TECHNICAL SPECS FOR SCRAPPER TRAP &

PIG SIGNALLERS
 MATERIAL REQUISITION
AND
TECHNICAL SPECIFICATION
 MATERIAL REQUISITION

Project : ENNORE – MANALI Natural Gas Pipeline

Project Client : IMC) Limited
Item : Scrapper Trap with Pig
Signallers

Item Description Tag No. Qty. Remarks

No.
1.0 Scrapper Traps and Accessories

1.1 Scrapper Launcher/Receiver with Pig Signaller,

Pig Handling System and Jib Crane
(Scrapper Receiver as per Specs & Pig Signaller
as per Specs

1.1.1 Scrapper Launcher/ Receiver with Pig SLB-101/ 02No.

Handling System and Jib Crane SRB-102
(24"** x16", 600#)
1.1.2 Pig Signaller on SLR-101 & SLR-102 XXLS-101 02No.
& XXLS-
102
1.1.3 Door Seal for QEC on Scrapper Receiver - 04 Nos. Commissioning
(SLR- 0101 & SLR-102 as Spare Spares (@ 2
Nos./ Scrapper
Receiver)
1.1.4 Complete set of spare seals for Two Pig Signallers - 04Sets Commissioning
at Item No. 1.2.2 Spares (@ 2
Sets/ Pig
Signaller)
1.2 Pig Signallers for Installation on the pipeline -
(as per Specs
1.2.1 Pig Signaller on 16" Pipeline XXLS-103 02Nos.
XXLS-
104
1.2.2 Complete set of spare seals for one Pig Signaller at - 04Sets Commissioning
Item No. 1. 2.1 Spares (@ 2
Sets/ Pig
Signaller)
** SIZE 24” by 16” to be examined and optimum size to be recommended with justification and
included.

Note:
1) Price evaluation shall be done on overall basis.
TECHNICAL SPECIFICATION
 CONTENT
S

Sl.No. Description

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MATERIALS

4.0 DESIGN AND CONSTRUCTION

5.0 INSPECTION AND TESTS

6.0 TEST CERTIFICATES

7.0 PAINTING, MARKING AND SHIPMENT

8.0 GUARANTEE

9.0 SPARES

10.0 DOCUMENTATION

11.0 VENDOR LIST

PREPARED BY CHECKED BY APPROVED BY

Abbreviations :
ASME : American Society of Mechanical Engineers

ASTM : American Society for Testing and

Materials API: American Petroleum Institute

BHN : Brinell hardness number

DN : Nominal Size

HAZ : Heat Affected Zone

LC : Lock Close (valve locked in full close

position) LO : Lock Open (valve locked in full open

position)

MSS-SP : Manufacturers Standardization Society – Standard Practice

NDT : Non-Destructive Testing

NPS : Nominal Pipe Size

RTJ : Ring Type Joint

SSPC : Steel Structures Painting Council

 SCOPE OF SUPPLY

General :

Launchers and receivers also commonly referred to as pig trap assemblies are used to introduce
and remove pigs, spheres and inspection tools from the pipeline.

1.0This Specification covers the requirement of scope of supply of Ball Valve along with all
accessories to be used in the proposed Filtration System.
The scope of supply covers the design, manufacture, inspection, testing, supply, erection &
supervision of installation and commissioning, shipment and documentation requirements of all
following items in accordance with the requirements of this Requisition.

1.1 DESCRIPTION OF EQUIPMENT and/or SERVICES

Design, manufacture, inspection, testing & supply of

scrapper launching & receiving traps to be installed in
1.0 2 Sets
pipeline system transporting non-sour hydrocarbons in
liquid or gaseous phase including Liquefied Petroleum
Gas (LPG). This specification does not cover scraper
launching & receiving trap for sour hydrocarbons
(liquid/ gas) services as defined in NACE Std. MR- 01-
75.

