GAIL (INDIA) LIMITED

(A.GOVT OF INDIA UNDERTAKING)

TERMINAL MODIFICATION PROJECT FOR

PHULPUR, DIBIYAPUR & PATA

BID DOCUMENT
FOR
SCRAPPER LAUNCHER / RECEIVER AT DIBIYAPUR & PATA

VOLUME II OF II TECHNICAL
BID DOCUMENT NO: 20038806/110330 L/WGI/GAIL/AU12/01-R0 )
E-TENDER NO. - 8000004770
OPEN INTERNATIONAL COMPETITIVE BIDDING
ISSUED DATE: 02.11.2012

ISSUED BY

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB
NO.

MATERIAL REQUISITION
OF
SCRAPER LAUNCHER / RECEIVER

DOCUMENT NO

11

0330L01

01

TOTAL SHEETS

13

09

06

002

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLIENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 2 of 54

TABLE OF CONTENTS

Sl.No.

DESCRIPTION

PAGE NO.

1.0

SCOPE OF SUPPLY

2.0

GENERAL NOTES TO MR

3.0

REMARKS

4.0

SPECIAL INSTRUCTIONS TO BIDDERS

5.0

DOCUMENTATIONS

6.0

CHECKLIST

7.0

COMPLIANCE STATEMENT

8.0

FORM A

10

9.0

FORM B

11

10.0

FORM C

12

11.0

VENDOR DRAWING DOCUMENT SUBMISSION SCHEDULE

13

MATERIAL REQUISITION
FOR
SCRAPER LAUNCHER / RECEIVER

Document No.

Rev

11-0330L01-01-09-06-002

SHEET 2 of 13
Page 3 of 54

LIST OF ATTACHMENTS

S.NO.

DOCUMENT TITLE

DOCUMENT NUMBER

NO. Of Pages

1.0

TECHNICAL SPECIFICATION FOR

SCRAPER LAUNCHER / RECEIVER

11-0330L01-01-09-02-002

14

2.0

DATA SHEET FOR SCRAPER LAUNCHER

/ RECEIVER

11-0330L01-01-09-03-002

3.0

TECHNICAL SPECIFICATION FOR QOEC

11-0330L01-01-09-02-003

4.0

DATA SHEET FOR QOEC

11-0330L01-01-09-03-003

5.0

TECHANICAL SPECIFICATION FOR PIG

SIGNALLER

11-0330L01-01-11-02-002

6.0

DATA SHEET FOR PIG SIGNALLER

11-0330L01-01-11-03-002

MATERIAL REQUISITION
FOR
SCRAPER LAUNCHER / RECEIVER

Document No.

Rev

11-0330L01-01-09-06-002

SHEET 3 of 13
Page 4 of 54

1.0

SCOPE OF SUPPLY (SOS)

1.1

General
This requisition describes the scope of supply of Scraper Launcher / Receiver to be used at PataDibiyapur Terminal.
The scope of supply includes the design manufacture, inspection, testing, packing, preparation for
shipment and documentation requirements of these items in accordance with the requirements of this
Requisition.

1.2

Material Delivery Requirements

The finished materials are to be delivered by the Supplier at the nominated delivery point at Pata &
Dibiyapur as per given below:
1) One Pair of Scraper Trap (Including Launcher & Receiver) Officer In Charge (OIC), GAIL(I)
Limited, U.P.B.C., PO : Pata 206241, District Auraiya, Uttar Pradesh
2) One Pair of Scraper Trap (Including Launcher & Receiver) Officer In Charge (OIC), GAIL(I)
Limited, Dibiyapur Compressor Station : Dibiyapur 206244, District Auraiya, Uttar Pradesh
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

Scraper Launcher / receiver:

The type and quantities of Scraper Launcher / Receiver are as detailed below:
S.NO

SIZE

TYPE

36 X 30

Eccentric
(Scraper
launcher
complete with
QOEC &
intrusive type
pig Signaller)

36 X 30

Concentric
(Scraper
receiver
complete with
QOEC &
intrusive type
pig Signaller)

QUANTITY

LOCATION

1 no Scraper Launcher : PATA

DESPATCH STATION
02
1 no Scraper Launcher :
DIBIYAPUR DESPATCH
STATION

1 no Scraper Receiver: PATA

RECEIVING STATION
02

MATERIAL REQUISITION
FOR
SCRAPER LAUNCHER / RECEIVER

1 no Scraper Receiver:
DIBIYAPUR RECEIVING
STATION

Document No.

Rev

11-0330L01-01-09-06-002

SHEET 4 of 13
Page 5 of 54

2.0

DELIVERY LOCATIONS

2.1

Scraper Launcher / Receiver shall be used for Natural Gas service. Accordingly, Impact test and
hardness tests as per clause 6.1 of same specification shall be applicable.

2.2

All material shall be delivered at nominated delivery point as given in Cls. 1.2.

2.3

Bidder shall quote separately for spares for two years normal operation of Scraper Launcher / Receiver
as per price schedule. List of spares quoted shall be furnished as per Form-C.

2.4

Bidder to include the start up and commissioning spares for Scraper Launcher / Receiver in the quoted
price. However, list of spares (start up and commissioning) shall be made available without cost as per
Form-B.

2.5

Bidder must submit duly filled up and signed data sheets, compliance statement, Check List and forms
(Form-A, Form-B, & Form-C) along with their offer.
In the absence of above information, Company reserves the right to reject bidders offer without any
reference to Bidder in this regard.

3.0

REMARKS

3.1

Suppliers Compliance
Supplier shall submit his bid in full compliance with the requirements of this MR and attachments.
Supplier must include following statement in his bid:
We certify that our bid is fully complying with your enquiry dated______ and reference______

3.2

Compliance with Specification

The supplier shall be completely responsible for the design, materials, fabrication, testing, inspection,
preparation for shipment & transfer of above material strictly in accordance with the MR & all
attachments.

3.3

Suppliers Scope
Suppliers scope of work includes the design, manufacturing & testing and supply of Scrapper Trap as
per attached specification of Scraper Trap.

3.4

Inspection
Supplier shall submit with their bid a list of 3 well known international Third Party inspection Agencies as
per enclosed vendor list, they intends to use for inspection. That 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 as
set out & specified in the codes & particular documents forming this MR. TPIA charges shall be paid by
the Manufacturer for all procured items.

MATERIAL REQUISITION
FOR
SCRAPER LAUNCHER / RECEIVER

Document No.

Rev

11-0330L01-01-09-06-002

SHEET 5 of 13
Page 6 of 54

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.

MATERIAL REQUISITION
FOR
SCRAPER LAUNCHER / RECEIVER

Document No.

Rev

11-0330L01-01-09-06-002

SHEET 6 of 13
Page 7 of 54

5.0

DOCUMENTATIONS

5.1

Documents to be submitted by bidder at the time of bidding

At the time of bidding the bidder shall submit the following documents along with fully detailed written
bid: Outline General Arrangement Drawings of the equipment, jib crane and pig handling trolley.
Completed Data Sheets.
Confirmation of scope of supply; including detailed material and painting specifications.
Thickness of major and minor barrel.
Vessel weight data; Erection weight; Operational weight; Maximum weight.
Materials of Construction.
Proposed manufacturing/delivery schedule.
Proposed Quality Assurance/Safety Plan.
Proposed Surface Treatment.
Typical Inspection and Test Plan.
Table of Compliance.
Catalogue of End Closure
FAILURE TO PROVIDE THE ABOVE INFORMATION MAY EXCLUDE THE MANUFACTURERS BID
FROM EVALUATION.

5.2

Documents to be submitted by successful bidder

The drawings and documents to be submitted after the Purchase Order shall be in accordance with
MANUFACTURER DATA REQUIREMENT FORM (VDRF) included in the Tender Documents.
The MANUFACTURER drawings shall be reviewed and approved by Client/Clients Representative,
against the Purchase order.
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)
b)
c)

Design calculations according to relevant codes for the end closure.

Welding procedure and method of manufacture.
Closure assembly and sectional drawings showing all parts with materials and dimensions.

Within four weeks from the approval date, Manufacturer shall submit two soft and two hard copies of the
approved drawings, documents and specifications.
Prior to shipment, the Manufacturer shall submit two soft and two hard copies of the Test certificates as
listed in clause 8.0 of Technical specification and manual for installation, erection, instructions,
maintenance and operation instructions.

Note:

All drawings, instructions, catalogues, etc., shall be in English language and all dimensions shall be metric
units.

MATERIAL REQUISITION
FOR
SCRAPER LAUNCHER / RECEIVER

Document No.

Rev

11-0330L01-01-09-06-002

SHEET 7 of 13
Page 8 of 54

REQUISITION FOR

SCRAPER LAUNCHER / RECEIVER

PROJECT

TERMINAL MODIFICATION FOR PHULPUR,DIBIYAPUR & PATA

6.0

CHECKLIST TECHNICAL
Bidder confirms following, as a minimum, has been enclosed in the offer.

S.NO.

Compiled by
Bidder

Requirements

Reference List of previous supply of Scraper Launcher /

Receiver (for similar design as quoted) enclosed.

Yes/No

Filled up Data Sheets, duly signed and stamped by bidder

enclosed.

Yes/No

List of recommended commissioning spares and accessories for

Scraper Launcher / Receiver enclosed.

Yes/No

List of spares and accessories for two year normal operation for
Scraper Launcher / receiver.

Yes/No

Compliance statement duly filled and stamped enclosed.

Yes/No

GA & assembly drawings, cross section drawings including part

list & material list enclosed.

Yes/No

Other technical details & vendors product catalogues enclosed.

Yes/No

11-0330L01-01-09-06-002

SHEET 8 of 13

Page 9 of 54

REQUISITION FOR

SCRAPER LAUNCHER / RECEIVER

PROJECT

TERMINAL MODIFICATION FOR PHULPUR,DIBIYAPUR & PATA

7.0

COMPLIANCE STATEMENT

S.No.

