INDIAN OIL CORPORATION LIMITED

PIPELINE DIVISION HEAD OFFICE, NOIDA

TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

CHAPTER-11
SPECIFICATION OF PIPE FITTINGS

1.0 Scope
1.1. This Specification shall be used in combination with enclosed “Specific requirement of Project”.
1.2. “Specific requirement of project“ indicates size, schedule/rating of pipe fittings, quantity,
connecting pipe thickness, connecting pipe material grade, fluid characteristics, any additional
tests and requirements, any modification to this specification based on particular project
design conditions and requirements.
1.3. This specification defines the technical requirements for the design, materials, manufacturing,
testing and inspection, marking and shipment of the weld end seamless and welded carbon
steel fittings such as elbows, tees and reducers.
1.4. This specification is applicable only to non-sour service and for onshore crude oil, petroleum
products and LPG pipeline.
1.5. This specification is applicable for pipe fittings equivalent to pressure rating 150# to 900#.
1.6. This specification is applicable for pipe fittings from size ½” to 48” with applicable pressure
rating as specified.

2.0 Reference codes and standards

2.1. Unless otherwise specified, requirements of the latest editions of the referenced Codes and
Standards at time of purchase order to be used.
2.2. Reference codes and standards to be used in conjunction with this specification.
2.3. Order of precedence of applicable documents shall be as under:
1. Specific requirement of project.
2. This specification
3. Reference codes and standards

Table-1: Reference codes and standards

S.No. Reference Description
1. ISO 15590-2 Petroleum and natural gas industries — Induction bends, fittings and
flanges for pipeline transportation systems — Part 2: Fittings
2. ASME B16.25 Butt welding Ends
3. ASME B 16.9 Factory-Made Wrought Butt welding Fittings
4. ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other
Liquids
5. ASME B31.8 Gas Transmission and Distribution Piping Systems
6. ASME section V Boiler and Pressure Vessel Code. Non-destructive Examination
7. ASME section VIII Boiler and Pressure Vessel code - Section VIII: Pressure Vessels Design
8. API 5L Specification for Line pipe
9. MSS SP 75 High-Strength, Wrought, Butt-Welding Fittings
10. ASTM A 370 Test Methods and Definitions for Mechanical testing of Steel Products
11. A 860/A 860M Standard Specification for Wrought High-Strength Low-Alloy Steel Butt-
Welding Fittings
12. ASTM E 10 Test method for Brinell Hardness of Metallic Materials
13. ASTM E 23 Method for Notched Bar Impact Testing of Metallic Materials
14. ISO 148 Charpy impact test (V-notch)

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

3.0 Design:
3.1. Pipe fittings shall comply with the requirements of ASME B16.9/MSS SP 75 as indicated in this
specification and as per “specific requirement of project”.
3.2. Pressure-temperature ratings shall be as per ASME B16.9/MSS SP 75/ISO 15590-2.
3.3. The capability of the fitting to withstand internal pressure shall equal or exceed that of the
matching pipe. The design calculations and/or results of proof testing shall be available for
review at the manufacturer’s facility and the same to be submitted to purchaser.
3.4. Wall thickness of fittings shall not be less than the connecting pipe thickness indicated in any
case.
3.5. Nominal bore of fittings shall be that of the connecting pipeline.
3.6. The welding end of fittings shall be in accordance with Figure 1 of MSS-SP-75 for wall
thickness (of intended connecting pipe) of 19 mm (0.88 in.) and less. For thicker walls greater
than 19, Figure 2 of MSS-SP-75 to be referred.
3.7. If the SMYS of the fitting material is less than that of the matching pipe, the minimum
thickness of the fitting end shall be increased such that the product of its thickness times its
SMYS shall at least equal the product of the specified wall thickness and the SMYS of the
matching pipe, in accordance with MSS SP-75.
3.8. When the fitting thickness at the welding end is greater than the adjoining pipe, the joint
design shall be as shown in any of the three sketches in Figure 3 of MSS-SP-75.
3.9. If SMYS of the fitting material and pipe to be joined are equal, then weld end thickness of pipe
fittings shall be same as that of pipe.
3.10. Fittings such as tees, elbows and reducers shall be seamless type for sizes ≤16” NB and shall be
welded type for sizes ≥ 18” NB.
3.11. Fittings shall conform to dimensional standard as per MSS-SP-75 for size 16” and larger and as
per ASME B 16.9 for size less than 16”.
3.12. For the tees installed in main pig receiving line, barred tees to be used. The bars shall be made
of mild steel and shall be welded with full penetration welds. No. of vertical bars shall be 3nos.
with no cross brace up to 12” branch size, 5 nos. vertical bars with one cross brace for branch
size 14” to 24” , 6 nos vertical bars with two cross brace for branch size above 24”. Vendor to
be provided detailed drawing of barred tee with detailed dimensional drawing for approval.
3.13. Welders and welding operators shall be qualified in accordance with ASME IX.
3.14. Welding and repair welding shall be performed in accordance with procedures qualified in
accordance with ASME IX. Procedure qualification shall include Charpy V-Notch test for
weld/HAZ and hardness test.
3.15. Weld repairs are only permitted to welds. Repair welding in base material is not permitted.
3.16. WPS shall be submitted to purchaser for approval before start of work. Any previously approved
WPS, PQR and WQT can also be submitted for purchaser review and clearance.
3.17. Fittings shall not contain girth welds.
3.18. All fittings shall be heat-treated (normalized) irrespective of pressure rating in accordance with
ISO 15590-2 Clause 8.3.3. Record and graph shall be maintained of each heat treatment batch.
Procedure for heat treatment to be submitted to purchaser for approval.
3.19. The reinforcement of inside weld seam shall be removed for a distance of 100 mm from each
end of the welded fittings.

4.0 Pipe Fittings material

4.1. General
4.1.1. Raw material used for fittings shall be of fully-killed steel. It shall have a grain size of ASTM 7
or finer, as defined in ASTM E 112

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

4.1.2. High-frequency welded and helical-seam submerged-arc welding pipes shall not be used.
4.1.3. Fittings shall be made from following material grade meeting the requirements of this
specification, applicable codes and material specification.

Table-2A: Material grade for pipe fittings (for crude oil and product pipelines)
Pressure Sizes Material grade
rating
150# For all sizes ASTM A 234 WPB
300# Up to 18” ASTM A 234 WPB
≥ 20” to ≤28” WPHY-52
≥32” to ≤48” WPHY-60
600# Up to 6” ASTM A 234 WPB
≥ 8” to ≤14” WPHY-52
≥ 16” to ≤20” WPHY-60
≥ 22” to ≤28” WPHY-65
≥ 30” to ≤36” WPHY-70
900# Up to 6” ASTM A 234 WPB
≥ 8” to ≤10” WPHY-60
≥ 12” to ≤24” WPHY-70

Table-2B: Material grade for pipe fittings (for LPG piping)

Pressure Sizes Material grade
rating
300# Up to 6” size ASTM A420 Gr.WPL6 (for drain, vent, cold flare, SV station
bypass piping and other low temperature piping)
≥8” to ≤16” ASTM A 234 WPB (For 8” size, if low temperature is specified, then
ASTM A420 Gr.WPL6 to be selected)
≥ 18” to ≤24” WPHY-52
600# Up to 6” size ASTM A420 Gr.WPL6 (for drain, vent, cold flare, SV station
bypass piping and other low temperature piping)
≥ 8” to ≤10” WPHY-52. (For 8” size, if low temperature is specified, then ASTM
A420 Gr.WPL6 to be selected)
≥ 12” to ≤14” WPHY-60
≥ 16” to ≤24” WPHY-70

4.2. Chemical composition

4.2.1. Manufacturer shall carry out a chemical analysis on each heat of steel used and also on two
products per heat.
4.2.2. Chemical composition of fittings material shall be as per Table-4 (Class C) of ISO 15590-2.
4.2.3. Maximum Carbon Equivalent shall be 0.43% when calculated with the following formula:
CE = C +MN/ 6 + (Cr+Mo+V)/5 + Cu+Ni)/15
4.2.4. If any chemical analysis (both raw material and product) fails to meet the requirements stated
above, the whole heat shall be rejected or each individual product shall be fully analysed and
all products failing to meet the requirements shall be rejected.
5.0 Inspection and testing:
5.1. General
5.1.1. Testing and inspection shall be carried out on fittings after final heat treatment.
5.1.2. Chemical, Mechanical, impact Testing shall be carried out for each heat under each lot and
each heat treatment batch unless otherwise specified.