2.0 200% Gasket as Mandatory Spares for SLB/SRB ~ 2 Sets

3.0 100% Fasteners as Mandatory Spares for SLB/SRB ~ 2 Sets

2 Sets
4.0 Seat Rings/O-Rings & other Mandatory Spares (SLB/SRB) ~

5.0 100% Commissioning Spares for SLB/SRB ~ 2 Sets

First fill of all lubricants, chemicals, hydraulic oils, heat transfer

6.0 ~ As
media (if any) and subsequent filling for each Ball Valve before
Required
handing over to owner

7.0 Recommended Spares for first two years of normal ~ Bidder to

operation and maintenance Specify
:
Bidder to
8.0 Special tools and Tackles, if any, required for maintenance ~
Specify
purpose
9.0 Supervision of Erection and Commissioning by Vendor for
05 days. Vendor to quote per diem rates, inclusive of all ~ Lump sum
expenses like travel, boarding lodging etc.
2.0 REMARKS

2.1 Supplier’s Compliance

Supplier shall submit his bid in full compliance with the requirements of this MR and
attachments. Bidder shall include the following statement in his bid

We certify that our bid is fully complying with your enquiry dated …... and
referenced …………,

Compliance with this material Requisition in any instance shall not relieve the Vendor of his
responsibility to meet the specified performance.

2.2 Compliance with Specification

The supplier shall be completely responsible for the design and engineering, materials,
fabrication, testing, inspection & transfer of above material to nominated delivery point
strictly in accordance with the MR & all attachments thereto.

2.3 Supplier’s Scope

Supplier’s scope of work includes the equipment with all internals & accessories shown on
the data sheets, specifications and all unmentioned parts necessary for a satisfactory
operation & testing except those which are indicated to be out of Supplier’s supply.

2.4 Inspection

Supplier shall submit with his bid a list of 3 well known international Third-Party inspection
Agencies as per enclosed vendor list, which he intends to use for inspection. This agency
will issue all relevant certificates as per specification & codes.

Inspection shall also be performed by a designated Third-Party Inspection agency and/or

purchaser as set out & specified in the codes & particular documents forming this MR.

3.0 SPECIAL INSTRUCTIONS TO BIDDERS

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

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

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

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

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

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

3.8 Vendors for bought out items to be restricted to the approved vendor list attached with Bid
document. Approval of additional vendor if required, for all critical bought out items shall
be obtained by the supplier from the purchaser before placement of order. Credentials/ PTR
of the additional vendor proposed to be submitted by supplier for review and approval of
Purchaser/ Purchaser’s representative.

3.9 All material shall be delivered at Ennore Terminal of M/s IMC, Chennai( with in the Ennore
Port Premises)
4.0 INFORMATION/ DOCUMENTS/ DRAWINGS TO BE SUBMITTED BY SUCCESSFUL
BIDDER

Successful Bidder shall submit six copies unless noted otherwise, of each of the following:
4.1 Inspection & test reports for all mandatory tests as per the applicable code as well as test
reports for any supplementary tests, in nicely bound volumes.

4.2 Material test certificates (physical property, chemical composition, make, heat treatment
report, etc.) as applicable for items in nicely bound volumes.

4.3 Statutory test certificates, as applicable.

4.4 Filled in Quality Assurance Plan (QAP) for Purchaser's/ Consultant's approval. These QAPs shall
be submitted in four copies within 15 days from LOI/ FOI.

4.5 WPS & PQR, as required.

4.6 Within two (2) weeks of placement of order, the detailed fabrication drawings along with
process and mechanical design calculations for Purchaser's/Consultant's approval.

4.7 Detailed completion schedule activity wise (Bar Chart), within one week of placement of order.

4.8 Weekly & fortnightly progress reports for all activities including procurement.

4.9 Purchase orders of bought out items soon after placement of order.

4.10 Manufacturer's drawings for bought out items, in 4 copies, for Purchaser's/Consultant's
approval within 4 weeks.

4.11 Manufacturer related information for design of civil foundation & other matching items within
6 weeks of FOI / LOI.

4.12 All approved drawings / design calculation / maintenance / operating manual documents as
well as inspection and test reports for Owner's / Consultants reference / record in nicely
category-wise bound volumes separately.

4.13 A list of documents to be furnished along with supply.

4.14 Vendor to furnish filled up documents / formats as per “Appendix 9” - “Special instruction to
Bidders” along with the offer.

Note: All drawings, instructions, catalogues, etc., shall be in English language and all dimensions
shall be metric units.
 Typical configuration of Pig Launcher

Tentative P&ID for the connecting nozzles

A typical pig trap comprises of the following components:

1 Major barrel
2 Minor barrel
3 End closure
4 Pig Signaller
5 Kicker line connection
6 Pressure gauge connection
7 Vent and drain connection
8 Utility connections

REFERENCE DOCUMENTS

Reference has also been made in this specification to the latest edition of
the following codes, standards and specifications :

a) ASME B 31.4 : Pipeline Transportation System for Liquid

Hydrocarbons and Other Liquids

b) ASME B 31.8 : Gas Transmission and Distribution Piping

System

c) ASME B 16.5 : Steel Pipe Flanges and Flanges Fittings

d) ASME B16.9 : Factory made Wrought Steel Butt Welding

Fittings

e) ASME B 16.11 : Forged Steel Fittings, Socket-Welding and

Threaded

f) ASME B 16.25 : Butt-Welding Ends

g) ASTM A370 : Mechanical testing of steel products

h) ASME Sec-VIII and IX : Boiler and Pressure Vessels Codes.

i) API 1104 : Specification for Welding Pipeline and

Related Facilities

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

Welding
Fittings.

