Replacement of 8

SHELL PAKISTAN LIMITED
REPLACEMENT OF TANKER DISCHARGE PIPELINE

(DIA 8”)- KEAMARI (SHELL LOBP)
CONSULTANTS: MAY, 2015
PETROCHEMICAL ENGINEERING CONSULTANTS

House No. C-2, Block No. 17, Gulshan-e-Iqbal, Near National Stadium, Karachi-75300,
Pakistan. Tel.: +92 (21) 34827780, 34961088, Fax: +92 (21) 34961089
E-Mail: shoaib@pcec.com.pk web site : www.pcec.com.pk
CONTENTS
REPLACEMENT OF TANKER
DISCHARGE PIPELINE
Doc. No.
Tender Package Contents Revision No. 2
2532-PM-DOC-0191
S.No. Description Document No. Rev
1. Preamble to Bill of Quantities 2532-PM-PR-0341 2
2. Bill of Quantities for Mechanical Works (Procurement) 2532-PIP-BOQ-4331 2
3. Bill of Quantities for Mechanical Works (Construction) 2532-PIP-BOQ-4332 2
Specifications
4. Piping , Fabrication & Installation 2532-ME-001 0
5. Painting Specification 2532-ME-002 2
6. Structural Steel Works Specification 2532-ME-003 0
7. Welding Specification 2532-ME-004 0
8. NDE Specification 2532-ME-005 0
Mechanical Drawings
9. Piping Layout for OPII and OPIII (KEY PLAN) 2532-PIP-KPL-4800 1
2532-PIP-PL-4801
10. Piping Layout for OPII and OPIII TO 1
2532-PIP-PL-4812
Annexure
11. Annexure-I (Polyken Specification) 0
12. Annexure-II (Approved Manufacturer’s List) 0
Tender Package Contents

DISCHARGE PIPELINE
Doc. No.
Tender Package Contents Revision No. 2
2532-PM-DOC-0191
S.No. Description Document No. Rev
13. Annexure-III (Google Map View) 0
Tender Package Contents

REPLACEMENT OF TANKER DISCHARGE

PIPELINE (DIA. 8”) - KEAMARI
PREAMBLE TO BILL OF QUANTITIES

DISCHARGE PIPELINES (DIA.
8”) – KEAMARI (LOBP)
Doc. No.
Preamble Revision No. 2
2532-PM-PR-0341
PREAMBLE TO BILL OF QUANTITIES
1. Shell Pakistan Limited (SPL) is planning to replace its existing Tanker Discharge
Pipeline dia. 8” from BOP II/III to Shell L.O.B.P, Keamaril. This project is a PCC
(Procurement, Construction & Commissioning) type. Contractor shall be
responsible for the supply of all material including pipe, fittings, valves, plate,
structure, stud bolts & nuts, gaskets, paints, civil material, etc., modifications,
repairing, fabrication, installation, erection, sand blasting to S.A. 2.5, painting and
coating, testing and commissioning complete in all respect as per SPL
requirement.
2. The items mentioned above also consist of furnishing all plant, labour,
equipment, machinery, consumables, and taxes / levies applicable for completing
the work. The work shall be done, complete in all respects in accordance with,
specifications, drawings and SPL requirements.
3. The prices and rates to be quoted in the Bill of Quantities are to be full inclusive
value of the works described under specified items including all costs and
expenses which may be required in and for the construction of the works
described, together with all risks, liabilities and obligations set forth and implied in
all the documents referred to on which the tender is based.
4. All work shall be carried out in accordance with the approved drawings and
specifications. Any item and/or work required for completion of the project but not
expressly indicated in this document shall be deemed to have been included in
the quoted price by the contractor.
5 The SPL may supply valves and pipe. Contractor is responsible to transport it to
work site.
6. All supply items should be accompanied with Test Certificate from manufacturer
for assurance and conformity of performance as per codes and standard,
import/shipment documents and other documents required by SPL for material
traceability check or any other reason.
7. Since As-built drawings of tanks/pipes are not available all proposed work shall
be verified by Contractor at site before fabrication.
Doc. No. 2532-PM-PR-0341 Page 2

Doc. No.
2532-PM-PR-0341
8. All drawings and other documents supplied for the purpose of bidding, shall be
returned with the tender bid. Tenderers unable to bid shall also return complete
bid documents on the date of opening of the tender.
9. The quantities set out in the Bill of Quantities are the estimated quantities of the
work and they are not to be taken as the actual and correct quantities of the work
to be executed by the Contractor in fulfillment of the Contract. The Contractor
shall be required to supply and install every thing necessary to provide a
complete operational system as per SPL requirement.
10. Contractor shall follow all safety and security rules/procedures of Shell Pakistan
Limited.
11. The contractor shall be responsible for supplying and arranging electricity and
potable water for construction and testing at his own cost.
12. Contractor shall familiarize himself with sites and existing installations related to
the work prior to submission of bid.
13. Contractor shall be responsible for the reinstatement of the system and cost of
reinstatement is included in their cost.
14. All new, repairs, replacement and modification works shall be done during
existing plant in operation.
15. Contractor shall be responsible for 100% radiography where new work is welded
with existing work. Contractor shall also be responsible for Non Destructive
Testing like Dye Penetration test, Magnetic Particle inspection, etc.,
16. Contractor shall be responsible for the development and submission of As-built
drawings.
17. Loading of materials from store/yard, transportation and unloading at the required
job site shall be the contractor’s responsibility and considered included in his unit
rates.
18. Contractor shall submit welding procedure for SPL approval.
19. Contractor shall arrange, store, erect proper scaffolding as per SPL requirement.

Doc. No.
2532-PM-PR-0341
20. Contractor shall submit Quality Assurance (QA)/ Quality Control (QC) documents
and HSE documents for SPL approval.
21. Contractor shall depute HSE personnel at site for assurance of following and
maintaining safe working.
22. The Contractor shall prepare all necessary work methodologies/

plans/procedures as required by SPL and shall submit the same for SPL approval
prior to execution.
23. All material furnished by Contractor shall be approved by SPL before work is
commenced. Only new, top quality materials from approved
vendors/manufacturers will be acceptable to SPL.
24. The information and data given is not intended to be an exhaustive list of all the
requirements of the Contract. The Contractor’s Scope of Work must be read in
conjunction with the referenced documents, site requirements and all parts of the
Contract. Contractor's Scope of works shall comprise all activities necessary to
complete the Work in accordance with SPL requirements.
25 All work shall be carried out by Contractor under the supervision of experienced
personnel in accordance with SPL approved procedures, and the best and latest
approved practices in the oil and gas industry.
26 Contractor shall also comply with the QA/QC, Safety, Planning and Scheduling
requirements of the Contract throughout the execution of the Project.
27 Contractor shall be responsible to get permits from KPT for work inside BOPs
area, KPT Pipe racks and KPT trenches. Contractor shall also be responsible for
taking permission for work from SPL, LOBP and other authorities in the way of
pipelines route. Cost involves in the permits shall bear by Contractor. Contractor
shall follow all safety & security rules of KPT in execution of work.
28. Scraps, rebel or damaged material shall be disposed off properly by Contractor
as per SPL requirement.
29. Contractor shall provide all material and equipment required for hydrostatic
testing, including supply of portable water (Soft Water) and electricity for test and
waste management plan.

Doc. No.
2532-PM-PR-0341
29. Hydrostatic Test water (after successfully completion of test) shall neither be
drained inside installation nor in sea. Water shall be disposed off properly by
Contractor as per SPL requirement.
30. Contractor has to add his own cost to provide alternate access / diversions with
floor markings & necessary sign boards for pedestrians and vehicles movements
inside LOBP Plant as per SHELL LOBP requirement.
31. Existing buried portion of TDL is not exactly known. It is passing through Third
Party terminal before railway crossing. Contractor is responsible to finalize
pipeline route and get approval from KPT, Third Parties and SPL before any
fabrication works. Contractor is responsible for reinstatement.
32. Part of existing TDL is buried inside LOBP. Contractor is responsible to route the
pipeline in such a way to disturb minimum existing infrastructure with approval of
SPL. Contractor is responsible for reinstatement
33. Burial depth (from NGL to top of pipe) shall be 1000 mm. All buried portion shall
be coated with Polyken tape as per project specification.
34 Safety
Prior to commencement of construction, the Contractor shall produce a written
safety policy and procedure for SPL approval, which he shall enforce during all
construction and commissioning activities.
The procedure shall include as a minimum contingency plans for a plant

emergency, fire precautions, accident procedure, safety training, lines of authority
and responsibilities, etc. The Contractor shall designate a Safety Officer who
shall be responsible for the day-to-day coordination with SPL representatives on
all safety aspects of the work.
SPL’s Permit to Work system and safety rules shall govern during installation and
commissioning works. It is contractor’s responsibility to obtain work permit. No
works shall be allowed in installation premises without a valid work permit.
Contractor shall, at his own expense, supply his personnel and Sub-Contractor’s
personnel, required in connection with the safe performance of the Work, with
adequate protective personal clothing and other protective equipment which shall

Doc. No.
2532-PM-PR-0341
be maintained in good condition or replaced, and shall be worn on all relevant

occasions as indicated by notices, instructions and good practice.
The Contractor shall be responsible for ensuring that the site is kept clean and
tidy and that all scrap materials and tools are removed from the job site on
completion of the Work.
Contractor shall at his own expense provide adequate first aid equipment, fire
extinguishers and other safety equipment or an approved type and amount, as
may be specified (or expected in accordance with good working practice), in
connection with this Contract and shall maintain this equipment in a professional
manner as directed by the legal and industry standards. In addition, Contractor
shall keep up-to-date records of all said equipment. Free access by all persons
on site to all fire extinguishing and safety equipment must be maintained at all
times.


BILL OF QUANTITIES
MECHANICAL
Consultant:
1 28/05/15 Bill of Quantities , Mechanical Ibad Shoaib

Rev. Date Description Prepared By Approved By
SHELL PAKISTAN LIMITED (LOBP) DOC. NO. : 2532-PIP-BOQ-4331
REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") "OP II" PREP. : AFA
AT KEAMARI - LOBP REV. :2
DATE : 15-06-2015
BILL OF QUANTITIES
FOR
PROCUREMENT
UNIT PRICE
SR# ITEM DESCRIPTION UNIT QUANTITY AMOUNT (PKR)
(PKR)
1.0 PIPE:
Pipe, Bevel Ends, SMLS Single Random Length, ASTM A-106

1.1
Gr. B / API 5L Gr. B, per ASME B 36.10
i Dia. 8" Std. Wt. m 425
2.0 ELBOWS:
90° 5D Bend,Bevelled ends to match pipe wall ,

2.1
ASTM A-234 Gr. WPB.
i Dia. 8" Std. Wt. Nos. 5
45° 5D Bend,Bevelled ends to match pipe wall, ASTM

2.3
A-234 Gr. WPB.
3.0 FLANGES:
Slip-On Flanges , 150#, R.F as per ASME B 16.5, ASTM A-
3.1
105.
4.0 GASKETS:
4.1 Spiral Wound Gasket, 3mm thick Flat ring, graphite filled 150#
as per ASME 16.20
5.0 STUDS/NUTS:
Studs with 2 Nuts, Stud Material :ASTM A 193 Gr. B7M and
5.1 Nuts Material: ASTM A 194 Gr. 2H, as per ASME B 16.5
i M20 x 110 mm Long Nos. 40
SUB-TOTAL (PKR)
TOTAL (PKR)
S.No NOTE:
The Quantities taken in this BOQ are estimated, only for bidding purpose. Contractor is responsible to estimate the quantities as per site
1
requirements, drawings & tender documents
Contractor should have to match the size of nozzle with the supply of vendor item. For matching the vendor item size reducers, gaskets,
2
studs/bolts, etc shall be provided and welded & fitted by Contractor
3 Contractor is responsible to add any missing / required item as per scope of works, drawings, specifications & tender documents.
4 Origin of material (pipe, pipe fittings, valves, flanges, gaskets, strainer etc) as per attached Annexure A (Approved Manufacturer's list).
Contractor is responsible to estimate the quantities before going to purchase the supply items. Left over / balance items may not be
5
taken by Shell.
6 NDE / Welding Inspection to be done by 3rd party as per Shell recommendation
7 Contractor is responsible to estimate the quantities before going to execute the job. Payments shall be made on actual work done.
Page 1 of 1
REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") OP II PREP. : AFA
BILL OF QUANTITIES REV. :2
FOR DATE : 15/06/2015

CONSTRUCTION
UNIT RATE TOTAL
SR# ITEM DESCRIPTION UNIT QTY. REMARKS
(PKR) (PKR)
1.0 PIPING WORKS
Works include shifting from store and placing of pipes &
fittings on existing supports, existing pipe trench / culvert at
required location for welding or threading as indicated in
project drawings or as per site requirement. Making weld
joints / thread as per ASME B 31.4 in joining pipe lengths and
welded pipe fittings such as flanges, bends, reducers, MPT/DPI is included in
1.1
scokolets,tees etc. The work also includes gas cutting/cold Contractor's scope
cutting as per requirement, grinding, beveling etc. the
welding of both the faces of slip-on Flanges will be
considered as one welding joint where used, complete in all
respect as per project specifications, drawings, relevant
international/codes and tender documents. 10% radiography
is included in Contractor scope.
i) Dia. 8"- Std. Wt. m 425
2.0 SURFACE PREPARATION WITH PAINTING :

Works include supply of all material, application of painting,
surface preparation to S.A. 2.5 and apply of painting system
2.1
as per relevant specification, complete in all respect as per
Shell requirement.
i) Dia. 8"- Std. Wt. m2 292
3.0 HYDROSTATIC TESTING:

Hydrostatic testing of piping at pressure of 225 Psig for 24 Contractor shall provide all
3.1 hrs. duration as per ASME B 31.4 as per project specification material and equipment
and Shell requirements. required for hydrostatic testing,
including supply of portable
water (Soft Water) and
ii) Dia. 8"- Std. Wt. M 425 electricity for test and waste
4.0 TIE-IN POINTS:

4.1 It includes emptying pipeline and disposal from the piping as
per Engineer's / SPL instructions, dismantling of pipes,
fittings, cold cutting, grinding and beveling, welding, 100%
Radiography of Tie-in Points, etc., loading, transportation
and unloading of pipe.
i) Dia. 8" Nos. 2
5.0 DISMANTLING OF EXISTING PIPING

5.1 It includes emptying and disposal of product from the piping Contractor shall quote price as
as per Engineer's / SPL instructions, dismantling of pipes, to purchase from SPL.
fittings, cold cutting, where required etc., loading,
transportation outside Depot and safe storage.
i) Dia. 8"- Std. Wt. m 425
TOTAL (PKR)
S.NO NOTE:
1 This quantity includes the replacing of the spools also refering in drawings.
The Quantities taken in this BOQ are estimated, only for bidding purpose. Contractor is responsible to estimate the quantities as per site
2
requirements, drawings & tender documents
Contractor should have to match the sizes of vendor item. For matching the vendor item size reducers, gas kits, studs/bolts, etc shall be provided and
3
welded & fitted by Contractor
5 Origin of material (pipe, pipe fittings, valves, flanges, gaskets, strainer etc) as per attached Annexure A (Approved Manufacturer's List).
6 Contractor is responsible to estimate the quantities before going to purchase the supply items. Left over / balance items may not be taken by Shell
7 NDE / Welding Inspection to be done by 3rd party as per Shell recommendation.
8 Contractor is responsible to estimate the quantities before going to execute the job. Payments shall be made on actual work done
Page 1 of 1
REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") "OP III" PREP. : AFA
DATE : 15-06-2015
BILL OF QUANTITIES
FOR
PROCUREMENT
UNIT PRICE
(PKR)
1.0 PIPE:
Pipe, Bevel Ends, SMLS Single Random Length, ASTM A-106

1.1
Gr. B / API 5L Gr. B, per ASME B 36.10
i Dia. 8" Std. Wt. m 425
2.0 ELBOWS:
90° 5D Bend,Bevelled ends to match pipe wall ,

2.1
ASTM A-234 Gr. WPB.
45° 5D Bend,Bevelled ends to match pipe wall,

2.3
ASTM A-234 Gr. WPB.
3.0 TEE
3.1 Equal Tee , B.W, ASTM A-234 Gr. WPB as per ASME B16.9
i Dia. 8" Std. Wt. No. 1
4.0 REDUCER:
Conc. Reducer B.W, ASTM A-234 Gr.WPB as per ASME B
4.1
16.9.
i Dia. 10" x 8" Std. Wt. Nos. 2
5.0 FLANGES:
Slip-On Flanges , 150#, R.F as per ASME B 16.5, ASTM A-
5.1
105.