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

5.1.3. Test pieces for all destructive testing shall be taken from finished fitting. All inspection and
testing cost shall be included in cost of fittings itself.
5.1.4. Test pieces shall be prepared in accordance with ISO 377. If thermal cutting has been used to
remove samples, the full extent of the heat-affected region shall be removed during the
preparation of the test pieces.
5.1.5. All fittings shall be visually inspected. The internal and external surfaces of the fittings shall be
free from any strikes, gauges and other detrimental defects.
5.2. Summary of testing, inspection requirements and extent of testing are detailed in Table-3

Table-3: Summary of testing, inspection requirements and extent of testing

SN. Tests Sample frequency Inspection by TPI
and/or IOCL
1. Heat analysis One per heat Review
(raw material)
2. Product analysis Two per heat 100% Witness
3. Tensile testing-Base One per heat 100% Witness
4. Transverse weld tensile One per heat 100% Witness
5. Guided bend test (weld seam) One per heat 100% Witness
6. Impact testing-Base One per heat 100% Witness
7. Impact testing- weld seam One per heat 100% Witness
8. Through thickness Hardness One per heat 100% Witness
9. Metallography One per heat 100% Witness
10. Visual inspection For all fittings 100% witness
11. Ultrasonic Testing of bevel and For all fittings 100% witness
weld ends for lamination
cracks/other defects up to a
length of 50 mm.
12. Ultrasonic testing of fitting body 20% or min. 2 nos. whichever is higher Witness as specified
(≥16” size)
13. Radiography of weld seam (Butt For all welded fittings 100% witness
welding) and repair welds, if any
c
14. Physical and Dimensional Check Rating Size Quantity Vendor to check 100%
150# & ≤16” 20% or min. 2 nos. dimensions for all
300# whichever is higher. fittings. TPI/IOCL will
≥18” 100% carry out random
600# & ≤8” 20% or min. 2 nos. witness of fittings as
900# whichever is higher specified depending
≥ 10” 100% on size and rating.
c
15. Hydro testing Rating Size Quantity Witness as specified.
150# & ≤16” 20% or min. 2 nos.
300# whichever is higher.
≥18” 100%
600# & ≤8” 20% or min. 2 nos.
900# whichever is higher
≥ 10” 100%

Note:
a) If fittings are made in different lots, then destructive testing to be carried out for each heat
under each lot and each heat treatment batch.

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

b) All samples drawn for testing to be witnessed by TPI and/or IOCL.

c) If order quantity is less than 2, minimum 1 no. to be witnessed.
d) Vendor shall carry out hydrostatic testing with pressure as specified below:

Table-4: Hydrotest pressure of pipe fitting

Rating Design pressure at Ambient Hydrotest pressure at ambient
temperature (kg/cm2g) temperature (kg/cm2g)
150# 19.5 29
300# 50.6 76
600# 101.3 152
900# 151.8 228

e) The fitting, which has been hydro tested, shall be clearly identified by marking.
f) The party shall provide extra lengths at the ends to enable hydro test for all the fittings. The
edges are to be machined only after hydrotest.
g) No visual bulging is allowed during hydrotest for any of the fitting.
h) Acceptance standards of Radiography of weld joints and repair welds shall be as per API 1104.
i) Any lamination larger than 6.35 mm shall not be acceptable in weld end ultrasonic testing.
j) Welds which cannot be radiographed shall be checked by ultrasonic testing upon purchaser
approval.
k) Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests as
per this specification at Manufacturer’s works prior to shipment. Manufacturer shall provide
reasonable notice of time and shall provide, without charge, reasonable access and facilities
required for inspection to purchaser’s inspector.

5.3. Tensile testing:

5.3.1. Sample orientation of tensile test is as per ISO 15590-2 Clause 9.4.2.1. For welded fittings,
weld tensile specimens shall be taken as shown in Table-6.
5.3.2. Tensile tests shall be carried out in accordance with ASTM A370.
5.3.3. Tensile properties of base sample tested shall meet values as per material specification grade
indicated in MSS-SP-75/ASME B16.9 as applicable w.r.t yield strength, ultimate strength,
elongation.
5.3.4. For transverse weld tensile, test result shall meet tensile strength values of respective grade as
indicated in MSS-SP-75/ASME B16.9 as applicable

5.4. Charpy V-notch impact test:

5.4.1. Charpy V-notch test pieces shall be prepared in accordance with ASTM A370/ ISO 148-1 with
the axis of the notch perpendicular to the fitting surface.
5.4.2. The orientation of test piece shall be as per Table-6 and size of the test pieces shall be as
follows:
5.4.2.1. If transverse specimen of 10 mm is not possible, then sub-size specimen can be taken. For
sub size test pieces, the minimum required absorbed energy values shall be adjusted in
accordance with ASTM A370.
5.4.2.2. If transverse test pieces with a minimum width of 5 mm are not possible, longitudinal test
pieces with the greatest possible width between 10 mm and 5 mm shall be used.
5.4.3. % shear area at the fracture surface to be reported.
5.4.4. Each set of impact tests shall consist of three adjacent test pieces.

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

5.4.5. The impact test temperature shall be 0°C for petroleum and crude oil service and -29°C for
LPG service unless otherwise specified. For low temperature carbon steel material, impact
energy and testing temperature shall be as per respective material grade specification.
5.4.6. Min. average and min. individual value for transverse direction shall meet the following
requirements.

Table-5: Impact energy for different pipe fitting grade

Material grade Min. Average Value (J) Min. individual value (J)
ASTM A234 WPB 27 22
WPHY 52 (360) 36 30
WPHY 60 (415) 42 35
WPHY 65 (450) 45 38
WPHY 70 (485) 50 40
5.4.7. The minimum average and individual Charpy V-notch values when testing test pieces taken in
the longitudinal direction shall be at least 1.5 times the values stated for transverse test pieces.

5.5. Hardness requirements

5.5.1. Through thickness hardness testing shall be performed as ISO 15590-2 Clause 9.4.4
5.5.2. No hardness reading shall exceed 248 HV10

5.6. Metallographic examination

5.6.1. Metallographic examination shall be performed as ISO 15590-2 Clause 9.4.6.
5.6.2. The specimens for metallographic examination shall be examined, prior to hardness testing, at
a magnification of not less than ×100. Grain-size measurement shall be performed in
accordance with ASTM E 112. The minimum average grain size number shall be 7.

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

Table-6: Sample/Test piece location

Type of fitting Sample location
Extruded Tee

1 – Transverse Base tensile sample, 2- Macro/Hardness sample, 3- Impact sample with

notch perpendicular to plate surface
Welded Tee

1 – Transverse Base tensile sample, 2- Macro/Hardness sample, 3- Impact sample with

notch perpendicular to plate surface
Elbow

1 – Transverse Base tensile sample, 2- Macro/Hardness sample, 3- Impact sample with

notch perpendicular to plate surface

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

Type of fitting Sample location

Welded Elbow

1 – Transverse Base tensile sample, 2- Macro/Hardness sample, 3- Impact sample with

notch perpendicular to plate surface
Reducer

1 – Transverse Base tensile sample, 2- Macro/Hardness sample, 3- Impact sample with

notch perpendicular to plate surface

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

Type of fitting Sample location

Welded
Reducer

1 – Transverse Base tensile sample, 2- Macro/Hardness sample, 3- Impact sample with

notch perpendicular to plate surface
Charpy Impact
test location

5.7. Non destructive testing:

Fittings shall be subject to the following inspection:
5.7.1. Ultrasonic testing of weld ends: The final 50 mm wide band of each weld end of the fitting
shall be UT inspected for the detection of laminar imperfections in accordance with ISO 11496.
The reference standard shall be a flat bottom hole. This 50-mm band shall extend from the
intersection of the weld bevel and fitting outside diameter back along the body of the fitting.
Laminar imperfections shall not exceed a length of 6 mm in the circumferential direction and
their area shall not exceed 100 mm2
5.7.2. The bevel faces shall be machined and shall be free from cracks, laminations, notches, scores,
pits etc.
5.7.3. Ultrasonic testing of fitting body:
- Ultrasonic examination for laminations :
In case the fitting is welded type, the area adjacent to the weld shall be tested in
accordance with ISO 13663. Acceptance level E1.