Bidders
Confirmation

Requirement

Bidder confirms that all materials proposed by the bidder are

same/ superior to those specified in specification/ data sheets
enclosed.

Bidder confirms that the offer is in total compliance with the

Technical requirements of the Material Requisition. Bidder
confirms that deviation expressed or implied any where else in
the offer shall not be considered valid.

Bidder confirms that all spares and accessories required for

two years of normal operation have been quoted separately as
per price Performa enclosed with Bid Document.

Bidder confirms that prices for start-up/commissioning spares

and accessories have been included in the quoted items

Bidder confirms that in the event of securing order for the

requisitioned item(s), good for manufacturing drawings of
ordered item(s) shall have complete details with dimensions,
part list and material list including back-up calculations in the
first submission, failing which the vendor shall be solely
responsible for any likely delay in delivery of item(s).

Bidders Signature with Stamp

11-0330L01-01-09-06-002

SHEET 9 of 13

Page 10 of 54

8.0

FORM A

REFERENCE LIST OF SUPPLY OF SCRAPER LAUNCHER / RECEIVER FOR THE LAST SEVEN YEARS

S.No.

Project

Client(Name &
Address)

Type

Size

Rating

Service

Year of
Supply

To be filled, signed and stamped by Bidder.

Bidders Seal
Signature of Bidder

11-0330L01-01-09-06-002

SHEET 10 of 13 Page 11 of 54

9.0

FORM B

LIST OF SPARES & ACCESSORIES FOR START UP & COMMISIONING FOR SCRAPER LAUNCHER /
RECEIVER
S.No.

Item No.

Description

Quantity

Note: Bidder to include the start up and commissioning spares for Scraper Launcher & Receiver in the
quoted price.
To be filled, signed and stamped by Bidder.

Bidders Seal
Signature of Bidder

11-0330L01-01-09-06-002

SHEET 11 of 13 Page 12 of 54

10.0

FORM - C

LIST OF SPARES AND ACCESSORIES FOR TWO YEARS OF NORMAL OPERATION FOR SCRAPER
LAUNCHER / RECEIVER
S.No.

Item No.

Description

Quantity

Note: Bidder shall quote separately spares for normal operation for Scraper Launcher & Receiver as per
price schedule Performa.
To be filled, signed and stamped by Bidder.

Bidders Seal
Signature of Bidder

11-0330L01-01-09-06-002

SHEET 12 of 13 Page 13 of 54

11.0

VENDOR DRAWING DOCUMENT SUBMISSION SCHEDULE FORM:

Status:
Vendor Drawing/ Document Submission Schedule

Client

Project

Item Description

PR No.
FOA No.
Date of LOA
PO No.

Wood Group Kenny Originating

Department
S.
No.

Equipment
Number

Drg./Doc.
Nomenclature

11-0330L01-01-09-06-002

Date:

Vendor
Name
Address

Contact Person:
Contact
Person(Wood Group
Kenny)
Vendor
Vendor
Drg./
Drg./Doc.
Doc.
Title
Number

Fax:

Phone:
Category
Review (R) /
Records

Email:

Scheduled
date of 1st
submission
(Rev.0)

Form
Electronic/
Print

Remarks

SHEET 13 of 13 Page 14 of 54

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB NO.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER / RECEIVER
DOCUMENT NO

11

0330L01

TOTAL SHEETS

01

09

14

02

002

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 15 of 54

TABLE OF CONTENTS

Sl.No.

DESCRIPTION

PAGE NO.

1.0

SCOPE

2.0

CODES, STANDARDS AND DOCUMENTS

3.0

GENERAL REQUIREMENTS

4.0

BASIC DESIGN DATA

5.0

DESIGN CRITERIA

6.0

MATERIALS

7.0

FABRICATION

10

8.0

INSPECTION & TESTING

11

9.0

NAME PLATE & MARKIG

13

10.0

SURFACE PREPARATION AND PAINTING

14

11.0

PREPARATION FOR SHIPMENT AND PACKING

14

12.0

SPARES

14

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 2 of 14
Page 16 of 54

1.0

SCOPE
This Specification details the minimum functional and testing requirements for the manufacturing and
supply of Scraper Launchers and Receivers complete with QOEC, Pig-Signaller & trolly/pig handling
device to be used in non sour Natural Gas transportation service.

1.1

Abbreviations
The following definitions shall apply:

1.2

1.3

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.

Purchaser

The Company which makes purchase order.

Manufacturer

Manufacturer who receives the purchase order.

Shall

This verbal form indicates requirements strictly to be

followed in order to confirm to the standards and form
in which no deviation is permitted.

Should

This verbal form indicates that among several possibilities

one is particularly suitable without mentioning or
excluding others or that a certain course of action is
preferred but not necessarily required.

May

This verbal form indicates a course of action permissible

within the limits of this standard.

Can

This verbal form used for statements of possibility &

capability, whether material, physical or casual.

Definitions

Compliance
Compliance by the manufacturer with this specification shall not relieve him from his responsibilities to
supply scraper launchers or receivers suited to meet the specified requirements and/or local codes
governing health and safety.
The MANUFACTURER shall notify the Purchaser / Purchasers Representative in writing, of any proposed
deviation from this Specification. The purchasers decision in respect of concession requests will be final.
The CONTRACTOR shall continually verify the quality and fitness for purpose of the Launchers/Receivers,
and shall propose appropriate actions/measures if any aspects of manufacture are found to be
unsatisfactory.
TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 3 of 14
Page 17 of 54

1.4

Quality Conformance
The MANUFACTURER shall demonstrate to the satisfaction of the Purchaser / Purchasers
Representative that his activities within the scope of this document are in accordance with the relevant
section of BS EN ISO 9001. The MANUFACTURER shall submit to the Purchaser / Purchasers
Representative for review and approval, a Quality Plan and procedural specifications prior to
commencement of work. The Quality Plan shall define all sub Manufacturers involvement in the work. The
review in this Specification shall only indicate a general requirement and shall not relieve the
MANUFACTURER of his obligations to comply with the requirements of the Contract.

1.5

Safety
Safety is paramount. All work shall be performed in accordance with the safety requirements listed in the
contract documentation.

2.0

CODES, STANDARDS AND DOCUMENTS

2.1

Codes and standards

Scraper Launchers/Receivers or combined Traps specified herein shall be designed, manufactured and
tested in accordance with the latest edition of the following codes and standards and/or others as
applicable. These Codes and Standards are the minimum requirements, and manufactured design shall
meet or exceed them.
API Spec 5L

Specification for Line pipe.

API 1104

Welding of Pipelines and Related Facilities.

ASME V

Boiler and Pressure Vessel Code - Non Destructive Testing.

ASME VIII

Boiler and Pressure Vessel Code - Div 1- Pressure Vessels.

ASME IX

Boiler and Pressure Vessel Code - Welding & Brazing

qualifications

ASME B 31.1

Power Piping.

ASME B 31.3

Process Piping.

ASME B 31.8

Gas Transmission and Distribution Pipeline System.

ASME B 16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B 16.9

Factory-made Wrought Steel Butt Welding Fittings.

ASME B 16.11

Forges Steel Fittings, Socket Welding and Threaded.

ASME B 16.25

Butt Welded Ends.

ASME B 16.47

Large Diameter Steel Flanges: NPS 26 through NPS 60.

ASTM A 105

Forging, Carbon Steel for Piping Components.

ASTM A 181

Forging, Carbon Steel for General-Purpose Piping.

ASTM A 234

Piping Fitting of Wrought Carbon Steel and Alloy Steel for

moderated and Elevated Temperatures.

ASTM A 370

Mechanical Testing of Steel products .

ASTM A 216

Carbon Steel Castings suitable for Fusion Welding for High

temperature Service.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 4 of 14
Page 18 of 54

ASTM A 20

General requirements for steel plate for pressure vessels.

ASTM A 516

Carbon steel pressure vessel plates for moderate and low

temperature service.

ASTM A 106

Carbon steel seamless pipe for high temperature service.

ASTM A 193

Alloy steel and stainless steel bolting materials for high

temperature.

ASTM A 194

Carbon and alloy steel nuts for bolts for high pressure or
temperature.

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.

MSS-SP-75

High test wrought butt-welded fittings.

ISO 9712

Non-destructive testing qualification and certification of

personnel.

ISO 10474

Steel and Steel Structures Inspection documents.

ISO 9000

Quality Management and Quality Assurance Standards.

ISO 9001

Quality Systems Model for quality assurance in design,

development, production, installation and servicing.

ISO 9002

Quality Systems Model for quality assurance in production,

installation and servicing.

2.2

Order of Precedence
In the event of any conflict of data or requirements in any of the above documents, it is the Suppliers
responsibility to resolve these conflicts before proceeding with design, manufacture or purchase. In any
case, the most stringent requirement shall prevail. However, Client / Clients Representative interpretation
shall be final.
In case of conflict, the order of precedence of the documents shall be as follows;

Equipment Data Sheets.

This Specification.

Project Specifications, Company Standards and International Codes as per Paragraph 2.1.

3.0

GENERAL REQUIREMENTS

3.1

Design
The barrel and hinged closure shall be designed as per as per latest edition of ASME 31.8.
The Launcher and Receiver shall be provided with pig tray, lifting devices and handling trolleys for pigs.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 5 of 14
Page 19 of 54

3.2

Drawings
MANUFACTURER shall furnish detail fabrication drawings, datasheet and/or specifications to the
PURCHASER / PURCHASERS REPRESENTATIVE for review / approval.
It is understood that the suggestions, recommendations for design, variations and fabrication changes
issued by the PURCHASER / PURCHASERS REPRESENTATIVE do not relieve the MANUFACTURER
from any responsibilities concerning the compliance with all requirements of this Specification and/or from
the fulfillment guarantees.
The drawings shall at least contain the following information:

Material (chemical composition, mechanical strength properties, material hardness & Impact
properties).
Data sheet
Design, maximum operating and allowable pressures / temperatures.
Test pressure.
Dimensions.
Only certified equipment to be used in zone 1 (electric) hazardous areas.
Welding procedure for each type of weld, including weld joint factor.

