating flow which is meeting the requirement or not

5 SAFETY PROCEDURE AND CHECK LIST

It should be borne in mind that Hot Tapping will be done on in-service pipeline which contains considerable quantity of hydrocarbons & hence any deviation from the establish procedure or committing any inadvertent mistake will result in serious consequences of product leak ,fire or explosion, which could be disastrous. It absolutely essential that all those concerned with the operation shall rigidly follow established procedure, be alert & vigilant all the time & ensure safety of personnel, property and environment around.

• Verify the atmosphere in the immediate area of the work is free of any and all flammable, explosive and toxic vapours. This is to be done by customer representative. The area shall be continuously monitored for vapours. The customer representative shall be present during any and all operation.

• Personnel at site should not wear 100% nylon; polyster clothing. It is preferable to use cotton clothes.

• No one should wear oil soaked clothes.


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 6 OF 9

• Appropriate personnel protective equipment-safety hats, safety shoes, gloves, goggles, welding hood, safety belts etc. should be used depending on the nature of job carried out.

• Proper means of exit should be readily available for Hot Tapping personnel at site.

• For working at height, metal scaffolds should be built sturdily & stable.

• The welder should be properly protected against welding fumes.

• Customer to assist in providing a fire watch squad using personnel trained in the use of the appropriate fire fighting equipment and procedure.

• Customer representative shall verify / certify the flow & pressure of the product. Velocity required for welding and hot tapping shall be checked before start of welding.

• No work should be carried out unless authorised by the company supervisor.

• Make sure that all the points in the check list furnished below are strictly met.

5.1 Fit-up and welding of the Tapping fitting

Hot permit shall be obtained before start-up of the activity

Provide fire fighting equipment and personnel.

Adequate lifting equipment to be used for fit up of the Tapping Fitting on the pipeline ( If required)

All lifting equipments like crane,chains,ropes and lifting tackles shall be maintained in good operating condition and certified

Necessary secure provision shall be made so far as is reasonably practical by fencing or otherwise using safety nets (if required)

Emergency escape route be install for speedy evacuation of the site personnel

Welding to be carried out as per the WPS and by using qualified welders. Crack to be detected conducting Dye Penetrant Test for root and for final weld. Preheating shall be done as per WPS after DP test

6. NON DESTRUCTIVE TESTING

a) During welding:

Visual inspection for discontinuities such as cracking, porosity, proper slag removal.

Dye penetrate test

b) After welding:

NDT personnel shall be qualified to ASNT recommended practice for non destructive testing. Only level II or level III personnel shall be used for interpretation of the test result.


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 7 OF 9

7. CHECK LIST IN ADDITION TO PRE-EXECUTION & EXECUTION CHECK LIST

a) Before starting the Hot Tap

Has the working permit been obtained? Yes / No

Does the tapping machine have suitable pressure & temperature rating & adequate travel for the job

Yes / No

Has the exact location of the hot tap on the line been identified & marked Yes / No

Has the weld area been inspected for thickness & freedom from lamination or other metallurgical imperfection

Yes / No

Has the metallurgy of the pipe wall is been established and is it compatible with the Hot Tap Fitting

Yes / No

Do the flanges, bolts, gaskets & valve to be installed meet the piping code for the line to be Hot Tapped?

Yes / No

Is there sufficient clearance to accommodate the operation of the Hot Tapping machine?

Yes / No

Is there sufficient clearance to retract the cutter through the valve? Yes / No

Have combustible & toxic gas tests have been conducted in the area of Hot tapping?