Plate for welded fittings may be examined ultrasonically in accordance with ISO 12094

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

before forming using an oscillating scanning pattern. Acceptance level B1 for the body,
and E1 for the longitudinal edges.

- Ultrasonic examination for imperfections than other laminations:

Fittings made from seamless pipe shall be examined using ultrasonic examination in
accordance with ISO 9303 for longitudinal and ISO 9305 for transverse imperfections.
Acceptance levels: for both ISO 9303 and ISO 9305 Class L2 subcategory C.

5.7.4. Final NDT shall be carried out after heat treatment and hydro testing.

6.0 Gauging:

The ends of each fitting shall be tested for out-of-roundness using an internal ring
gauge with a diameter of 5 mm less than the nominal internal diameter. The gauge
shall pass freely into each end of the fitting when held normal to the fitting axis. For
bends the internal diameter shall be verified by passing a double gauge plate through
each bend. The gauge shall have two parallel 6 mm thick aluminium plates, each a
minimum of 92 % of the nominal pipe ID, separated by a distance of 100 mm.

7.0 Dimensional requirements and Tolerance:

Butt weld end thickness of fittings shall not be less than the connecting pipe thickness.
Other dimensional requirements and tolerance shall be as per ASME B 16.9 for size ≤
14” and as per MSS-SP-75 for size ≥ 16”.

8.0 Marking
8.1. Marking shall be such that complete traceability is demonstrated in all stages of manufacture.
8.2. One or both ends of each fitting shall be marked with the following information:
1. Purchase Order and Item number
2. Fitting material grade
3. Nominal wall thickness at fitting ends/pipe schedule
4. Manufacturer’s name/logo/trade mark
5. DN / NPS
6. Serial no. and Heat number
7. Heat Treatment batch number
8. TPI witnessed mark on fittings tested.

8.3. For fittings designed with a lower SMYS than the matching pipe, both the fitting designation
and the intended matching pipe grade shall be marked.
8.4. For fittings of DN 100 and larger, markings shall be executed in block capitals of minimum
height of 19 mm. For smaller fittings, the character height shall be appropriate. Identification
markings shall not be applied on weld bevels.
8.5. Markings shall be made with indelible paint on the inside surface or, if it is not possible to
mark on the inside surface (i.e. for smaller diameter fittings <10”), on the outside.

9.0 Handling, storage and packing

Manufacturer shall ensure that all finished fittings are handled and stored in such a manner so
as to preserve the machined faces and general surface condition of the fitting. The
manufacturer shall ensure that all fittings are adequately protected against corrosion during
transportation and storage by applying proper rust protective coating. Manufacturer shall take

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PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

suitable corrective action if damage is observed by the Inspector/IOCL site representative due
to inadequate handling or storage conditions.

10.0 Documentation
10.1. During bid submission
- Confirmation on specific requirement of project (Annexure-I)
- Supporting documents as per BQC indicated in Annexure-II
- Confirmation on standard quality assurance plan as per Annexure-III
- Compliance letter from the fitting manufacturer that the fittings shall be manufactured
as per the furnished specification.
10.2. After purchase order
- Confirmation on standard quality assurance plan as per Annexure-III
- Sketch showing test specimen location for each test for the size of fittings proposed
under each heat.
- Manufacturing drawing of steel fittings for each size and rating with tolerance where
SMYS of fitting ≤ SMYS of connecting pipe.
- Design calculations and/or results of proof testing for all sizes and rating of fittings
indicated in purchase order.
- WPS, PQR and WQT as per ASME IX
- Procedure for NDT viz. Radiography and Ultrasonic testing
- Procedure for Heat treatment.
10.3. At the time of Despatch for each lot
- List of fittings produced/lot – size and rating, quantity, heat no.
- Manufacturer test/Mill certificate to signify compliance with specification.
- Raw material test certificate from original steel manufacturer
- Duly witnessed/reviewed documents, as applicable, as per QAP from TPI.
- Record of Heat treatment with graph, date of heat treatment for all size and rating
along with Heat no.
- All Mechanical, chemical test, Hardness, impact, NDT test reports and certificates
- Dimensional inspection test reports.
- All other documents as indicated in QAP.
- The fittings shall be guaranteed by the vendor against defective materials, poor
workmanship, improper design and failure in normal usage within 18 months from the
date of supply.
- The supplied fittings shall be guaranteed for withstanding hydrostatic testing along with
the piping system at a pressure of 1.5 times the pressure rating specified in the
summary of requirement.

Note –QAP for the Pipe fittings is attached as Annexure-IIB-1A

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

Note: The indicative thickness is for the connecting pipe thickness

Sl.NO Nom. Size Connecting pipe

(Inch)
1. 16 16 " OD x 0.375" WT API 5L X70 PSL 2 PIPE
2. 14 14 " OD x 0.375" WT API 5L X60 PSL 2 PIPE
3. 12 12.75" OD x 0.375" WT API 5L X60 PSL 2 PIPE
4. 12 12.75" OD x 0.375" WT API 5L Gr B PSL 2 PIPE
5. 10 10.75" OD x 0.365" WT API 5L x 52 PSL 2 PIPE
6. 10 10.75" OD x 0.365" WT API 5L Gr B PSL 2 PIPE
7. 8 8.625" OD x 0.322" WT API 5L x 52 PSL 2 PIPE
8. 8 8.625" OD x 0.322" WT API 5L Gr B PSL 2 PIPE
9. 6 6.625" OD x 0.280" ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
10. 4 4.5" OD x 0.237"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
11. 3 3.5" OD x 0.216"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
12. 2 2.375" OD x 0.218"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
13. 1.5 1.315" OD x 0.179" WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe

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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No. operation Method documents Norms Inspection
of check Vendor TPI
and/or
IOCL
1 Raw material 1. Manufacturing Critical Verification Each heat Applicable Applicable MTC and Perform Review
process of steel with MTC Material Material Material
2. Chemical Spectro Each heat Spec./STD/ Spec./STD/ incoming
composition Analysis IOCL-MECH- IOCL-MECH- register
PF-061 PF-061
2 Forming/ Visual, Dimension Critical Measurement 100% STD STD Internal Perform Review
Welding/ and alignment Manufacturin Manufacturin Quality
Machining g Procedure g Procedure document
/Internal /Internal s
Quality Quality
Procedure Procedure
3 Heat Heat Treatment Major Verification of Each Heat Treatment As per As per Heat Perform Review
Treatment- Cycle Heat batch Material Material Treatment
Normalizing Treatment Spec./STD/ Spec./STD/ Graph
Cycle IOCL-MECH- IOCL-MECH-
PF-061 PF-061
4 Mechanical 1. Tensile Major Tensile testing 1 sample per heat As per As per MTR & TC Perform Witness
testing Test-Base (TS, YS, % Machine Refer Note-2 Material & Material &
RA, % EL) testing testing Spec./
2. Tensile Test-weld Spec./STD/ STD/
(UTS) IOCL-MECH- IOCL-MECH-
3. Guided bend test PF-061 PF-061
4. Hardness Hardness
tester
5. Charpy V-Notch- Impact testing
Base and weld machine

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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No. operation Method documents Norms Inspection
of check Vendor TPI
and/or
IOCL
seam

