REVISION CONTROL SHEET DOCUMENT TYPE : TECHNICAL SPECIFICATION TITLE : TECHNICAL SPECIFICATION FOR AUSTENITIC STAINLESS STEEL PIPES

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2 REVISION CONTROL SHEET DOCUMENT TYPE : TECHNICAL SPECIFICATION NO. : PC-M-308 TITLE : AUSTENITIC STAINLESS STEEL PIPES REV. NO. & DATE DESCRIPTION OF REVISION PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

3 PAGE NO : 1 of SCOPE This specification establishes the technical requirements for Austenitic Stainless Steel Pipes. These requirements are supplementary to the technical requirements of the applicable material specifications. 2. CONTENTS The requirements of this specification are presented under the following headings: Section Scope 1.0 Contents 2.0 Specification, Codes/Standards 3.0 Material and Technical Requirements 4.0 Examination Procedure 5.0 Acceptance Standards 6.0 Repair of Pipes 7.0 Quality Control (QC) and Quality Assurance (QA) 8.0 Cleaning 9.0 Certification and Identification 10.0 Shipment 11.0 Standard Quality Assurance Plan for Seamless Pipes Standard Quality Assurance Plan for Welded Pipes Standard Quality Assurance Plan for OPRD Pipes Appendix-A Appendix-B Appendix-C

4 PAGE NO : 2 of SPECIFICATIONS,CODES/STANDARDS All specifications, codes/standards listed below shall govern the tendering conditions. The latest revision, as available on the date of tendering shall be applicable. The manufacturer shall indicate the date of issue of the standards he proposes to use at the bidding stage itself. In the event of conflict between the provisions of this specification and the documents listed below this specification shall govern. 3.1 Specifications and codes/standards ASME Section III, Div.1 Subsection NB, NC & ND Section II Part A Section V Section IX ANSI ANSI B ANSI-B 46.1 ASME SA-312/ SA-312 M - Boiler and Pressure Vessel Code. - For Class 1, Class 2 & Class 3 Components - Ferrous Material Specification - Non Destructive Examination - Welding and Brazing Qualification - American National Standards Institute - Stainless Steel Pipe - Surface Texture - Seamless and Welded Austenitic Stainless Steel Pipes SA-358/SA-358 M - Specification for electric fusion welded austenitic chromium nickel alloy steel pipe for high temperature service ASME SA-530/ SA-530 M ASME SA-577/ SA-577 M ASME SA-578/ SA- 578 M ASME SE-94 ASME SE General Requirements for Specialised Carbon and Alloy Steel Pipe. - Specification for Ultrasonic Angle Beam Examination of Steel Plates. - Specification for Straight Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special Applications. - Standard Guide for Radiographic Testing. - Standard Method for Controlling Quality of Radiographic Testing.

5 PAGE NO : 3 of 16 ASME SE 165 ASME SE-213 ASTM A 262 NPCIL Specification No. PP-E-1209 PP-E Standard Test Method for Liquid Penetrant Examination. - Standard Procedure for Ultrasonic Inspection of Metal Pipe & Tubing - Standard Procedure for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steel. - Specification for Liquid Penetrant Examination of Metallic Surfaces. - Specification for Radiographic Examination of Welds. 4.0 MATERIAL & TECHNICAL REQUIREMENTS Technical/inspection requirements stated herein, are in addition to the requirements of basic material specification. Pipes have been classified in three classes namely class 1,2 and 3, generally intended to correspond to class 1,2 and 3 of ASME Section III Div.1. Austenitic stainless steel pipe shall be offered to grades and standards tendered and to the applicable SA material specifications with the following reservations. SA 312 Product offered to ASME SA 312/SA 312 M shall be of `SEAMLESS variety only. SA 358 Product offered to ASME-SA 358 / SA 358 M shall be pipe welded with filler metal only. Pipes welded without filler metal (i.e. Class 4 of SA 358) are NOT acceptable. OPRD pipe are classified as class I of this specification and shall fulfill all the requirements including transverse guided weld bend testing. Delta Ferrite determination, as determined in accordance with ASME Section III Clause 2433 of Subsection NB, NC & ND and shall be within 5 FN to 10 FN. Welding consumables shall be used only after prior approval of the Purchaser. Technical Requirements for the pipes have been grouped into : 4.1 Requirements for Seamless Pipes The requirements for seamless pipe have been summarized in Table-1. These requirements are over and above the basic material specification. In addition, examination of Class 1, Class 2 and Class 3 pipes shall comply with Clause 2550 of ASME-Section III NB, NC & ND respectively.