ii Dia. 8" Std. Wt. Nos. 16
5.2 Blind Flanges , 150#, R.F as per ASME B 16.5, ASTM A-105.

ii Dia. 8" Std. Wt. No. 1
6.0 GASKETS:
6.1 Spiral Wound Gasket, 3mm thick Flat ring, graphite filled 150#
as per ASME 16.20

ii Dia. 8" Std. Wt. Nos. 12
Page 1 of 2
REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") "OP III" PREP. : AFA
DATE : 15-06-2015
BILL OF QUANTITIES
FOR
PROCUREMENT
UNIT PRICE
(PKR)
8.0 STUDS/NUTS:
Studs with 2 Nuts, Stud Material :ASTM A 193 Gr. B7M and
8.1 Nuts Material: ASTM A 194 Gr. 2H, as per ASME B 16.5
i M24 x 115 mm Long Nos. 12

ii M20 x 110 mm Long Nos. 96
9.0 VALVES:
Gate valve 150#, RF as per ASME B16.5, Bolted Body, OS&Y,
as per API 600, Body ASTM A-216 Gr. WCB. Trim:13% Cr.
S.Steel.
9.1 Dia. 6" Std. Wt. Nos. 2
SUB-TOTAL (PKR)
TOTAL (PKR)
S.No NOTE:
The Quantities taken in this BOQ are estimated, only for bidding purpose. Contractor is responsible to estimate the quantities as per
1
site requirements, drawings & tender documents
Contractor should have to match the size of nozzle with the supply of vendor item. For matching the vendor item size reducers,
2
gaskets, studs/bolts, etc shall be provided and welded & fitted by Contractor
Origin of material (pipe, pipe fittings, valves, flanges, gaskets, strainer etc) as per attached Annexure A (Approved Manufacturer's
4
list).
Contractor is responsible to estimate the quantities before going to purchase the supply items. Left over / balance items may not be
5
taken by Shell.
6 NDE / Welding Inspection to be done by 3rd party as per Shell recommendation
7 Contractor is responsible to estimate the quantities before going to execute the job. Payments shall be made on actual work done.
Page 2 of 2
REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") OP III PREP. : AFA
FOR DATE : 15/06/2015

CONSTRUCTION
UNIT RATE TOTAL
(PKR) (PKR)
1.0 PIPING WORKS
Works include shifting from store and placing of pipes &
fittings on existing supports, existing pipe trench / culvert at
required location for welding or threading as indicated in
project drawings or as per site requirement. Making weld
joints / thread as per ASME B 31.4 in joining pipe lengths
and welded pipe fittings such as flanges, bends, reducers, MPT/DPI is included in
1.1
scokolets,tees etc. The work also includes gas cutting/cold Contractor's scope
cutting as per requirement, grinding, beveling etc. the
welding of both the faces of slip-on Flanges will be
considered as one welding joint where used, complete in all
respect as per project specifications, drawings, relevant
international/codes and tender documents. 10% radiography
is included in Contractor scope.
i) Dia. 8"- Std. Wt. m 220
2.0 INSTALLATION OF VALVES

Installation of valves includes the placing of valve between
flanges and bolting up with gasket. Work also includes It includes installation of
2.1
Lifting and Transportation from store and unloading at work Gate and Ball valves.
site.
i) Dia. 8"- 150# Nos. 2
3.0 SURFACE PREPARATION WITH PAINTING :

Works include supply of all material, application of painting,
surface preparation to S.A. 2.5 and apply of painting system
3.1
as per relevant specification, complete in all respect as per
Shell requirement.
i) Dia. 8"- Std. Wt. m2 151
4.0 HYDROSTATIC TESTING:

Hydrostatic testing of piping at pressure of 225 Psig for 24 Contractor shall provide all
4.1 hrs. duration as per ASME B 31.4 as per project material and equipment required
specification and Shell requirements. for hydrostatic testing, including
supply of portable water (Soft
Water) and electricity for test
ii) Dia. 8"- Std. Wt. M 425 and waste management plan.
5.0 TIE-IN POINTS:

5.1 It includes emptying pipeline and disposal from the piping as
per Engineer's / SPL instructions, dismantling of pipes,
fittings, cold cutting, grinding and beveling, welding, 100%
Radiography of Tie-in Points, etc., loading, transportation
and unloading of pipe.
i) Dia. 8" Nos. 2
6.0 DISMANTLING OF EXISTING PIPING

6.1 It includes emptying and disposal of product from the piping Contractor shall quote price as
as per Engineer's / SPL instructions, dismantling of pipes, to purchase from SPL.
fittings, cold cutting, where required etc., loading,
transportation outside Depot and safe storage.
i) Dia. 8"- Std. Wt. m 360
7.0 DISMANTLING OF VALVES

7.1 Dismantling of Valves including removal of bolting up with
gasket, Lifting and Transportation site to store.
i) Dia. 8" Nos. 6
Page 1 of 2
REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") OP III PREP. : AFA
FOR DATE : 15/06/2015

CONSTRUCTION
UNIT RATE TOTAL
(PKR) (PKR)
8.0 ROAD CROSSING
8.1 It includes KPT Road Crossing, Railway crossing by Thrust Specification for sleeve coating
Boring/ Directional Drilling method and approval from refered in the painting spec.
concerned authorities. Works also include supply of all Coating the sleeve is also in
material including Pipe Sleeves with Insulators and end contractor scope
Job 1
seals, arrangement of machinery, tools and tackles, also
reinstatement of the Road crossing via black top or metal top
complete in all respect. Carrier Pipe supply is included in
Procurement BOQ.
Carrier Pipe Dia. 8" & Sleeve Pipe dia. 12" Std. Wt.
i) Road Crossing m 24
ii) Railway Crossing m 14
9.0 PIPELINE IN THIRD-PARTIES BOUNDRY

9.1 It includes approval from concerned authorities. Works
Coating refered in the painting
include shifting from store and placing of pipes & fittings on
spec.
excavated pipe trench / culvert at required location. Works
also include supply of all material arrangement of machinery,
Job 1
tools, also reinstatement of complete area complete in all
respect.
i) Burried Pipe Length in Third Parties Boundary. Dia 8" m 40
10.0 PIPELINE IN THIRD-PARTIES BOUNDRY

10.1 Excavation in any kind of strata upto required depth as per Coating refered in the
drawings, identificaion of any kind of existing piping and painting spec.
structure, marking of proposed pipeline route , loading,
transportation, unloading of pipes and fittings at site,
stringing, lowering-in , grinding , beveling , cutting , welding, Minimum soil cover 1m from
backfilling fee of stone, dewatering where required, top of pipe to top of ground
reinstatement in LOBP Boundary.
i) Burried Pipe Length Dia 8" m 175
TOTAL (PKR)
S.NO NOTE:
1 This quantity includes the replacing of the spools also refering in drawings.
2 The Quantities taken in this BOQ are estimated, only for bidding purpose. Contractor is responsible to estimate the quantities as per site requirements,
drawings & tender documents
3 Contractor should have to match the sizes of vendor item. For matching the vendor item size reducers, gas kits, studs/bolts, etc shall be provided and
welded & fitted by Contractor
5
Origin of material (pipe, pipe fittings, valves, flanges, gaskets, strainer etc) as per attached Annexure A (Approved Manufacturer's List).
6 Contractor is responsible to estimate the quantities before going to purchase the supply items. Left over / balance items may not be taken by Shell
7 NDE / Welding Inspection to be done by 3rd party as per Shell recommendation.
8 Contractor is responsible to estimate the quantities before going to execute the job. Payments shall be made on actual work done
Page 2 of 2
SPECIFICATIONS

SPECIFICATIONS FOR
PIPING, FABRICATION & INSTALLATION
DOCUMENT NO. : 2532-ME-001
Consultant:

DISCHARGE PIPELINE
(DIA 8”)-KEAMARI (LOBP)
MECHANICAL
Specifications for Piping
Doc. No. 2532-ME-001 Revision No. 0
Fabrication & Installation
Disclaimer
This specification has been prepared on behalf of and for the exclusive use of Shell Pakistan
Ltd., and is subject to and issue in accordance with the agreement between Petrochemical
Engineering Consultants and SPL. Petrochemical Engineering Consultants accept no liability
or responsibility whatsoever for it in respect of any use of or reliance upon this report by any
third party.
Copying this report without the permission of Petrochemical Engineering Consultants is not
permitted.
Specifications for Piping Fabrication & Installation Page 1

DISCHARGE PIPELINE
MECHANICAL
TABLE OF CONTENT
1.0 SCOPE ................................................................................................................... 3
2.0 DESIGN CODES & SPECIFICATIONS. .................................................................. 5
3.0 STORAGE AND HANDLING .................................................................................. 7
4.0 FABRICATION........................................................................................................ 8
5.0 PIPING INSTALLATION ....................................................................................... 14
6.0 EQUIPMENT/MACHINERY INSTALLATION AND ERECTION............................. 15
7.0 INSPECTION ........................................................................................................ 17
8.0 PIPE SUPPORTS/PLATFORMS .......................................................................... 18
9.0 HYDROSTATIC TESTING .................................................................................... 19
10.0 CLEANING ........................................................................................................... 21

DISCHARGE PIPELINE
MECHANICAL
1.0 SCOPE
This specification covers the minimum requirements for the fabrication, installation
and erection of piping including pipe supports, installation, erection and alignment of
equipment and piping involved in the Project.
The Contractors scope of work shall include, among others the following items of
work:
 Storage and handling of all materials forming part of the permanent work.
 Preparation of working area as required to bring the equipment / material at

job site.
 Transportation of equipment/ material from any location within the premises to

the job site.
 Checking & preparation of foundation prior to erection work.
 Supply of all material including erection materials, such as temporary

connections, blinds and spacers for hydrostatic testing, temporary strainers,
temporary supports, scaffolding, shims required for leveling, pumps and
piping for hydrostatic testing, etc, required for satisfactory completion of work.
 Verification of all dimensions and elevations mentioned in the drawings and

/or adjustment of dimension / elevation as per site requirement
 Supply of all consumables and erection equipment.
 Supply of all pipe supports and operating / access platform
 Supply of all material as per scope of work
 Supply and storage of water for hydrostatic testing.
 Welding shall be carried out according to qualified welding procedures. All

charges pertaining to these qualifications shall be borne by the contractor.
 Only qualified welders shall be allowed to work on -the job. Welder's

qualification tests shall be arranged by the Contractor, before commencement

DISCHARGE PIPELINE
MECHANICAL
of work. All charges pertaining to this qualification shall be borne by the

contractor.
 Removal of all temporary facilities and cleaning the job site after completion of
work.
 Supply of fuel and electricity for construction purposes.
 Field bending and pipe threading where required.
 Development of As-Built drawings.
1.1 DEFINITIONS
COMPANY : Shell Pakistan Limited.
CONSULTANT/ENGINEER : Petrochemical Engineering Consultant
CONTRACTOR : The Company named as such in the deed.
SUB CONTRACTOR / : The Manufacturer / Supplier engaged by Contractor

VENDOR
SHALL/MUST/IS TO BE : A mandatory requirement
SHOULD : A non-mandatory requirement, advisory or Recommendation

DISCHARGE PIPELINE
MECHANICAL
2.0 DESIGN CODES & SPECIFICATIONS.
Unless otherwise stated the design of piping systems shall confirm to the
requirement of latest edition of following Codes and Standards.
ASME B31.3 - Process piping, code for pressure piping.
ASME B 31.4 - Pipeline transportation systems for liquid

hydrocarbons and other liquids.
API STD 598 - Valve Inspection and Test.
OISD 118 - Layout for Oil and Gas installations
DEP 31.38.01.10-Gen. Piping classes - basis of design
DEP 31.38.01.11-Gen. Piping - general requirements
DEP 31.40.21.30-Gen. Pipeline fittings (amendments/supplements to ISO

15590-2)
DEP 31.40.00.10-Gen. Pipeline engineering (amendments/supplements to ISO

13623)
DIMENSIONAL STANDARDS
Flanges - ASME B16.5
Welding Fitting - ASME B16.9, B16.11
Pipe - ASME B36.10
Gaskets - ASME B16.20, B16.21
Block valves - ASME B16.10, API 6D
Check valves - ASME B16.10, API 6D

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MECHANICAL
Butt Weld Ends - ASME B 16.25
Spec. for line pipe - API 5L
Valves – Flanged, - ASME B 16.34

threaded end / welding end
In the event of conflict between this specification and any code, standard or
regulation, the contractor shall inform the Company / Consultant / Engineer in writing
and receives written clarification from the Company / Consultant / Engineer. The
Contractor shall have readily available for use, at the request of the Company /
Consultant / Engineer latest editions of all codes, specifications and standards
necessary for the execution of the work at the work site.
All such requirements are part of his contractual scope and considered in his bid
prices.

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MECHANICAL
3.0 STORAGE AND HANDLING
3.1 All piping material shall be stored by the Contractor in areas demarcated for this
purpose.
3.2 Valves, instruments, strainers, bolts, small fittings and gaskets shall be stored in
covered lock premises. In no case shall the marking on the equipment be removed.
Valves, strainers and other equipment provided with protective caps should be stored
with the caps up to the moment they are installed.
3.3 Contractor shall be entirely responsible for safekeeping of all materials and
equipment. If any item is lost or damaged, the contractor shall be required to replace
it at his own cost.
3.4 Handling of material shall be done with suitable mechanical equipment and safety of
workers shall be given top priority.

DISCHARGE PIPELINE
MECHANICAL
4.0 FABRICATION
4.1 General
a) Fabrication of all piping shall be in accordance with the requirements of piping

standards, drawings and specifications.
b) The piping drawings give the layout of equipment and piping with reference to a set
of coordinates established for the Project. Therefore, before doing any prefabrication
on the basis of drawings, the Contractor shall verify all elevations, dimensions, tie-
ins. Coordinates, location of equipment and structure.
c) The cutting and extra lengths for adjustments, if not indicated on drawings, shall be
left to the judgment of the contractor so as to facilitate the execution of piping
erection work.
d) Normally, for pipe sizes 2" and above, butt welded fittings of thickness equal to that
of pipe, shall be used and, for sizes l-1/2" and below, socket weld or screwed end
connections (Class 3000/6000 # ) shall be used, unless otherwise specified in the
drawings.
4.2 Pipe Cutting
a) Pipe below 2" diameter shall be cut by pipe cutter only. Flame cutting is not allowed.
b) It would be preferable to cut the larger sizes also with pipe cutter, but flame cutting is
also acceptable, provided after cutting, the edges are prepared by grinding or
machining.
c) After cutting, the pipe ends shall be beveled and prepared according to the
dimensions and tolerances shown in the drawings and project specifications.
4.3 Field Bending
a) Pipe bending can be either hot or cold. For welded pipe, the weld shall be placed on

DISCHARGE PIPELINE
MECHANICAL
the neutral fiber of the bend.
b) The bend radius shall be equal to at least 5 times the nominal diameter of the pipe
unless otherwise specified.
c) When the final elongation of the outer fiber exceeds l5%, heat treatment to relieve
stresses shall be performed.
d) Hot bending if required shall be carried out in the following manner:
Pipe shall be filled with dry sand (grain size less than 1.00 mm), compacted and pipe
ends plugged with wooden blocks. The part to be bent shall be heated to a suitable
temperature. During the whole operation, temperature shall be controlled.
Successive heating shall be carried out to avoid a sudden lowering of strength on the
outer part of the bend of the tube. After bending, the pipe shall be completely cleaned
of the sand.
e) The bend shall have no defects, such as crack blisters, which may affect the pipe
quality.
f) The bend made from pipe shall not be thinner than 90% of the initial wall thickness of
the pipe nor having out of roundness more than 10% of the initial diameter.
4.4 Welding
4.4.1 Allowed Welding Processes
The welding processes to be used shall conform to the piping welding specifications
after they have been duly qualified. The allowable welding processes are indicated
here below, according to the AWS definitions:
 SMAW : Shielded Metal Arc Welding

 GTAW : Gas Tungsten Arc Welding
The definitions of said processes are given in the ASME Section, which also includes

DISCHARGE PIPELINE
MECHANICAL
permissible variations of these processes.
4.5 Qualification of Welding Procedure
The qualification of welding procedures shall comply with the terms of article UW-28
of the ASME section VIII. Each welding procedure shall be supplied and approved.
The Contractor shall record in detail such procedure.
The ASME section IX shall govern the qualifications. Any deviation to the present
specification shall be ruled by QW-400 about welding variable. The procedure shall
be established according to ASME Section IX, QW-482 form. This welding procedure
qualification shall take into consideration the terms of said article II, paras QW-200 to
QW 280.
A P.Q.R. shall be established according to the QW 483 form and kept up-to-date.
A copy of the said form shall be sent to the Owner for information and possible
comments.
4.6 Qualification of Welder / Operator
The qualification of Welder or welding operator shall comply with the terms of article
UW-29 of the ASME Section VIII.
The Contractor shall keep a record of welders and welding operators showing the
date and results of qualifying tests as well as the identification mark or number
attached to each of them. The ASME Section IX shall govern the qualification under
its article III terms.
Any deviation to the present specification shall be ruled by QW-350 about welding
variables for welders or welding operators.
The welding performance qualification shall take into consideration the terms of