6. Micro test Metallography

7. Product chemical Spectro Two samples per heat
analysis Analysis Refer Note-2
5 NDT- UT of bevel and Major Ultrasonic flaw 100% As per IOCL- As per IOCL- MTR & TC Perform Witness
Ultrasonic weld ends for detector MECH-PF- MECH-PF-061
Testing lamination cracks/ 061
defects up to width
of 50 mm from the
end.
6 NDT- UT of fitting body Major Ultrasonic flaw 20% or min 2 nos. As per IOCL- As per IOCL- MTR & TC Perform Witness
Ultrasonic detector whichever is higher MECH-PF- MECH-PF-061
Testing 061
7 NDT- RT of weld seam Major Radiography 100% As per IOCL- As per IOCL- MTR & TC Perform Witness
Radiography and any repair weld MECH-PF- MECH-PF-061
061
8 Hydrotesting Leakage testing Major 150# 20% or min. 2 As per IOCL- No visible Hydrotest Perform Witness
& nos. whichever MECH-PF- leakge at 1.5 report
300# is higher for 061 times the
≤16” pressure
100% ≥18” rating
600# 20% or min. 2
& nos. whichever
900# is higher ≤8”
100% ≥ 10”

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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No. operation Method documents Norms Inspection
of check Vendor TPI
and/or
IOCL
6 Final Visual Major Visual 100% As per As per MTR & TC Peform Witness
Inspection Material Material
Dimension Measurement 150# 20% or min 2 Spec./STD/ Spec./STD/
& gauging & nos. whichever IOCL-MECH- IOCL-MECH-
300# is higher for PF-061 PF-061
≤16”
100% for sizes
≥ 18”
600# 20% or min. 2
& nos. whichever
900# is higher for
≤8”
100% for sizes
≥10”
7 Marking and Marking, color Major Visual 100% As per As per MTR & TC Peform Random
Rust coding, Rust Material Material witness
prevention, prevention & Spec./STD/ Spec./STD/
packing Packing IOCL-MECH- IOCL-MECH-
PF-061 PF-061
8 Certification/ As per EN 10204 Major Verification of 100% As per As per MTR & TC Peform Review
Warranty, Type 3.2/ PO Spec. & Material Material
Gurantee Manufacturer’s test QAP Spec./STD/ Spec./STD/
Certificates certificate IOCL-MECH- IOCL-MECH-
PF-061 PF-061
9 Release note. Inspection Release Major Verification of 100% As per As per Release Hold Review
note PO Spec. & Material Material note
QAP Spec./STD/ Spec./STD/

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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No. operation Method documents Norms Inspection
of check Vendor TPI
and/or
IOCL
IOCL-MECH- IOCL-MECH-
PF-061 PF-061
10 Shipping & Verification of Major - - As per As per Shipping Hold Review
Packing Surface Material Material document
coating/type of Spec./STD/ Spec./STD/ /
packing IOCL-MECH- IOCL-MECH- Packing
PF-061 PF-061 list

Note :.
1. In case, sub-vendor is performing operations/testing, the same is to be witnessed by vendor and relevant test certificates, reports, registers will be reviewed and/
or witnessed by TPI and/or IOCL as applicable.
2. If fittings are made in different lots, then tensile test, guided bend test, impact test, Hardness and Metallography to be carried out for each he at under each lot
and each heat treatment batch.
3. All samples drawn for testing to be witnessed by TPI and/or IOCL.
4. If order quantity is less than 2, minimum 1 no. to be witnessed.
5. Fittings inspected by TPI and/or IOCL shall be clearly identified by marking.
6. Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests as per this specification at M anufacturer’s works prior to shipment.
Manufacturer shall provide reasonable notice of time and shall provide, without charge, reasonable access and facilities requ ired for inspection to purchaser’s
inspector.
7. Reference IOCL specification - IOCL-MECH-PF-061, Rev-1
8. Reference codes and standards as per IOCL-MECH-PF-061 Clause No.2.0
9. Material grade of fittings shall be as per technical specification IOCL-MECH-PF-061 – Table 2.
10. Manufacturing and Dimensions of Fittings shall be as per technical specification IOCL-MECH-PF-061 –. Clause No.7 unless otherwise specified
11. Color coding: Circumferential color band of 25 mm width in fitting
For ASTM A420 Gr.WPL6, SMLS- material grade fitting – Yellow color
For WPHY 52- Material grade fitting – Green color
For WPHY 60 -Material grade fitting -Red color

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For WPHY 65 -Material grade fitting -White color

For WPHY 70 -material grade fitting –Purple/Violet color
For ASTM A234 WPB -material grade fitting – No color coding.

Legends : STD-Standard, PO– Purchase Order, UT – Ultrasonic examination, NDT-Non destructive testing, Spec.- Specification, MTC-Material test certificate, TC-Test
certificate, MTR-Material test report

All the NDT / Heat Treatment / Special manufacturing procedures have to be specially approved by purchaser or only previously approved procedures have to be used
upon review by purchaser.

In case of conflict between specific requirements of project, technical Spec., purchasing documents, contract documents and I TP, more stringent conditions shall be
applicable. The document describes generally the requirements pertaining to all types of fittings. Requirements specific to particular item are only applicable

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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

CHAPTER -12
SPECIFICATIONS OF CARBON STEEL FLANGES

1.0 Scope
1.1 This Specification shall be used in combination with enclosed “Specific requirement of Project”.
1.2 “Specific requirement of project“ indicates size, rating of flange, quantity, connecting pipe
thickness, connecting pipe material grade, fluid characteristics, any additional tests and
requirements, any modification to this specification based on particular project design conditions
and requirements.
1.3 This specification defines the technical requirements for the design, materials, manufacturing,
testing and inspection, marking and shipment of forged carbon steel flanges of the welding neck
type, blind flange and Slip on Flanges.
1.4 This specification is applicable only to non-sour service and for onshore crude oil, petroleum
products and LPG service.
1.5 This specification is applicable for flanges of pressure rating 150# to 900#.
1.6 This specification is applicable for flanges from size ½” to 48” with applicable pressure rating as
specified.

2.0 Reference codes and standards

2.1 Unless otherwise specified, requirements of the latest editions of the referenced Codes and
Standards at time of purchase order to be used.
2.2 Reference codes and standards to be used in conjunction with this specification.
2.3 Order of precedence of applicable documents shall be as under:
a. Specific requirement of project (As per Annexure-I)
b. This specification
c. Reference codes and standards
S.No. Reference Description
15. ISO 15590-3 Petroleum and natural gas industries — Induction bends, fittings and
flanges for pipeline transportation systems — Part 3: Flanges
16. ASME B16.25 Butt welding Ends
17. ASME B 16.20 Ring-Joint Gaskets and Grooves for Steel Pipe Flanges
18. ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60
Metric/Inch Standard
19. ASME B 16.5 Pipe flanges and flanged fittings
20. ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other
Liquids
21. ASME B31.8 Gas Transmission and Distribution Piping Systems
22. ASME section V Boiler and Pressure Vessel Code. Non-destructive Examination
23. ASME section VIII Boiler and Pressure Vessel code - Section VIII: Pressure Vessels Design
24. API 5L Specification for Line pipe
25. MSS SP 44 Steel pipe line flanges
26. ASTM A 370 Test Methods and Definitions for Mechanical testing of Steel Products
27. ASTM A 388/A 388M Practice for Ultrasonic Examination of Heavy Steel Forgings
28. ASTM A 694/A 694M Specification for Forgings, Carbon and Alloy Steel for Pipe, Flanges,
Fittings, Valves and Parts for High – Pressure Transmission Services
29. ASTM E 10 Test method for Brinell Hardness of Metallic Materials
30. ASTM E 23 Method for Notched Bar Impact Testing of Metallic Materials
31. ASTM E 709 Guide for Practice of Magnetic Particle Examination
32. ISO 148 Charpy impact test (V-notch)

Section-II(B)
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 TECHNICAL SPECIFICATION FOR MATERIALS
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S.No. Reference Description