6 PAGE NO : 4 of Requirements for Pipes Welded with Filler Metal The requirements for pipes welded with filler metal have been summarized in Table-2. These requirements are over and above the basic material specifications. In addition examination of Class 1, Class 2 & Class 3 pipes shall comply with Clause 2560 of ASME-Section-III NB, NC & ND respectively. 5.0 EXAMINATION PROCEDURE For class 1 and 2 pipes, the examination procedure shall be as detailed in this Section. For Class 3 Pipes, examination procedure shall be as per relevant material specification. All procedures shall be submitted by Supplier to Purchaser for approval. 5.1 Radiographic Examination For Welded Pipes : In conformance with ASME Section V Article 2 and as modified by Clause 5111 of ASME Section-III NB, NC & ND for Class 1, Class 2 and Class 3 pipes respectively and NPCIL s specification no. PP-E Ultrasonic Examination For Plates : All plates 51 mm nominal thickness and less used for piping shall be examined by the angle beam ultrasonic method in accordance with ASME Section-III NB For Pipes : Pipes shall be examined by the ultrasonic method in accordance with ASME Section-III NB Liquid Penetrant Examination In conformance with ASME Section V, Article 6; which is generally in accordance with ASME-SE-165 `Method for liquid penetrant inspection and NPCIL s specification no. PP-E The penetrant material shall be analysed for sulphur content and total halogens. The sulphur content and total halogens shall not each exceed 25 ppm. Inspection procedure and reagents used shall be subject to approval of the Purchaser. 5.4 Delta Ferrite Examination Delta Ferrite No. (FN) to be determined in accordance with Clause 2433 of ASME-Section-III NB, NC & ND for weld metal analysis.

7 PAGE NO : 5 of Intergranular Corrosion Test In conformance with ASTM-A 262, Practice A/E. 6.0 ACCEPTANCE STANDARDS The acceptance standards shall be as detailed in this section as well as per relevant material specification. 6.1 For Radiographic Examination Pipes welded with filler metal : Welds that are shown by radiography to have any of the following types of discontinuities are unacceptable as per Clause 2553(c) of ASME Section-III NB & NC for Class 1 and Class 2/Class 3 pipes. i) Any type of cracks or zone of incomplete fusion or penetration. ii) iii) iv) Any other elongated indication which has a length greater than (a) 6 mm for T upto 19 mm inclusive, (b) 1/3 T for T 19 mm to 57 mm inclusive, where T is the thickness of the weld. Any group of aligned indications having an aggregate length greater than T in a length of 12 T, unless the minimum distance between successive indications is 6 L where L is the length of the longest imperfection in the group. Rounded indications in excesses of that shown as acceptable in Appendix VI of ASME Section III, Div For Ultrasonic Examination a) Seamless Pipes and Welded Pipes with Filler Metal Pipes with defects that produce indications in excess of indications produced by the standard defects in the reference specimen are unacceptable as per ASME Section-III NB 2553 (c). b) Plates for Welded Pipes : Material which shows one or more imperfections which produce indication exceeding in amplitude the indication from the calibration notch is unacceptable unless additional exploration by straight beam method

8 PAGE NO : 6 of 16 shows the imperfections are laminar in nature and are acceptable in accordance with ASME Section-III NB (b). 6.3 For Liquid Penetrant Examination Following relevant indications are not acceptable as per Clause (b) of ASME-Section-III NB, NC & ND. a) Any linear indication greater than 1.6 mm long for materials less than 16 mm thick, greater than 3.2 mm long for materials from 16 mm thick upto 51 mm thick and 4.8 mm long for material 51 mm thick and greater. b) Rounded indication with dimensions greater than 3.2 mm for thickness less than 16 mm and greater than 4.8 mm for thickness 16 mm and greater. c) Four or more relevant indications in a line separated by 1.6 mm or less edge to edge. d) Ten or more relevant indications in any 3871 mm 2 of area whose major dimension is no more than 152 mm with dimensions taken in the most unfavorable location in relation to the indication being evaluated. 6.4 For Delta Ferrite Examination Delta Ferrite No. FN, shall be 5 FN to 10 FN. 6.5 For Intergranular Corrosion Test As per ASTM A 262 Practice A/E. 7.0 REPAIR OF PIPES 7.1 Repair by Machining or Grinding All defects revealed during non destructive examination in the base material or in the weld metal may be removed by grinding or machining provided that the following requirements are met. a) The depression after defect elimination shall be blended uniformly into the surrounding surfaces. b) After defect elimination, the area shall be re-examined by the method which originally disclosed the defect to assure that the defect has been removed.