Any conflict between this specification, datasheet and the information contained in the equipments
drawings must be communicated, in writing, to the purchaser / purchasers representative in order to
obtain the pertinent approval.

4.0

BASIC DESIGN DATA

4.1

Detailed design data shall be as per attached Data Sheet.

4.2

Language
English shall be used for all documents, drawings and correspondence on the project including design
calculations.

5.0

DESIGN CRITERIA

5.1

Equipment Description
The Scraper launcher and Scraper Receiver units are to be provided for 30NB Natural Gas
transportation pipeline.
This equipment shall be designed to handle latest intelligent Pig. Refer to the attached Equipment data
sheets for rated design conditions and other details. Scraper launchers and receivers shall be designed to
provide smooth pigging operation for the entire section of pipeline between the Scraper Launcher and
Scraper Receiver including valves, tees, bends, flanges and insulating joints and shall allow unhindered
passage of all types of pigs, including intelligent pigs, cleaning pigs, gauging pigs and spheres.

5.2

Mechanical Design and Fabrication

Scraper Launchers and Scraper Receivers are important for any pigging systems to ensure safe and
efficient working and handling of pigs. Both Launchers and Receivers are required with suitable bandlock
type hinged closure and shall be provided for easy and safe access during pig loading and unloading.
Such closure shall be as per data sheets. Barrel shall be designed to suit the intelligent pigging. Launcher /
Receiver dimensions shall be suitable for intelligent pigging and as specified in the respective datasheets.
The inlet diameter of the minor barrel shall match with the inside diameter of the connecting pipeline.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 6 of 14
Page 20 of 54

The design factor to be used for calculating the shell thickness of major and minor barrel shall be as
specified in the respective pig trap data sheet. The pig traps shall be designed for an operating life of 25
years.
The complete Scraper Launcher and Receiver assembly shall be stress relieved as per the provisions of
the relevant design codes.
Repair by welding on parent metal is not allowed. Repair of welds shall be carried out only after specific
approval by third party Inspection agencys representative for each repair. Records for each repair shall be
maintained. All welds and repair welds shall be made by welders and welding procedures qualified in
accordance with the provisions of ASME Section IX.
The Scraper Launcher and Receiver cylindrical barrels shall be fabricated from single pieces of prefabricated pipes, i.e. there shall be no circumferential welds within the body of the cylindrical sections.
The Scraper Launcher and Receiver barrel diameters, neck diameters and minimum lengths shall be as
indicated in the Data Sheets. No intermediate circumferential weld on neck shall be permitted.
The reducer between the major and minor barrel shall be as per attached data sheet of Scrapper Trap.
The reducer shall confirm to MSS-SP-75 Gr WPHY-60. Thickness of reducer shall match with the adjoining
body/neck thickness.
Drain points shall be provided on the bottom of both Launcher and Receiver to drain the liquid
accumulated in the barrel. The minimum slope for receiver barrel shall be (1:100) downwards the end
closure while the launcher barrel shall have minimum slope of (1:100) downwards the pipeline. Drain
location shall be designed to provide complete drainage of the Scraper Launcher and Receiver barrels.
Vents shall be provided on the top of the Scraper Launcher and Receiver. Size of vents and drains shall
be as indicated in the data sheet.
Branch connections shall be provided with weldolets for the permitted pipe size range indicated in the
Pipeline Specification. Pipe sizes in the range for which weldolets are not permitted shall be provided with
an extruded opening for the branch connection.
Scraper traps shall be provided with a Pig signaller at location indicated in the scraper trap data sheet. Pig
signaller shall have visual Flag and manual reset mechanism. The Pig signaller confirms to the
requirement of relevant Pig signallers specifications & Data sheets.

5.3

Nozzles and other connections

All opening for nozzles shall be from material conforming to the same requirements as the pressure
containing parts, and adequately reinforced as per ASME B31.8. All nozzles shall be flushed with the
inside contour of the barrel.
The minimum distance between the edges of any attachment weld of a pressure part (e.g. a nozzle) to the
edge of another pressure weld of the trap body shall be 50 mm or twice the thickness of the pressure part,
whichever is the greater.
The nozzles shall be terminated with weld neck type raised faced flanges conforming to ASME B
16.5/16.47.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 7 of 14
Page 21 of 54

5.4

End Closure
The quick opening end closure shall be Quick Actuating type GD Band lock type or equivalent. The design
of the quick opening end closure shall be in accordance with design code adopted for the adjoining pig
trap as stated in the data sheet. The design of the end closure shall be robust and should consider fail
safe design of the opening mechanism and allow opening and closing by one man in a period of
approximately one minute without the use of additional devices.
Threaded/ screwed/ Plug-In type end closures are not permitted. The end closure shall be equipped with
pressure interlock system allowing its opening only when there is no pressure inside the Scraper
Launcher and Receiver. Safety bleeder device shall alert operator of possible hazard unless pressure in
the pig trap is relieved completed.
The closure hinge shall be so designed that the weight of the end closure is fully supported without
sagging. The end closure shall be designed in accordance with safety requirement of ASME Sec. VIII Div.
1, Clause UG-35.
End closure hinge axis shall be horizontally aligned, not withstanding any slope on the barrel section.
Enclosure for 36 X 30 scraper shall be fitted with worm gear operation for the operation of closure.

5.5

The Pig Handling Facility

The pig handling facility shall be complete with pig handling trolley, jib crane as detailed below.

5.5.1

Pig handling trolley

Pig handling trolley shall be designed from structural steel and shall be suitable to move on rail through a
gear train. Trolley shall be designed to contain pig tray which will contain pig. Trolley shall have proper
braking system.
Pig tray shall have perforated holes and shall be suitable to contain any type of pig, including intelligent
pig. Tray shall have proper strengthening system to avoid bending with load. The tray shall be provided
with suitable stops. Lock bracket shall be provided to such that the tray does not within the Launcher /
Receiver. Rear end of the tray shall be provided with suitable lug to enable retrieval of the tray by hooks.
The handling system (for inserting and retracting the intelligent pigs from the equipment) shall be complete
with handling devices. In case any rails are required for sliding of the handling system, the same shall be
provided by the Scraper Launcher / Receiver manufacturer.
Mechanical pushing system to push tray and pig inside the launcher shall be provided. Complete system
shall be designed to operate by one person. Manufacturer shall provide complete technical details.

5.5.2 Jib Crane

Jib Crane shall be designed as per IS: 3177, IS: 3832, IS: 3938 of latest edition and shall be mounted on a
structural column. Jib Crane shall swivel 3600 with one person and shall have antifriction bearing for swivel
operation. Lifting of equipment and movement of Trolley shall be anti-spark type Hoist-Trolley system,
suitable to operate by one person. Crane shall be balanced with load at maximum span and shall have
counter weight if required.
Suitable locking and braking system shall be provided. End stoppers shall be provided for trolley
movement. Crane shall be tested with 1.5 times of rated load at maximum radius. Deflection test shall be
as per IS: 807 of latest edition. Wire ropes used for hoisting and traveling shall be checked as per IS: 6594
and IS: 3973 latest edition. Crane shall be complete with foundation bolts.
Jib crane shall be designed for 3000 kg capacity at maximum span of 3 Meter radius, lift 3 Meter (from
0
floor to hook centre) 360 swiveling and operation by one man for all operation. Manufacturer shall furnish
all technical parameters along with offer.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 8 of 14
Page 22 of 54

5.5.3

Supports
The Scraper Launcher and Receiver shall be provided with a minimum of two saddle supports, located at
suitable spacing for mounting on concrete plinths. Supports shall be designed to carry the weight of the pig
trap system filled with water. These supports shall be sliding type and not be subjected to pipeline
anchorage forces. Manufacturer shall provide slide bearings for sliding type supports. The material for
support shall be of established quality and compatible with Scraper Launcher and Receivers Shell material
to which they are welded.
Anchor bolts for supports shall be supplied by Manufacturer.

MATERIALS

6.1

General
Material for the major components of the Scraper Launcher and Receiver shall be as specified in the
respective Scraper launcher and Receiver Data Sheets. Other components shall be as per the
Manufacturers Standard, which shall be subject to approval by Purchaser. Material for barrel, neck,
flanges and fittings shall be as specified in the Data Sheet. All fitting and flanges shall be confirm to low
temperature service and to ANSI 600#. In addition to the above, the material used for the quick opening
end closure shall comply with the following:

Carbon steel used for the manufacture of end closure shall be killed steel and consistent with the
barrel material to be welded.

End closure seals /O-rings shall be VITON Grade hardness 90 Shore D and shall be AED
certified. MANUFACTURER shall however confirm suitability for service conditions.

V- Notch charpy impact test shall be done at (-20) deg C and 0 deg C for Material for barrel, Neck.
And Impact values shall be as underTransverse impact Energy of Base Metal and Weld

Material

Test
Temperature

Minimum Average
Value
( for 3 specimen )

Minimum Single Value

Base Metal
And weld

-20C

35 J

27 J

Base Metal
And Weld

0C

100 J

75 J

The above values are applicable for full size specimens, 10mm x 10mm as per ASTM E23 and A370.
Impact test shall he carried out on samples with the notch at the following locations for the weld zone:

Weld Metal
Fusion line
Fusion line + 2mm
Fusion line + 5mm

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 9 of 14
Page 23 of 54

The four sample locations specified above shall constitute of 3 test specimens each, and shall be taken
from the mid-thickness of the weld.
Impact test shall also be carried out on a transverse sample (3 test specimens) removed from the base
metal. The samples shall beat 90 shore D to weld scam.
Shear area at the fracture surface shall be recorded. The shear area shall be determined for base metal
samples only. The required levels are 85% average fibrous shear, and 75% individual minimum.
The test specimens shall be in a transverse direction with the notch axis oriented through the pipe wall
/plate wall thickness.
All carbon steel forgings shall be heat-treated either in the normalized, normalized and tempered or
quenched and tempered condition.
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.