33. AWWA C207 Steel Pipe Flanges for Waterworks Service, Sizes 4 ln. Through 144 In.
(100 mm Through 3,600 mm)

3.0 Design:
3.1 Flanges shall comply with the requirements of ASME B16.5/ASME B16.47/MSS SP 44 as indicated
in this specification and as per “specific requirement of project”.
3.2 Pressure-temperature ratings shall be as per MSS SP 44/ISO 15590-3
3.3 Flanges shall be made from forging material meeting the requirements of this specification,
applicable codes and material specification.
3.4 The dimensions of flanges shall be as per ASME B16.5 for NPS ½” to 24” (except 22”), ASME
B16.47 Series A/MSS SP-44 for 22” size and from NPS 26” to 36” and ASME B16.47 series B for
above 36”.
3.5 Design factor of flanges shall be 0.6 and the flanges are to be guaranteed by vendor for Hydrotest
pressure of 1.5 times the pressure rating.
3.6 Wall thickness of flange weld neck (hub) shall not be less than the connecting pipe thickness
indicated in any case.
3.7 Pipe flanges end thickness and grade shall be selected in such a way that flange meets the design
stress criteria mentioned in Annex-A of MSS-SP-44.
3.8 Nominal bore of WNRF shall be that of the connecting pipeline.
3.9 Bore of slip on flanges shall suit the outside diameter of matching pipe.
3.10 The welding end shall be in accordance with Figure 2 of MSS-SP-44 for wall thickness (of intended
connecting pipe) of 22 mm (0.88 in.) and less. For thicker walls greater than 22, Figure 3 of MSS-
SP-44 to be referred.
3.11 When the mechanical (specified minimum yield strength) properties of all sections of the flanges
are equal to or higher than those of the pipe to be matched, the hub dimensions to be
maintained same as those indicated in ASME B16.5/ASME B16.47/MSS-SP-44 as applicable.
3.12 When the specified minimum yield strength of any portion of flange is less than that specified for
the pipe to be matched, the minimum thickness of the hub at the welding end shall be such that
the product of its thickness times its yield strength shall be at least equal to the product of the
specified nominal wall thickness and minimum specified yield strength of the pipe to be matched
in accordance with MSS-SP-44.
3.13 When the hub thickness at the welding end is greater than the adjoining pipe, the joint design
shall be as shown in any of the three sketches in Figure 1 of MSS-SP-44.
3.14 Unless otherwise specified, raised face shall be used for flange rating 150# to 900#.
3.15 Flange facings shall be in accordance with MSS SP 44/ASME B 16.47 and ANSI B 16.5, as
applicable. Flange Facing Finish Imperfections shall not exceed the dimensions shown in Table 11
of MSS SP 44. Adjacent imperfections shall be separated by a distance of at least four times the
permissible radial projection. Protrusions above the separations are not allowed.
3.16 The surface finish of raised face and flat face of all flanges shall have serrated concentric surface
finish with an average roughness of 3.2 μm (125 μin) to 6.3 μm (250 μin).
3.17 AWWA type flanges shall be as per AWWA C207 Class E with Hub type and to be supplied with
flat face.
3.18 Steel forgings to be used in the manufacture of AWWA flanges and mechanical and chemical
properties shall meet clause 4.1.3.1 of AWWA C207.

4.0 Flange material

4.1 Chemical composition
a. All flange forged material shall be fully killed and made to fine grain practice.

Section-II(B)
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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

b. All flanges shall be normalised irrespective of size and rating. Vendor shall submit the heat
treatment procedure for purchaser’s approval. A record (heat treat chart) shall be
maintained of each heat treatment batch and shall be included in the inspection document.
c. The final microstructure produced after heat treatment shall be uniform with average grain
size of ASTM 7 or finer as per ASTM E 112.
d. Manufacturer shall carry out a chemical analysis on each heat of steel used and also on two
products per heat.
e. Chemical composition of flanges shall be as per Table-4 of ISO 15590-3 with the following
changes.
 Nitrogen concentration shall be limited to 0.012% Max.
 V+Nb+Ti shall not exceed 0.15%
 Cr+Mo+Ni+Cu shall not exceed 0.6%.
f. Maximum Carbon Equivalent shall be 0.43% when calculated with the following formula:
CE = C +MN/ 6 + (Cr+Mo+V)/5 + Cu+Ni)/15
g. If any chemical analysis (both raw material and product) fails to meet the requirements
stated above, the whole heat shall be rejected or each individual product shall be fully
analysed and all products failing to meet the requirements shall be rejected.

4.2 Material grade

Flange material shall comply with as per the requirements indicated below unless otherwise
specified. Please refer specific requirement of project for connecting pipe thickness and grade.
Material grade for flanges (for crude oil and product pipelines)
Material grade Flange type Pressure rating
150# 300# 600# 900#
ASTM A105 WNRF/SORF/BLRF 1/2”-48” 1/2”-18” 1/2”-6” 1/2”-6”
ASTM A694 F52 WNRF/BLRF - 20”-28” 8”-14” -
ASTM A694 F60/F65/F70# WNRF/BLRF - 30”-48” 16”-36” 8”-24”
Material grade for flanges (for LPG piping)
Material grade Flange type Pressure rating
300# 600#
ASTM A350 LF2 Cl2 WNRF/BLRF 1/2”-6” 1/2”-6”

ASTM A105 WNRF/BLRF 8”-16” -

ASTM A694 F52 WNRF/BLRF 18”-24” 8”-10”
ASTM A694 F60/F65/F70# WNRF/BLRF - 12”-24”

Note:
1. # - If flange material SMYS is less than connecting pipe SMYS, then clause 3.10 & 3.11 to be
followed.
2. For 8” size, if low temperature is specified, then ASTM A350 LF2 to be selected.

5.0 Manufacturing & Dimensional requirements

Manufacturing & Dimensional requirements of flanges shall be as per following:
Details Up to 20” & 24” 22” & 26” to 36” > 36” (only for 150# and
300#)
For WNRF & BLRF Flange

a Manufacturing & ANSI B 16.5 / ANSI B 16.47 Series A / ASME B16.47 Series B
Dimension MSS SP 44 (12”-24”) MSS SP 44

Section-II(B)
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For SORF Flanges (for 150# only)

b Manufacturing, ANSI B 16.5 AWWA C207 Class E AWWA C207 Class E
Dimensions

6.0 Inspection and testing:

6.1 General instruction
a. Test pieces shall be prepared in accordance with ISO 377. If thermal cutting has been used to
remove samples, the full extent of the heat-affected region shall be removed during the
preparation of the test pieces.
b. Mechanical testing samples shall consist of sacrificial forging. The testing of separately forged
bars should not be permitted. All inspection and testing cost shall be included in cost of
flange itself.
6.2 Summary of testing, inspection and extent of testing:

S.No. Tests Sample frequency Inspection

1 Heat analysis One per heat Review
(raw material)
2 Product analysis Two per heat 100% Witness

3 Tensile testing, Impact testing, One per heat/lot/each heat treatment 100% Witness
Hardness and Metallography batch
4 Visual inspection For all flanges 100% witness
5 Ultrasonic Testing of weld For all flanges 100% witness
ends for lamination
cracks/other defects up to a
width of 50 mm from weld
end
6 Physical and Dimensional 150# & 20% or min. 2 nos. 100% witness
Check 300# whichever is higher for
sizes ≤16”
100% for sizes ≥ 18”
600# 100%
900# 100%
Note:
l) If fittings are made in different lots, then destructive testing to be carried out for each heat
under each lot and each heat treatment batch.
m) All samples drawn for testing to be witnessed by TPI and/or IOCL.
n) If order quantity is less than 2, minimum 1 no. to be witnessed.
o) Flanges inspected by TPI and/or IOCL shall be clearly identified by marking
p) Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests as
per this specification at Manufacturer’s works prior to shipment. Manufacturer shall provide
reasonable notice of time and shall provide, without charge, reasonable access and facilities
required for inspection to purchaser’s inspector.

6.3 Tensile testing:

10.3.1. Tensile tests shall be carried out in accordance with ASTM A 370.
10.3.2. Sample orientation of tensile test is as per ISO 15590-3.
6.4 For weld-neck flanges:

Section-II(B)
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Note: Marking 1- Welding neck flange, Marking 2- Longitudinal tensile specimen.

10.3.3. For Blind flanges:

Note: Marking 3- Blind flange, 4- Transverse tensile specimen.

10.3.4. Tensile properties of sample tested shall meet values as per material specification grade
indicated viz. ASTM 105/ASTM A694 w.r.t yield strength, ultimate strength, elongation.