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MECHANICAL
article III, paras QW-300 to QW-350. A record of welder of welding operator

qualification tests shall be established according to the QW-484 test form, kept up-to-
date and sent to the Owner for information and possible comments.
4.7 Flanges
All necessary action shall be taken to avoid damage to the flange face.
Bolt holes shall straddle the axis of pipe for all flanged connections. Where flanges
are to be fastened to equipment flanges, the bolt holes shall match the equipment
flange orientation.
4.8 Welding Joints
a) Contractor shall take precautions during all pipe-handling operations to prevent

damage to piping components including pipe, fittings valve and prefabricated items.
Normally, piping components containing surface defects or damage that may affect
their strength or reduce their serviceability shall not be welded in the piping. Such
surface defects and damage include but are not limited to gauges, dents, buckles,
dented or nicked bevels, split ends, seam cracks and pits or any other stress
concentrator.
b) Cleaning
Each joint of pipe or fitting to be welded shall be swabbed with a leather or canvas
disc of proper diameter or blown with air to remove rust, loose mill scale and other
foreign substances before being placed in alignment for welding.
c) End Preparation
Butt welding ends shall be prepared according to the dimensions given in the welding
procedure specifications. Where dimensions are not given the following shall be

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MECHANICAL
used:
 Bevel 30 deg. plus 7.1/2 deg. minus 0 degree

 Land 1/16," plus 1/32", - 0"
 Gap 1/16," plus 1/32", - 0"
Bevelling shall be done by grinding or machining and the finished bevel shall be free
of nicks or grooves. Prior to welding, the bevelled surface and the inside surface of
the pipe, within 1/4" of the weld joint shall be cleaned of all foreign material.
d) Weld Joint Alignment
Pipes to be welded shall be aligned by suitable means such as external clamps,

yokes etc. Yokes if used shall be tack welded using electrodes compatible with
parent material. After joint fit-up, yokes shall be hammered off and tacks shall be
ground flush with the outside surface of the pipe.
Misalignment in piping joints shall not exceed 1/16" and this will be preserved during
welding. Hammering shall not be carried out to compensate for dimensional
variations.
The distance between two adjacent welds shall not be less than 4"
Tack welding shall be done by qualified welders only and shall confirm to the quality
of root weld.
Longitudinally welded seams in adjacent lengths of pipe shall be offset by a minimum
distance equal to one fourth pipe diameter.
Approval of joint fit-up by Company / Consultant / Engineer shall be required prior to

the welding operations.

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MECHANICAL
4.9 Threaded Pipe
a) The contractor shall use good quality cutters and dies when cutting and threading
pipe. The ends of cut pipe shall be square and true.
b) Threaded joints shall be properly aligned. Pipe entering unions shall be true to
centerline so that the union does not have to be forced to make-up.
c) Threaded pipe shall not project through fittings to cause interference with valves or
other operating mechanisms.
d) Threaded connections may use with sealing tape.
e) Threaded joints shall be seal welded wherever indicated in the drawings. Seal
welding shall be carried out after hydrostatic testing and seal welds shall not be used
to stop hydrostatic test leaks.

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MECHANICAL
5.0 PIPING INSTALLATION
5.1 Flange protections on equipment nozzles shall be left in place until piping is
connected.
5.2 All valves provided with protective caps stored with the caps up to the moment
actually installed.
5.3 Before fastening the faces of flanges shall be cleaned.
5.4 All piping and equipment connections shall be accurately aligned and the Contractor
shall ensure that all flange faces are parallel and correctly centered before bolting.
Force shall not be used in attaining alignment.
5.5 Non Asbestos filled gaskets of the proper size shall be installed in each joint.
5.6 Globe and non-return valves shall be installed according to the direction of flow
marked on the valve. If no direction is marked, it shall be checked and painted on the
valve prior to installation.
5.7 Piping shall be installed true and level or plumb. Where slope is required, it shall be
maintained without sags in the piping run. The alignment of piping shall be within plus
minus 1/8" of dimensions shown on drawings.

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MECHANICAL
6.0 EQUIPMENT/MACHINERY INSTALLATION AND ERECTION
6.1 General
The Contractor shall set, level, align and properly grout to the foundation all
equipment/machinery in strict compliance with the location, dimensions and
elevations as shown in the drawings and in accordance with the manufacturer's
recommendations and instructions.
Prior to installation, the Contractor shall remove any temporary protective coating,
such as rust inhibitors applied for ocean shipment, in accordance with the information
supplied by the manufacturer. Machinery shall be drained and flushed of factory
lubricants and replaced with new lubricant as directed by the owner's representative.
6.2 Preparation of Foundation for Installation
The foundations for equipment and pipe support shall be checked for location and
level prior to start of erection. The erection Contractor shall provide all material and
workmanship for preparing the finished level of foundations and elevation
adjustments needed at the time of the erection of the equipment, machinery and
piping.
6.3 Erection & Alignment
a) Protective flanges, covers or caps on the equipment and machinery shall not be
removed until piping connections are ready to be made. Vent and drain connection of
the equipment and machinery shall be cleaned before start-up.
b) Foundation bolts shall not be fully tightened until grout has hardened.
c) The centerlines of equipment/machinery to be installed shall be accurately aligned

with reference to the coordinates established for the plant, using benchmarks. The
centerlines shall be within 3 mm of the dimensions shown on drawings.

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MECHANICAL
The suction and discharge flanges of pump shall be checked for level and verticality
and adjustments made if necessary by placing thin steel shims under the base plate.
d) The Contractor shall perform alignment check for alignment of the driven machinery and
its drive in the cold condition, according to manufacturer's instructions.
e) The alignment of the driven machinery to its drive shall also be carried out for the
motor operating condition. A hot alignment check shall be made after the machine
has been operated and has reached the operating temperature.
This check shall be made immediately after the machine has been stopped and
before it has been allowed to cool and shrink to the cold position.
6.4 Grouting
a) The Contractor shall supply grouting material and carry out all grouting work related
to Equipment and machinery foundations
b) Grout material shall consist one part of cement and three parts of sand.
c) Once setting and preliminary alignment has been approved by the Company /
Consultant / Engineer, the Contractor sha1l grout the equipment/machinery base
plates.
d) Steel surface that will be in contact with the grout shall be clean and dry.
e) Concrete surfaces shall be clean, dry and free of oil, dirt or grease. The concrete
shaI1 have the top layer chipped to expose a uniform thoroughly cured surface.

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MECHANICAL
7.0 INSPECTION
a) The quality of welding shall be checked visually and by non-destructive methods, in

accordance with ANSI B 31.3.
The Contractor shall bear the cost of radiographic inspection. All welds which are
unacceptable shall be repaired and retest radiographically at Contractor's expense.
b) The Contractor shall be solely responsible for coordinating inspection work with
construction activities.
7.1 Repair & Removal of Defects
a) Welds, which do not meet the acceptance standards of this specification, shall be cut
out at the Contractor's expense by removing a cylinder of pipe containing the weld, or
repaired with the prior approval of the Company / Consultant / Engineer.
b) Allowable repairs
Repairs may normally be allowed at the Company / Consultant / Engineer’s
discretion, if there are no cracks in the weld and if the segment of weld to be repaired
was not previously repaired.
c) Repair Procedure
i. Defect removal: Weld defects shall be removed by grinding. The repair cavity shall
be of sufficient size to allow adequate access for welding.
ii. Cleaning: Scale and slag shall be removed from each weld bead and groove before
depositing the next weld bead.
d) Arc Burns
Arc burns shall be removed by grinding. Grinding shall have a smooth contour. After
grinding, the remaining wall thickness in the area shall not be less than 90% of the
nominal wall thickness.

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MECHANICAL
8.0 PIPE SUPPORTS/PLATFORMS
8.1 Supply/fabrication/installation of steel support.
a) The contractor shall supply all material, fabricate and install all supports and
platforms marked on drawings.
b) All temporary supports necessary for erection work shall be provided by the
Contractor and removed when permanent supports have been installed as per
drawings.
8.2 Grouting of Supports
a) The Contractor shall supply grouting material and carry out all grouting work related
to pipe sleepers and other supports.
b) Grout pads shall be constructed for the supports where necessary.
c) Grout material shall consist of one part of cement and three parts of sand.
d) Pads, iron bars etc. shall not be loaded until grout has cured for at least seven days.

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MECHANICAL
9.0 HYDROSTATIC TESTING
9.1 After completion of welding a hydrostatic test shall be performed at pressures

indicated by the Company / Consultant / Engineer.
9.2 Before starting hydrostatic testing operations, the lines shall be purged by
compressed air so as to clear the lines of any foreign materials.
9.3 Contractor shall inform the Company / Consultant / Engineer well in advance about
the performance of hydrostatic tests.
9.4 Contractor shall keep a record of all hydrostatic tests performed on complete piping
system or on sections of piping. He shall record the date of test, test conditions and
results. These reports will be signed by the Contractor's Representative and
witnessed by the Company / Consultant / Engineer.
9.5 All material and labor required for hydrostatic testing shall be provided by the
Contractor. Only clean water shall be used for hydrostatic testing of pipelines.
9.6 Pumps shall not be subject to hydrostatic pressure and shall be isolated from the
piping system during the test.
9.7 Pressure gauges mounted on piping may be tested together with the piping if the test
pressure does not exceed the pressure gauge range. Pressure Gauges shall be
blocked off from piping during blowing or flushing operations
9.8 Pressure test shall not be carried out against closed valves. Valve seats shall not be
subject to pressure exceeding their specified pressure.
9.9 After pressurizing the line up to the specified pressure, all welded and flanged joints
shall be inspected by the Contractor's and Company / Consultant / Engineer. During
this period, the line shall be maintained under pressure. Minimum duration of
maintaining pressure in hydrostatic testing shall be 1 hour.

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MECHANICAL
9.10 If leaks are detected, the line shall be completely drained and the leak repaired by
the contractor in the manner specified for repairs. After repair the line shall be retest
at the same pressure following the above procedure.
9.11 After successful completion of hydrostatic testing, all equipment/lines shall be

completely drained by the Contractor.
9.12 Lines, which are normally open to atmosphere, may not be pressure tested. These
lines shall, however, be visually inspected to ensure proper workmanship.
9.13 Hydrostatic test shall include, but not be limited to the following equipment
and instruments.
9.13.1 Pigs for filling, cleaning and gauging:
 Cleaning pigs with nylon / polyurethane / steel brushes.

 Pigs with gauge plate diameter equal to 95% of the nominal inner dia of
heavy wall pipe in the pipe sections.
9.13.2 The Contractor shall provide sufficient number of pigs, including spares.
 Pressure gauges of suitable pressure range (1.5 x pressure to be measured)

and accuracy of ± 0.1% of the full scale value.
 Pressure and temperature recording charts. Injection facilities to inject

additive for anti corrosion into the test medium in the required proportions.
 The duration of hydrostatic test shall be minimum 24 hours after stabilization

and the test pressure shall be as indicated in approved hydrostatic test
diagram.

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MECHANICAL
10.0 CLEANING
10.1 After successful completion of hydrostatic tasting all lines shall be cleaned by
flushing, blowing or swabbing.
10.2 The Contractor shall provide all equipment required and shall carry out all operations
involved in cleaning. .
10.3 All foreign material, including but not limited to scale, rust, dirt moisture, welding rods
and particles shall be removed from the inside of all piping systems.
10.4 Equipment like pumps, strainers, etc. shall be removed before cleaning operations.
The contractor shall provide temporary connections to by pass these items. After
cleaning, the contractor shall install these items in the piping system using new
gasket if required.
10.5 All product piping shall be blown by compressed Air until clean.
10.6 Water lines shall be flushed with water until clean.
10.7 Cleaning operations shall be performed until the Company / Consultant / Engineer is
satisfied that the piping systems are thoroughly clean.


(DIA 8”)-KEAMARI (SHELL LOBP)
SPECIFICATIONS FOR
PAINTINGS
Consultant:

DISCHARGE PIPELINE
SHELL PAKISTAN LIMITED MECHANICAL
Doc. No. 2532-ME-002 Specification For Painting Revision No. 2
Disclaimer
Ltd., and is subject to and issue in accordance with the agreement between Petrochemical
Engineering Consultants and SPL. Petrochemical Engineering Consultants accept no liability
or responsibility whatsoever for it in respect of any use of or reliance upon this report by any
third party.
permitted.
Specifications for Painting Page 1

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TABLE OF CONTENT
1.0 PAINT WORK ..................................................................................................3
1.1 GENERAL ....................................................................................................3
2 CODES & STANDARDS .....................................................................................4
3. MATERIALS ........................................................................................................ 5
4.0 SURFACE PREPARATION .............................................................................6
5.0 APPLICATION .................................................................................................9
6.0 PAINTING SEQUENCE ................................................................................ 10
6.1 Piping: ........................................................................................................10
7.0 INSPECTION................................................................................................. 11
ANNEXURE-I : Polyken Field Coating System Application Specification

DISCHARGE PIPELINE
1.0 PAINT WORK
1.1 GENERAL
1.1.1 This specification covers the minimum requirements for supply of painting and Epoxy
coating materials, app lication of pa inting and coating materials on p iping, structur e
and platforms.
1.1.2 The painting works to be performe d by the Contractor shall include all necessar y
steps like supply of material, surf ace preparation to S.A. 2.5 “near White Metal”,
protection o f the other works, application of primers, intermediate and top (fin ish)
coats, cleaning of the working area as well a s all intermediate and fina l inspe ction
works.
1.2 DEFINITIONS

VENDOR

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2.0 CODES & STANDARDS
The followin g codes an d standards shall be followed for the work covered by this
contract.
BS 4232 : Specification for Painting requirement, surface
preparation
SSPC –Pittsburg. U.S.A. : Good Painting Practice and Surface specification
SP 1 to 10 Manual volume-1
DIN Standard 55928 : Specification for paint requirement for field painting
work
BS 4593 sec.4 : Specification for Inspection of finished painting.
DEP 30.48.00.31-Gen. : Protective coatings for onshore facilities
The accept able standa rd for surf ace prepar ation of storage tanks, piping a nd
structures shall be ISO 8501-1 “SA 2 ½ “or SSPC-“SP10, near white metal".

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3. MATERIALS
3.1 Painting an d finish ing products for all work shall be be st grade produ ced for ea ch
particular kind of material.
3.2 Before supply the Contractor will provide sampl es of primer and paints for Compan y/
Consultant / Engineer’s approval.
3.3 Material for primers and paints will be supplied in 20 liters containers.
3.4 Materials for primer an d succeedin g coats shall preferably be the pro ducts of the
same manu facturer. Compatibility of primer and succeed ing coats shall be checked
before execution of work.
3.5 The storage and preparation of paints and coating materials shall b e strictly in
accordance with the manufacturer’s instructions.

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4.0 SURFACE PREPARATION
4.1 Prior to the commence ment of the work, Cont ractor shall submit for Compan y /
Consultant / Engineer's review a blast cleaning procedure, details of equipment an d
personnel assigned to t he blast cleaning operation. Blast cleaning sha ll be done for
all piping, storage tanks and structure.
4.2 Abrasive material for blast clean ing shall be of a particle size to ach ieve the ancho r
profile/surface cleanliness detailed in 4.19 and 4.20.
4.3 Steel surfaces to be blast cleaned shall be free from grease, oil, dirt, weld slag or any
other contamination. Oil and grease shall be removed with a suitable solvent. On ly
approved safety solvents, which do not l eave a residue, sh all be used. Pipes which
have been subjected to salt spray in transportation shall be water washed and dried.
4.4 Surface shall be prepared generally during the day hours. When the surfaces sho w
traces of condensation and if the relative humidity of the ambient air is higher than 80
to 85% the work shall be interrupted.
4.5 All metal parts which show traces of oxidation after cleaning and before painting shall
be cleaned again, Greasy substances on surfa ces to be r e-cleaned a nd shall be
removed through solvent scrubbing before re-cleaning.
4.6 All tools sha ll be used so as not to leave rough or sharp sur faces. No cuts shall be
made on steel surface.
4.7 After beveling, rolling a nd cleaning plates should be transferred to a shot-blasting

area remote from other cleaning or coating operations.
4.8 During transportation and coating care shall be taken to avoid damage to bevels, and
the steel surface.
4.9 Particle size and abrasive contamination shall be regularly checked.