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

Welding
 Fittings

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

Fittings
Socket Welding Threaded and Butt-Welding
Ends

m) SSPC-VIS-1 : Steel Structure Painting Council

In case of conflict between the requirements of this specification and the

requirements of above referred documents, the requirements of this
specification shall govern.

3.0 MATERIALS

3.1 Materials and thicknesses of main components used in manufacture of

traps shall be indicated by Manufacturer and shall be suitable for service
conditions indicated in the data sheets and annexures. These shall be
subject to approval by purchaser. The steel used shall have a minimum
SMYS of 70,000 psi.

3.2 Fully killed carbon steel shall be used.

3.3 Material of the ends to be field welded by purchaser shall have carbon
equivalent less than or equal to 0.45 based on check analysis, for each
heat of steel, calculated according to the following formula.

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

3.4 For Scraper Traps, specified to be used for Gas service or High Vapour
Pressure (HVP) liquid service, Charpy V-notch test shall be conducted at 0C
for each heat of steel used in the manufacture of pressure containing parts
of the traps. Test procedure shall conform to ASTM A-370. The Charpy V-
notch test specimens shall be taken in the direction of principal grain flow
and notched perpendicular to the original surface of the plate or forging.
The minimum average absorbed impact energy values of three full sized
specimens shall be as under, unless otherwise indicated in the Data sheets
:-

Diameter Base Metal Weld Metal and HAZ

(inches) (Joules) (Joules)

For all size 27 27

The minimum impact energy value of any one specimen of the three
specimens analysed as above, shall not be less than 80% of the above-
mentioned average values.

For scrapper Traps, specified to be used for other hydrocarbon service, the
Charpy V- notch test requirements as stated above are not applicable.
3.5 For Scraper Traps, specified to be used for Gas service or High Vapour
Pressure (HVP) liquid service, hardness test shall be carried out as per
ASTM A370 for each heat of steel used. A full thickness cross section shall
be taken for this purpose and the maximum hardness of the base material,
weld metal and heat affected zone (HAZ) of all the pressure containing
parts shall not exceed 248 HV 10. The maximum difference in hardness of
Base metal, Weld metal and Heat affected zone (HAZ) of pressure
containing parts of the traps shall be less than 80 points Vicker’s HV10.

For scrapper Traps, specified to be used for other hydrocarbon service, the
hardness test requirements as stated above are not applicable.

4.0 DESIGN AND CONSTRUCTION

4.1 The cylindrical portion of the trap shall be designed as per design code and
design factor indicated in the data sheets. Quick end closure shall be
designed as per sec. ASME Sec. VIII, Div. 1 for design conditions indicated
in data sheets. A corrosion allowance of 3 mm shall be considered in design
of the traps. Quality of welding shall be such that weld efficiency factor of
1.0 is achieved.

4.2 The trap shall be capable of handling instrumented pigs, supplied renowned
vendors, by Rosen etc., or British gas magnetic inspection vehicle or
equivalent and scraper pigs as specified in scraper Trap data sheet.

4.3 The trap body and neck, diameter has been indicated in the data sheet.
Trap length to suit the purpose and thickness to meet the class rating shall
be suggested by the manufacturer and approved by the purchaser.
Circumferential weld on scraper tarp body and neck shall not be permitted.

4.4 Concentric or eccentric reducer, as indicated in data sheets, used in the

manufacture of traps shall conform to MSS-SP-75.

4.5 Vents and drains shall be provided on each trap. The trap shall be provided
with a suitable slope and the drain location shall be such that complete
drainage of the trap is possible. Sizes for vent and drain shall be as
indicated in data sheet.

4.6 All branch connections shall be made by Weldolets/ nippolet or by

extrusions as indicated in the data sheet. All Weldolets shall confirm to
MSS-SP-97 and nippolets shall be manufacturer’s standard. The extruded
opening shall be adequately heat treated and stress relieved.