10.4. Charpy V-notch impact test:

10.4.1. Charpy V-notch test pieces shall be prepared in accordance with ASTM A 370/ ISO 148-1 with
the axis of the notch perpendicular to the flange surface.
10.4.2. The orientation and size of the test pieces shall be as follows:
10.4.2.1. Actual location of specimen shall be that nearest to the welded end from which 10 mm × 10
mm Charpy specimens can be taken.
10.4.2.2. If transverse specimen of 10 mm is not possible, then sub-size specimen can be taken.
10.4.2.3. If transverse test pieces with a minimum width of 5 mm are not possible, longitudinal test
pieces with the greatest possible width between 10 mm and 5 mm shall be used.
10.4.3. % shear area at the fracture surface to be reported.
10.4.4. Each set of impact tests shall consist of three adjacent test pieces.
10.4.5. The impact test temperature shall be 0°C for petroleum and crude oil service and -29°C for LPG
service. For low temperature carbon steel material, impact energy and testing temperature
shall be as per respective material grade specification.
10.4.6. Min. average and min. individual value for transverse direction shall meet the following
requirements.
Material grade Min. Average Value (J) Min. individual value (J)
ASTM A105 27 22
F52 (360) 36 30
F60 (415) 42 35
F65 (450) 45 38
F70 (485) 50 40

Section-II(B)
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10.4.7. The minimum average and individual Charpy V-notch values when testing test pieces taken in
the longitudinal direction shall be at least 1.5 times the values stated for transverse test pieces.

10.5. Hardness requirements

10.5.1. Three through thickness macro sections shall be taken at 120 º intervals from the hub and ring
of the test flange.
10.5.2. Three hardness traverses shall be made on each macro section as follows:
 1.5±0.5 mm from the outer surface
 Mid-thickness
 1.5±0.5 mm from the inner surface
10.5.3. Each traverse shall consist of five indents.
10.5.4. No hardness reading shall exceed 248 HV10

10.6. Non destructive testing:

Flanges shall be subject to the following inspection:
10.6.1. Ultrasonic inspection as specified - Ultrasonic testing shall be carried out in accordance with
ASME V or ASTM A 388/A 388M.
 The final 50 mm of weld end of the flange shall be UT inspected for the detection of
laminar imperfections in accordance with ISO 11496. The reference standard shall be a
flat bottom hole.
10.6.2. The bevel faces shall be machined and shall be free from cracks, laminations, notches, scores,
pits etc.
10.6.3. 100% visual inspection of internal and external surfaces- Forgings shall comply with the
workmanship, finish and appearance requirements of ASTM A 694/ASTM A105.
10.6.4. Final NDT shall be carried out after heat treatment with the forging in the finish-machined
condition.
10.7. Hydrostatic testing
Hydrostatic testing of flanges is not required unless otherwise specified. Flanged joints may be
subjected to system hydrostatic tests at a pressure limited to 1,5 times the pressure rating. The
manufacturer shall certify and guarantee that the flange can withstand the hydrostatic test
pressures.
10.8. Dimensional requirements:
10.8.1. WNRF and Blind Flanges shall be machined according to the dimensions of ASME B16.5 for sizes
up to 24” (except 22”), as per MSS SP 44/ASME B 16.47 series A for sizes 22” and above 24” to
36” and as per ASME B16.47 series B for sizes above 36”.
10.8.2. For slip on flanges, dimensions shall be as per ASME B 16.5 for sizes up to 24” and as per AWWA
C207 Class E (275PSI) hub type for size above 24”.
10.8.3. If flange material SMYS is less than connecting pipe SMYS, then clause 3.10 & 3.11 to be
followed.

10.9. Tolerance:
Tolerances shall be as per ASME B 16.5 for sizes ≤ 10” and as per MSS-SP-44 for sizes > 10”

10.10. Repair of defects

Minor surface defects on flanges shall be ground out leaving a smooth gradual profile provided
that the wall thickness is not reduced below the tolerances specified. Any ground areas (except
for cosmetic grinding) shall be examined by ultrasonic Inspection. Forgings containing larger
defects shall be rejected. Repair welding of forgings is not allowed.

7.0 Marking

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11.1. Marking shall be such that complete traceability is demonstrated in all stages of manufacture.
11.2. Each flange shall be clearly identified on the outside rim using the following marking
11.3. Each flange shall be marked as a minimum with the following information:
9. Company’s name/logo/trade mark
10. DN / NPS
11. Wall thickness/pipe schedule
12. Class
13. Serial no. and Heat number
14. Purchase order No.
15. Material grade of forging
16. TPI witnessed mark on flange tested.
8.0 Handling, storage and packing
Manufacturer shall ensure that all finished flanges are handled and stored in such a manner so
as to preserve the machined faces and general surface condition of the forging. The
manufacturer shall ensure that all flanges are adequately protected against corrosion during
transportation and storage by applying proper rust protective coating.

Manufacturer shall take suitable corrective action if damage is observed by the Inspector/IOCL
site representative due to inadequate handling or storage conditions.

9.0 Documentation
13.1. During bid submission
- Confirmation on Specific requirement of project (As per Annexure-I)
- Supporting documents as per BQC indicated in Annexure-II
- Confirmation on Standard Quality assurance procedure (As per Annexure-III)
- Compliance letter from the flange manufacturer that the flanges shall be manufactured
as per the furnished specification.
13.2. After purchase order
- Confirmation on Standard Quality assurance procedure (As per Annexure-III)
- Sketch showing test specimen location for each test for the size of flange proposed
under each heat.
- Manufacturing drawing of steel flange for each size and rating with tolerance where
SMYS of flange ≤ SMYS of connecting pipe.
13.3. At the time of Despatch for each lot
- List of flanges produced – size and rating, quantity, heat no.
- Manufacturer test/Mill certificate to signify compliance with specification.
- Raw material test certificate from original steel manufacturer
- Duly witnessed/reviewed documents, as applicable, as per QAP from TPI.
- Record of Heat treatment with graph, date of heat treatment for all size and rating
along with Heat no.
- All Mechanical, chemical test, Hardness, impact, NDT test reports and certificates
- Dimensional inspection test reports.
- All other documents as indicated in QAP.
- The flange shall be guaranteed by the vendor against defective materials, poor
workmanship, improper design and failure in normal usage within 18 months from the
date of supply.
- The supplied flanges shall be guaranteed for withstanding hydrostatic testing along with
the piping system at a pressure of 1.5 times the pressure rating specified in the
summary of requirement.
Note: QAP for Carbon Steel Flanges is attached as Annexure – IIB-2A

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MECHANICAL SUPPLY ITEMS

Note: The indicative thickness is for the connecting pipe thickness

Sl.NO Nom. Size Connecting pipe

(Inch)

1 14 14 " OD x 0.375" WT API 5L X60 PSL 2 PIPE

2 12 12.75" OD x 0.375" WT API 5L X60 PSL 2 PIPE
3 12 12.75" OD x 0.375" WT API 5L Gr B PSL 2 PIPE
4 10 10.75" OD x 0.365" WT API 5L x 52 PSL 2 PIPE
5 10 10.75" OD x 0.365" WT API 5L Gr B PSL 2 PIPE
6 8 8.625" OD x 0.375" WT API 5L x 52 PSL 2 PIPE
7 8 8.625" OD x 0.322" WT API 5L Gr B PSL 2 PIPE
8 6 6.625" OD x 0.280" ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
9 4 4.5" OD x 0.237"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
10 3 3.5" OD x 0.216"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
11 2 2.375" OD x 0.218"WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe
12 1.5 1.315" OD x 0.179" WT ASTM A 106 Gr B Pipe / A333 Gr 6 Pipe

Section-II(B)
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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No operation Method documents Norms Inspection
. of check Vendor TPI
and/or
IOCL
1 Raw 3. Manufacturing Critical Verification Each heat Applicable Applicable MTC and Perform Review
material process of steel with MTC Material Material Material
4. Chemical Spectro Each heat Spec./STD/ Spec./STD/ incoming
composition Analysis IOCL-MECH- IOCL-MECH- register
FLANGES-66 FLANGES-66
2 Forging 1. Reduction ratio Critical Measurement Minimum 1 per size STD STD Forging Perform Review
2. Temperature Optical Manufacturing Manufacturing process
during forging Pyrometer Procedure Procedure record
/ Internal
3. Forging Measurement 100% ASME B16.5/
Register
dimensions ASME B16.47/
MSS-SP-44 as
applicable
3 Heat Heat Treatment Major Verification of Each Heat As per Material As per Material Heat Perform Review
Treatment Cycle Heat Treatment batch Spec./STD/ Spec./ Treatment
Treatment IOCL-MECH- STD/ Graph
Cycle FLANGES-66 IOCL-MECH-
FLANGES-66
4 Mechanical 8. Tensile Test Major Tensile testing 1 sample per heat As per Material As per Material MTR & TC Perform Witness
testing (TS, YS, % RA, % EL) Machine Refer Note-2 & testing & testing Spec./
Spec./STD/ STD/
9. Hardness Hardness IOCL-MECH- IOCL-MECH-
tester FLANGES-66 FLANGES-66
10.Charpy V-Notch Impact testing
machine