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4.10 The surface shall then b e cleaned of all remaining grit and residual dust in a manner
such that no contamination of the steel surface, or any other surface, which will affect
coating qua lity, will occur. The surface sha ll b e regularly t ested for cleanliness by
applying white tape and examining the tape for residue.
4.11 After grinding, any grou nd area larger than 50 mm in diameter shall be re-blasted to
attain the desired profile.
4.12 A primer coat should be immediately applied on the proper cleaned surfaces.
4.13 Before primer application Company/ Consultant / Engineer or Coating Manufacturer’s

representative shall approve preparation of the surfaces.
4.14 Cleaning sh ould be sto pped each day leaving sufficien t time to permi t the surfaces
cleaned to be primed before the end of the working day.
4.15 The Contractor shall immediately re view any de fect produced in primer coat due to
handling or any reason.
4.16 Any blast-cleaned surfa ce not pr imed before a ny apparent surface oxidation occur s,
or not primed, within 4 hours after blasting, shall be re-blasted.
4.17 Second primer coat, two finish coats and shades for pattern will be applied after
fabrication, erection and welding works.
4.18 All damaged and loosely adhering p aint shall be removed and the surface thoroughly
cleaned, pr eferably by sandblasting or if not practical then by mecha nical device s
such as with brushes or descalers to "near white metal" finish.
4.19 Blasted surf aces shall conform to SA 2.5 by visual comparison with the Swedish
Standard SIS 05 59 00.

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4.20 An average surface a mplitude of 50 microns peak he ight shall be obtained (+ 25

microns), every hour an d tested eve ry hour with a Testex Press-o-Film and retained
with the inspection records.

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5.0 APPLICATION
5.1 The painting and coating work shall be performed carefully in accordance with the
manufacturer's instructions using skilled labour. In particular dripping, corrugations
and other application defects shall be avoided.
5.2 Painting shall not be carried out during following weather conditions:
– Rain
– Fog
– Relative humidity of air causing condensation on the metal surface at ambient
temperature
– Temperature of metal surface higher than 60oC
– Rainy weather
5.3 Each coat of each painting /coating sequence shall be of a slightly different shade so
as to ensure the complete covering by means of the next coat.
5.4 Approved Paint/Coating Manufacturer are as under:
ICI Paint
Jotun Paint
5.5 Paint / Coating Manufacturer’s inspector shall supervise and witness the surface
preparation and application of primer / paint /coating.

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6.0 PAINTING SEQUENCE
The following sequence shall be applied: Necessary number of layers is as follows:
6.1 Piping & Structure :
1st Coat Alkyed Zinc Silicate 75 microns DFT

2nd Coat Apikot Epoxy 75 microns DFT
3rd Coat Aliphatic Polyurethane 75 microns DFT
4th Coat Aliphatic Polyurethane 75 microns DFT
Total dry film thickness (DFT) 300 microns minimum
Painting / coating scheme shall be as per Shell Pakistan requirement.
For painting sequence of underground piping refer Annex-I

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7.0 INSPECTION
7.1 All works and materials applied und er this specification sha ll be subject t o inspection
by Company / Consultant / Engineer / Manufacturer representative.
7.2 All parts of the work shall be readily accessible for inspection.
7.3 Approval of each of th e following shall be ob tained befor e proceedin g with any
subsequent phase:
– Location of Work.
– Equipment.
– Surface Preparation.
– First Coat.
– Each Subsequent Coat.
7.4 Applicator shall correct work found defective under this spe cification at no cost to the
Company/ Consultant / Engineer.
7.5 Micro-test t hickness g auge or comparable instrument shall det ermine coatin g
thickness.


SPECIFICATIONS FOR
STRUCTURAL STEEL WORKS
Consultant:

DISCHARGE PIPELINE
Specification for Structural

Steel Works
Disclaimer
Ltd. (SPL), and is subject to and issue in accordance with the agreement between
Petrochemical Engineering Consultants and SPL. Petrochemical Engineering Consultants
accept no liability or responsibility whatsoever for it in respect of any use of or reliance upon
this report by any third party.
permitted.
Specification for Structural Steel Works Page 1

DISCHARGE PIPELINE

Steel Works
TABLE OF CONTENT
1 GENERAL ........................................................................................................... 3
1.1 Scope ........................................................................................................... 3
2 APPLICABLE STANDARDS ............................................................................... 4
3.0 DESIGN .............................................................................................................. 5
4.0 GENERAL ........................................................................................................... 6
5.0 FABRICATION .................................................................................................... 7
6.0 ERECTION ......................................................................................................... 9
7.0 MISCELLANEOUS STEEL WORK ................................................................... 11

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Steel Works
1.0 GENERAL
1.1 Scope
This specification covers the minimum requirements of design of steel structure, steel
work fabrication, methods including precautions for erection of steel structures,
painting and other general requirements incidental to steel work, for complete job as
shown on the Drawings.
The work covered by this specification consists of design, supply of all material,
labour, plant, equipment and appliances including welding, bolts, nuts, washers,
anchor bolts, embedded parts etc.
1.2 DEFINITIONS

VENDOR

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Steel Works
2.0 APPLICABLE STANDARDS
Latest edition of the following standards are relevant to these specifications,

wherever applicable:
AISC American Iron and Steel Construction Manuals
AISC Specification for Architecturally exposed structural steel.
ASTM Specifications for structural joints using ASTM A 325 or A 490 Bolts.
AISC/SSPC Guide to shop painting of structural steel.
AWS Specifications for welding of steel structures (AWSD 1.1)
BS 449 Use of structural steel in Buildings.

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Steel Works
3.0 DESIGN
The design of steel structure shall as per American Iron and Steel Construction
Manuals and good industrial practices

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Steel Works
4.0 GENERAL
4.1 Structural steel work shall be provided and fixed complete with all plates, cleats,
bolts, etc, cut to lengths and sizes and drilled as shown on the drawings.
4.2 Unless otherwise required by the Contract all forms of steel used shall be of standard
section and shall be of the exact dimensions. Should the Contractor be unable to
obtain steel to the required dimensions he shall submit alternative proposals to the
Company/Consultant/Engineer for approval.
4.3 Welding electrodes shall comply with the requirements of AWS series E60XX.
4.4 The workmanship shall be of the best quality and all persons employed at the site
shall be competent and skilled in their respective trades.
4.5 The allowance welding processes are according to AWS A 3.0.

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Steel Works
5.0 FABRICATION
The Contractor shall notify the Company/ Consultant/Engineer doubts / errors

discovered in the drawings for clarification / rectification well in advance to prevent
any fabrication errors. Fabrication shall not be commenced until approval has been
obtained from the Company/ Consultant/Engineer.
5.1 Straightening of Material
Rolled material, before being worked upon must be straightened within tolerances by
ASTM specifications A6. Straightening, necessarily shall be done by mechanical
means or by the application of limited amount of localized heat. The temperature of
heated areas, as measured by approved methods, shall not exceed 1100 degree F
for A 514 steel or 1200 degree Fahrenheit for other steels.
5.2 Cutting
As far as possible cutting must be done by shearing. Oxygen cutting shall be done
where shear cutting is not possible and shall preferably be done by Machine. All
edges shall be free from gauges, notches or burs. If necessary the same shall be
removed by grinding.
5.3 Holes Punching Drilling
Holes shall be punched where thickness of the material is not greater than the
diameter of bolt + 3 mm. where the thickness of the material is greater the holes shall
either be drilled or sub-punched and reamed to size. The die for all sub-punched
holes and the drill for all sub-drilled holes shall be at least 2 mm smaller than the
nominal diameter of the rivet or bolt.
5.4 Plates and sections shall be true to form. Stiffeners, plates and the like shall be
ground to fit the profile of the member.

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Steel Works
5.5 Welding
 The work shall be erected, fitted and temporarily bolted together for the approval of
the Company/ Consultant/Engineer before any welding is carried out.
 Maximum and minimum size and lengths of fillet welds shall be in accordance with
AISC specifications.
 Welding shall be carried out in accordance with Standards of American Institute of

Steel Construction using electrodes as specified. Welders shall be suitably qualified
and experienced and efficient methods shall be employed to remove all welding slag,
spatter and flux residues thoroughly.
5.6 Purlins shall, where possible, be fabricated to span continuous over two bays. To
achieve this purlin joints should be staggered, with suitable continuity joints for single
bay length members.
5.7 Holding down bolts shall be supplied as required for building into the supporting
concrete members.
5.8 Tolerances
A variation of 1 mm is permissible in the overall length of members with both ends

finished for contact bearing. The bearing surfaces shall be prepared to a common
plane by milling.
Members without end finished for contact bearing which are to be framed to other
steel parts of the structure shall have a variation from detailed length not greater than
3 mm.

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Steel Works
6.0 ERECTION
6.1 Test Assembly
6.1.1 Fabricated shop assemblies of all components such as Columns, Beams, Girders,
Purlins, Bracing, Trusses, shall be test assembled together after fabrication, prior to
field erection.
6.1.2 Test assembly of beams and bracings of each floor and columns, beams, and
bracing of each grid/axis may be done separately and partly, but involving, all
components of at least 3 bays.
6.1.3 Test assembly work and procedure should be planned during fabrication process.
Major fabrication work of locating of gussets etc. marking and drilling of holes for inter
connecting joints, spliced connections leveling, placing of bracings should be done
simultaneously with test assembly.
6.1.4 Each test assembly will be inspected by the Company/ Consultant/Engineer and will
be dismantled only after his approval in writing.
6.2 Bracing
The frame of steel skeleton buildings shall be carried up true and plumb within the
limits defined in the AISC code of standard practice, and temporary bracing shall be
introduced wherever necessary to take care of all loads to which the structure may
be subjected including the equipment and the operation of the same. Such bracing
shall be left in place as long as required for safety.
Wherever piles of material, erection equipment and other loads are carried during
erection, proper provision shall be made by the Contractor to take care of the
stresses resulting from such loads.

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Steel Works
6.3 Alignment
No riveting, permanent bolting or welding shall be done at site during erection until as
much of the structure as will be stiffened thereby has been properly aligned.

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Steel Works
7.0 MISCELLANEOUS STEEL WORK
7.1 General
The work covered shall include furnishing, fabricating, installing and painting
miscellaneous steel work including the following:
 Steel stairs
 Steel Ladders
 M.S. pipe handrails
 Steel protection angles and Channels
 Steel fencing
 Grating and chequered plate covering
 Embedded plate, anchor bolts and other miscellaneous items
7.2 Steel Stairs
7.2.1 Structural steel stairs complete with grating treads or chequered plate treads,
landings, supporting structures, hand rail supports etc. shall be furnished and
installed in accordance with working drawings.
7.2.2 Except otherwise indicated in the working drawings, materials shall conform to the
requirements of ASTM A 36 (specifications for structural steel).
7.2.3 The stairs shall be installed in a first class workman like manner. Connections to
adjacent concrete structures shall be made with anchor bolts or shall be welded to
embedded part at site as shown on the drawings.
7.3 Steel Ladder
Steel ladder shall be welded assemblies with safety cages fabricated in accordance
with the drawings. Material and standard of fabrication shall be the same as
specified for stairs.

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Steel Works
7.4 M.S Pipe Handrails
M.S. pipe handrails consisting of posts, handrails, knee rails and toe rail shall be
fabricated in suitable units having two posts or three posts in one unit with erection
joints between handrail and knee rails. Top handrail, knee rail and toe rail may be
brought at site in stock length then the same is cut and welded at site. Locally
manufactured M.S. pipe shall be used for the hand railing. The handrails shall be as
per design details shown on drawings.
7.5 Steel Protection Angles
Steel protection angles required for the protection of concrete work shall be erected
true to line and level. Steel angles shall be grouted and fixed in position by using
anchors as shown on the drawings or as directed by the Company/ Consultant/
Engineer.

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Steel Works
8.0 PAINTING
All structural steel work shall be as per project specification.


SPECIFICATIONS FOR
WELDING
Consultant:

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Doc. No. 2532-ME-004 Specification for Welding Revision No. 0
Disclaimer
permitted.
Specification for Welding Page 1

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TABLE OF CONTENT
1 GENERAL .......................................................................................................................... 3
1.1 SCOPE ....................................................................................................................... 3
1.2 CODES, STANDARDS AND REGULATIONS ............................................................. 3
2 WELDING PROCEDURES ................................................................................................ 5
2.1 GENERAL ................................................................................................................... 5
2.2 WELDING METHODS ................................................................................................. 6
2.3 MATERIALS AND EQUIPMENT ................................................................................. 9
2.4 JOINT PREPARATION ............................................................................................. 13
2.5 PREHEATING ........................................................................................................... 14
2.6 WELDING DETAILS.................................................................................................. 14
2.7 WELDING TECHNIQUES ......................................................................................... 16
2.7.1 GENERAL .......................................................................................................... 16
2.7.2 HORIZONTAL ROLL WELDS............................................................................. 17
2.7.3 HORIZONTAL FIXED WELDS ........................................................................... 17
2.7.4 VERTICAL WELDS ............................................................................................ 17
2.7.5 FILLET WELDS .................................................................................................. 17
2.7.6 TREATMENT OF UNDERSIDE OF WELD ......................................................... 17
2.7.7 CLEANING ......................................................................................................... 18
2.7.8 WELD IDENTIFICATION .................................................................................... 18
2.8 DEFECTS AND REPAIRS ........................................................................................ 18
2.9 POST WELD HEAT TREATMENT (PWHT) .............................................................. 18
2.10 INSPECTION .......................................................................................................... 21

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1.0 GENERAL
1.1 Scope
This specification shall govern the electric arc welding processes permitted for use
in the fabrication of all pressure piping.
This specification shall apply to all suppliers, sub contractors, vendors,

manufacturers, and fabricators of welded pipes. The Contractor is responsible for
all and shall ensure that all components to be incorporated into the work meeting
this specification.
No supplier, sub contractors, vendor, manufacturer or fabricator shall subcontract

the welding fabrication of any item without written approval from the Company /
Consultant / Engineer, and the Company / Consultant / Engineer will not issue
such an approval unless the proposed welding fabricator has received prior
Company / Consultant / Engineer approval for the type of welding to be carried out.
1.2 Codes, Standards And Regulations
All welding performed under this Specification shall meet or exceed the
requirements specified by the latest revisions of the following applicable Codes and
Regulations
a) AWS - (American Welding Society)

1. A2.4 (Symbols for Welding and Nondestructive Testing)
2. A3.0 (Standard Welding Terms and Their Definitions)
3. A5.1 (Specification for Mild Steel Covered Arc Welding Electrodes).
4. A5.5 (Specification for Low-Alloy Steel Covered Arc Welding Electrodes).
5. A5.17 (Specification for Bare Carbon Steel Covered Electrodes).
6. A5.18 (Specification for Carbon Steel Filler Metals for Gas Shielded Arc
Welding).

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7. A5.20 (Specification for Mild Steel Electrodes for Flux Cored Arc Welding
Electrodes).
b) Applicable Local Boilers and Pressure Vessels Act and Regulations.
c) ASME B31.3 Chemical Plant and Petroleum Refinery Piping.
d) ASME Sec. VIII Div. 1 - Pressure Vessels.
e) ASME Sec. IX - Welding.
f) ASME B31.4 - Pipeline transportation systems for liquid hydrocarbons and

other liquids.
g) API STD 1104 Standard for Welding Pipelines and Related Facilities.
h) AWS D1.1
i) DEP 30.10.60.18-Gen. Welding of metals (amendments/supplements to API

RP 582)
j) DEP 61.40.20.30-Gen. Welding of pipelines and related facilities

(amendments/supplements to ISO 13847:2000)
All welding procedures used by Contractor / fabricator shall have been established
and qualified in accordance with the appropriate sections of one or more of the
codes and standards listed above and approved by the Company / Consultant /
Engineer.
These Specifications apply to materials found in the P-1 grouping of Section IX of

the ASME Codes and the equivalent material in the API Standards. The Company /
Consultant / Engineer, on an individual basis, shall review all other “P” groupings.
Where a conflict occurs between these specifications and / or any of the above
codes or Standards the more stringent shall apply.

