Annexures – 3

SPECIFICATION FOR HYDRANT PIPE FITTINGS

1. SCOPE OF SUPPLY

1.1 General

This requisition covers the scope of supply of Coated Line Pipe Welded / forged
fittings as per ASME B 16.9 / 16.11 , for use on the Aviation Fuel Hydrant System at
Bangalore International Airport.

The scope of supply includes the manufacture, inspection, testing and preparation for
shipment and documentation requirements of these items in accordance with the
requirements of this requisition and the attached Data Sheets to our project at
Bangalore.

1.2 Material Delivery Requirements

The finished materials are to be delivered by the Supplier to the nominated delivery point.

The Supplier shall be responsible for all handling and transportation between his
production plant and the Purchasers nominated point in accordance with the specification.

1.3 Line Pipe Fittings

The type and quantities of line pipe are detailed in the document. Butt Welding Fittings :

Parameter Requirement
Type Forged
Eccentric Weld Reducer
Concentric Weld Reducer
Equal Tee
Reducing Tee
90° Long Radius Weld Elbow
45° Long Radius Weld Elbow
(Note: to match pipe wall thickness in all cases)

Material ASTM A234 WPB (carbon content 0.23 % Max)

Dimensions ANSI B16.11

1.4 Purpose and Coverage

This Specification defines the minimum technical requirements for line pipe fittings
required as part of the Bangalore International Project.The line pipe fittings shall be
supplied in accordance with ANSI B 16.9 / 16.11 together with the additional
requirements and amendments detailed in this specification.
1.5 Additional Notes

Minimum pipe size for fittings DN15

All forgings shall be normalised and tempered

Carbon content shall be limited to 0.23 % max for pipe and 0.25 % max for other items
(carbon equivalent shall be limited to 0.45 % max)

All unconnected branches DN40 and below shall be Class 6000/Schedule 160

For selection of branch connections standard industry practice shall apply.

Where screwed fittings are specified on drawings, threads shall be NPT

Material Pipe fittings are supplied with EN 10204 3.1.C.

2. FACTORY-APPLIED INTERNAL EPOXY LINING OF PIPE AND FITTINGS

2.1 This section of the OTS covers factory internal lining of pipe of fittings, in unit lengths,
with US MIL-STD-C-4556E standard coating.

2.2 All internal lining shall be factory applied and only minor repairs shall be permitted
on site.Soak period of minimum 10 days shall be allowed .

2.3 The proposed coating type shall be compatible with Jet A-1 and shall be reviewed
without objection by BIAL prior to its use. The coating/lining must have been tested and
approved by a major supplier of aviation fuel as suitable for use with Jet A-1.
Documentary evidence of this approval is required and a letter stating that the
coating/lining has not been re-formulated since the approval. A major supplier of aviation
fuel is considered to be one of the members of JIG (Joint Inspection Group) (currently
the members are Agip, BP, Chevron, ExxonMobil, Kuwait Petroleum, Shell, Statoil,
Texaco, Total).

Epoxy resin as per MIL-C-4556E standard suitable for Jet A-1 fuel. The color of coating
shall be preferably white since deficiencies or presence of impurities is better perceptible.

The raw material for Internal Lining shall be as follows: Primer Epoxy Coat :
75 µm minimum
Epoxy Coating : 52-77 µm minimum
Finished DFT : 127-152 µm minimum

Primer Coat – 522 Sigmarite Sealer, Finish Coat – 650 Sigma guard CSF or COPON EA4
2217

DFT – As recommended by paint manufacturer

A length of 50 –100mm from the pipe ends shall be kept uncoated for field welding
purpose.
The detailed application procedures shall be submitted to purchaser for approval.
The primary coat shall be applied within 2 hours of blast cleaning. The manufacturers
instructions shall be observed on mixing, time limited for application of the missed paint
and on time limits between two coats.

Lining material application shall be by airless spray or as otherwise agreed with the
paint manufacturer and reviewed without objection by purchaser. Lining materials
shall be applied when the temperature of the prepared surface is below the dew point,
or when the atmospheric temperature is below 10 deg.C, or when the relative humidity
is above 85% or when airborne dust may be deposited on the painted surface.

Temporary protective coatings, oil, grease and paint (such as mill marking paint) shall
be removed. Lining materials shall be applied in two or more coats to a dry film thickness
of 0.127 mm to 0.152 mm also over welds DFT of 0.1 mm is acceptable or as suggested
by the paint manufacturers for Jet A-1 fuel. The finished lining material shall be smooth
and glossy and free from drips and runs. It shall be fully cured before the ends are sealed
and before external coating is commenced. The finished lining material film shall be
tested for cure and adhesion as detailed below:

Surface preparation shall be by blast cleaning to “near white” as specified in the

standards.