4.7 End connections of traps shall be flanged or butt welded as indicated in data
sheet.
a) Flanged ends, if specified shall have dimension as per ASME B16.5
for sizes up to 24" NB (excluding 22 NB) and as per ASME B16.47 /
MSS-SP-44 for sizes 22 NB and 26 NB and above. Flanges shall be as
indicated in data sheets.
 b) Butt weld ends if specified shall have ends prepared as per ASME
B16.25. However, end preparation for butt welding ends having
unequal thicknesses with respect, to connecting pipe shall be as per
ASME B31.4/ ASME B31.8 as applicable.
c) The location & orientation of all nozzle connections shall be
submitted for purchaser's approval before manufacturing.

4.8 The quick opening end closure shall be of clamp ring or band lock type or
equivalent design. The closure shall also consist of a safety relief system
allowing the opening only when there is no pressure in the trap. Screwed
type or plug-in type of end closures are not acceptable. End closure shall
be hand operated and operable by one operator. End closures of size 24"
and above shall be fitted with worm gear operator for the opening of the
closure. Hinge of the closure shall be so designed that the weight of the
end closure is fully supported without sagging.

4.9 Receiving traps shall be provided with a pig indicator in the middle of the
neck and the indicator shall conform to the specification issued for the
purpose. Pig indicator shall be suitable for bi-directional operation and shall
have visual flag and manual reset. The same shall also have provision for
remote indication.
4.10 Suitable handling system for inserting and retracting the scraper and
instrumented pigs from the trap shall be provided with each trap. Handling
system shall consist of a fabricated structural steel framework comprising a
bench fitted with a purpose-designed cradle for the pig. A pusher/ puller
mechanism operated by a cable system employing a hand cranked winch
shall be mounted on the bench framework for inserting/ retracting the pig
from the trap. The bench frame should be suitable for bolting to the floor.
All parts of the handling system in contact with each other shall be of the
anti- spark type.

4.11 Fabricated steel supports, minimum two numbers at suitable spacing shall
be provided with traps for mounting on concrete blocks. These supports will
not be subjected to pipeline anchorage forces. The material of support shall
be compatible with trap material for welding purposes. All welds shall be
examined by magnetic particle method.

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

4.13 All welds shall be made by welders and welding procedures qualified in
accordance with the provisions of ASME Sec. IX. The procedure qualification
shall include impact test and hardness test when required as per clause 3.4
& 3.5 of this specification and shall meet the requirements as specified
therein.
4.14 Repair by welding on parent metal is not allowed. Repair of welds shall be
carried out only after specific approval by purchaser's representative for
each repair. The repair welding shall be carried out by the welders and
welding procedures duly qualified as per ASME Section IX and records for
each repair shall be maintained. The repair welding procedure qualification
shall include impact test and hardness test when required as per clause 3.4
& 3.5 of this specification and shall meet the requirements as specified
therein.

4.15 The traps shall be equipped with a half internal removable filtering basket
consisting of a punched plate with a least five rows of drain holes.

4.16 The filtering basket shall slide on guides on wheels and in all cases the
material of the parts being in contact with each other shall be of the anti
spark type.

4.17 The tolerance on internal diameter and out of roundness at the ends for the
welding end of the neck (at the end where connecting pipeline will be
welded) shall be as per applicable connected pipe specification as indicated
in the data sheet.

5.0 INSPECTION AND TESTS

5.1 The manufacturer shall perform all inspections and test as per the
requirements of this specification and the relevant codes prior to shipment
at his works. Such inspections and tests shall be, but not limited to the
following :-

5.1.1 All trap shall be visually inspected.

5.1.2 Chemical composition and mechanical properties including hardness shall

be checked for each heat of steel used.

5.1.3 Dimensional check shall be carried out as per the approved drawings.

5.1.4 Hydrostatic test shall be conducted for all scraper traps complete in all
respects including mounting of pig indicators at a pressure equal to 1.5
times the design pressure. The test pressure shall be held for a minimum
period of one hour.

5.1.5 All butt welds shall be 100% radiographically inspected. Procedure and
acceptance criteria shall be as per API 1104.

5.1.6 Ultrasonic or magnetic particle inspection shall be carried out on all welds
which in Purchaser's Representative's opinion cannot be radiographically
inspected. Procedure and acceptance criteria shall be as per ASME Sec. VIII,
Appendix-U and VI respectively.
5.1.7 All finished wrought weld shall be 100% ultrasonically inspected for
lamination type defects for a distance of 50mm from the end. Any
lamination larger than 6.35 mm shall not be acceptable.