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2.0 WELDING PROCEDURES
2.1 General
The Contractor / Sub Contractor / Vendor as applicable shall submit to the

Company / Consultant / Engineer for review and approval all welding procedures.
The Contractor / Sub Contractor / Vendor as applicable shall have a separate

welding procedure for each method of welding he intends to employ.
A procedure qualification record (PQR) shall be included for each WPS. The PQR
shall be witnessed and shall be supported with the lab report from the pre
approved testing laboratory, if so previously agreed to by the Company /
Consultant / Engineer.
All testing shall be performed by Contractor / Sub Contractor / Vendor as the case
may be and certified by an Company / Consultant / Engineer approved testing
laboratory, agency or equivalent. The minimum acceptable written procedure shall
detail information on the following parameters.
1. The scope of work performed under the procedures.
2. The base metals and applicable specifications.
3. The welding process.
4. Type, size, classification, and composition of filler metals. (The specific brand
name(s) of the flux-wire shall become an essential variable of the procedure
qualification).
5. Type and range of current and voltage.
6. Width of electrode weave or oscillation.
7. Joint preparation and cleaning procedures.
8. Tack welding procedures. Method of marking the location of tack welds to
facilitate post weld inspection shall also be included.
9. Electrode polarity.
10. Applicable welding positions.
11. Preheat and inter pass temperatures. (Control method)

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12. Welding travel speed.

13. Root preparation prior to welding from second side, (where applicable).
14. Wire feed speed, rate of travel (GMAW & SAW)
15. Removal methods for weld defects and stray arc strikes.
16. Inter pass-cleaning method.
17. Repair welding,
18. Post welding heat treatments (if required).
19. Type of (GMAW & GTAW) shielding gas, and flow rates
20. Type of (GTAW) electrode, size and tip angle.
21. Welders qualified and deployed in production welds shall always bear an
identity card in the manner so approved by Company / Consultant / Engineer.
The Contractor / Vendor shall only employ welders who have a valid welding
certificate for the procedures being used.
The Contractor shall have all welders tested in accordance with the applicable
code or standard. Testing shall be at the Contractor’s / Vendor’s expense including
test pieces. Irrespective of pre-qualification all welders proposed to be deployed in
the work shall be tested and qualified afresh.
No welder shall be allowed to make any weld for which he is not qualified.
2.2 WELDING METHODS
The following welding processes are permitted, provided satisfactory evidence is

submitted that the procedure has been qualified in accordance with the applicable
Codes:
1. Shielded Metal-Arc Welding (SMAW).
2. Gas tungsten Arc Welding (GTAW).
3. Submerged Arc Welding (SAW).
4. Gas metal arc welding (GMAW)

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The following processes are acceptable for the fabrication of piping by welding with
limitations as noted.
Shielded metal arc welding (SMAW): may be used on all ferrous P1 & P8 materials
with the following restrictions:
1. For low-hydrogen electrodes: 4.0 mm (5/32 inch) for out-of-position welding

2G, 3G, and 4G and 5.0 mm (3/16 inch) for flat welding 1G.
2. For other non-low-hydrogen electrodes: 5.0 mm (3/16 inch) for out-of-position

welding 2G, 3G, and 4G) and 6.0 mm (7/32 inch) for flat welding 1G.
3. Welding with larger-size electrodes for specific applications may be allowed

only if each welder qualifies with the largest-size electrode to be used in
production. This option is strictly at the Company / Consultant / Engineer
discretion. The Company / Consultant / Engineer shall specify the details of
the welder qualification tests if required.
Gas tungsten arc welding (GTAW) may be used on all ferrous P1 & P8 materials.
1. GTAW is required for the butt joint root pass of P-8 material.
2. SAW of carbon steel (P-1) materials shall not utilize active (Mn-Si) fluxes.
3. As-deposited weld metal for carbon steel (P-1) materials shall meet A-1 weld
metal analysis.
4. For carbon steel (P-1) material; flux / wire combinations shall be chosen such
that the deposited hardness of the cap pass shall not exceed 240 BHN. For
low-temperature materials and other materials heat input shall be minimized
and comply with the WPS parameters.
5. The carbon arc gouging process may be used. All carbon arc gouged surface
areas shall be ground to clean bright metal prior to subsequent welding.
6. The Contractor may propose alternate process in addition to those listed. Any
proposed process shall require written Company / Consultant / Engineer

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approval and qualification prior to implementation. Contractor and Company /

Consultant / Engineer shall agree on tests, results, and other criteria before
Company / Consultant / Engineer approval is granted.
Gas metal arc welding (GMAW) may be used on all P1 & P8 materials with the
following restrictions:
1. GMAW in the short-circuiting transfer mode is limited to 10.0 mm (3/8-inch)

maximum material thickness.
2. GMAW in the spray transfer mode shall be used in the flat position 1G only.
3. GMAW in the globular transfer mode is not acceptable.
4. GMAW in the vertical position 3G shall be uphill, except for the root pass on
butt joints, which may be downhill.
5. GMAW welds that require radiography shall be Radio graphed with extra fine
grain film.
6. The Company / Consultant / Engineer reserves the right to utilize ultrasonic

inspection to confirm any GMAW welds interpreted to have lack of fusion
defects (sidewall or inter pass).
7. If the as deposited weld exceeds 1.60 percent Mn, then all such welds shall
not exceed 200 BHN. If these welds exceed 240 BHN, then they shall be
removed.
All fillet welds, including weldolets, threadolets, and socket welds, shall be made as
below:
The root and hot with two subsequent pass by GTAW and rest are by Shielded
Metal Arc Welding (SMAW) process.
All butt welds in pipe smaller than 60.3 mm O/D (NPS 2” inch) Schedule 40 shall
be made by GTAW and shielded metal arc process. Root pass by gas metal arc is
acceptable for pipe larger than 60.3 mm O/D NPS (2”) inch.

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All welds in pressure equipment must be qualified for Charpy impact testing when
the code requirements indicate that the parent material requires impact testing.
When impact tests are required, tests shall be taken from the weld and heat
affected zone.
The Contractor shall give special attention to welding of dissimilar base metals
(different P numbers). Choice of electrodes / filler metals preheats, and the
Contractor shall propose post weld heat treatment to Company / Consultant /
Engineer for approval. Welds between carbon steel (P-1) and austenitic stainless
steel (P-8) shall utilize ENiCrFe-2, ENiCrFe-3, ERNiCr-3, E309L, ER309L or
equivalent filler metal approved by the Company / Consultant / Engineer.
Permanently installed backing rings shall not be used.
All butt welds in pressure equipment shall have the same chemical and mechanical
properties as the parent metal.
All welding procedures must be qualified for Charpy impact testing when the Code
requirements indicate that the parent material requires impact testing.
2.3 Materials And Equipment
2.3.1 The work under this section covers welding on materials listed under Material
Group P-1, Section IX, Welding Qualifications, ASME Boiler and Pressure Vessel
Code, latest edition.
Welding electrodes shall conform to the appropriate of ASME Boiler and Pressure
Vessel Code II Part C and / or the appropriate section of - Welding Electrodes as
follows:
a) SMAW to SFA 5.1 covered carbon steel arc welding electrodes Class E7016,
E7018, or E7018-1.
b) GTAW to SFA 5.18 carbon steel filler metals for gas shielded arc-welding
class ER70-S2

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c) SAW to SFA 5.17 carbon steel electrodes and fluxes for submerged arc
welding, wire / flux classification EM 12K with a suitable neutral flux.
2.3.2 Welding Consumables.
The use of all welding consumables shall be subject to the Company / Consultant /
Engineer’s approval.
All coated metal arc-welding electrodes shall comply with AWS specification A 5.5,
A 5.1. Submerged arc wire and flux shall comply with AWS A 5.17. Flux shall be of
the non-active type unless approved otherwise by the Company / Consultant /
Engineer.
All welding consumables, including fluxes shall be supplied in sealed containers

and stored in a dry location at a minimum temperature of 68ºF, and a maximum
relative humidity of 60%. Low-hydrogen electrodes, after removal from factory seal
containers, shall be baked at 250º C for 2 hours and then stored / handled in
portable ovens at a minimum temperature of 150ºF prior to use.
The welding filler metals shall have a chemical composition as near as possible to
the parent metals to be welded. The finished weld as deposited, or after post weld
heat treatment (PWHT) when required, shall be at least equal to the parent metal
as to unit strength, ductile, and other physical properties and in resistance to
corrosion, hydrogen attack, or other operating environment factors as required.
Permission to change filler metals to those other than the ONES QUALIFIED IN
ACCORDANCE WITH THIS SPECIFICATION must be obtained in writing, from
the Company / Consultant / Engineer.
Electrode and rod diameters shall conform to the parameters of the weld
procedure.
The Contractor / Vendor shall provide adequate drying ovens and take proper
precautions in the storage and handling of low-hydrogen electrodes.
The Contractor / Sub Contractor / Vendor shall provide suitable wind guards,

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welder's platforms or bell holes when conditions warrant their use.
Electrodes and filler rods shall be protected from mechanical damage or

deterioration. All unidentified, damaged or deteriorated electrodes or filler wires
shall be removed from the working area and rejected. Any low hydrogen type
SMAW electrodes not contained in heated quivers shall be removed from the site.
Electrodes shall not be exposed to wet or high humid conditions.
Care of welding consumables is the responsibility of the Contractor; however, the

following are minimum requirements:
Low-hydrogen SMAW electrodes shall be kept in commercial electrode ovens after

the factory container has been opened. The electrode holding oven temperature
shall be maintained between 175ºF (79ºC) and 250ºF (121ºC). Any low-hydrogen
SMAW electrodes that have been exposed for more than 4 hours prior to
restocking into the holding oven or any SMAW low-hydrogen electrodes that have
become wet or have damaged coatings shall not be used and the same shall be
rejected and removed from site.
Other (non-low-hydrogen) SMAW electrodes shall be kept in a dry and dust-free

enclosure after opening of the factory container. These non-low-hydrogen
electrodes shall be held at a temperature below 150ºF (66ºC).
SAW fluxes and FCAW electrodes shall be stored in the factory containers in a dry
and relatively dust-free area. Un-fused SAW fluxes may not be recycled for high
strength, low alloy, or high alloy materials unless recycle procedures are Company
/ Consultant / Engineer approved.
Bare wire (SAW and GMAW) and bare filler rod (GTAW and FGW) filler metals
shall be stored in a dry and relatively dust-free area.
Extreme care shall be taken to ensure that electrode separation by classification is

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maintained in the Contractor’s inventory. All storage bins and ovens for welding
consumables shall be clearly labeled. In addition, all GTAW bare rod filler metals
shall be tagged with the AWS designation of the filler metal. Any welding
consumables, which are not readily identifiable, shall not be used.
All pressure containing welds shall be of a minimum of two passes with overlap of
starts and stops. This shall include socket welds and seal welds of threaded
connections.
Weld stops and starts shall be staggered so that adjacent weld passes do not
contain stops / starts within 25mm (1 inch) of each other.
The electrodes shall be purchased from the list of approved manufacturer’s OR

well known & reliable manufacturer and the same shall be supplied with proper
certificates and batch certificates.
The width of weave during production welding shall be within the acceptable limit of
the Company / Consultant / Engineer approved and qualified welding procedure,
qualification certificates, and production welding operating sheets. As a norm this
will be limited to a maximum of 3 times the core diameter of SMAW electrodes,
whichever is the lesser.
Each weld pass / layer shall be completed in one full cycle / circumference before
proceeding with the next. Blocking out or segmental welding is not permitted.
All tools and equipment used in the welding operations shall be in first class
operating condition and shall be of sufficient capacity to ensure welds of the
specified quality are achieved throughout the work. It shall be the right of the
Company / Consultant / Engineer to request at any times the re-calibration of
gauges and meters, etc. to ensure compliance with welding procedure operating
sheets / WPS.

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2.4 Joint Preparation
The surface of the pipe at the weld area shall be free from dirt, grease, scale,
paint, grit or any other foreign material, which may adversely affect the final weld
quality.
Bevels shall be 37½ º and all field cuts shall be normal to the axis of the pipe.
Miter welds are prohibited. All pipes shall be beveled for welding with an approved
mechanical beveling machine.
Damage to bevels, which could possibly affect the quality of the weld shall be
rectified prior to welding. If beyond repair the pipe shall be cut and the pipe end re
beveled.
Where welding a pipe to a flange or another pipe or component, there must be a

band of at least 25.0 mm (1” inch) wide around the internal / external joint weld
preparation that is ground to bright metal, and is free of all foreign matter.
To assure proper spacing and alignment in accordance with the applicable Code,
an approved lineup clamp shall be used.
All welded joints shall conform to the straightness and alignment specified herein.
Correction of improperly fitted parts shall be accomplished by disassembly and
refitting. Reworking by hammering or flame straightening shall not be permitted.
The ends of piping components to be joined shall be aligned as accurately as is
practicable within existing commercial tolerance on diameters, wall thickness, and
out of roundness. Maximum bore mismatch shall not exceed 1/16 inch (1.6 mm).
Alignment shall be preserved during welding.
When joints of unequal thickness are joined, the internal offset shall not exceed 1.6
mm (1/16"). If this value is exceeded, the excess thickness of the heavier end shall
be machined or ground back from the bevel on a one-to-four (1:4) taper.
Maximum bore mismatch shall not exceed 0.8mm (1/32 inch). Where ends are to
be joined and the internal misalignment due to difference in wall thickness, etc.

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exceeds 1.6 mm (1/6 inch), the wall extending internally shall be internally trimmed.
Internal machining shall be performed so that the inside diameters of the
components coincide.
When cutting pipe to length, it should be cut by mechanical means, if practical.

Ends that are to have flanges attached either in the shop or field must be cut true
and square.
2.5 Preheating
Preheat for pressure piping and furnace tubes shall be in accordance with ASME
B31.3 and B31.4.
All pipe joints having a wall thickness greater than 9.5 mm (0.375”) shall be
preheated to 100°C (212°F) prior to welding.
Preheating shall be carried out with an approved torch system or with electrical
induction coils, which will provide uniform heating.
The preheat area shall be at least 200 mm (8”) wide centered about the weld and
shall extend around the entire circumference of the pipe.
Preheat temperatures shall be checked with temperature sensitive crayons (such

as "Tempilstick") or by other approved methods.
If a joint requires preheating, the same temperature requirements shall be

maintained for each succeeding pass.
2.6 WELDING DETAILS
2.6.1 All pressure welding shall be performed in accordance with approved and qualified
welding procedures as required per code.
2.6.2 Each weld shall be uniform in width and size throughout its full length.

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2.6.3 Each layer of welding shall be smooth and free of slag, cracks, pinholes, undercuts
(internal and external), porosity and excessive bead shall be completely fused to
the adjacent weld beads and base metal.
2.6.4 The cover pass shall be free of coarse ripples, irregular surface, non-uniform
pattern, high crown, deep ridges or valleys undercut, arc strikes, porosity,
undercut, slag, or spatter.
2.6.5 Butt welds shall be slightly convex, of uniform height, and have full penetration,
unless otherwise approved.
2.6.6 For piping, limitations on weld reinforcement shall apply to the internal surfaces as
well as to the external.
2.6.7 Fillet welds shall be of a specified size with full throat and the legs of uniform
length.
2.6.8 Arcs shall only be struck in the weld groove. A controlled arc must be maintained
while welding. Should an arc strike occur, it shall be removed by grinding and the
area shall be etched (10% Nital) to confirm heat affected area removal, and MPT
examined to ensure absence of any surface cracking?
2.6.9 After each pass, the layer of weld metal must be cleaned to remove all slag, scale,
dirt, etc. Wire brushes, grinder, or chipping hammer shall be used as needed to
prepare proper surface for each succeeding weld pass.
2.6.10 Repair, chipping or grinding of welds shall be done in such a manner as not to
gouge, groove, or reduce the base metal thickness.
2.6.11 No welding shall be done if the temperature of the base metal is below 50ºF. Nor
shall there be any welding done if there is moisture, grease, or any foreign material
on the joint to be welded.
2.6.12 An ASME qualified welder shall make tack welds. Cracked tack welds shall be
completely ground out and NDE by MPT / DPT prior to re-welded.

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2.6.13 The Contractor shall make no substitution of materials or modifications to details

without the prior written approval of the Company / Consultant / Engineer.
2.6.14 Welders and welding operators shall not be qualified on production welds.
2.6.15 The Contractor shall ensure that welders and welding operators are only employed
on those parts of the work for which they are qualified.
2.6.16 Each welder and welding operator shall possess an appropriate temperature-
measuring device. All supervision shall possess a copy of the approved welding
procedures.
2.6.17 Alternatively, welding procedures may be clearly displayed at each welding

location. Welders shall be familiar with the requirements of the appropriate
approved welding procedures. Any welder found not complying with the approved
welding procedures during production welding shall be removed from the work and
the non-conforming weld(s) may be completely rejected, at the discretion of the
Company / Consultant / Engineer.
Welder having repairs more than 3% in his production weld shall be given a
warning and if no improvement after first warning shall be removed from the project
or requalified, at the discretion of the Company / Consultant / Engineer.
2.6.18 No welding shall be undertaken without approved WPS and qualification of welding
procedure.
2.6.19 The Company / Consultant / Engineer will not provide any WPS for the Contractor.
2.7 Welding Techniques
2.7.1 General
a) All welding shall be performed in accordance with an approved and qualified

welding procedure.
b) Each weld shall be uniform in width and size throughout its full length.