The proposed internal lining shall be compatible with Jet A-1 fuel and shall be reviewed
without objection by the purchaser prior to its use.

2.4 Surface Preparation

The internal surface of the pipe shall be blast cleaned to BS 7079:1993 second quality,
maximum amplitude of surface roughness shall be 0.1 mm.
The type of abrasive and its particle size shall be to BS 7079:1993
The blast cleaning procedure shall be to BS 7079:1993
The photographic standard of surface preparation shall be to Svensk Standard
SIS 055900-1967 Grade Sa.2.5

2.5 Application

Lining material application shall be to US MIL-STD-C-4556E standard. The brand and

type shall be without objection by BIAL The primary coat shall be applied within 2 hours
of blast cleaning. The manufacturer’s instructions shall be observed on mixing, time limits
for application of the mixed paint and on time limits between coats.

Lining material application shall be by airless spray or as otherwise agreed with the paint
manufacturer and reviewed without objection by BIAL. Lining material shall not be
applied when the temperature of the prepared surface is below the dew point, or when
the atmospheric temperature is below 10 ºC, or when the relative humidity is above 85
% or when airborne dust may be deposited on the painted surface.

Lining material shall be applied in two or more coats to a dry film thickness of
0.127 mm to 0.152 mm, as measured by an Elcometer inspector or equipment
instrument reviewed without objection by BIAL. Over welds, a minimum dry film
thickness of 0.1 mm is acceptable. The finished lining material film shall be smooth and
glossy and free from drips and runs. It shall be fully cured before the ends are sealed
and before external coating is commenced. The finished lining material film shall be
tested for cure and adhesion as detailed below.

▪ The entire internal surface of the pipe and fittings shall be lined except for a band of
width 50 mm at the butt welding end. Welding bevels shall be tape- masked during
application of the lining.

2.6 Testing Procedure

Before the lined pipe leaves the manufacturer’s works, the lining shall be fully cured as
indicated by Ketone Test. The coating shall be rubbed for 1 minute with a clean white
rag soaked in methyl ethyl ketone (MEK). The surface rubbed by the MEK rag shall show
no sign of discoloration.

The adhesion of each coat shall be checked separately. This is to be tested by the Cross-
cut Test as shown in BS 3900:1991 Part E6, or by cutting a grid pattern of approximate
square side dimension of 1 mm with a sharp knife. A strip of household transparent sticky
tape shall be pressed down on to the grid pattern and then ripped off. If squares of lining
appear on the tape, adhesion is not adequate.

To allow testing of the adhesion of the first coat in a fully cured state, test pieces shall
be provided. The test pieces shall be a minimum of 100 mm x 50 mm of 1.626 mm (16
gauge) mild steel which has been shot blasted to Sa 2.5 at the same time as the inside
of the pipe. Test piece shall be coated at the same time as the pipe.

The number of test pieces to be provided shall be whichever of the following is the sooner:
at the beginning, middle and end of each shift at the beginning and end of each paint
mix.

Test pieces shall be given a traceable serial number such that they can be identified
with given batches of pipe.

Subsequent to the adhesion and curing test specified above, test pieces shall be retained
and sent to Site for extended soak tests.

2.7 Inspection

The Contractor shall give twenty-eight days notice to the BIAL prior to pipe preparation
and lining works being carried out.

Any lining which fails the tests for cure and/or adhesion shall be blasted off to bare metal
and made good. Lining which is too thin may be built up provided that the full inter-coat
adhesion is achieved.
Each pipe shall be given a serial number (in chalk on the outside) after satisfactory
shot/grit blasting and inspection. The date and time of each of the various processes and
inspection shall be recorded.

Each batch of lining material shall be mixed to the manufacturer’s instructions under the
supervision of an inspector and the details of the mix recorded (see Annex 1). It shall be
possible to relate the paint batch mix number to specific lengths of pipe.

2.8 End Closures

The ends of each lined pipe shall be firmly closed and sealed with recessed plastic end
caps so as to prevent the ingress of foreign matter during shipping and handling of the
pipe. Before closing, the beveled ends shall be freed from any trace of paint material and
shall be protected from rusting by a layer of anti- corrosion tape. Lengths of pipe which
are received on site without such end closures shall be rejected.

3. FACTORY-APPLIED EXTERNAL WRAPPING AND COATING OF PIPE

FITTINGS

3.1 Scope

This section of the OTS covers surface preparation, priming and application of
polyethylene external wrapping/coating to DIN30670 ( Polyethylene Coating of steel
Pipes and fittings )
All external wrapping/coating shall be factory applied and only minor repairs shall be
permitted on site.
The proposed wrapping/coating type shall be reviewed without objection by BIAL prior
to its use.
The system, including the epoxy primer shall be suitable for working under cathodic
protection and written certification to such effect shall be supplied. The adhesive layer
and extruded high density polyethylene shall be applied to AS/NZS 1518:2002 or
other standard reviewed without objection by the Employer.