Yes / No

Has fire fighting devices / equipment been provided Yes / No

Has suitable protective equipment been provided to all the personnel in the Hot Tap area

Yes / No

Is there adequate hoisting & support equipment for the tapping machine Yes / No

b) Before welding & after welding:

Is preheating of the weld area done as per approved WPS / PQR? Yes / No

Is the Hot Tap fitting properly positioned so misalignment of the hot tap machine will not occur

Yes / No

Has the pressure & temperature of the pipeline been checked Yes / No

Is there liquid or flowing gas in contact with the area to be hot tapped Yes / No

Has the weld been tested Yes / No

c) Before Tapping (Cutting):

Have the hot tap valve, packing, gasket, bolts been checked for possible leakage

Yes / No

Has the packing or seals of the tapping machine been checked Yes / No

Has the bleeder valve been checked to be sure that it will hold, is operable, is not obstructed

Yes / No


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 8 OF 9

Are all the bolts on the cutter are tight Yes / No

Is the retainer rod(u-rods) are free Yes / No

Is the valve centred on the flange Yes / No

Has the tapping distance is been calculated Yes / No

Has the boring bar run through the valve to ensure free passage Yes / No

Have the manufacturers instructions been followed to be sure that the boring bar is completely retracted before closing the hot tap valve

Yes / No

Has the hot tap valve been closed Yes / No

Has the bleeder valve been opened Yes / No

Has the pressure been bleeder off from the machine before removing Yes / No

8. RESPONSIBILITY MATRIX

S.No. Activity Responsibility

1 Location marking for Hot Tapping Client / Contractor

2 Preparation of Pit for Hot Tapping Client / Contractor

3 Pipe preparation (Coating removal, UT Testing) Client / Contractor

4 Fit-up & welding Client / Contractor

5 Non destructive testing Client / Contractor

6 Hot tapping Client / Contractor

7 Final coating Client / Contractor

8 Back filling Client / Contractor

9 House keeping Client / Contractor

9. WELDING RECOMMENDATIONS FOR FULL ENCIRCLEMENT FITTINGS

9.1 Recommended installation of full encirclement fittings

• Weld procedures and welders should be qualified to the relevant code, applicable to the client where as in this case as per API 1104.

• The installation location should be checked for roundness after it has been cleaned thoroughly. The external condition of the pipe should be examined for corrosion.

• Throughout the area of the installation location an ultrasonic examination should be performed to establish.

a) Actual wall thickness

b) Actual condition of the pipe wall

• Thoroughly clean both the pipe and the weld areas of the fitting, removing ail wrapping, paint, corrosion and scale.


DOCUMENT NO. REV

11-0398A-01-08-02-002 0

SHEET 9 OF 9

• In high moisture areas (If moisture content is more than 80%) the line should be preheated to a predetermined amount to reduce the moisture on the line before the installation is commenced.

• Rest the Top (branch) of the fitting on the pipe, with the backing strips (if required) inserted in place. Ensure that the fitting, in total, is a snug fit around the pipe. The circumferential (fillet weld) gap is recommended to be between 1/16” 1/8” ( 1.5 – 3mm ).On occasions field modification of the fitting may be required due to variations in pipe O.D. tolerance .In addition it is recommended that spiral or seam welds on the pipe O.D. are ground flush to facilitate a correct fit.

• Centre and level the fitting. Flange centreline should intersect the centreline of the pipe. Flange gasket face should be parallel to the pipe.

• Welding electrodes recommended for this operation are 4.00 mm diameter of E8010 is normally used for all passes to complete entire welding as per approved WPS / PQR.

• With consideration to ambient and line temperature, and flow, hence cooling rate of the pipeline product, consideration should be given to establishing the welding cycle available. This may be done by preheating the fitting / line to the upper welding limit (250 degree C) and then timing the temperature decay to the lower welding limit ( 100 deg C ) this would define the welding cycle.

• After preheating, if required, tacks weld the four comers of the longitudinal seams, each tack being no longer than 12.5 mm ( ½” ).On no account should the tack, or any portion of the longitudinal weld come into contact with the pipe.

• After positioning of the fitting by tack welding, prepare both ends of the tack welds by grinding .Pre heat the fitting, if required, to the requisite figure, then commence welding for branch joint and as well as for reinforcing pad as described above, i.e. 4 mm (5/32”) electrodes for all passes until completion, ensure that welding is carried out diagonally in opposition.