6.2

Material Traceability and Certification Requirements

Material Test Certificates provided by the MANUFACTURER shall conform to ISO 10474 for the following:
Components
All pressure retaining parts (for minor and
major barrel, reducer and quick opening
closure)
All parts in contact with fluid (for nozzles and
flanges)
All attachments welded to the vessel
Trap assembly inspection and test
Vessel structural supports and non pressure
parts
Others, if any

Material Certification Required.

EN10204Type 3.2C
EN10204Type 3.2 C
EN10204Type 3.2C
EN10204Type 3.2C
EN10204Type 3.2C
EN10204Type 3.2C

Certified mill test report, showing the chemical and physical properties for each item of material furnished
by the Manufacturer, shall be witnessed / reviewed by third party Inspection agency (TPIA).
A report of results obtained from magnetic particle and radiographic examinations of welds indicating all
defects were identified and the disposition of all repairs shall be provided. All original radiographs shall be
available to the PURCHASER / PURCHASERS REPRESENTATIVE/TPIA for review upon request.
A list of welders shall be provided on the drawings that made each weld.
A certified copy of all hydrostatic test charts shall be provided.
Owners approved Third Party Inspection Agency (TPIA) shall be deputed by the MANUFACTURER for
inspection at manufacturer premises to witness / review material Tests certification as per EN-10204 type
3.2C certification at manufacturers cost.
7.0

FABRICATION

7.1

General
Prior to commencement of fabrication, calculations and fabrication drawings, welding procedures (WPSs,
PQRs and supporting lab test reports), procedures for NDT, PWHT, hydrostatic test, coating, production
weld hardness testing, and quality assurance plan (QAP) shall be submitted to purchaser / purchasers
representative review and approval.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 10 of 14
Page 24 of 54

The inside of the trap barrel shall be free from obstructions which could prevent the free rolling of spheres,
or travel of pigs or carriers. All inside welds shall be ground smooth and nozzle ends shall be made to suit
inside curvature of barrel.
The inside diameter of the minor barrel of the trap and the main flange shall match the inside diameter of
the pipeline on which it is to be installed.
Gasket contact surface of flanges shall be protected against oxidation during the PWHT.
7.2

Welding
Welding shall be performed with procedures and operators who have been qualified in accordance with
the design code and ASME code Section IX.
All welding procedures, qualification of welders and welding procedure qualifications, design and
preparation of joints, inspection and testing, standards of acceptability of welding, repairs and radiography
shall be fully in accordance with design code and shall be documented by MANUFACTURER before
fabrication commences.
No welding shall be carried out after post weld heat treatment.
The final non-destructive testing of welds for acceptance purposes shall be carried out after completion of
any post weld heat treatment (PWHT).
Tack welds for welding fit-up shall be removed when making the final welds.
All welds shall be continuous unless specified otherwise.
All main seam welds and nozzle to shell welds shall be of full penetration type. Double side welding shall
be carried out wherever possible. Single welded butt joints are permitted for circumferential joints and will
be 100% radiographically tested.
All weld spatters and arc strikes shall be removed by grinding prior to inspection and testing of welded
joints.
All repair works on pressure parts welding shall be in accordance with approved weld repair procedure.
No attachments weld shall intersect any seam weld or lie in 50 mm or less than 2 times the thickness of
shell whichever is greater (if this is not applicable, MANUFACTURER shall provide the practicable limits
and perform the necessary NDT / calculation). Corners of reinforcement pad shall be radiuses.

7.3

Tolerance
Diameter and out of roundness tolerances for the minor barrel shall be in accordance with the
requirements of Project Specification for Line Pipe.
The maximum straightness deviation, measured at the outside surface of the cylinder from a straight line
parallel to the vessel axis, shall not exceed 1.5mm per 1000 mm cylindrical shell length. Tolerance on
overall length shall be to + 10 mm with respect to approved drawings. Nozzles tolerances with respect to
approved drawings shall be in accordance with the following requirements:

Position: measure from neck end + 6 mm.

Projection: measure from shell outer surface + 3 mm

Alignment of nozzle flange face: max. deg in any direction from true vessel axis and true radial
centre line.

Radial: measured from reference centre line to centre line of nozzle + 2mm

Bolt hole: maximum total indicated run-out 0.2 mm from true position.

Alignment of end closure flange face shall be max + 1 deg in any direction.
TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 11 of 14
Page 25 of 54

8.0

INSPECTION AND TESTING

The client / clients representative shall reserve the right to perform all inspection and tests as per the
requirements of this specification and the relevant codes at suppliers 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 Third Party Inspector. Inspection and tests performed/
witnessed by Inspector shall in no way relieve the Manufacturers obligation to perform the required
inspection and tests. The TPIA hired by Purchaser / Purchasers Representative shall not be retained by
manufacturer for its inspection.
MANUFACTURER shall submit to client / clients representative a detailed inspection and QUALITY
ASSURARANCE PLAN (QAP) for approval with scheduled activities and acceptance criteria before start
of manufacturing.
The client / clients representative reserves the right to inspect materials, manufacturing process; testing,
etc. such inspection does not relieve the MANUFACTURER of the responsibility of suitable design and
workmanship.

8.1

Visual Inspection
Undercuts, overlaps, craters and other unacceptable defects on the welds shall be removed and / or
welded.

8.2

Mechanical Testing
All material pertaining to pig trap including pig trap shall be confirmed to mechanical test only certified by
TPIA as per design requirement.

8.3

Non Destructive Examination

Non-destructive examination shall be carried out as per code but shall not be less than the following:

QOC forgings and mainline flange UT.

All pressure part butt joints 100% RT and UT.

Nozzle to shell joint 100% UT and MPT.

Attachments welds and lifting lug welds 100% MPT and PT.

All mating clamp and machined surfaces, door hinges attachment of end closure 100% MPT or
PT.

100% Ultrasonic Inspection of Pig Trap barrel / Body material; 100% RT scan of seam.
Ultrasonic inspection is required on Pig trap shell material where locally reinforced fittings are to be
welded. Prior to welding all weld ends are also to be checked using ultrasonic inspection.
NDT examination and acceptance criteria shall be as follows:
NDT METHOD
Ultrasonic Testing for Forgings

PROCEDURE
ASME Sect. V. Article 5 & 23

Ultrasonic Testing for Shell &

Welding Ends
Ultrasonic Testing for welds

ASME Sect. V. Article 5 & 23

Magnetic Particle

ASME Sect. V. Article 5 & 23

Dye Penetrant

ASME Sect. V. Article 5 & 23

ASME Sect. V. Article 5 & 23

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

ACCEPTANCE CRITERIA
ASME Sect. VIII, Div. 3, Art.
AM 203.2(c)
ASTM A 578, Level I Cracks
Not Allowed
ASME Sect. VIII, Div. 1, App.
12
ASME Sect. VIII, Div. 1, App.
6
ASME Sect. VIII, Div. 1, App.
Document No.

Rev

11-0330L01-01-09-02-002

SHEET 12 of 14
Page 26 of 54

Radiography

8.4

ASME Sect. V. Article 5 & 23

8
ASME Sect. VIIII, Div. 1, Art.
UW51

Personnel Qualification
Experienced operators certified to ASNT SNT-TC-1A Level II shall perform all NDT examinations.

8.5

Dimensional Inspection
All dimensions of all attachments such as nozzles, saddles, weldolets, etc., shall be checked and verified
in accordance with approved construction drawings.

8.6

Air Test
If the traps are provided with welded reinforced attachments, tell-tale holes shall be provided in order to
test with dry air at 7 bar g pressures and checked with foam agent for leaks. This shall be carried out prior
to the final hydrostatic pressure test.

8.7

Hydrostatic Pressure Test

Hydrostatic pressure tests shall be carried out at a test pressure equal to 1.5 times the design pressure.
The test pressure shall be held a minimum of 4 hours.
The temperature of the trap material and test liquid shall not be less than 10C during the hydrostatic test.
A continuous recording of the pressure test is to be made including a calibration (witnessed and certified)
and is to be included in the documentation to be provided by MANUFACTURER.
The pressure test shall be performed after completion of all welding, heat treatment, installation of any
specified instrument and building of all flanges, and before painting.
Quick opening type end closure shall be hydro-tested for minimum 24 hours plus 20 cycles from zero to
hydrostatic test value.

8.8

Functional Test
The end closure will be fully operable after pressure cycles have been applied. No excessive force should
require to be applied to operate mechanism. The pressure locking and bleeding device shall be checked to
ensure correct operation in both positions. Minimum two opening and closing cycles shall be performed.

9.0

NAMEPLATE & MARKING

Each piece of equipment shall be provided with a securely fixed stainless steel (SS-316) nameplate. The
nameplate shall be permanently protected during, painting and shipping. The following information shall be
stamped onto the nameplate:

Order number
Manufacturers Name
Year of Manufacture
Tag number
Serial number
size and rating
Design Pressure
Design Temperature

Connections furnished on the equipment shall be identified as to use and shall be tagged to agree with
Purchasers connection table or general arrangement drawing.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 13 of 14
Page 27 of 54

10.0

SURFACE PREPARATION AND PAINTING

Unless otherwise specified by purchaser / purchasers representative, the scraper launcher / receiver shall
be grit blasted and painted as follows.
Blast clean to ISO 8501-1, Grade Sa 2 ;
MANUFACTURER to propose 1 coat Red Oxide Zinc Phosphate Epoxy primer + 2 coat HB epoxy paint
system for purchasers approval.
The inner surfaces must be free of loose particles, lamination flakes, welding spatter and sharp edges or
any protruding element that interferes with the pig / scraper.