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

5.1.9 A minimum of two closing and opening cycles shall be performed and
correct operation of both quick opening closure and safety system shall be
ascertained.

5.2 Purchaser's Representative reserves the right to perform stage wise

inspection and witness tests including hydrostatic test, as indicated in
specification at manufacturer’s works prior to shipment. Manufacturer shall
give reasonable notice of time & shall provide without charge reasonable
access and facilities required for inspection, to the purchaser's
representative.

Inspection and tests performed / witnessed by Purchaser's Representative

shall in no way relieve the Manufacturer's obligation of specific integrity of
the scraper traps.

Manufacturer's equipment shall be subject to examination and approval by

purchaser to ensure proper fabrication and testing of traps.

6.0 TEST CERTIFICATES

Manufacturer shall furnish the following certificates

a) Test certificates relevant to the chemical and Mechanical properties

including Hardness of the materials used for manufacture of trap as
per relevant standards and this specification.

b) Hydrostatic test certificates.

c) Test reports on radiography, ultrasonic inspection and magnetic

particle examination.

d) Test reports on heat treatment carried out, if any.

The certificate shall be considered valid only when signed by purchaser’s

representative.
7.0 PAINTING, MARKING AND SHIPMENT

7.1 After all inspection and test required have been carried out, all external
surfaces shall be thoroughly cleaned to remove grease, dust and rust.
Surface preparation shall be carried out by shot blasting to SP-6 in
accordance with "Steel Structures Painting Council Visual Standard - SSPC-
VIS-1". Machined parts shall be coated with anti-rust removable paint and
non machined parts shall be applied with two coats of protective paint.
Manufactures shall indicate the type of paint used in the drawings
submitted for approval.

7.2 Marking shall be done on a stainless steel plate and affixed to the body by
means of corrosion resistant fasteners. Marking shall include the following
:-

a) Manufacturer's Name
b) Trap/ Neck Diameter, Thickness
c) Material
d) ASME Class Rating
e) Tag Number
f) Design Pressure
g) Design Temperature
h) Test Pressure
i) Design Factor
j) Year of Manufacture
k) Empty weight of the trap assembly.

7.3 Before shipment, traps shall be properly packed against damage during
transportation. All machined surface subject to corrosion during transit
shall be well protected by coat of grease or other suitable material. All
traps shall be provided with suitable protectors, for flange faces, securely
attached to the traps. Bevel ends shall be protected with metallic or high
impact plastic bevel protectors.

7.4 Only those traps, which have been inspected and certified by the
purchaser’s inspector shall be supplied.

8.0 GUARANTEE

8.1 Manufacturer shall guarantee that the trap along with accessories is in
compliance with the requirements of this specification for materials and
workmanship. Manufacturer shall replace or repair all parts which should
result defective due to inadequate design or the workmanship. In case the
defect can not be eliminated, Manufacturer shall replace the trap without
any delay. Any defect occurring within the time period specified elsewhere
shall be repaired making all necessary modifications and repair of defective
parts free of charge to the purchaser.
9.0 SPARES

9.1 Manufacturer shall furnish list of recommended spares and accessories for
Scrapper Traps required during start up and commissioning. As a minimum,
the commissioning spares shall include 200% extra consumable spares viz.
gaskets/ O-rings/ seals etc. for each trap. Cost of such spares shall be
included by the Manufacturer in the item rates indicated in Purchase
Requisition.

9.2 Manufacturer shall furnish separately a list of recommended spares and

accessories required for two years of normal operation and maintenance of
Scraper Traps.

10.0 DOCUMENTATION

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

a) General arrangement drawing of scraper trap, pig signallers, quick

opening end closure with overall dimensions.

b) Clause wise list of deviations from this specification, if any listed at

one place in the document.

c) Reference list of similar supplies for the past five years including
project, client year of supply & contact person.

d) Quality Assurance Plan (QAP) enclosed with this tender duly signed,
stamped and accepted.

10.2 Within two weeks of placement of order, the manufacturer shall submit four
copies of, but not limited to, the following drawings, documents and
specifications for approval.

a) Calculations according to the relevant codes for the body

including branch connections and quick end closures.

b) Trap assembly and sectional drawings showing all parts with

materials and dimensions.

c) Support Assembly Drawing.

d) Arrangement & details of foundation bolts for pig handling and

lifting system, where applicable.

e) Welding procedure and method of manufacture.