Section-II(B)
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 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No operation Method documents Norms Inspection
. of check Vendor TPI
and/or
IOCL
11.Micro test Metallography
12.Product chemical Spectro Two samples per
analysis Analysis heat
Refer Note-2
5 NDT- UT of bevel and Major Ultrasonic flaw 100% As per Material As per Material MTR & TC Perform Witness
Ultrasonic weld ends for detector & testing & testing
Testing lamination cracks/ Spec./STD/ Spec./STD/
defects up to a IOCL-MECH- IOCL-MECH-
length of 50 mm FLANGES-66 FLANGES-66
from the end.
6 Final Visual Major Visual 100% As per Material As per Material MTR & TC Peform Witness
Inspection Spec./STD/ Spec./STD/
Dimension Measurement 150# 20% or min IOCL-MECH- IOCL-MECH-
300# 2 nos. FLANGES-66 FLANGES-66
whichever is
higher for
≤16”
100% for
sizes ≥ 18”
600# 100%
900# 100%
7 Marking Marking, color Major Visual 100% As per Material As per Material MTR & TC Peform Random
and Rust coding, Rust Spec./STD/ Spec./STD/ witness
prevention, prevention & IOCL-MECH- IOCL-MECH-
packing Packing FLANGES-66 FLANGES-66
8 Certificatio As per EN 10204 Major Verification of 100% As per Material As per Material MTR & TC Peform Review
Section-II(B)
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way and private use permitted by any written consent of the lender.
 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

S. Stages/ Characteristics Category Type/ Quantum of check Reference Acceptance Record Scope of
No operation Method documents Norms Inspection
. of check Vendor TPI
and/or
IOCL
n/ Type 3.2/ PO Spec. & Spec./STD/ Spec./STD/
Warranty, Manufacturer’s test QAP IOCL-MECH- IOCL-MECH-
Gurantee certificate FLANGES-66 FLANGES-66
Certificates
9 Release Inspection Release Major Verification of 100% As per Material As per Material Release Hold Review
note. note PO Spec. & Spec./STD/ Spec./STD/ note
QAP IOCL-MECH- IOCL-MECH-
FLANGES-66 FLANGES-66
10 Shipping & Verification of Major - - As per Material As per Material Shipping Hold Review
Packing Surface Spec./STD/ Spec./STD/ document/
coating/type of IOCL-MECH- IOCL-MECH- Packing list
packing FLANGES-66 FLANGES-66

Note :.
12. In case, sub-vendor is performing operations/forging/testing, the same is to be witnessed by vendor and relevant test certificates, report s, registers will be
reviewed and/ or witnessed by TPI and/or IOCL as applicable.
13. If flanges are made in different lots, then tensile test, impact test, Hardness and Metallography to be carried out for each heat under each lot and each heat
treatment batch.
14. All samples drawn for testing to be witnessed by TPI and/or IOCL.
15. If order quantity is less than 2, minimum 1 no. to be witnessed.
16. Flanges inspected by TPI and/or IOCL shall be clearly identified by marking.
17. Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests as per this specification at Manufacturer’s works prior to shipment.
Manufacturer shall provide reasonable notice of time and shall provide, without charge, reasonable access and facilities requ ired for inspection to purchaser’s
inspector.
18. Reference IOCL specification - IOCL-MECH-FLANGES-066, Rev-2
19. Reference codes and standards as per IOCL-MECH-FLANGES-066 Clause No.2.0

Section-II(B)
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way and private use permitted by any written consent of the lender.
 TECHNICAL SPECIFICATION FOR MATERIALS
MECHANICAL SUPPLY ITEMS

20. Material grade of flanges shall be as per technical specification IOCL-MECH-FLANGES-066 Clause No.4.2.
21. Manufacturing and Dimensions of Flanges shall be as per technical specification IOCL-MECH-FLANGES-066 Clause No.5 unless otherwise specified
22. Color coding: Circumferential color band of 25 mm width in flange hub in WNRF and line of 25 mm width in BLRF
For ASTM A350 LF2 Cl2 material grade flange – Yellow color
For ASTM A694 F52 material grade flange – Green color
For ASTM A694 F60 material grade flange -Red color
For ASTM A694 F65 material grade flange -White color
For ASTM A694 F70 material grade flange –Purple/Violet color
For ASTM A105 – No color coding.

Legends : STD-Standard, PO– Purchase Order, UT – Ultrasonic examination, NDT-Non destructive testing, Spec.- Specification, MTC-Material test certificate, TC-Test
certificate, MTR-Material test report

All the NDT / Heat Treatment / Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used.

In case of conflict between specific requirements of project, technical Spec., purchasing documents, contract documents and I TP, more stringent conditions shall be
applicable. The document describes generally the requirements pertaining to all types of Flanges. Requirements specific to particular item are only applicable

Section-II(B)
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way and private use permitted by any written consent of the lender.
 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

CHAPTER-13
SPECIFICATION FOR HALF COUPLING & NIPPLE

Clause Area Description Requirements / Remarks

1.0 Scope Design, manufacture, testing and supply of Rating and Quantity as per specific
Butt-welded steel nipples and half couplings requirement of the project.
2.0 Service Liquid Hydrocarbon/ LPG
3.0 Design and A) Specific Requirement for Nipple
codes Code of Conformity- ANSI B 16.9
Ends - Butt-welded and plain bevel
Material - ASTM A 105/ASTM A350 LF2 (for LPG
service)
Pressure rating- 3000 lbs.
Normalised or quenched and tempered. Tempering temperature shall not be less
0
than 1100 F.
B) Specific Requirement for Half Couplings
Code of Conformity- - ANSI B 16.11
Ends - Socket-weld ends
Material - ASTM A 105 ASTM A350 LF2 (for LPG
service)
Pressure rating- 3000 lbs.
Normalised or quenched and tempered. Tempering temperature shall not be less
0
than 1100 F.
4.0 Testing  All tests as specified in code shall be carried out at manufacturer’s works
 Test certificates (material test) review and physical dimensional check shall be
carried out by owner or authorised third party inspector.
 TPI TO BE ENGAGED BY CONTRACTOR
5.0 Painting Brush Cleaning + Rust Preventive Coating
6.0 Documentation i) With Bid
h) Supply record
ii) After inspection for Despatch clearance (In 4 sets)
a) Inspection report and certification as per requirement of code ASTM A 234.
7.0 Shipment  All fittings shall be dried and packed properly for shipment.
 All openings shall be properly covered before packing.
8.0 Warranty  The vendor shall guarantee that the  All nipples and half couplings
supplied nipples and half couplings shall shall be free of any defects due to
successfully withstand the applicable design, manufacture and material.
hydrostatic test pressure of connecting Any defective nipples and half
pipes as per ASME 31.4 standard, during couplings, so detected within one
hydro-test of pipes at field year of operation or 18 months
from the date of supply shall be
replaced free of cost by the
supplier.