• On completion of one circumferential weld again giving consideration to pre heat and using 4 mm electrodes to complete the fillet welds. The normal sequence to be followed is that a number of buttering layers are welded to the pipe wall, but not in contact with the fitting, and the following run is then applied to the ‘throat’ of the tee, between the tee and the innermost buttering run. The remaining weld sequence is then to fill the rest of the fillet. The normal fillet size (leg length) deposited is between 1 and 2 times the wall thickness.

PROJECT: GAIL ARC PROJECT QAP NO

CLIENT: GAIL ITEM DESCRIPTION / QUANTITY: SPLIT TEE

VENDOR

Verification of size marking &

correlation with mill TC

Applicable

codes and approved

Drawing

Mill TC or check

test reports if any

Visual, dimensions, verification

of marking with MTC & check

test if any

100% H w

Verification of form, shape, size and

thickness.

As per ANSI, ASME

codes, approved drgs. &

applicable spec

Stage Inspection Report

Visual, dimensions, verification

of

profile & dimension

100% H W

Normalising, quenching, temperingApplicable codes &

approved drawingHT Records

Visual & review

Certification as per EN 3.2100% H W

Verification of sizeApplicable codes &

approved drawingInternal Inspection Visual & dimension 100% H -

Mechanical de-scalingApplicable codes &

approved drawing- Visual 100% H -

Material Spec., Heat No., Lot No.,

Size Vendors monogram

Applicable codes &

approved drawing- Visual 100% H -

Mechanical Strength

ASTM A 370, Client

Spec & Approved

dawing

Laboratory report Witness / Scrutiny of reports 100% H W

Mechanical Strength

ASTM A 370, Client

Spec & Approved

dawing

Laboratory report Witness / Scrutiny of reports 100% H W

Imapct Test

3.2 Heat Treatment

3.3

4.0 DESTRUCTIVE TESTING

3.5 Marking

3.1 WPS/ PQR / WPQ

4.2 Micro Test & Hardness

4.1

ASME SEC IV / IX

3.4 Cleaning & Finishing

Machining

1.0

2.1 Sleeve to Flange set up

3.0

IN PROCESS

SLEEVES & FLANGES

Chemical / Physical / Imapct

test (@ -20C)

1.1

WPS / PQR / WPQ Witnessing welding & testing 100% H WApproved WPS / PQR / WPQ

2.0

WELDING

RAW MATERIAL IDENTIFICATION

FORM OF RECORD TYPE OF CHECKSCOPE OF INSPETION

VENDOR TPI

CONSULTANT: WGK

CHARACTERISTIC REF. DOC.OPERATIONSR.

No.

Page 1 of 2

PROJECT: GAIL ARC PROJECT QAP NO

CLIENT: GAIL ITEM DESCRIPTION / QUANTITY: SPLIT TEE

VENDOR

CONSULTANT: WGK

Review of 100% Radiography

UT & MPT testing

API 1104

Radiograph report and

radiographs

UT / MPT Reports

Review of radiograph

Visual

100% H

R & W(100%)

W

DPT, MPT API 1104 DPT / MPT Reports Visual 100% H W

1.5 x Design Pressure Client Spec Hydrotest report & Graph Witnessing Hydro Test 100% H W

Checking for dimensions, surface

finish, marking, stampingApproved Drawings

Final offer list and other

relevant documentsVisual and Dimensions 100% H W

Checking for colour code,

dimensions, surface finish, markingApproved Drawings

Final offer list and other

relevant documentsVerification 100% H W

Packing suitably to avoid transit

damages marking each cartoon, for

proper identification.

Client PO & SpecLR, Invoice, Challan /

despatch file etc.Verification 100% H W

5.0

7.1 Completeness, Dim, Workmanship & Finish

Final Inspection

5.1

5.2

NON DESTRUCTIVE TESTING

7.3 Packing List & Dispatching

7.0

7.2Final Painting , Field Joint Cating & Quality

Doc.