11.0

PREPARATION FOR SHIPMENT AND PACKING

One complete set of installation, operating and maintenance instructions shall be packed and shipped with
the equipment.
Equipment shall be drained of test liquid, cleaned and thoroughly dried prior to shipment. Surfaces subject
to atmospheric corrosion or rusting shall be coated with rust preventive. External non-painted surfaces
including bolting and flange faces also shall be coated with rust preventive designed for at least six months
of storage.
All components shall securely anchor to the skid and package supports.
All opening, flange facings, etc., shall be sealed with waterproof coverings for shipping. Threaded coupling
shall be provided with steel plugs.
Two extra O-rings and the closure actuation tool shall be attached to the inside of the barrel to prevent
loss. The scrapper barrels shall be handled in such a manner to prevent damage, including damage to the
bevel or closure. Service bolting and gaskets shall be suitably rated and properly marked.
Flanged openings shall be protected with one-piece plywood cover and rubber gasket. Plywood covers
shall be 3/8 inch thick, for flanges 6 inches and smaller, inch thick for 8 inch through 12 inch flanges,
and inch thick for larger sizes.
A minimum of four 3/8 inch bolts shall be used for flanges 12 inches and smaller end eight 3/8 inch bolts
for larger flanges.
Large washers shall be used on the flange side of the bolt. Suitable washers shall be used on the plywood
side of all such covers.

12

SPARES
Spare parts / special tools for start-up/commissioning shall be supplied by MANUFACTURER as part of
the base offer.
MANUFACTURER shall also recommend spares required for two years of normal operation with special
attention to consumable items such as gaskets, seals, etc. for end closures.

TECHNICAL SPECIFICATION
FOR
SCRAPER LAUNCHER/RECEIVER

Document No.

Rev

11-0330L01-01-09-02-002

SHEET 14 of 14
Page 28 of 54

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB NO.

DATA SHEET
FOR
SCRAPER LAUNCHER / RECEIVER
DOCUMENT NO

11

0330L01

TOTAL SHEETS

01

09

03

002

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLIENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 29 of 54

CLIENT

GAIL (India) Limited

TAG NO.

QUANTITY

02

SIZE

39-SL-101
39-SL-103
36 X 30

PIG LAUNCHER

DESGIN DATA
DESIGN CLASS : 600#
DESIGN CODE : ASME B 31.8/ ASME Sec VIII
SCRAPER LAUNCHER TYPE
FLUID
: NATURAL GAS / R-LNG
5 SWEET SERVICE
SOUR
LETHAL
DESIGN PRESSURE AND TEMPERATURE:
92 Kg/cm2 and

(-)29 to 65

MATERIALS
SHELL
ECCENTRIC
MAJOR BARREL : API 5L Gr. X 60 (PSL 2)/ Equivalent
MINOR BARREL : API 5L Gr. X 60 (PSL 2)/ Equivalent
ECCENTRIC REDUCER : MSS SP 75 Gr WPHY - 60
THICKNESS
MAJOR BARREL(mm) : (Note-4)
MINOR BARREL (mm) : (Note-4)

OPERATING PRESSURE
PATA LAUNCHER (Kg/cm2)
:
DIBIYAPUR LAUNCHER (Kg/cm2) :

45 - 55
50 70

OPERATING TEMPERATURE

45

HYDRO TEST PRESSURE

5 PWHT

:
138Kg/cm2
@ AMBIENT temp

5 CHARPY IMPACT TEST

RADIOGRAPHY AS PER CODE

JOINT EFF: SHELL 100% HEAD 100%
ULTRASONIC TESTING As Per CODE
HYDROTEST As Per CODE
5 HORIZ.
VERT.

REDUCER LENGTH
MAJOR BARREL LENGTH
MINOR BARREL LENGTH

CORROSION ALL (mm) : 3

QUICK OPENING END CLOSURE

TYPE
: BAND LOCK
MATERIAL OF CONSTRUCTION : SA 694 Gr. F 5 /
SA 350 Gr.LF2
DESIGN THK. (mm)
: BY VENDOR
CORROSION ALL (mm) : 3.0
TOTAL MIN. THK
: BY VENDOR
MISCELLANEOUS
SADDLE
: SA 36
WELD PADS : SAME AS BARREL MATERIAL
SUPPORT : N/A
SKID FRAME : N/A

VESSEL DIMENSIONS (mm)

610 (Note-2)
6600 (Note-2)
1500 (Note-2)

DATA SHEET
FOR
SCRAPER LAUNCHER /
RECEIVER

DOCUMENT NO.

REV

11-0330L01-01-09-03-002

SHEET 2OF 6
Page 30 of 54

PIPELINE DETAILS
DIAMETER
WALL THK.
MATERIAL

30 (NB)
17.5 mm
API 5L Gr.X60 (PSL 2)

PART NO.

DESCRIPTION

DIA.

BODY
(MAJOR BARREL)

914 mm(36)

NECK
(MINOR BARREL)

762 mm
(30)

REDUCER

36X30

END CLOSURE

36

5A/B

LIFTING LUGS

MARK

SIZE

QTY

FLANGED
RATING
TYPE
600#
WNRF
600#
WNRF
600#
WNRF
600#
WNRF
600#
WNRF
600#
WNRF

N1
N2
N3
N4
N5
N6

4
30
2
2
2
4

1
1
1
1
1
1

N7

10

600#

N8

36

N9

N10

ENDS/TYPE
BUTT WELDED TO SUIT
REDUCER,END CLOSURE
ONE END BUTT WELDED TO SUIT
REDUCER AND ONE END FLANGED
TO SUIT PIPELINE
BUTT WELDED TO SUIT BOTH MAJOR
& MINOR BARREL THICKNESS
BUTT WELDED TO SUIT
BARREL THICKNESS

MATERIAL

SERVICE

ASTM A 105
ASTM A 350 Gr. LF2
ASTM A 350 Gr. LF2
ASTM A 350 Gr. LF2
ASTM A 350 Gr. LF2
ASTM A 350 Gr. LF2

DRAIN
INLET
PRESSURE INDICATOR
VENT
PRESSURE RELIEF
BALANCE

WNRF

ASTM A 350 Gr. LF2

KICKER LINE

600#

N/A

N/A

CLOSURE

600#

WNRF

ASTM A 350 Gr. LF2

PIG SIGNALLER

600#

WNRF

ASTM A 350 Gr. LF2

DRAIN

N11

600#

WNRF

ASTM A 350 Gr. LF2

INERT GAS PURGE

N12

600#

WNRF

ASTM A 350 Gr. LF2

BALANCE

All Flange Connection Shall confirm to ASME B 16.5

DATA SHEET
FOR
SCRAPER LAUNCHER /
RECEIVER

DOCUMENT NO.

REV

11-0330L01-01-09-03-002

SHEET 3OF 6
Page 31 of 54

CLIENT

GAIL(India) Limited

QUANTITY

02

39-SR-102
39-SR-104
36 X 30

TAG NO.
SIZE

PIG RECIEVER

DESGIN DATA
DESIGN CLASS : 600#
DESIGN CODE : ASME B 31.8
SCRAPER RECEIVER TYPE
FLUID
: NATURAL GAS / R-LNG
5 SWEET SERVICE
SOUR
LETHAL

MATERIALS
SHELL
CONCENTRIC
MAJOR BARREL : API 5L Gr. X 60 (PSL 2) / Equivalent
MINOR BARREL : API 5L Gr. X 60 (PSL 2)/ Equivalent

DESIGN PRESSURE AND TEMPERATURE:

CONC. REDUCER : MSS SP 75 Gr WPHY - 60

92 Kg/cm2 and

(-)29 to 65

THICKNESS
MAJOR BARREL (mm) : (Note-4)
MINOR BARREL (mm) : (Note-4)

OPERATING PRESSURE
PATA RECEIVER (Kg/cm2)
:
DIBIYAPUR RECEIVER(Kg/cm2) :
OPERATING TEMPERATURE :
HYDRO TEST PRESSURE

5 PWHT

50 70
45 55
45 C

:
138 Kg/cm2
@ AMBIENT temp

5 CHARPY IMPACT TEST

CORROSION ALL (mm): 3

QUICK OPENING END CLOSURE
TYPE
: BAND LOCK
MATERIAL OF CONSTRUCTION : SA 694 Gr. F5 / SA
350 Gr. LF2
DESIGN THK. (mm)
: BY VENDOR
CORROSION ALL (mm) : 3.0
TOTAL MIN. THK

RADIOGRAPHY AS PER CODE

JOINT EFF: SHELL 100% HEAD 100%
ULTRASONIC TESTING As Per CODE

: BY VENDOR

MISCELLANEOUS
SADDLE
: SA 36
WELD PADS : SAME AS BARREL MATERIAL

HYDROTEST As Per CODE

5 HORIZ.
VERT.

SUPPORT : BY VENDOR
SKID FRAME : N/A
VESSEL DIMENSIONS(mm)

DATA SHEET
FOR
SCRAPER LAUNCHER /
RECEIVER

DOCUMENT NO.