 Once the above said documents have been approved by the Purchaser, any
changes in design, material and method of manufacturer shall be notified
to the Purchaser, whose approval in writing of all changes shall be obtained
before the traps are manufactured.

10.3 Within four weeks from the approval date Manufacturer shall submit one
reproducible and six copies of all approved drawings, documents and
specification as listed in clause
10.2 of this specification.

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

a) Test certificate as listed in clause 6.0 of this specification.

b) Manual for installation, erection instructions, maintenance and

operations instruction.

10.5 All documents shall be in English Language.

SUGGESTED VENDOR LIST

 TD WILLIAMSON LTD. Faraday Road, Dorcan Way, Swindon Wittshire

SN3 5HF ENGLAND +44793524971 +44793643969 112
 FORAIN S.r.l. Via G. Boeri, 11 20141, Milano, ITALY +39028467345
+39028465325 113 Skelton Hall 70, Carwood Road Sheffield S4 7SD England
44(0)114243 1332 44(0)114 244 9579 114
 GD ENGINEERING Nottinghamshire S82 PY ENGLAND +441909482323
+441909477902 115
 EQUIP ENGINEERS INDIA PVT. LTD. 120, Maker chamber, V-221, Nariman
point, Mumbai-2 (022)20443635, 2042473 (022)2845910 116
 GEA Energy System (India) Ltd. 443, Anna Salai, Teynampet, CHENNAI - 600 018
+9144-433-5958 +9144-4334940 +9144-43605 9144-434-3374 117
 Gastech USA Gastech Engineering Pvt. Ltd., B20, 1st Floor, Lajpat Nagar-II, New
Delhi-110024 011 251721141 118
 Fouress India Pvt. Ltd Fouress Engineering (India) Ltd., Mahalaxmi Chambers, 22
Bhulabhai Desai Road, Mumbai – 400 026 022-24964400 022-2493754
SPECIFICATION
FOR
PIG
SIGNALLERS
 CONTENT
S

Sl.No. Description

1.0 SCOPE

2.0 MATERIALS

3.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.0 INSPECTION AND TESTS

5.0 TEST CERTIFICATES

6.0 PAINTING, MARKING AND SHIPMENT

7.0 SPARES AND ACCESSORIES

8.0 GUARANTEE

9.0 DOCUMENTATION

10.0 QAP

PREPARED BY CHECKED BY APPROVED BY

1.0 SCOPE

This specification covers the basic requirements for the design

and manufacture testing & supply of pig signallers, used for the
detection of passage of scraper and instrumented gauging pigs, to
be installed in pipeline systems handling hydrocarbons in liquid or
gaseous phase including Liquefied Petroleum Gas (LPG). This
specification does not cover pig signallers for sour hydrocarbons
(liquid/ gas) service as defined in NACE Standard MR 0175–98.

2.0 MATERIALS

2.1 All materials used in the manufacture of the main components of the
pig signallers shall be as indicated in the data sheets. Other
components shall be as per manufacturer's standard suitable for the
service conditions indicated in Annexure – I and data sheets which
will be subject to approval by Purchaser.

2.2 Scarfed welding base, shall have Carbon Equivalent (CE) not greater
than 0.45 on check analysis, calculated as per the following formula :

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

2.3 Fully killed carbon steel shall be used in the manufacture of pig signallers.

2.4 The maximum hardness of the base material, weld metal heat
affected zone of the pressure containing parts shall be 248 HV 10.
Hardness test shall be carried out as per ASTM A370 for each heat of
steel used.

3.0 DESIGN AND CONSTRUCTION REQUIREMENTS

3.1 Pig signallers shall be bi-directional type having pivot-less tumbler

mechanism and laminated trigger blades.

3.2 Pig signallers shall be designed to meet the requirements of pipeline

material, diameter, wall thickness & service conditions indicated in
the data sheet.

3.3 Design of pig signallers shall be such that any possibility of

signaller being operated by line pressure is eliminated.
3.4 Design of pig signallers shall also be such that repair and installation
of internals/ accessories are possible under pressure, without
removing the unit from the line.

3.5 Pig signallers shall be provided with a visual indicator to indicate

the passage of pigs, by means of spring-loaded metal shaft. The arm
shall lock in down position when manually reset.