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

CHAPTER-14
SPECIFICATION FOR WELD-O-LET

Clause Area Description Requirements / Remarks

1.0 Scope Design, manufacture, testing and Rating, Quantity and size of Run
supply of weld-o-lets for branch pipe & Outlet pipe as per specific
connections for the piping system requirement of the project
2.0 Service Liquid Hydrocarbon
3.0 Design and Manufactured in accordance with- ANSI B 31.1(American standard code for
Codes pressure piping) Methods of making branch connections /MSS-SP 97
standard
4.0 Provisions Maximum working pressure for design of Weld-O-Lets shall be as follows:
a) For ANSI 150 Sr.- 275 Psi
b) For ANSI 300 Sr.- 720 Psi
c) For ANSI 400 Sr.- 960 Psi
d) For ANSI 600 Sr.- 1440 Psi
O O
Weld ends shall have a bevel of 30 deg. (+ 5 – 0 ) measured from a line
drawn perpendicular to the axis of the pipe with a root face of 1/16”  1/32”.
Root face is square and normal to the bore.
The weld-O-lets shall be able to withstand hydrostatic test pressure as per the
following:
a) 412.50 psi (150#)
b) 1080.0 psi (300#)
c) 1440.0 psi (400#)
d) 2160.0 psi (600#)
5.0 Material ASTM A105/ ASTM A350 LF2 (for LPG service)
6.0 Testing  For Testing- ANSI B 16.9
 For material & manufacturing process –ASTM A 105
TPI TO BE ENGAGED BY CONTRACTOR
7.0 Painting Brush Cleaning + Rust Preventive Coating
8.0 Documentation With Bid
a) Supply record of similar Weld-o-lets in past.
After inspection for Despatch (In 4 sets)
a) Inspection report and certification as per requirement of code ASTM A 105.
9.0 Warranty  Vendor to guarantee that supplied  All weld-O-lets are to be free of
weld-o-let shall withstand the any defects due to design,
hydrostatic testing as given above at manufacture and material. Any
site. defective Weld-O-lets, so
detected during one year of
service or within 18 months of
supply shall be replaced free of
cost by the supplier.
Note:
1. The minimum wall thickness anywhere in the Weld-O-let shall be in line with thickness for various
schedule requirements and shall comply the requirement of hydro test value as specified in the
clause 4.0 of the specification.

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

IOCL–MECH–MAT SPEC Page 89 of 216

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

CHAPTER – 15
THREADED O RING FITTING

1. SCOPE

This Technical Specification establishes the basic requirements for the design, manufacture, testing
and supply of Thread-O-Ring (TOR) fittings required for carrying out Hot tapping activity in pipeline
carrying Liquid Hydrocarbons.

2. DESIGN

2.1. Thread-O-Ring (TOR) fitting consists of a cap, plug, o-ring & nipple (as depicted below). It should
be suitable to use with hand tapping machine used for tapping a liquid hydrocarbon pipeline
through it.

2.2. Nipple:
2.2.1. Material: ASME A-333 Gr. 6 or ASTM A-106 Grade B. Hot finished normalized, tempered carbon
steel seamless pipe.
2.2.2. Dimensions: Size: - 2” Sch./ Length 102 mm / OD: 61 mm / W.T.: 11.00 mm
2.2.3. Thread: 2” NPT internal as well as external.

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

2.3. Plug:
2.3.1. Material: ASTM B-16 Brass.
2.3.2. Thread: 1.5” NPT external to fit on internal threads of nipple.
2.3.3. Plug to be supplied with O-ring suitable for proper sealing.

2.4. O-ring:
2.4.1. Material: Buna-N (Standard).
2.4.2. Dimension: To fit on external groove provided in plug for sealing of nipple.

2.5. Cap:
2.5.1. Material: ASTM A-105.
2.5.2. Thread: 2” NPT internal to fit on nipple.

3. Documentation:
3.1. After placement of order following documents to be submitted
3.1.1. Dimensional drawing of material (cap, plug, o-ring & nipple).
3.1.2. Inspection & test plan to be submitted
3.2. After inspection for dispatch clearance following documents to be submitted
3.2.1. Material Test Certificates (cap, plug, o-ring & nipple).
3.2.2. Hydrostatic Pressure Test reports
3.2.3. Visual & dimension check report.
3.2.4. Third Party Inspection reports.

4. Third Party Inspection:

4.1. A third party inspection agency (to be arranged by contractor) will be lined up for inspection at
supplier/ manufacturer’s works. The supplier/ manufacturer shall provide space to the TPI for
inspection. However, all the testing shall be in the scope of supplier only.
4.2. TPI shall review the Material Test Certificates (MTC) for cap, plug, o-ring & nipple, which shall be
as per this technical specification.
4.3. TPI shall review & witness the hydrostatic pressure test report for TOR fitting assembly.
4.4. TPI shall check all the dimensions, end connections, threading for cap, plug, o-ring & nipple in line
with this technical specification.
4.5. Visual inspection of the TOR fittings.
4.6. After completion of all testing & inspection, the inspection reports including above documents to
be submitted for review and acceptance by IOCL for issuance of dispatch clearance.

5. Packing:

5.1. All openings shall be covered against dirt and foreign material and the surface shall be protected
from corrosion.

5.2. Packing shall be suitable to the tropical weather, handling and transportation.

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

CHAPTER-16
TECHNICAL SPECIFICATION FOR SPIRAL WOUND METALLIC GASKET

Clause Area Description Requirements/Remarks

1.0 Scope Design, manufacture, testing, inspection and Rating and Quantity as per
supply of spiral wound metallic gaskets for specific requirement of the
raised face carbon steel forged flanges. project
2.0 Service Liquid Hydrocarbon/LPG/Gas/Water

3.0 Design and Codes Size of Gasket - Suitable for WNRF/ The gasket configuration
BLRF/SORF (up to 24”) manufactured to – shall be as per ASME B
 ANSI B 16.5 standard up to 24” size except 16.20 with SS 316L spiral
22” strip + graphite filler
 MSS SP 44/ASME B16.47 Series A for flanges (Grafoil) + SS 316L inner
22” and between 26” – 36” compression ring + Carbon
 ASME B16.47 Series B for sizes more than Steel outer (centering)
36”. rings. Material of Inner
Compression ring shall be
same as Spiral Strip
material

Filler material for spiral

wound gaskets shall not
have any colour or dye.
Colour coding shall be as
per ASME B 16.20
4.0 Material- As per ASME B 16.20 standard
5.0 Testing and i) Dimensional W-10% or minimum 1 By Owner and/ or TPI (third
Inspection Check no. whichever is higher party Inspection).
for each rating and size
2) Physical and Review -100% TPI to be arranged by
Chemical Manufacturer’s Raw CONTRACTOR
properties material test certificate
for filler material and Test reports shall be
spiral material, inner and supplied for all tests of
outer ring for each heat gaskets as per the
as per applicable standards specified
material specification.
3) Compression Review-100%
and Sealability Manufacturer's test
recovery test certificate for
Compression and
Sealability recovery test
for gasket to be
submitted for each size
and rating.

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

Clause Area Description Requirements/Remarks

6.0 Marking & Packing The centering ring of each spiral wound Gaskets of different types
gasket shall be permanently marked with the and sizes shall be placed in
following information separate shipping
- Nominal size containers and each
- Pressure rating container clearly marked
- Winding material mark as “ANSI type 316”. with the size, rating,
- Filler material mark as “Grafoil”. material specification and
- Identification ASME B 16.20 item code
- Temperature
- centering and inner ring metal abbreviation
- flange identification. (ASME B16.5/16.47
A/16.47B/MSS-SP-44)
- Manufacturer’s name and trademark
7.0 Documentation v) With Bid
i) Supply record of similar size and rating. c) Compliance letter from
j) Dimensional drawing indicating material the manufacturer that
grade, design code etc. the gasket shall be
manufactured as per the
furnished specification
vi) After Order, for approval (In 4 sets)
a) Dimensional drawing indicating material b) Testing and inspection
grade, design code etc. plan.
b) Inspection and test plan(ITP)

vii)After Inspection for dispatch clearance (In 4 sets)

1. Inspection report and certification as per
requirement of code /ITP
8.0 Warranty  Vendor to furnish guarantee that supplied  All gaskets shall be free
gaskets shall withstand the hydrostatic of any defects due to
testing at the pressure up to 1.5 times the design, manufacture and
pressure rating specified in the specific material.
requirement.

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 INDIAN OIL CORPORATION LIMITED
PIPELINE DIVISION HEAD OFFICE, NOIDA
TECHNICAL SPECIFICATIONS FOR MECHANICAL SUPPLY ITEMS

SPIRAL WOUND METALLIC GASKET

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