3.2 Surface Preparation and Priming

Pipe end protectors shall be removed and stored for re-use.Temporary protective
coatings, oil, grease and paint (such as mill marking paint) shall be removed.
Surface preparation shall be by blast cleaning to “near white” as specified in BS
7079:1993 (Standard for preparation of steel substrates before application of paint )
Second Quality.
3.2 References :

Sr.No. Code Standard Specification / Test Method for

Preparation of steel substrates before application of

SIS 055900 (ISO
1. paints and related products – visual assessment of
8501-1)
surface cleanliness

2. CAN/CSA-Z 245.21 External Polyethylene Coating for Steel Pipe

Polyethylene Coatings for Steel Pipes and
3. DIN 30670
Fittings

3.4 Coatings

The pipe fittings shall be externally and internally coated as follows:

External Coating:

3 Layers of Polyethylene shall be as per DIN 30670 of Normal ( n ) Type

Coating .
The three Polyethylene coating system shall consist of the following layers:
Fusion Bonded Epoxy - 70 μm minimum
Polyethylene copolymer adhesive - 200 μm minimum
Finished Polyethylene coating - 3 mm minimum
The raw materials and combinations for external coating shall be as follows:
Epoxy Powder Jotun Corro-coat EP-F-2002 HW/3M-Scotchkote 226N

Adhesive Borealis (Polyethylene ME0420) / SK Polyglue LE 149V

Polyethylene Borealis (Borstar HE 3450/SK ET 509B)

3.5 Testing Procedure:

Before the lines pipe leaves the manufacturer’s works, the lining shall be fully cured as
indicated by Ketone Test. The coating shall be rubbed for 1 minute with a clean white
rag soaked in methyl ethyl ketone (MEK). The surface rubbed by the MEK rag shall show
no sign of discoloration.
The adhesion test of each coat shall be checked separately. This is to be tested as per
DIN 30670 or by cutting a grid pattern of approximate square side dimension of
1mm with a sharp knife. A strip of household transparent stick tape shall be pressed
down on to the grid pattern and then ripped off. If squares of lining appear on the tape,
adhesion is not adequate.
Any lining, which fails the tests for cure and/or adhesion, shall be blasted off to bare
metal and made good. Lining which is too thin may be built up provided that the full
inter-coat adhesion is achieved.
Each batch of lining material shall be mixed to the manufacturers instructions under the
supervision of an inspector and the details of the mix recorded.
The ends of each lined pipe fittings shall be firmly closed and sealed with recessed plastic
end caps so as to prevent the ingress of foreign matter during transportation and
handling of the pipe.

3.6 Marking

Each section of pipe and fitting shall, after wrapping/coating but before shipping, be
marked externally with a unique number to identify it. This number shall also be marked
on field fabrication and spool drawings to facilitate erection. Marking shall also identify
the supplier and order number.

4. QUALITY ASSURANCE REQUIREMENTS (ADDITIONAL TO ASME B 16.11 )

4.1 The Manufacturers Quality Requirement :

Manufacturer shall establish and maintain a quality assurance system in accordance with
ISO 9001:2000 or an approved equivalent. IOSL nominated representative shall have
the right to undertake such audits, as he deems necessary to assess the effectiveness of
the Manufacturer’s quality system.

Materials shall meet the requirement of all applicable standards.

Materials and manufacturer of piping fitting shall be supplied with certificates to EN
10204-3.1.C.Materials and fabrication of coatings and linings shall be supplied with
minimum Inspection certificate-3.1.C issued and signed by manufacturers
representative.

5. End Finish:

Unless otherwise specified on the purchase order, plain-end pipe fittings shall be
furnished with ends beveled to an angle of 30 degrees (+/- 5 degree), measured from a
line drawn perpendicular to the axis of the pipe, and with a root face of 1/16in. +/-
1/32in. (1.6+/- 0.8mm)

The specification together with attached defines the minimum requirements for supply of
the following line pipes (With external coating and Internal lining).

6. INSPECTION

Vendor shall give IOSL a minimum of ten (10) working days written notice, prior to
commencement of any loading/unloading operations. IOSL reserves the right to inspect
at any time, without advance notice, at point of loading, or at any point in transit, any
loading/unloading or transportation operation.

7. SAFETY

Vendor shall comply with local occupational Health and Safety laws and regulations and
with local laws and regulations governing transportation of goods by railroad, truck
or water as applicable.