REV

11-0330L01-01-09-03-002

SHEET 4OF 6
Page 32 of 54

REDUCER LENGTH
MAJOR BARREL LENGTH
MINOR BARREL LENGTH

610 (Note-2)
6600 (Note-2)
6600 (Note-2)
PIPELINE DETAILS

DIAMETER
WALL THK.
MATERIAL
PART NO.
1

DESCRIPTION
BODY
(MAJOR BARREL)

30 (NB)
17.5 mm
API 5L Gr.X60 (PSL 2)
PRODUCT FORM
DIA.
PIPE/FABRICATION

36

NECK
(MINOR BARREL)

PIPE/FABRICATION

30

REDUCER

CONCENTRIC
REDUCER

36 X 30

END CLOSURE

FORGED

36

5A/B

LIFTING LUGS

PLATE

ENDS/TYPE
BUTT WELDED TO SUIT
REDUCER,END CLOSURE
ONE END BUTT WELDED TO
SUIT REDUCER AND ONE
END FLANGED TO SUIT
PIPELINE
BUTT WELDED TO SUIT BOTH
MAJOR & MINOR BARREL
THICKNESS
BUTT WELDED TO SUIT
BARREL THICKNESS

CONNECTION SCHEDULE
MARK

SIZE

QTY

FLANGED
MATERIAL
RATING
TYPE
N1
4
1
600#
WNRF
ASTM A 350 Gr. LF2
N2
30
1
600#
WNRF
ASTM A 350 Gr. LF2
N3
2
1
600#
WNRF
ASTM A 350 Gr. LF2
N4
2
1
600#
WNRF
ASTM A 350 Gr. LF2
N5
2
1
600#
WNRF
ASTM A 350 Gr. LF2
N6
4
1
600#
WNRF
ASTM A 350 Gr. LF2
N7
1
600#
WNRF
ASTM A 350 Gr. LF2
10
N8
1
600#
N/A
N/A
36
N9
1
600#
WNRF
ASTM A 350 Gr. LF2
2
N10
1
600#
WNRF
ASTM A 350 Gr. LF2
4
N11
1
600#
WNRF
ASTM A 350 Gr. LF2
2
N12
4
1
600#
WNRF
ASTM A 350 Gr. LF2
All Flange connection Shall confirm to ASME B 16.5

SERVICE
DRAIN
INLET
PRESSURE NDICATOR
VENT
PRESSURE RELIEF
BALANCE
KICKER LINE
CLOSURE
PIG SIGNALLER
DRAIN
INERT GAS PURGE
BALANCE

FABRICATOR TO FURNISH
5 SADDLE
5 SUPPORTS
5 GROUND LUG 5 SPARES
5 EXT. PAINTING / COATING
VESSEL EMPTY WT : BY VENDOR
OPERATING WT
: BY VENDOR

5 SAND BLASTING REPORT 5 LIFTING LUG

5 NAME PLATES
5 DETAILED FABRICATION DRGS
5 DETAILED MECHANICAL CALCULATIONS
WEIGHTS
SHIP WT
: BY VENDOR
HYDROTEST WT : BY VENDOR

NOTES:
1) ALL DIMENSIONS ARE IN MILLIMETER.
2) TRAP LENGTH ARE INDICATIVE ONLY, HOWEVER VENDOR TO VERIFY THE SIZE AS PER LATEST
INTELLIGENT PIG AVAILABLE IN THE MARKET.

DATA SHEET
FOR
SCRAPER LAUNCHER /
RECEIVER

DOCUMENT NO.

REV

11-0330L01-01-09-03-002

SHEET 5OF 6
Page 33 of 54

3) SCRAPER LAUNCHER PROVIDED WITH QUICK OPENING TYPE END CLOSURE DESIGNED TO ASME
SECTION VIII Div 1 & PROVIDED WITH MECHANICAL INTERLOCK ARRANGEMENT TO PREVENT
OPENING UNLESS THE INTERNAL PRESSURE IS DEPRESSURIZED.
4) VENDOR TO CONFIRM.
5) SUITABLE JIB CRANE TO BE PROVIDED AT EACH SCRAPER LAUNCHER/ RECEIVER.
6) PIG HANDLING FACILITY INCLUDING PORTABLE TROLLEY WITH MOVEMENT BY WINCH OR OTHER
ALTERNATIVE OPERATING MANNUALLY AND PIG HANDLING TRAY WITH PIG TRAVELLING
MECHANISM SHALL BE INCLUDED FOR EACH EQUIPMENT.
7) THIS DATA SHEET IS TO BE READ IN CONJUCTION WITH SCRAPER LAUNCHER / RECEIVER SPEC
NO. 11- 0330L-01-09-02-002.
8) THE BLANK DATA IN THIS DATA SHEET SHALL BE FILLED BY VENDOR AND SUBMITTED
ALONG WITH THE BID.
9) THE PIG SIGNALLER SHALL BE INTRUSIVE TYPE.
10) TWO NO. PIG SIGNALLER TO BE SUPPLIED LOOSE TO BE FITTED ON PIPE (DIA 30 & THICKNESS
17.5) AND FOUR TO BE FITTED ON LAUNCHER / RECEIVER.
11) SUCCESSFUL VENDOR SHALL PROVIDE COMPLETE CALCULATION & DRAWINGS FOR APPROVAL
AND ANY CHANGES SUGGESTED SHALL BE PROVIDED WITHOUT COST IMPLICATION.
12) SUPPORT LOCATION TO BE FINALISED BY THE VENDOR

DATA SHEET
FOR
SCRAPER LAUNCHER /
RECEIVER

DOCUMENT NO.

REV

11-0330L01-01-09-03-002

SHEET 6OF 6
Page 34 of 54

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB NO.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE
DOCUMENT NO

11

0330L01

TOTAL SHEETS

01

09

02

003

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLIENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 35 of 54

TABLE OF CONTENTS

Sl.No.

DESCRIPTION

PAGE NO.

1.0

SCOPE

2.0

CODES, STANDARDS AND DOCUMENTS

3.0

MATERIAL

4.0

DESIGN AND CONSTRUCTION

5.0

INSPECTION & TESTS

6.0

TEST CERTIFICATES

7.0

PAINTING, MARKING & SHIPMENT

8.0

SPARES

9.0

DOCUMENTATION

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 2 of 8
Page 36 of 54

1.0

SCOPE
This specification covers the minimum requirements for design, manufacture and supply of quick opening
end closures (QOEC) to be installed at blow-down points handling hydrocarbons in gaseous phase.
This specification does not cover quick opening end closures for sour hydrocarbons service as defined in
NACE Standard MR0175-98.

1.1

Abbreviations
The following definitions shall apply:

1.2

1.3

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.

Purchaser

The Company which makes purchase order.

Manufacturer

Manufacturer who receives the purchase order.

Shall

This verbal form indicates requirements strictly to be

followed in order to confirm to the standards and form
in which no deviation is permitted.

Should

This verbal form indicates that among several possibilities

one is particularly suitable without mentioning or
excluding others or that a certain course of action is
preferred but not necessarily required.

May

This verbal form indicates a course of action permissible

within the limits of this standard.

Can

This verbal form used for statements of possibility &

capability, whether material, physical or casual.

Definitions

Compliance
Compliance by the manufacturer with this specification shall not relieve him from his responsibilities to
supply Quick opening end closure suited to meet the specified requirements and/or local codes governing
health and safety.
The MANUFACTURER shall notify the purchaser / purchasers representative in writing, of any proposed
deviation from this Specification. The Purchasers decision in respect of concession requests will be final.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 3 of 8
Page 37 of 54

The MANUFACTURER shall continually verify the quality and fitness for purpose of the
launchers/receivers, and shall propose appropriate actions/measures if any aspects of manufacture are
found to be unsatisfactory.
1.4

Quality Conformance
The MANUFACTURER shall demonstrate to the satisfaction of the PURCHASER / PURCHASERS
REPRESENTATIVE that his activities within the scope of this document are in accordance with the
relevant section of BS EN ISO 9001. The MANUFACTURER shall submit to the Purchaser / purchasers
representative for review and approval, a Quality Plan and procedural specifications prior to
commencement of work. The Quality Plan shall define all sub Manufacturers involvement in the work. The
review in this Specification shall only indicate a general requirement and shall not relieve the
MANUFACTURER of his obligations to comply with the requirements of the Contract.

1.5

Safety
Safety is paramount. All work shall be performed in accordance with the safety requirements listed in the
contract documentation.

2.0

CODES, STANDARDS AND DOCUMENTS

2.1

Codes and standards

Scraper launchers, receivers or combined traps specified herein shall be designed, manufactured and
tested in accordance with the latest edition of the following codes and standards and/or others as
applicable. These Codes and Standards are the minimum requirements, and manufactured design shall
meet or exceed them.
API Spec 5L

Specification for Line pipe.

API 1104

Welding of Pipelines and Related Facilities.

ASME V

Boiler and Pressure Vessel Code - Non Destructive Testing.

ASME VIII

Boiler and Pressure Vessel Code - Div 1- Pressure Vessels.

ASME IX

Boiler and Pressure Vessel Code - Welding & Brazing

qualifications

ASME B 31.1

Power Piping.

ASME B 31.3

Process Piping.

ASME B 31.8

Gas Transmission and Distribution Pipeline System.

ASME B 16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B 16.9

Factory-made Wrought Steel Butt Welding Fittings.

ASME B 16.11

Forges Steel Fittings, Socket Welding and Threaded.

ASME B 16.25

Butt Welded Ends.

ASME B 16.47

Large Diameter Steel Flanges: NPS 26 through NPS 60.

ASTM A 105

Forging, Carbon Steel for Piping Components.

ASTM A 181

Forging, Carbon Steel for General-Purpose Piping.

ASTM A 234

Piping Fitting of Wrought Carbon Steel and Alloy Steel for

moderated and Elevated Temperatures.

ASTM A 370

Mechanical Testing of Steel products.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 4 of 8
Page 38 of 54

ASTM A 216

Carbon Steel Castings suitable for Fusion Welding for High

temperature Service.

ASTM A 20

General requirements for steel plate for pressure vessels.

ASTM A 516

Carbon steel pressure vessel plates for moderate and low

temperature service.

ASTM A 106

Carbon steel seamless pipe for high temperature service.

ASTM A 193

Alloy steel and stainless steel bolting materials for high

temperature.

ASTM A 194

Carbon and alloy steel nuts for bolts for high pressure or
temperature.

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.

MSS-SP-75

High test wrought butt-welded fittings.

ISO 9712

Non-destructive testing qualification and certification of

personnel.

ISO 10474

Steel and Steel Structures Inspection documents.

ISO 9000

Quality Management and Quality Assurance Standards.

ISO 9001

Quality Systems Model for quality assurance in design,

development, production, installation and servicing.

ISO 9002

Quality Systems Model for quality assurance in production,

installation and servicing.

2.2

Order of Precedence
In the event of any conflict of data or requirements in any of the above documents, it is the Suppliers
responsibility to resolve these conflicts before proceeding with design, manufacture or purchase. In any
case, the most stringent requirement shall prevail. However, Client / Clients Representative interpretation
shall be final.
In case of conflict, the order of precedence of the documents shall be as follows;

Equipment Data Sheets.

Technical Specification For QEOC.

Project Specifications, Company Standards, and International Codes as per Paragraph 2.1.