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c) The cover pass shall be free of coarse ripples, irregular surface, non-uniform
bead pattern, high crown, and deep ridges or valleys between beads.
Butt welds shall be slightly convex, of uniform height, and have full penetration.
2.7.2 Horizontal Roll Welds
When Shielded Metal Arc Welds are made in the horizontal (1G) rolled position,
the root pass shall be deposited by the "down hill" method of welding while the pipe
remains in a horizontally fixed position. For all remaining passes, the pipe may be
horizontally rotated as the weld metal is deposited in the approximate top quadrant
in the "uphill" progression method.
2.7.3 Horizontal Fixed Welds
a) When Shielded Metal Arc welds are made with the pipe in the horizontal fixed
position, all passes shall be deposited by the "up hill" method of welding.
2.7.4 Vertical Welds
When Shielded Metal Arc welds are made with the pipe in a vertical position, (2G) ,
the deposition of the weld metal shall be multiple beads in a horizontal plane.
2.7.5 Fillet Welds
a) All fillet welds shall be slightly concave and the length of each leg nearly
equal.
b) Socket welds shall have a minimum of 2 weld beads – root+3 pass by GTAW
remainder by SMAW. The length of each leg of the fillet weld shall be equal.
The width of the weld shall extend to the outer rim of the fitting where practical.
2.7.6 Treatment of Underside of Weld
a) The use of backing rings for butt welds is prohibited.
b) Excessive burn through shall be removed.

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2.7.7 Cleaning
a) All weld impurities shall be removed between passes. Cleaning may be done
with either hand or power tools.
b) All rough irregularities in the cover pass and weld spatter shall be removed.
2.7.8 Weld Identification
Each finished weld shall be clearly marked to identify the portion made by each
welder.
2.8 Defects And Repairs
Welds containing defects not exceeding an aggregate of five (5) percent of the
length of the root bead may be removed by grinding, chipping or arc gouging and
re-welded in accordance with an approved procedure. Welds containing defects
exceeding that amount shall be cutout and replaced.
When defects are ground out the entire weld shall be preheated to a temperature
of 150 °C (300 °F) prior to welding.
All repaired welds shall be radio graphed or by the same method of original defect
detection.
2.9 Post Weld Heat Treatment (PWHT)
2.9.1 Contractor / Sub Contractor / Vendor is responsible for all PWHT requirements,
which shall be performed as specified in accordance with ASME B31.3.
2.9.2 PWHT of pressure piping and furnace tubes shall be in accordance with ASME
B31.3, B31.4 and the specification for Post Weld Heat Treating.
2.9.3 Controlled atmosphere furnaces are preferred for heat treatment. Procedures using
electric resistance, induction, or flame burner rings are acceptable for shop or field
heat treatment. The Contractor must take an approval from Company / Consultant /
Engineer prior to go for heat treatment.

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2.9.4 Contractor / Sub Contractor / Vendor must notify the Company / Consultant /
Engineer prior to starting PWHT operations.
2.9.5 Following Company / Consultant / Engineer approval, Contractor / Sub Contractor

shall permanently stamp each weld receiving PWHT with “HT” on two locations of
the weld. If piping orientation is known, the stamping shall be on the top and north
sides.
2.9.6 The Contractor / Sub Contractor shall furnish a PWHT record chart. The chart must
be dated, numbered, and labeled with job identification, Contractor / Sub
Contractor name, and person responsible for the PWHT. Heat-treated line, welds
and spool numbers shall be identified on the chart.
2.9.7 The completed PWHT record chart shall be submitted for Company / Consultant /
Engineer approval following completion of heat treatment.
2.9.8 Stress relieving of piping shall be performed as per ASME B31.3 / ASME B31.4, as
applicable.
2.9.9 Stress relieving may be performed by electrical induction or by electric resistance
heating devices, or by furnace that has a large enough capacity to accommodate
the entire piece being heat-treated.
2.9.10 The stress relieving temperature to be attained shall be 1100ºF minimum, 1150ºF
maximum. The soak period at this temperature shall be one hour per 25.0 mm (1
inch) of pipe wall thickness and in no case shall the soak period be less than one
hour.
2.9.11 Rate of heating and cooling shall be in accordance with the requirements for
thermal stress relief presented in Section VIII of the ASME Boiler and Pressure
Vessel Code. In any event, the rate of heating above 600ºF may not be more than
400ºF per hour, nor the rate of cooling more than 500ºF per hour when above
600ºF.

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2.9.12 For field stress relieving, a continuous temperature record Log shall be furnished of
the program from heating, soaking and cooling to 600ºF. A minimum of two
thermocouples shall be installed at each weld so that continuous readings can be
assured in the event of thermocouple failure.
2.9.13 Local heat treatment of welds shall consist of heating 1D pipe length completely
around the circumference of the pipe welds or pipes as required to eliminate
thermally induced stresses. A continuous record of time and temperature shall be
maintained for at least two points on each weld during the course of heat treatment
with methods other than exothermic kits.
2.9.14 During heat treatment, the ends of the pipe shall be temporarily plugged to
minimize air-cooling. Sufficient insulation shall be applied to maintain the required
heat treatment temperature. The full thickness of 75mm (3”-inch) insulation shall be
continued for a minimum distance of 610 mm (2 feet) on each side of the heating
elements, and shall be left in place until the weld has cooled to below 100ºF.
2.9.15 When local heat treatment is used, care shall be exercised with restrained piping
so that no upsetting will be caused by thermal expansion.
2.9.16 A minimum 10% of all locally (field) heat-treated welds shall require Brinell
hardness testing.
2.9.17 Unless otherwise indicated by Company / Consultant / Engineer, Brinell hardness

limits apply to welds after PWHT. The hardness of the weld shall be determined by
the average value of three tests (of 3 indentations) taken per 120 degrees quadrant
around the weld. The test areas of the weld shall be ground or filed to provide a
suitable surface for testing. If a Telebrineller is used to measure the hardness, the
bar shall be as close as practical to the anticipated weld hardness. If a poor
indention is obtained on an individual test, a retest shall be made on an adjacent
area.
2.9.18 Hardness tests other than Brinell may be used if the values obtained can be
equated to the Brinell hardness numbers, and the proposed equipment and
procedures have received prior Company / Consultant / Engineer approval.

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2.9.19 Flange facing and threaded connections must be adequately protected against
oxidation during stress relieving and must be cleaned and free of defects after
stress relieving.
2.9.20 No heating or welding may be applied to any piping or weld joint after stress
relieving is complete.
2.9.21 All stress relieving equipment and execution shall be supplied at Contractor’s
expense.
2.10 INSPECTION
2.10.1 The Contractor / Sub Contractor / Vendor shall extend all facilities, assistance and
co-operate fully in all aspects of inspection and NDE and shall give adequate
notice of any required fabrication inspection stages, together with sufficient time for
thorough inspection. The Company / Consultant / Engineer shall have the right to
establish hold points at any point in the fabrication sequence.
2.10.2 Although it is the Contractor’s primary responsibility to perform weld examination,

the Company / Consultant / Engineer shall have the right to observe the
examination of all welds by non-destructive means. The inspection may be at any
time before, during, and after fabrication. The Contractor shall conduct daily NDE
percentage of welds to assess weld quality. Up to- date examinations are required
to identify and prevent the re-occurrence of weld defects on subsequent welds.
Records and evidence of all weld examinations shall be available at all times for
the Company / Consultant / Engineer to review and approve.
2.10.3 Company / Consultant / Engineer may use any method of inspection necessary to
establish quality control and ensure adherence to welding procedures. Company /
Consultant / Engineer shall have the right to accept or reject any weld not meeting
the requirements of this specification, or if Company / Consultant / Engineer terms
a weld unacceptable to the service for which it is intended.

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2.10.4 Repair rates in excess of 5% by joint basis may result in stoppage of work by
Company / Consultant / Engineer until the Contractor demonstrates that the
welding problem has been resolved.
2.10.5 The Company / Consultant / Engineer reserves the right to perform additional
inspection of production welds made using GMAW in the short-circuiting transfer
mode. The Company / Consultant / Engineer may:
a) Perform ultrasonic inspection for the purpose of detecting lack of fusion. This
inspection shall not replace any radiographic or other non-destructive
examination requirement.
b) Perform a shop inspection to evaluate the capability of shop procedures and

personnel to make acceptable welds.
c) Require re-qualification of procedures and / or personnel. This option will be
exercised only in the presence of a significant number of weld repairs.
2.10.6 Any discrepancies between the approved WPS and the production welds noted by
the Company / Consultant / Engineer, any or all of the work made under these
conditions is subject to rejection.
2.10.7 Welds made by unqualified welders shall be rejected and shall be completely
removed by the Contractor.
2.10.8 Welds that are not welder-identified shall be rejected.
2.10.9 The completed weld shall be presented in a uniform and workman like appearance
and shall be symmetrical to the centerline of the weld.
2.10.10 The Contractor shall submit a daily production weld count report, itemized by ISO
drawing number, diameter, weld number, and welder I.D. in addition to a weekly
defect classified repair percentage report based on joint count.
2.10.11 The weld quality of branch connections shall meet the acceptance standards of
this specification.

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2.10.12 Welds between dissimilar materials shall be examined by the method and to the
extent required for the material requiring the more stringent examination.
2.10.13 When examination of welds requiring random NDE (RT, UT, MT) reveals defects
requiring repair, then two additional welds of the offending welder production shall
be examined. For each rejected weld of the two welds, two more additional welds
made by that welder shall be examined. If any of these welds are rejected, then the
welder shall be re-tested or removed from the fabrication at the Company /
Consultant / Engineer’s option, and all welds (represented by the original group)
made by the welder shall be 100 percent NDE (RT, UT, MT).


SPECIFICATIONS FOR
NDE
Consultant:

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Doc. No. 2532-ME-005 Specifications for NDE Revision No. 0
Disclaimer
permitted.
Specifications for NDE Page 1

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TABLE OF CONTENT
1.0 GENERAL ............................................................................................................ 3
2.0 ABBREVIATIONS ................................................................................................ 4
3.0 NDE COMPANY CERTIFICATION ...................................................................... 6
4.0 VISUAL INSPECTION.......................................................................................... 7
5.0 NON-DESTRUCTIVE TESTING ........................................................................ 10
6.0 EXTENT OF INSPECTION AND TESTING ....................................................... 13

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1.0 GENERAL
a) This specification shall govern the basic requirements for Non Destructive
Examination (NDE) as it applies to the fabrication, testing and inspection of all
Pressure Piping, and Transmission Piping.
b) No supplier, subcontractor / vendor, manufacturer or fabricator shall subcontract the

non destructive examination of any such equipment without written approval from the
Client / Consultant / Engineer, and the Client / Consultant / Engineer will not issue
such an approval unless the proposed NDE Sub-Contractor has received prior Client
/ Consultant / Engineer’s approval for the type of NDE work proposed.
1.1 CODES AND STANDARDS
a) Work performed under this section shall confirm to the latest edition of following
codes and standards:
i) ASME B31.3 – Process Piping.
ii) ASME Section V – Non destructive Examination.
iii) ASME B31.4 – Pipeline Transportation System For Liquid Hydrocarbons and
Other Liquids.
iv) ASNT / PCN / CGSB Standards for certification of Non Destructive testing Personnel.
v) ASME Section VIII Div. 1 – Pressure vessel fabrication
vi) DEP 61.10.08.11-Gen. Field inspection prior to commissioning of mechanical
equipment
b) Work shall also be carried out in compliance with all general specification dealing
with welding and fabrication of various equipment.
1.2 CONFLICT
Where a conflict occurs between this Specification and any of the above Codes or
Standards the more stringent shall apply. The contractor shall inform the Client /
Consultant / Engineer in writing and receive written certification form the Client /

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Consultant / Engineer. The contractor shall have readily available for use at the
request of the Client / Consultant / Engineer, latest editions of all codes, specification
and standards necessary for execution of the work at work site.
1.3 DEFINITIONS
CLIENT : Shell Pakistan Limited.

VENDOR

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2.0 ABBREVIATIONS
ASME : American Society of Mechanical Engineers

ANST : American Society for Non-Destructive Testing
ASTM : American Society for Testing and Materials
AWS : American Welding Society
DPI : Dye Penetrant Inspection
HS&E : Health Safety and Environment
MPI : Magnetic Particle Inspection
NDT : Non-Destructive Testing
PCN : Personnel Certification in Non-Destructive Testing
PWHT : Post Weld Heat Treatment
UT : Ultrasonic Testing

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3.0 NDE COMPANY CERTIFICATION
All Non Destructive Examination (NDE) NDT Agency appointed by the Contractor /
Sub Contractor or working for fabricators shall have in place an up-to-date Quality
Control Manual and Code of Practice which shall cover the following:
i) All aspects of NDE of which the NDT Agency is qualified.

ii) Current resumes of all presently employed personnel including their certifications
(PCN, ASNT, CGSB or equivalent).
iii) All proposed specific NDE procedure.
A registered copy of QC manual shall be made available to the Client / Consultant /

Engineer and shall be reviewed and approved by the Client / Consultant / Engineer
prior to services being used. Updates to the Manual shall be forwarded to the
registered holder as they become available.
The Client / Consultant / Engineer will review and approve element’s i), ii) & iii)
above: prior to start on any said company work. Any approval given by the Client /
Consultant / Engineer does not relieve the Contractor of his obligations under
governing, codes, rules and specifications.
All equipment shall be certified and current, to recognized calibration standard and in
first class working condition.

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4.0 VISUAL INSPECTION
a) Visual examination shall be carried out before, during and after fabrication in
accordance with ASME Sec. V article 9 and ASME B31.3.
b) Cracks, (regardless of size and location) and under cutting or any evidence of poor
workmanship, materials, etc., if not repairable shall be cause for rejection.
c) Welds shall be visually inspected wherever accessible in accordance with the
following requirements:
1. Internal misalignment 1.5 MM or Less
2. Cracks or lack of fusion Not permitted
3. Incomplete penetration (for other than Depth shall not exceed the lesser
100% Radiography butt-weld) of 0.8 MM or 0.2 times thickness
of thinner component joined by
butt-weld.
The total length of such
imperfections shall not exceed 38
MM in any 150 MM of weld
length.
4. Surface porosity and exposed slag Not Permitted

Inclusions (4.7mm. Nom Wall
thickness and less)
5. Concave root surface For single sided welded joints

(SUCK UP) concavity of the root surface
shall not reduce the total
thickness of joint including
reinforcement to less than the
thickness of the thinner of the
components being joined.

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6. Weld ripples irregularities 2.5 MM or Less
7. Lack of uniformity in 2.5 MM or Less

bead width
8. Lack of uniformity of 2.5 MM or Less

leg length
9. Unevenness of bead 2.0 MM or Less
10. Weld undercutting 0.8 MM or ¼ thickness of thinner

components joined by butt weld,
whichever is less. (shall be
smooth finished)
11. Overlap 1.5 MM or Less
12. Bead deflection 2.5 MM or Less
13. External weld reinforcement and internal weld protrusion (when backing rings
are not used) shall be fused with and shall merge smoothly into the
component surfaces. The height of the lesser projection of external weld
reinforcement or internal weld protrusion from the adjacent base material
surface shall not exceed the following limits.
Wall thickness of thinner Weld reinforcement

component joined by or internal weld protrusion
butt weld (MM) (MM) Max
6.4 and under 1.6
Over 6.4 – 12.7 3.2
Over 12.7 –25.4 4.0
Over 25.4 4.8

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14. Throat thickness of fillet welds: Nominal thickness of the

thinner component x 0.7 or more.
15. Flattering
Flattening of a bend, as measured by difference between the nominal outside

diameter and minimum or maximum diameter at any cross section shall not
exceed 5% of the nominal outside diameter of pipe.
16. Reduction of Wall Thickness
No reduction of wall thickness at any place of a bend is permitted. Wall

thickness of the bend shall be 5% more than the specified minimum thickness
to the respective pipe size and class.
Welds having any imperfections which exceed the limitations specified in various
clauses shall be repaired by welding, grinding or overlaying etc.