6.0 HYDROTEST

V: VISUAL, R: REVIEW, N: NORMALISING, D: DIMENSION, LR: LABORATORY REPORT, W: WITNESS, H: HOLD, TPI: THIRD PARTY INSPECTION AGENCY, IRN: INSPECTION RELEASE NOTE

NOTE 1 : Calibration Measuring & testing Instruments shall be used with valid calibration certificate, such calibration certificate shall be produced at the time of inspection.

2 : Material & Type shall be as per tender Specs / Data Sheet

3 : TPIA to issue 3.2 Certificate as per EN 10204 SPEC.

4 : Supplimentary Condistions : If any as per PO shall be fulfilled.

5 : For Split Tee QAP along with GAD & Mechanical Design Calculation shall be submitted for Client approval.

Butt Weld

Fillet Weld

Page 2 of 2

S.NO NAME OF TPI ADDRESS PHONE NO FAX NO

1 Tata Projects Ltd.22,Sarvodaya

Society,Nizampura,Baroda-3900020265-2392863 0265-2785952

2Bax counsel Insepection

Bureau Pvt. Ltd.

303, Madhava,Bandra Kurla Complex,

Bandra(E),Mumbai-400051

022-26591526,022-

26590236022-26591526

3 Germanischer Lloyd

4th Floor, Dakshna Building, Sec-11,

Plot NO.2, CBD Belapur, Navi Mumbai

400 614

022-4078 1000 022-4024 2935

4Velosi Certification

Serrvices,Mumbai

Velosi Certification

Services(I)Pvt.Ltd.,212,Shivkrupa

Complex Centre,Off Ghokhale

Road,Navpada Thane(W)400602

022-25376770 022-25426777

5ABS Industrial Verification

Ltd., Mumbai

404,Mayuresh Chambers,Sector-

11,CBD Belapur(E),Navi Mumbai-

400614

022-27578780 /1 /2 022-27578784 / 5

6Certification Engineers

International Ltd.

EIL Bhavan,5th floor,1,Bhikaji Camma

Place,New Delhi-110066

011-

26167539,26102121011-26101419

7 Dalal Mott MacDonald501, Sakar -II, Ellisbridge,Ahemedabad-

380006079-26575550 079-6575558

8International Certification

Systems

E-7,Chand Society, Juhu Road, Juhu,

Mumbai-4000049022-26245747 022-226248167

9 SGS

SGS India Pvt. Ltd.,SGS

House,4B,A.S.Marg,Vikhroli(W),Mumbai-

400083

022-25798421 to 28 022-25798431 to 33

10 Intertek Moody9th Floor, Kanchenjunga Building, 18-

Barakhamba Road, New Delhi-110001011-4713 3900 011-4713 3999

11 TUV SUD South AsiaC-153/1, Okhla Industrial Ara, Phase-1,

New Delhi-110020011-3088 9611/9797 011-3088 9598

12TUV Rheinland (India)

Pvt. Ltd.

F-51, Kailash Complex GF, Veer

Savarkar Marg, Vikhroli Park Site,

Vikhroli(W), Mumbai-400079

022-4215 5435 022-4215 5434

13

Vincott International India

Assessment Service Pvt.

Ltd.

C-301, Mangalya Premises Cooperative

Soc. Ltd, Off. Marol Maroshi Road,

Andheri(E), Mumbai-400959

022-4247 4100 022-4247 4101

Note: The details of TPIs indicated in this list are based on the information available with WGI, Contractor

shall verify capabilities of each for producing the quantity with proper Quality. Purchaser / purchaser's

representative does not take any responsibility on the performance of TPI.

PROJECT: INVENTORY CREATION PROJECT

CLIENT: GAIL INDIA LIMITED

CONSULTANT:WOOD GROUP KENNY INDIA PVT. LTD.

LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY

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