3.0

MATERIALS

3.1

Carbon steel material used in the manufacture of pressure containing parts of quick opening end closure
shall be fully killed. In addition, the material shall also meet the requirements specified herein. Other
components shall be as per Manufacturers Standard. However, all the materials used shall be suitable for
the service conditions indicated in the Data Sheets, which will be subject to approval by Purchaser.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 5 of 8
Page 39 of 54

3.2

Material of the ends to be field welded by Purchaser shall have Carbon Equivalent not more than
0.43 based on Check analysis for each heat of steel used, calculated as per the following formula:
CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15

3.3

Unless specified otherwise, Charpy V-notch test shall be conducted for each heat of steel, in accordance
with the impact test provisions of ASTM A 370 at temperature of -20 deg. C. The average absorbed impact
energy values of three full-sized specimens shall be 35 joules. The minimum impact energy value of any
one specimen of the three specimens analyzed as above shall not be less than 27 Joules.

3.4

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 the pressure containing parts shall not exceed 248 HV10.

4.0

DESIGN AND CONSTRUCTION

4.1

End closures shall be designed in accordance with the provisions of ASME B 31.8 and ASME Sec.
VIII Division 1. Design factor and corrosion allowance shall be as indicated in the Data Sheet.

4.2

The quick opening end closure shall be of band lock or equivalent type and operable
by a single lever operation. The closure shall also consist of a safety system allowing the opening
only when there is no pressure in the line.

4.3

Threaded / screwed / Plug- In type end closures are not acceptable.

4.4

End closure shall be suitable for installation in horizontal position at an elevation of 1meter for 36X30
Scraper Launcher / Receiver above ground level.

4.5

The handling device shall be attached to the welding end hub, which shall be suitable for such attachment.

4.6

All welds shall be made by qualified welders and welding procedures qualified in accordance with the
provisions of ASME Sec. IX. The procedure qualification shall also include impact test and hardness test
when required as per Clause 3.4 and 3.5 of this specification and shall meet the requirements as specified
therein.

4.7

Completed assembly shall be stress relieved as per the provisions of the design codes.

4.8

Enclosure for 36X30 scraper shall be fitted with worm gear operation for the operation of closure.

5.0

INESPECTION AND TESTING

5.1

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 shall be, but not limited to,
the following:

5.1.1 Chemical composition and mechanical properties shall be checked.

5.1.2 All closures shall be visually inspected.
5.1.3 Dimensional check shall be carried out as per the approved drawings.
5.1.4 All butt welds shall be 100% radiographically inspected. Procedure and acceptance criteria shall be as per
API 1104.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 6 of 8
Page 40 of 54

5.1.5 Hydrostatic test shall be conducted for all end closures complete in all respects, at a pressure equal to 1.5
times the design pressure. Test duration shall be 15 minutes.
5.1.6 Welds, which cannot be radiographically inspected, shall be inspected by ultrasonic or magnetic particle
methods. Procedure and acceptance criteria shall be as per ASME Sec. VIII, Appendix U and Appendix VI
respectively.
5.1.7 All finished butt weld ends shall be ultrasonically inspected for lamination type defects for a distance of 50
mm from the end. Any lamination larger than 6.35 mm shall not be acceptable.
5.1.8 A minimum of two closing and opening cycles shall be performed and correct operation of both quick
opening and safety system shall be established.
5.2

Purchasers Inspector reserves the right to perform inspection and witness tests including hydrostatic test,
as indicated in clause 5.1 at Manufacturers 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 Purchasers Inspector. Inspection and tests performed/witnessed by Purchasers Inspector shall in no
way relieve the Manufacturers obligation to perform the required inspection and tests.

6.0

TEST CERTIFICATES
Manufacturer shall furnish the following certificates:
a)

Test Certificates relevant to chemical and mechanical properties of the material used as
per the relevant standards.

b)

Report on Non-Destructive examination.

c)

Hydrostatic test certificates

d)

Certificate of satisfactory performance of end closure as per Clause 5.1.8.

7.0

PAINTING, MARKING AND SHIPMENT

7.1

Exterior surface of Quick Opening End Closures shall be thoroughly cleaned, free from rust
& grease and applied with sufficient coat of corrosion resistant paint.

7.2

Marking shall be done on a stainless steel plate and affixed to the body permanently. Marking
shall include the following:

Order number

Manufacturers Name

Year of Manufacture

Tag number

Serial number

size and rating

Design Pressure

Design Temperature

7.3

Before shipment, closures shall be properly packed against damage during transportation. Suitable
protection shall be provided for the weld ends.

7.4

Only those closures, which have been inspected and certified by Purchasers Inspector, shall be
shipped.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 7 of 8
Page 41 of 54

8.0

SPARES

8.1

Manufacturer shall furnish list of recommended spares and accessories for Quick Opening End Closures
required during start up and commissioning. Cost of such spares shall be included by the Manufacturer in
the item rates indicated in purchase Requisition.

8.2

Manufacturer shall furnish separately a list of recommended spares and accessories required for two
years of normal operation and maintenance of Quick Opening End Closures.

9.0

DOCUMENTATION

9.1

All documents shall be in English Language only.

9.2

Manufacturer shall furnish at the time of bidding, the following documents:

a)
b)
c)

9.3

General arrangement drawing of end closure with overall dimensions.

Clause wise list of deviations from this specification, if any.
Quality Assurance Plan.

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)
b)
c)

Design calculations according to relevant codes for the end closure.

Welding procedure and method of manufacture.
Closure assembly and sectional drawings showing all parts with materials and dimensions.

9.4

Within four weeks from the approval date, Manufacturer shall submit two soft and two hard copies of the
approved drawings, documents and specifications listed in Clause 9.3 of above.

9.5

Prior to shipment, the Manufacturer shall submit two soft and two hard copies of the Test certificates as
listed in clause 6.0 of this specification and manual for installation, erection, instructions, maintenance and
operation instruction.

TECHNICAL SPECIFICATION
FOR
QUICK OPENING END CLOSURE

Document No.

Rev

11-0330L01-01-09-02-003

SHEET 8 of 8
Page 42 of 54

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB NO.

DATA SHEET
FOR
QUICK OPENING END CLOSURE

DOCUMENT NO

11

0330L01

01

TOTAL SHEETS

09

03

003

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLIENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 43 of 54

CLIENT

GAIL (India) Limited

TAG NO.

QUANTITY

04

SIZE

39-QOEC-101
39-QOEC-102
39-QOEC-103
39-QOEC-104

36

SERVICE
DESIGN CONDITIONS:

NATURAL GAS

Type
PRESSURE (Kg/cm2)
TEMPERATURE (C)
CORROSION ALLOWANCE(mm)
DESIGN CODE
ANSI RATING
HYDROSTATIC TEST PRESSURE(Kg/cm2)
OPERATING CONDITIONS:
PRESSURE AT PATA LAUNCHER & RECEIVER(Kg/cm2)
PRESSURE AT DIBIYAPUR LAUNCHER & RECEIVER
(Kg/cm2)
TEMPERATURE (C)

BAND LOCK
92
(-)29 to 65
3.0
ASME SEC. VIII DIV. 1
600#
138
45 55

& 50 70

50 70

& 45 55

45

CONNECTING PIPELINE DETAILS

S.NO.

O.D(inch) x W.T(mm)

TOTAL NO OF PIPELINE

30 x 17.5

QOEC MATERIAL SPECIFICATION

PART

SPECIFIED MATERIAL

PRESSURE CONTAINING
PARTS

SA 694 Gr.F5/SA 350 Gr LF2

INSERTS/GASKETS

VITON 75

DATA SHEET
FOR
QUICK OPENING END
CLOSURE

MATERIAL OFFERED BY VENDOR

DOCUMENT NO.

REV

11-0330L01-01-09-03-003

SHEET 2 OF 2
Page 44 of 54

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB NO.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER
DOCUMENT NO

11

0330L01

TOTAL SHEETS

01

11

02

006

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLIENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 45 of 54

TABLE OF CONTENTS

Sl.No.

DESCRIPTION

PAGE NO.

1.0

SCOPE

2.0

CODES, STANDARDS AND DOCUMENTS

3.0

GENERAL REQUIREMENTS

4.0

BASIC DESIGN DATA

5.0

DESIGN CRITERIA

6.0

MATERIALS

7.0

FABRICATION

8.0

INSPECTION & TESTING

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER

Document No.

Rev

11-0330L01-01-11-02-006

SHEET 2 of 5
Page 46 of 54

1.0

SCOPE
This specification covers the minimum requirements for the design, manufacture, testing and supply of
Pig Signallers, used for the detection of passage of intelligent and instrumented gauging pigs, to be
installed in pipeline systems handling Natural GAS.

2.0

MATERIAL
The material used in manufacture of the main components of the Pig Signaller shall be as under:
a) All metallic parts except scarfed welding base : SS 316
Other components shall be as per Manufacturers Standard, suitable for the service conditions indicated
in Data Sheet, which will be subject to approval by Purchaser.
Welding base shall have Carbon Equivalent
analysis, calculated as per the following formula:

(CE)

not

greater

than

0.45

on

check

CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15

3.0

4.0

DESIGN AND CONSTRUCTION REQUIREMENT

3.1

Pig Signallers shall intrusive & mechanical type

3.2

Pig Signallers shall be designed to meet the requirements of pipeline material, diameter, wall
thickness and service conditions indicated in the Data Sheet.

3.3

Pig Signallers shall be provided with a visual indicator to indicate the passage of pigs.

3.4

All welds shall be made by welders and welding procedures qualified in accordance with the
provisions of ASME Section IX.

3.5

When indicated in Data Sheet, Pig Signallers shall be fitted with sealed, weather proof and
explosion proof micro switch for remote signal indication. The area classification and rating of
micro switch shall be as indicated in Data Sheet.

INSPECTION AND TESTS

4.1
4.2
4.3
4.4

5.0

Manufacturer shall perform all inspection and tests required to supply the Pig Signallers as per
the requirements of this specification.
NDT shall be performed on each weld.
The welding end shall be inspected ultrasonically over the entire circumference for lamination
type defects. Any lamination larger than 6.35 mm shall not be acceptable.
Manufacturers shall perform functional tests to establish satisfactory performance of both
manual and electrical indications.