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5.0 NON-DESTRUCTIVE TESTING
5.1 GENERAL
a) All NDT shall be performed in accordance with ASME B31.3 / ASME B31.4 / ASME
code Section V except as modified by this specification.
b) Category of piping are defined by categories I, II, III as shown in Table.1
c) The minimum requirement for extent of NDT inspection shall be as stated in Table 2.
d) The Contractor / NDT Sub Contractor shall prepare NDT procedure covering all
aspects of the work. The NDT procedure shall be submitted to Client / Consultant /
Engineer for review and approval. Approval of the NDT procedure shall be required
before any NDT can be performed.
e) The Contractor / NDT Sub Contractor shall prepare and maintain documentation to
track percentage of welds tested and the weld repair rate. The proposed
documentation shall be made available for review and approval.
f) For vent stack piping, 10% of welds shall be inspected by NDT.

g) All non-pressure tie-in welds and all field welds, regardless of pipe class shall be
examined by 100% visual, radiography and MPI / DPI.
h) Contractor / NDT Sub Contractor shall not deviate from any requirement of this
specification without written approval to do so from Client / Consultant / Engineer.
i) No exemption permitted in regards to full HSE compliance.
5.2 RADIOGRAPHIC EXAMINATION
5.2.1 General
a) The quality of radiographs shall meet or exceed all requirements of the appropriate
International standards and applicable general specifications.
b) X – Ray is the preferred radiographic method. Use of Gamma ray for examination will
be allowed for tie-ins and wherever radiography by X-Ray is not possible, subjected

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to approval of Client / Consultant / Engineer. Contractor shall submit the detailed

procedure for the same for approval of Client / Consultant / Engineer.
c) Particular attention shall be paid to using radiographic ultra fine grain film suitable for
the application, maintaining correct radiographic geometry during exposure, obtaining
correct density also required by the appropriate standard and the correct placement
and exposure of image quality indicators (IQI’s or penetrameters).
d) ASTM wire type IQI’s are preferred. The Client / Consultant / Engineer may permit
the use of ASTM hole type IQI’s on a pre-approved basis, provided the NDT
Contractor can demonstrate satisfactory results.
e) Radiographic technique shall produce maximum contrast and good definition of IQI
wires and shall obtain minimum radiographic density of 2.0 in the weld image.
Fluorescent intensifying screens shall not be used.
f) Max radiographic density shall be 4.0 in all areas of the weld and parent metal.
g) The inability to view the appropriate wire or hole on any radiograph shall be cause for
automatic rejection of that radiograph which shall be re-radiographed at no extra cost
to the Client.
5.2.2 Operator Certification
a) Radiographers supplied by the NDT Agency shall be certified to ASNT Level II, AWS
QC1 and as per AWS B1.10 (guide for non-destructive inspection of welds).
b) An operator qualified to ASNT Level I may assist the Level II operator but all film and
sentencing interpretation shall be carried out by a Level II or higher operator who
shall sign off all report sheets.
c) Visual welding inspection shall be conducted only by a qualified welding inspector,

who shall have a minimum AWS (QC.1) CWI or CSWIP 3.1 certification.
d) The Client / Consultant / Engineer shall review and approve all QA/QC personnel

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prior to deployment on the project.
5.3 MAGNETIC PARTICLE INSPECTION (MPI)
a) MPI shall be carried out in accordance with the requirements of ASME, Section V.
Article 7, & Section VIII DIV 1, Appendix 6, and as modified by this specification.
b) AC electromagnetic yokes shall be used. A background of white contrast paint shall
be used in conjunction with a black magnetic ink (wet particle). The technique shall
be carried out in the continuous mode and two examinations shall be carried out a
right angle to cover for both transverse and longitudinal defects. There shall be
sufficient overlap to allow 100% coverage.
c) All unacceptable or spurious indications found by this method shall be investigated
and removed by grinding followed by thickness check.
5.4 DYE PENETRATE INSPECTION (DPI)
a) DPI shall be carried out in accordance with the requirements of ASME BPV, Section
V, Article 6, & ASME Section VIII DIV 1, Appendix 8, and as modified by this
specification.
b) Unless requested otherwise, DPI shall be carried out using the solvent removable
method.
c) If necessary welds may be lightly dressed to facilitate DPI testing or to assist in the
interpretation of any indications.
d) All unacceptable or spurious indications found by this method shall be investigated

and removed by grinding followed by thickness check.
5.5 ULTRASONIC WELD EXAMINATION (UT)
5.5.1 Ultrasonic Operators
a) Ultrasonic operators supplied by the NDT Agency shall be certified to a General

Standards Board (ASNT/PCN) approved by the Client / Consultant / Engineer.

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6.0 EXTENT OF INSPECTION AND TESTING
6.1 a) Piping systems which are designed and constructed in accordance with ASME
Standard B31.3, Chemical Plant and Petroleum Refinery Piping, shall be
radiographed as per Table II.
b) Piping systems which are designed and constructed in accordance with ASME B31.4
standard for gas pipeline systems shall have all welds radiographically inspected for
100%.
6.2 Hardness testing shall be carried out of welds on vessels and piping in sour or
corrosive service and 10% of local P.W.H.T weld as per ASTM Specification E10,
ASME B31.3.
6.3 Ultrasonic Testing
a) UT testing shall be carried out as per ASME B31.3 and ASME Sec. V article 5.
b) All category ‘D’ welds which are not being radiographed and all other welds
configuration, which does not permit to be radiographed, shall be ultrasonic tested.
c) All tie-in welds where pressure testing are not possible.

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TABLE-I
EXAMINATION CATEGORIES
CATEGORY I HIGHER DUTY PIPING
CATEGORY I HIGHER DUTY PIPING

Severe cyclic conditions as indicated in the respective
isometric drawings, all service.
Carbon Steel material, ASME rating 600# /900# /1500#, all

services.
All ASME classes for lethal substances.(Category ‘M’ fluid

service)
CATEGORY II NORMAL FLUID SERVICE

ASME rating 150# & 300# not covered by Categories I & III
CATEGORY III CATEGORY D FLUID SERVICE

ASME rating 150# for all systems in Category
‘D’ Fluid services such as:
Service air
Instrument air
Open Drains

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TABLE – II
EXTENT OF TESTING AND INSPECTION
METHOD EXAMINATION
METHOD EXAMINATION EXAMINATION EXAMINATION
CATEGORY I CATEGORY II CATEGORY III
Visual 100% 100% 100%
MPI (or DPI for non 100% examination of 100% examination of 100% examination of
ferromagnetic all branch and 1 in 10 branch and 1 in 10 branch and
materials) (Note 2) attachment welds attachment welds attachment welds
RT (butt weld) (Note 100% examination of 100% examination of 100% examination of

1) all welds 1 in 10 welds (Note 1 in 10 welds
6)
UT (Branch weld) 100% examination of 0 0
(Note 5) all welds
Hydrotest (or Yes Yes (Note 3) Service Test

pneumatic test)
Minimum Duration 1 hour 1 hour 1 hour
Records Yes Yes Yes
Notes:
1) Ultrasonic testing, in lieu of radiography, is acceptable only where radiography is not
practicable, e.g. branch connections.
2) MPI or DPI of branch welds to be performed prior to and after attachment of
compensating plate if applicable.
3) Open drains vents or other open ended line shall be leak tested only.
4) For piping within skid packages, the Contractor shall use this table as a guide only
and prepared NDE plan for review and approval by Client / Consultant / Engineer as
required in the respective package specification.

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5) Not required where wall thickness of scanning surfaces are less than 10mm and
where branch size is less than NPS 4”. Non-ferritic materials shall not be examined
with UT methods.
6) RT shall be 100 % of welds for all class 300# series.

MECHANICAL DRAWINGS
PIPING LAYOUTS
REPAIR WORK OF TANKER DISCHARGE PIPELINE

ANNEXURE
Consultant:
0 15-06-15 Annexure Ibad Shoaib

Rev. Date Description Prepared By Approved By
SHELL
L PAK
KISTAN
N LIM
MITED

AN
NNEXU
URE-I
PO
OLYKEN
N SPEC
CIFICA
ATION
Consultaant:

PETR
ROCHE
EMICAL ENGINE
EERING
G CONS
SULTANTS

Polyken 980-955 Field Coating System
Application Specifications
AG-980-955-FC-REV4-0509
POLYKEN FIELD COATING APPLICATION SPECIFICATION
980, 955
SCOPE
1.0 Materials to be covered:

Polyken N° 1027 Primer
Polyken N° 980 (anti-corrosion protection innerwrap)
Polyken N° 955 white (mechanical protection outerwrap)
Polyken N° 934 (holiday patch and repair coating)
Polyken N° 933 (longitudinal or girth weld stripping tape)
Polyken N° 931 (longitudinal or girth weld stripping tape)
2.0 Storage Conditions
3.0 Project Site Conditions
4.0 Pipe Surface Preparations
5.0 Coating Applications Conditions (directly prior to and during application)
6.0 Inspection and Patch Repair
7.0 Special Conditions
AG-980-955-FC-REV4-0509 2
1.0 MATERIALS
1.1 Polyken 1027 Primer is a synthetic rubber/resin blend in a solvent solution. Polyken 1027 serves
to rapidly wet out the pipe’s surface with synthetic rubber solids, preparing it for proper bond of
the 980, anticorrosion protection innerwrap, as well as Polyken 933 or Polyken 931.
1.2 Polyken 980 (anti-corrosion protection innerwrap) total thickness of a laminated butyl rubber
adhesive with stabilized, specially blended polyethylene backing.
1.3 Polyken 955 white (adhesive mechanical protection outerwrap) total thickness of laminated butyl
rubber adhesive with stabilized, specially blended polyethylene backing. Polyken 955 serves as
the mechanical protection layer bonded to and protecting the 980 anti-corrosion protection
innerwrap.
1.4 Polyken 933 or 931 (weld stripping tape) and 934 (patch and repair tape) total thickness, is a
specialized butyl rubber adhesive with stabilized, specially blended polyethylene backing.
Polyken 933 or 931 is to be used as the coating to strip the raised welds (where applicable).
1.5 Polyken 934 is to be used as the holiday patch and repair coating.
2.0 STORAGE CONDITIONS
2.1 Polyken primers and tapes should not be stored at temperatures above 105º F (40.56º C).
2.2 Polyken products should be stored in a secure, dry location.
2.3 Polyken products packaged in cases can be stacked to a limit of 6 feet (182.9 cm) high. All
packages should be stacked right side up at all times.
2.4 Inventoried Polyken products should be used on a first-in, first-out basis.
3.0 PROJECT SITE CONDITIONS
· Ambient temperature conditions

· Pipeline temperature conditions
Project site conditions should be routinely monitored. Project site temperature issues should be
used to determine the optimum roll-body application temperature for Polyken’s System. Polyken
recommends that the minimum roll body temperature of (980/955) be approximately 70º F (21º C)
during application.
Particular site conditions may require that the system application temperature be higher than the
minimum requirement of approximately 70º F (21º C). Please refer to data below for guidance of
when higher than minimum roll body temperature of approximately 70º F (21º C) would be
required. Polyken 933, 931 and/or 934 can be suitably applied at a minimum roll body
temperature of 50º F (10º C).
AG-980-955-FC-REV4-0509 3
3.1 Cold conditions/Cold pipe:
· Ambient temperature: below 40º F (4.5º C)
· Pipeline temperature: below 40º F (4.5º C)
The Polyken (980, 955) system roll body temperature should be 80ºF to 90ºF (27º C to 32.2º C).
When conditions as noted above are in the 28ºF (2.2ºC) and below range, it is recommended that
this system be applied at approximately a 90ºF (32.2ºC) roll body temperature. The system
should be applied in a prompt manner to ensure that the heated roll body temperature does not
decrease by more than 20ºF (7ºC) by roll end.
3.2 Cold Conditions/ Warm pipe:

· Ambient temperature: below 40º F (4.5º C)
· Pipeline temperature: 70ºF to150ºF (21ºC to 65.5ºC)
The Polyken system roll body temperature should approximate that of the pipeline temperature
85ºF to 115ºF (29.4º C to 46.1ºC) roll body maximum of 120ºF (49ºC). Decrease in roll body
temperature during application process should not be more than 20ºF (7ºC). If decrease in roll
body temperature is expected to be more than 20ºF (7ºC) by roll end then initial roll body
temperature should be increased accordingly up to 120ºF (49º C).
3.3 Warm Conditions / Warm pipe:

· Ambient temperature: above 40ºF to 100ºF (4º C to 38º C)
· Pipeline temperature: Identical to ambient
The Polyken system roll body temperature should be minimum of 70ºF (21ºC). Application should
be prompt enough so that roll body temperature would not decrease by more than 20ºF (7ºC). If
decrease in roll body temperature is expected to be more than 20ºF (7ºC) by roll end then initial
roll body temperature should be slightly higher than minimum 70ºF (21ºC).
3.4 Warm Temperature Conditions:

· Ambient temperature: above 40ºF to 100ºF (4.5º C - 38º C)
· Pipeline temperature: 90ºF to 150ºF (32.2º C to / 65.5º C)
The Polyken system roll body temperature should approximate that of the pipeline temperature
85ºF to 115ºF (29.4ºC to 46.1º C) roll body to maximum of 120ºF (49ºC). Decrease in roll body
temperature during application process should not be more than 20ºF (7ºC). If drop in roll body
temperature is expected to be more than 20ºF (7ºC) by roll end then initial roll body temperature
should be increased accordingly, but never above 120ºF (49º C).
4.0 PIPE SURFACE PREPARATION
The pipe’s surface should be sand, grit or shot blasted to a commercial blast finish SSPC-SP6
NACE No. 3, or power wire brush per SSPC-SP3. The steel surface blast pattern should have a
profile of 1 to 3 mils (25 to 76 microns). The steel pipe surface should be free of all blast material,
dirt, or foreign debris and should be free of any grease or oils. Proper solvents should be used to
thoroughly remove any surface oil or grease. A Polyken representative should be contacted for
further information regarding use of solvents for surface cleaning.
5.0 POLYKEN COATING APPLICATION CONDITIONS