3.7 Pig signallers shall be fitted with sealed, weather proof and explosion
proof microswitch for remote signal indication. The area classification
and rating of microswitch shall be as indicated in data sheet. Suitable
for installation in NEC class I Division 1, hazardous area. Microswitch
shall have the following rating:

2 Amp, 24 Volts, 50
Hz. Type : SPDT.
Contacts : 2 NO and 2 NC

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

The procedure qualification shall include hardness test and shall

meet the requirements of clause 2.4 of this specification

3.9 Whenever specified in the data sheet, pig signallers shall be provided
with extension, suitable for installation on underground pipeline.

4.0 INSPECTION AND TESTS

4.1 Manufacturer shall perform all inspection and tests required to

supply the signallers as per the requirements of this specification.

4.2 All pig signallers shall be visually inspected.

4.3 Chemical composition & mechanical properties including hardness

shall be checked for each heat of steel used.

4.4 All welds shall be non-destructively examined.

4.5 The welding end shall be inspected ultrasonically over the entire
circumference for lamination type defects. Any lamination larger
than 6.35 mm shall not be acceptable.
4.6 Hydrostatic test shall be conducted at a pressure equal to 1.5 times
the design pressure. Hydrotest duration shall be 15 Minutes.

4.6 Manufacturersshall perform functional tests to establish

satisfactory performance of both manual and electrical
indications

5.0 TEST CERTIFICATES

5.1 Manufacturer shall supply the test certificates for material

compliance as per the relevant Material Standards.

5.2 Certificate for hydrostatic test and functional test

5.3 Test reports on heat treatment carried out, if any.

6.0 PAINTING, MARKING AND SHIPMENT

6.1 Exterior surface of the pig signallers shall be thoroughly cleaned,

freed from rust and grease and applied with sufficient coats of
corrosion resistant paint. Manufacturer shall indicate the type and
corrosion resistant paint used in the drawings submitted for
approval. In case of pig signallers with extension, the buried portion
shall be coated with three coats of coal tar epoxy resin. The
minimum dry film thickness shall be 300 microns.

6.2 A corrosion resistant metal tag shall be permanently attached with

each unit, with the following marking:-

i) Manufacturer’s name

i) Suitable for installation in mm dia. pipeline

ii) ANSI Rating

iii) Tag No.

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

7.0 SPARES AND ACCESSORIES

7.1 Manufacturer shall furnish list of recommended spares and

accessories for Pig Signallers required during start up and
commissioning. Cost of such spares shall be included by the
Manufacturer in the item rates indicated in Purchase Requisition.

7.2 Manufacturer shall furnish separately a list of recommended spares

and accessories required for two years of normal operation and
maintenance of Pig Signallers.

8.0 GUARANTEE

8.1 Manufacturer shall guarantee that the pig signallers comply with the
requirements stated in this specification and in the purchase order.
Manufacturer shall replace or repair all parts found to be defective
due to inadequate engineering or quality of material. Manufacturer
shall replace the signaller without delay, if the defect or
malfunctioning cannot be eliminated.

8.2 Any defects occuring within the time period specified elsewhere shall
be repaired making all necessary modifications and repair of
defective parts free of charge to the purchaser.

9.0 DOCUMENTATION

9.1 At the time of bidding, bidder shall submit the following documents :-

a) General Arrangement drawing with overall dimensions.

b) Clause wise list of deviation from this specification, if any.
c) Reference list of similar supplies of pig signaller shall be
furnished including project, year of supply, client, size, rating
and service for last five years.
d) Quality Assurance Plan (QAP) enclosed with this tender duly
signed, stamped and accepted.
9.2 Within two weeks of placement of order, the manufacturer shall
submit four copies, but not limited to, of the following drawings,
documents and specifications for approval.

a) Fabrication drawings/ sectional arrangement drawings showing

all parts with reference numbers and material specification.

b) Assembly drawing with overall dimension.

c) Welding and testing procedure.

e) Cable connection details and cable specification.

Once the approval has been given by Purchaser, any change in

design, material, etc. shall be notified to the Purchaser whose
approval in writing for all changes shall be obtained before Pig
Signallers are manufactured.

9.3 Within four weeks from the approval date, Manufacturer shall submit
one reproducible and six copies of the approved drawings and
specifications as listed in 9.2 of this specification.

9.4 Prior to shipment, Manufacturer shall submit one reproducible and

six copies of following :

a) Test certificates as per clause 5.0 of this specification.

b) Manual for installation, erection instructions, maintenance and

operation instructions.