TEST CERTIFICATES
Manufacturer shall submit the test certificates for material compliance as per the relevant material
standards and certificates for functional tests.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER

Document No.

Rev

11-0330L01-01-11-02-006

SHEET 3 of 5
Page 47 of 54

6.0

PAINTING, MARKING AND SHIPMENT

6.1

Exterior surface of the Pig Signaller shall be thoroughly cleaned, free from rust and grease and
applied with sufficient coats of corrosion resistant paint. In case of Pig Signallers with extension,
the buried portion shall be coated with three coats of coal tar epoxy resin. The minimum dry film
thickness shall be 300 microns.

6.2

A corrosion resistant metal tag shall be permanently attached with each unit, with the
following marking:

i)
ii)
iii)
iv)

Manufacturers name.
Suitable for installation in mm dia. Pipeline
ANSI Rating
Tag No.

6.3

Each unit shall be suitably protected to avoid any damage during transit. Care shall be
exercised during packing to prevent any damage to the welding ends. All machined surfaces
subject to corrosion shall be well protected by a coat of grease or other suitable materials.

.
7.0

SPARES AND ACCESSORIES

Manufacturer shall furnish list of recommended spares and accessories for Pig Signallers required
during start up and commissioning. Cost of such spares shall be included by the Manufacturer in the item
rates indicated in Purchase Requisition. Manufacturer shall furnish separately a list of recommended
spares and accessories required for two years of normal operation and maintenance of Pig Signallers.

8.0

DOCUMENTATION
8.1

All documents shall be in English language.

8.2

At the time of bidding, Manufacturer shall submit the following documents:

i)

General arrangement drawings with overall dimensions.

ii)

Clause wise list of deviations from this specification, if any.

iii)

Reference list of similar supplies of Pig Signaller shall be furnished including Project, Year of
supply, Client, Size, Rating and Service for the last five years.

8.3

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.

i)

Fabrication drawings Sectional arrangement drawings showing all parts with reference numbers
and material specification.

ii)

Assembly drawing with overall dimensions

iii)

Welding and testing procedure.

iv)

Cable connection details and cable specification.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER

Document No.

Rev

11-0330L01-01-11-02-006

SHEET 4 of 5
Page 48 of 54

Once, the approval has been given by Purchaser, any change in design, material, etc. shall be notified to
Purchaser whose approval in writing of all such changes shall be obtained before - Pig Signallers are
manufactured.
8.4

Within four weeks from approval date, Manufacturer shall submit two soft and two hard copies of
the drawings, documents and specifications as listed in clause 8.2 of this specification.

8.5

Prior to shipment, Manufacturer shall submit one reproducible and six copies of the following:

i)

Test Certificates as per clause 5.0 of this specification

ii)

Manual for installation, erection instructions, maintenance and operation instructions.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER

Document No.

Rev

11-0330L01-01-11-02-006

SHEET 5 of 5
Page 49 of 54

GAIL (India) Limited

TERMINAL MODIFICATION FOR
PHULPUR,DIBIYAPUR & PATA
CLIENT JOB NO.

DATA SHEET
FOR
PIG SIGNALLER
DOCUMENT NO

11

0330L01

TOTAL SHEETS

01

11

03

006

10/10/12

ISSUED FOR TENDER

MK

DD

EUR

20/02/12

ISSUED FOR CLIENTS REVIEW

MK

DD

EUR

15/02/12

ISSUED FOR IDC

MK

DD

EUR

REV

DATE

DESCRIPTION

PREP

CHK

APPR

Page 50 of 54

DATA SHEET FOR PIG SIGNALLER

GENERAL
Pig Signaller Manufacturer
Pig Signaller Type

Intrusive, Mechanical
Pig Signaller
No
39-XXIS-1001,
39-XXIS-1002
39-XXIS-1101,
39-XXIS-1102
39-XI-3001
39-XI-4001
39-XI-4005
39-XI-3005

Pig Signaller Tag No.

Connecting
Equipment
Main Line
Main Line
Pig Launcher
Pig Launcher
Pig Receiver
Pig Receiver

Connecting
Equipment Tag
No
30-P-39-1004D1A
30-P-39-1104D1A
39-SL-101
39-SL-103
39-SR-102
39-SR-104

PROCESS DATA
Fluid
Design Pressure (Kg/cm2)

Natural Gas (Non-Sour Service)

92

Design Temperature ( C)

(-29) to 65

Operational Requirement

Piggable(Suitable for intelligent pigging)

DESIGN DATA
Design Life
Design code
Design factor
Corrosion allowance,(mm)
ANSI Class Rating
Installation
Run Pipe Material
Run Pipe Diameter x Run Pipe Wall Thickness
End Connections
Hydrostatic test Pressure
Supplementary Requirements

25 years
ASME B31.8, ASME B16.5 & ASME SEC VIII Div. 1
0.5
3.0
600#
Above Ground
API 5L Gr. X60, PSL-2
30 x 17.5 mm
Flanged (RF), Smooth Finish , ASME B16.5
As per ASME B16.5
Should be repairable under line pressure

MATERIAL (EQUIVALENT OR SUPERIOR)

Body

ASTM A 105
Metallic Components : SS 316
ORing and Shaft Seal : PTFE
ASTM A 105 / A 216 Gr. WCB
Metallic Components : SS 316
ORing and Shaft Seal : RTFE

Internals
Valve Body
Valve Internals
MICRO SWITCH DETAILS
Rating

Potential free contact of Rating 24v DC, 2A, SPDT

Weather proof to IP55 & Flame proof Exd. Enclosure
certified for area classification.
NPTF
IEC-ZONE-II, GAS GROUP IIA&IIB, TEMP CLASS-T3

Enclosure
Cable Connection
Electrical area classification
INSPECTION AND TESTING

Yield strength, Min. / Max. : As per ASTM A105

Ultimate Tensile strength : As per ASTM A105
As per ASTM A370
As per ASTM E92 (Note-3 )

Mechanical tests
Tensile test
Hardness Test

DATA SHEET
FOR
PIG SIGNALLER

DOCUMENT NO.

REV

11-0330L01-01-11-03-006

SHEET 2 OF 2
Page 51 of 54

Visual Inspection
Magnetic Particle Examination
Ultrasonic Examination
Radiography Examination / Acceptance Criteria
Heat Treatment
Certification

Note-4
As per ASME VIII Div. 1, Appendix-6
As per ASME VIII Div. 2,Clause 3.3.4 (2007 Edition)
As per ASME V Article 2 / ASME Section VIII-UW 51
Yes
As per EN 10204 Type 3.1 & 3.2

Notes:
1. Design of associated Pipeline shall be as per ASME B31.8.
2. Design of the Pig Signallers shall be in full compliance with the applicable Design Code. Data supporting the
design in the form of drawings shall be submitted for approval prior to commencement of manufacture.
3. Maximum hardness shall not be more than 248 HV10 for Base, Weld & HAZ Metal.
4. Completed Pig Signallers shall be 100% visually inspected to ensure free from surface defects and to ensure
compliance with dimensional tolerances.
5. Pig Signaller for only Main Line shall be provided with isolation valve for on-line repair.
6. Flag reset mechanism shall be provided.
7. Threaded connections shall not be used in any of the pressure containing components except when required
to facilitate the removal of the internals of Pig Signaller.

DATA SHEET
FOR
PIG SIGNALLER

DOCUMENT NO.

REV

11-0330L01-01-11-03-006

SHEET 2 OF 2
Page 52 of 54

LIST OF RECOMMENDED VENDORS

S.NO

ITEM

NAME OF VENDOR

TD Williams

Skeleton Hall

EQUIP ENGINEERS INDIA PVT.

LTD.

GEA Energy System (India) Ltd.

Scrapper Traps (Pig

Launcher / Pig Receiver)

PHONE NO

FAX NO

QUALIFIED FOR
SIZE

Multitex Engg

Gastech

V K Vikram

Control Plus

GD ENGINEERING

10

Forain S.r.l

11

PECO

12

GD ENGINEERING

13

R&M Energy Systems

14

ADDRESS

TD Williams
Quick Open Closure

15

Peerless

16

Huber Yale

16

Pipeline Technologies - France

17

Multitex Filtration Engineers Ltd.

18

Chemtrol Industries Limited

19

Crowcon Detection Instruments Ltd.

20

Detection Instruments (I) Pvt. Ltd.

21

Detector Electronics Corp. (Kidde

Co.)

22

Grager Safety AG & Co. KGAA

23

General Monitors Ireland Ltd.

Gas Detection System

24

Honeywell Analytics

25

Industrial Scientific Oldham

26

Mine Safety Appliances Company

27

MSA (India) Ltd.

28

Riken Keiki Co. Ltd.

29

Simrad Optronics Icare

NOTE: IF THE VENDOR WANTS TO GO TO ANY OTHER VENDOR OTHER THAN THOSE APPEARING IN APPROVED VENDOR LIST, HE HAS TO SUBMIT PTR &
FINANCIAL STATUS OF THE SAME FOR OWNER/CONSULTANT REVIEW BEFORE COMMENCING PROCUREMENT.
LIST OF RECOMMENDED VENDORS
FOR SCRAPER TRAP, QOEC and GAS DETECTION SYSTEM

Page 53 of 54

LIST OF RECOMMENDED TPIAs

S.NO

ITEM

NAME OF VENDOR

ADDRESS

Tata Projects Ltd.

Indian Register of Shipping

Bax counsel Insepection Bureau Pvt.

Ltd.

Bureau VeritasQl

Germanischer Lloyd

TPIA

PHONE NO

FAX NO

QUALIFIED FOR
SIZE

Velosi Certification
Serrvices,Mumbai

ABS Industrial Verification Ltd.,

Mumbai

Certification Engineers International

Ltd.

Dalal Mott MacDonald

10

International Certification Systems

SGS

LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCIES

Page 54 of 54