(Directly prior to and during application)
5.1 Primer is applied to the pipe steel surface with a brush or paint roller to a wet thickness of no less
than 2 mils (50 microns) and no greater than 4 mils (100 microns). The primer shall be
thoroughly mixed prior to application on pipe. Primer container shall remain covered when not in
use. Primer coverage should be between approximately 200 and 400 square feet per gallon.
AG-980-955-FC-REV4-0509 4
Metric 18.5 to 37 square meters per gallon (1 gallon = 3.785 liters = 9.8 m2 per liter).
5.2 Under special conditions, more than one coat of primer can be applied (see Section 7.0, Special
Conditions.)
5.3 The Polyken 933 or 931 (longitudinal and girth weld stripping tape) 4 or 6 inches (10, 1 cm or
15.2cm) wide should be applied over the primed longitudinal weld (where present) in a length-
wise fashion. A splice (roll end) of 933 or 931 should overlap the previously coated longitudinal
weld by approximately 1 inch (2.54 cm) and continue its application in length-wise fashion over
the longitudinal weld at mid-width such that the weld is coated 2 inches (5 cm) on each side along
its length.
5.4 Application of Polyken 980 (anti-corrosion protection inner wrap) to the 1027 primed pipe.
Important application issues:
· Roll body temperature
· Proper application tension of the 980 during application as determined through routine
tape “neck down” measurements.
The application tension of the Polyken tape systems is directly related to and should be
monitored by measuring the “neck down” or reduction of the product’s width. Polyken 980 6
inches x 200 feet (15.24 cm X 60.69 m) rolls, should “neck down” approximately 1/8” or 3.2mm
during application to achieve the specified tension 12-18 lb. per inch of width (21 to 32 N/10 mm
width).
The 980 roll body temperature is important for two application reasons (also see Section 3.0 for
reference):
1) The minimum roll body temperature of 70º F (21º C) allows “neck down” to occur within
the 12-18lb. per inch width (21 to 32 N/10 mm width) application range. This corresponds
to a 1/8 inch / 3.2 mm neckdown. If the tape is colder than 70º F (21º C), it will take more
than 12-18lb. per inch width (21 to 32 N/10 mm width) width to achieve the 1/8” or 3.2
mm “neck down” specification.
2) The 70º F (21º C) and above roll body temperature reduces the effect of thermal
expansion of the cold applied tape system on warmer operating temperature pipelines,
thus maintaining the proper amount of tangential force on the wrapped tape system.
5.41 The 980 should be applied by a Polyken approved power wrapping machine
incorporating a Polyken approved brake tensioning device in a spiral fashion with a ¾ ”
(1.9 cm) to 1” (2.54 cm) overlap. Application tension on 980 should begin only after the
first third of the pipe’s circumference is wrapped. This prevents crawl back of the tape,
which could otherwise be induced, from high tension at the very· beginning of the
wrapping process.
Once the application of 980 is completed, it can be holiday tested using a holiday
detector and NACE standard RP-02-74 (square root of coating thickness in mils x 1250
+/- 20%). Using this industry standard, the voltage for 980 would range between 5,000
and 7,500 volts. If holidays are detected, they should be patch/repaired using the practice
described in the Patch/Repair section (Section 6.0).
5.5 Application of Polyken 955 White (mechanical protection outerwrap) over the 980 (anti-corrosion
protection inner wrap).
Important Application Issues:
· Roll body temperature
· Tension applied to the 955 during application as determined through product “neck
down” measurements.
AG-980-955-FC-REV4-0509 5
5.51 Polyken 955 should be applied with a Polyken approved power wrapping machine in a
spiral fashion with a ¾ ” (1.9 cm) to 1” (2.54 cm) overlap. The beginning wrap of 955
should start so its mid-width is placed directly over the overlap of the 980. Application
practice should be identical to 980. The Polyken 955 should be applied at a tension of 12-
18 lb. per inch width (21 to 32 N/10 mm width). The application tension of 955 should be
monitored by the “neck down” of the tape’s width. Polyken 955-5 6 inch x 200 feet (15.24
cm x 60.96 m) should “neck down” approximately 1/8” (3.2 mm) during application to
achieve the 12-18 lb. per inch of width (21 to 32 N/10 mm width) specification. The 955
roll body temperature is important for the same reasons as for 980.
The wrap of the 955 should begin with the beginning lap facing in a down side position on
the pipe (8 to 10 o’clock or 2 and 4 o’clock position). The wrapping process should
proceed from that point (clockwise or counter-clockwise respectively) around the pipe.
This process prevents back fill from potentially working against or pulling away the 955,
which could occur if the beginning lap was facing upward.
Special Note: The overlap of 955 can be increased to a 50% overlap to achieve thicker
outerwrap for rocky back fill areas (refer to Special Conditions, 7.0)
The entire 50 mil (1.27mm) system can be holiday tested at a voltage of 8,000 minimum
and 11,000 maximum.
6.0 INSPECTION AND REPAIR
6.1 Holiday inspection is covered in Section 5.41 and 5.51. Usual practice involves holiday detection
of the 980 innerwrap prior to the application of the 955 outerwrap.
6.2 Repair can be accomplished with the use of Polyken 934 or 980.
6.3 Polyken 934 or PERP 60 may be used as a patch repair or mislap repair. The holiday area
should be primed and the 934 should be applied in postage stamp or strip fashion over the
holiday area, overlapping it in all directions by 4 inches (10.16 mm). 955 should then be wrapped
over the 934 in a cigarette wrap around the pipe. However, if the 955 outerwrap procedure has
yet to occur, then it can simply be spiral wrapped over the 934 patch in accordance with Section
5.5.
6.4 980 as a patch or mislap repair. The holiday area should be primed and the 980-25 should be
cigarette wrapped under tension over the holiday or mislap. 955 should then be wrapped over the
980 as the usual mechanical protection.
7.0 SPECIAL CONDITIONS
7.1 Multiple Application of Polyken’s 1027 Primer, Complete Application of Polyken’s system may not
always be possible due to weather or other construction conditions.
Example: Sand or shot/grit blasted sections of the pipe’s surface have been completed, but for
various reasons, coating of the line with the full Polyken systems must be delayed. The newly
sand or shot/grit blasted surface can be temporarily protected by coating with Polyken 1027
Primer. The area temporarily protected in this manner can be re-primed at a later time (not
exceeding 48 hours) and coated with the Polyken system in accordance with Section 4.0.
AG-980-955-FC-REV4-0509 6
However, if the temporarily primed surface is contaminated with dirt, grease or other
contaminates, prior to the subsequent primer application, the original primed surface must be
removed by blasting, use of appropriate solvents or wire brush until the contaminated primed
area is thoroughly cleaned. The re-cleaned area must be dry and surface profile acceptable prior
to application of the Polyken 1027 primer.
7.2 On-Site Coating Thickness for Rocky Backfill Conditions

The overlap of either the 980 or 955 (or both) can be increased from the standard ¾ ” or 1.9 cm
to 1” or 2.54 cm overlap to a ½ lap (50% overlap) to achieve an extra thickness coating for
increased protection from rocky back fill areas. This system could also receive multiple spiral
wraps of the 955 applied in accordance with Section 5.5.
APPENDIX I
RECOMMENDED APPLICATION TENSION
* Neckdown tape width (inch)

Original Roll Body width 4” 6” 9” 12”
1% neckdown tension 3 31/32” 5 15/16” 8 29/32” 11 7/8”
2% neckdown tension 3 15/16” 5 7/8” 8 13/16” 11 ¾”
* Neckdown tape width (cm)

Original Roll Body width 10.16 cm 15.25 cm 22.9cm” 30.48 cm
1% neckdown tension 10.05 cm 15.09 cm 22.67 cm 30.18 cm
2% neckdown tension 39.95 cm 14.94 cm 22.44 cm 29.87 cm
AG-980-955-FC-REV4-0509 7
Annexure-II
Approved Manufacturer’s List
Consultant:

Globe/Ball/Gate/Check/Butterfly Valves
Company registered name Brand name Address manufacturing location
Adams GMBH & Co. Armaturen KG Adams Germany: Herne
B.F.E. S.p.A. B.F.E. Italy: 24061 Albano S.Alessandro (BG)
BAC Valves S.A. BAC Valves Spain: Figueras
Bonney Forge (supplied through B.F.E. S.p.A.) B.F.E. USA USA: Mount Union, PA
Brooksbank Valves Ltd Brooksbank Valves United Kingdom, Skipton
Cameron Orbit Little Rock, AR, USA
Cameron Valve & Measurement (C-A-M) -Cameron Valves operations Cameron Grove Italy: Vogera
Cameron Valve & Measurement (C-A-M) -Ring-O valve operations Ring-O valve Italy: 23823 Colico (LC)
Circor - Pibiviesse SpA Pibiviesse Italy: Nerviano (Milan)
Coyard Valves Coyard France, Beaucouze
Crane Energy Flow Solutions Crane-Stockham United Kingdom: Belfast
Della Foglia s.a.s. Della Foglia Italy: 21050 Marnate (VR),
Douglas Chero Spa Douglas Chero Italy: Piacenza
FangZheng Valve Group Co. FZV Plant 2 - Nanjiang East Road, Oubei Town, Wenzhou, China
Flowserve Ahaus GmbH Atomac Germany: Ahaus
Flowserve Flow Control GmbH - Argus Argus valves Ettlingen, Germany
Flowserve Valbart Srl Valbart Italy: Cenate Sotto and 20050 Mezzago (Mi)
Fluitek Orsenigo Orsenigo Italy: 24060 Costa di Mezzate (BG)
Fluval Spain S.L. Fluval Spain: Amurrio
Galperti Engineering and flow control SRL Galperti Italy: 23823 Colico
Goodwin PLC - Goodwin International Ltd. Goodwin England: Stoke on Trent
Goodwin-Noreva Noreva Germany, Mšnchengladbach
JC Fabrica de Valvulas S.A. JC Ball valves Spain: Sant Boi de Llobregat (Barcelona)
Kitz Corporation Kitz Spain: 08930 Sant Adia deBesos (Barcelona), Taiwan: Kaohsiung Plant, Japan: INA plant
Kitz Corporation Kitz Japan: Ina and Nagasaka plant, China: Jiangsu Kunshan (KJK), B-2 Zone, Kunshan Processing, Jiangsu
Lazaro Ituarte Internacional S.A. Lazaro Ituarte Spain, Amurrio

LVF SrL - Forged Steel Valves LVF Italy: 24060 San Paolo d Argon (Bergamo)
Ball valve (Huanshan) plant:= Add. No.999 Xiangliang Road, Suzhou New District,Post code: 215129, Jiangsu
Neway valves (Suzhou) Co. Ltd Neway valves
Province, P.R. of China.
Neway valves (Suzhou) Co. Ltd Neway valves China: Taishan Plant = No. 666 Taishan Road, Suzhou New District 215129
Newdell Company Smith USA: Houston, Texas
Oliver Twinsafe Ltd Twinsafe United Kingdom: Knutsford, England
OMB Valves SpA - Europe OMB Italy: 24069 Cenate Sotto (Bergamo)
OMS Saleri S.R.L. OMS Saleri Italy: 25076 Odole (BS)
Orion Orion Trieste, Italy
Orton s.r.l. Orton Piacenza, Italy
Pentair Valves & Controls - Flow Control Technology S.A. FCT France: Albi, Saint Juéry
Pentair Valves & Controls - Griss S.A. Keystone-Paraseal France: Ham
Pentair Valves & Controls – Gulf Valve FZE Gulf Valve UAE: Sharjah
Pentair Valves & Controls - Hindle Cockburns Ltd Hindle United Kingdom: Leeds
Pentair Valves & Controls - Vanessa Vanessa Italy: Luganano Val dArda - Piacenza
Pentair Valves & Controls Italia Srl - Fasani Fasani Italy: Rescaldina
Perar SpA Perar Italy: Rescaldina
PetrolValves S.R.L. Petrol Valves Italy: 21053 Castellanza (VA)
Poyam Valves Poyam Valves Spain: 20200 Beasin (province of Gipuzkoa)
RBR Valvole SpA RBR Italy: Pogliano Milanese
Shipham Valves (Wärtsilä Valves Ltd) Shipham United Kingdom, Hull
Starline Spa Starline Bergamo, Italy
TIV Valves srl (previously Tong Yung Ind. Italy) TIV Valves Via Provinciale Saronnese 58-20027 Rescaldina, Italy
Tong Yung Ind. Co. ltd Korea TY Valve Corporation South Korea: Dadae assembly factory & valve test shop, Pusan; Hakjang-Diong foundry & machining, Busan
Valvitalia SpA ValvItalia Italy: 27055 Rivanazzano
Valvitalia SpA - Tormene Gas Technology division Tormene Gas Technology (TGT) Italy: 35020 Due Carrare (Padova)
Valvitalia SpA - Vitas division Vitas Brendola, Italy

Viar Valvole S.R.L. Viar Valvole Italy: Sumirago (Va)
Virgo Europe Spa Virgo Italy: Via Sicilia 96. Magnago (Mi)
Virgo Valves & Controls Limited Virgo India: 277 Hinjewasdi Phase II, Maan (Mulshi), Pune-411057
Wouter Witzel Eurovalve B.V. (AKV) Wouter Witzel Eurovalve The Netherlands: 7581 CZ Losser
Yoneki Yoneki Japan
Zwick Armaturen GmbH Zwick Germany: Ennepetal
Company Identification Product Description Product model Sizes Ratings Contact Phone E-mail Website
designation,
style or figure
Spiral Wound Gaskets number.
DN DN
1500
2500
150
300
600
900
Name Country Site Min Max
Cartec Sealing Technologies (CST) South Korea Pusan Gaskets, semi metallic, spiral wound, designed acc. Flexicarb CGI 15 600 x x x x x x Mr. Hun Ho, Lee +82-51-831-0875 cartecst@unitel.co.kr www.carteccst.com
= Flexitallic Licensee ASME B16.20 and SPE 85/103, with SS 316L inner ring
CS centring ring and graphite filler.
Flexitallic Ltd. UK Cleckheaton, West GASKET, SEMI-METALLIC, SPIRAL-WOUND DESIGN Flexicarb CGI 15 600 x x x x x x +44 1274 851 273 enquiries@flexitallic.eu www.flexitallic.com
Yorkshire TO ASME B16.20 AND SPE 85/103 WITH INNER RING
AND GRAPHITE FILLER
Flexitallic Ltd. USA Deer Park GASKET, SEMI-METALLIC, SPIRAL-WOUND DESIGN 15 600 x x x x x x +1 281 604-2400 www.flexitallic.com
TO ASME B16.20 AND SPE 85/103 WITH INNER RING
AND GRAPHITE FILLER
Klinger Ltd UK Bradford GASKETS, SEMI-METALLIC, SPIRAL-WOUND TO BS Maxiflex CRIR 15 600 x x x x x x +44 (0)1274 688222 international@klingeruk.co.uk www.klinger.co.uk
3381, ASME B16.20B AND SPE 85/103 WITH INNER
RING AND GRAPHITE FILLER
Lamons Gasket Company USA Houston, Texas GASKETS, SEMI-METALLIC, SPIRAL-WOUND TO BS Spiraseal 15 600 x x x x x x +1-713-222-0284 www.lamons.com
3381, ASME B16.20B AND SPE 85/103 WITHOUT WR:SS316/CSCR/graphit
INNER RING AND GRAPHITE FILLERS e
Lamons Gasket Company China Zhangjiagang GASKETS, SEMI-METALLIC, SPIRAL-WOUND TO BS Spiraseal 15 600 x x x Mr. Richard Xu +86 512 56720109 Richard.Xu@lamons.com www.lamons.com
3381, ASME B16.20B AND SPE 85/103 WITHOUT WR:SS316/CSCR/graphit
INNER RING AND GRAPHITE FILLER. e
Liaoning Cartec Sealing Technologies China Benxi city Gaskets, semi metallic, spiral wound, designed acc. Flexicarb CGI 15 600 x x x x x x Mr.Vicky Wang +86-414-3537508 carteclcst@vip.sina.com http://www.carteclcst.com
(LCST = Flexitallic Licensee & allied distributor) ASME B16.20 and SPE 85/103, with SS 316L inner ring
and windings, CS centring ring and graphite filler, without
oxidatiion inhibitor.
Annexure-III
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SHELL PAKISTAN LIMITED

REPLACEMENT OF TANKER DISCHARGE PIPELINE

CONSULTANTS: MAY, 2015

PETROCHEMICAL ENGINEERING CONSULTANTS

S.No. Description Document No. Rev

1. Preamble to Bill of Quantities 2532-PM-PR-0341 2

2. Bill of Quantities for Mechanical Works (Procurement) 2532-PIP-BOQ-4331 2

3. Bill of Quantities for Mechanical Works (Construction) 2532-PIP-BOQ-4332 2

4. Piping , Fabrication & Installation 2532-ME-001 0

5. Painting Specification 2532-ME-002 2

6. Structural Steel Works Specification 2532-ME-003 0

7. Welding Specification 2532-ME-004 0

8. NDE Specification 2532-ME-005 0

9. Piping Layout for OPII and OPIII (KEY PLAN) 2532-PIP-KPL-4800 1

11. Annexure-I (Polyken Specification) 0

12. Annexure-II (Approved Manufacturer’s List) 0

Tender Package Contents

S.No. Description Document No. Rev

13. Annexure-III (Google Map View) 0

Tender Package Contents

REPLACEMENT OF TANKER DISCHARGE

PREAMBLE TO BILL OF QUANTITIES

PREAMBLE TO BILL OF QUANTITIES

Doc. No. 2532-PM-PR-0341 Page 2

18. Contractor shall submit welding procedure for SPL approval.

Doc. No. 2532-PM-PR-0341 Page 3

22. The Contractor shall prepare all necessary work methodologies/

Doc. No. 2532-PM-PR-0341 Page 4

The procedure shall include as a minimum contingency plans for a plant

Doc. No. 2532-PM-PR-0341 Page 5

be maintained in good condition or replaced, and shall be worn on all relevant

Doc. No. 2532-PM-PR-0341 Page 6

REPLACEMENT OF TANKER DISCHARGE PIPELINE

PETROCHEMICAL ENGINEERING CONSULTANTS

1 28/05/15 Bill of Quantities , Mechanical Ibad Shoaib

Pipe, Bevel Ends, SMLS Single Random Length, ASTM A-106

i Dia. 8" Std. Wt. m 425

90° 5D Bend,Bevelled ends to match pipe wall ,

i Dia. 8" Std. Wt. Nos. 5

45° 5D Bend,Bevelled ends to match pipe wall, ASTM

i Dia. 8" Std. Wt. Nos. 8

i Dia. 8" Std. Wt. Nos. 5

i Dia. 8" Std. Wt. Nos. 7

i M20 x 110 mm Long Nos. 40

6 NDE / Welding Inspection to be done by 3rd party as per Shell recommendation

REPLACEMENT OF TANKER DISCHARGE PIPELINE (DIA 8") OP II PREP. : AFA

BILL OF QUANTITIES REV. :2

FOR DATE : 15/06/2015

i) Dia. 8"- Std. Wt. m 425

2.0 SURFACE PREPARATION WITH PAINTING :

i) Dia. 8"- Std. Wt. m2 292

3.0 HYDROSTATIC TESTING:

4.0 TIE-IN POINTS:

i) Dia. 8" Nos. 2

5.0 DISMANTLING OF EXISTING PIPING

i) Dia. 8"- Std. Wt. m 425

7 NDE / Welding Inspection to be done by 3rd party as per Shell recommendation.

Pipe, Bevel Ends, SMLS Single Random Length, ASTM A-106

i Dia. 8" Std. Wt. m 425

90° 5D Bend,Bevelled ends to match pipe wall ,

i Dia. 8" Std. Wt. Nos. 10

45° 5D Bend,Bevelled ends to match pipe wall,

i Dia. 8" Std. Wt. Nos. 15