9.5 All documents shall be in English Language.

 MISCELLANEOUS ITEMS

Annexure-I Data Sheets for Scrapper Launcher/Scrapper Receiver & Pig Signallers

Annexure-II QAP for Scrapper Launcher, Scrapper Receiver & Pig Signallers
 ANNEXURE-I

DATA SHEETS OF PIG SIGNALLERS

 DATA SHEET FOR PIG SIGNALLERS

Pig Signaller On Equipment

Tag No. On Line XXLS-0103, XXLS-0104 on 16" dia.
Pipeline
Pig Signaller Manufacturer ✦
Purchaser's Specification
Pig Signaller Model ✦

DESIGN CONDITIONS
QUANTITY 4 Nos
Maximum Allowable Operating Pressure, 98.0
kg/cm2(g)
Temperature, °C -29 TO +65
Design Code ASME B 31.8
Corrosion Allowance (MM) 1.5
ANSI Rating (#) 600 #
Design Factor 0.5
Service NATURAL GAS
End Connection RF
Installation Aboveground
Electrical Area Classification IEC - Zone-1, Gas Group-IIA & IIB, Temp.
Class-T3
DETAILS OF PIPELINE ON WHICH PIG SIGNALLERS SHALL BE MOUNTED
Diameter (NB, mm) x Thk. (mm) 406.4 (16") x 11.91 mm WT
Material API 5L Gr. X-70, PSL 2
PIG SIGNALLERS’ MATERIAL
SPECIFICATION

Body ASTM A 105

Internals SS-316
MICRO SWITCH DETAILS
Rating Potential Free Contact of Rating 24V DC, 2A,
SPDT
Enclosure Weather Proof to IP55 & Flame Proof
Enclosure certified for area classification

CABLE CONNECTION HALF AN INCH NPT

NOTE : 1) ✦ - VENDOR TO INICATE

2) PIG SIGNALLERS SHALL BE PROVIDED WITH ISOLATION VALVE FOR ON-LINE REPAIR.
3) PAINTING SHALL BE SUITABLE FOR CORROSIVE INDUSTRIAL ENVIRONMENT.
 ANNEXURE-II

10.0 QAP FOR SCRAPPER LAUNCHER/ SCRAPPER

RECEIVER & PIG SIGNALLERS
 QUALITY ASSURANCE PLAN QAP No. : Rev. 0 PIG
LAUNCHER / RECEIVER Date :
Prepared : Check :
Approved :

Acceptance Inspection
Sr. No. Inspection & Testing Procedure Document Type Remarks
Criteria Vendor TPIA / Client
1 Chemical Analysis API / ASTM E350 each API / ASTM Certificate P 100% W
heat and product

2 Mechanical Properties API / ASTM A370 API / ASTM Certificate P 100% W

on samples taken from mill.

3 R T each piece ASME V, Art. 2 ASME VIII-UW 51 Certificate P 100% W

4 Low temperature certificate Charpy test at - ASTM A-370 2

35 J/cm (A) / 28 Certificate with impact test P 100% W
20°C 2
J/cm (S)

5 HT Each heat treatment batch ASTM A-370 API / ASTM Certificate P 100% W

6 VT Each piece ASME V, Art. 9 API / ANSI Certificate P 100% W

FINAL INSPECTION TEST

7 Hydrostatic Test As per specification 153 during 4 Certificate P 100% W
hours
8 Visual examination As per specification As per specification Report P 100% W
9 Dimensional examination As per specification As per specification Report P 100% W
10 Making As per specification As per specification Report P 100% W
11 Final Certificates As per specification As per specification Certificate P 100% W
LEGENDS :

RT : Radiographic Test PT : Liquid Penetrant Test VT : Visual Test

P : Performed R : Review HT : Hardness Test TPIA : Third Party
Inspection Agency

Notes :
1 The above Testing and acceptance criteria are minimum requirements; however, equipment shall ensure and that the product also comply to the
additional requirements as per Technical Specifications and data sheets.
2 The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative.
3 Supplier shall submit calibration certificates of all Instruments / Equipments to be used for Inspection and Testing to TPIA with relevant procedures and updates standards for TPIA
review / approval.
4 TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.
5 TPIA along with Owner / Owner representative shall review / approve all the documents related to QAP / Quality manuals / drawings etc. submitted by supplier.to6 Supplier shall in
coordination with sub vendor shall be issued detailed production and Inspection schedule including the dates and the locations to
facilitate Owner / Owner's representative and TPIA to organise Inspection.
7 Certification requirements shall comply with European Standard EN 10204 (latest edition).- type 3.2