9 PAGE NO : 7 of 16 c) The elimination of the defect should not reduce the wall thickness of the pipe below 87.5 present of nominal wall thickness. 7.2 Repair by Welding If the elimination of the defect reduces the wall thickness below the minimum specified wall thickness, then the pipes may be repaired by welding with prior approval of Purchaser. The depth of the repair cavity does not exceed 1/3 the nominal wall thickness of pipe and the following requirements are met as per Clause 2539 of ASME-Section-III NB, NC and ND. a) The defect shall be removed by suitable mechanical or thermal cutting or gauging methods and the cavity prepared for repair. b) The welding procedure and welders or welding operators shall be qualified in accordance with Clause 4000 of ASME-Section-III NB, NC and ND and Sec. IX. c) After repair, the surface shall be uniformly blended into surrounding surface. d) The repaired area shall be examined by the magnetic particle method or by the liquid penetrant method. In addition when the depth of the repair cavity exceeds 10 mm or 10 percent of the wall thickness whichever is smaller, the repair weld shall be radiographed after repair. e) A report shall be made to the Purchaser describing the extent and location of each repair. 8.0 QUALITY CONTROL (QC) AND QUALITY ASSURANCE (QA) 8.1 All QC and QA procedures shall confirm to ASME Section III, Div.1, Sub-section NCA Quality Assurance Plan (QAP) shall be in line with that given in Appendix-A, B and C and same shall be submitted for Purchaser s approval. 9.0 CLEANING All inside and outside surfaces shall be degreased and then flushed with clean water. The degreasing agent shall not contain halogens. Final

10 PAGE NO : 8 of 16 cleaning shall be performed with a hot water wash using a detergent followed by a hot water rinse. The pipes shall be pickled from scale and shall be passivated. For pickling and passivation, it is recommended to use nitric acid. In case, Hydrofluoric acid is required to be used, specific approval of NPCIL shall be required CERTIFICATION & IDENTIFICATION Heat Nos. and Heat Code should be marked to facilitate traceability of reports of all tests and examinations performed on the material. Each piece of pipe shall be marked in accordance with the appropriate ASME Specification. The marking shall be imprinted by electric etching or other approved and permanent method of identification. Metal stamps shall not be used. Paints if used shall be free from halogens and sulphur. In addition to the above, each length of pipe shall be painted as below : Class 1 : Blue Stripe Class 2 : Red Stripe Class 3 : Grey Stripe 11.0 SHIPMENT The supplier shall be responsible for preparing, preserving and packing the materials supplied to this specification to protect them against corrosion and damage of any kind during shipment to the destination and also during storage at Site. All pipes shall be clean and dry and both ends shall be blanked, plugged, capped or otherwise suitably sealed to prevent the ingress of moisture and particulate matter. All boxes shall be designed to include adequate cushioning, bracing etc. with provisions of lifting. The package shall be clearly and legibly marked with following information. Purchase Order No.. Brief Description of the Content. The boxes shall contain a packing slip and a copy of the authorization in form of a shipping release from Purchaser s quality surveillance respresentative.

11 PAGE NO : 9 of 16 The material manufacturer shall provide a certified material test report. The certified material test report shall include the actual test results of all required chemical analysis, mechanical tests etc. Report shall also include the special requirements which have been met.

12 PAGE NO : 10 of 16 TABLE-1 ADDITIONAL REQUIREMENTS FOR SEAMLESS PIPES Class Ultrasonic Examination Intergranular Corrosion Test Class-1 100% on each pipe On one sample for each size per heat per heat treatment batch Class-2 Not required On one sample per heat treatment batch Class-3 Not required On one sample per heat treatment batch Product Analysis On one sample from each size of each heat On one sample on 10% of lengths from each heat (max. no. of sizes to be covered) Required. TABLE-2 ADDITIONAL REQUIREMENTS FOR PIPES WELDED WITH FILLER METAL Class Class-1 Ultrasonic Examination 100% on pipe OR 100% on plate used for making pipe Radiographic Examination 100% on weld seam Class-2 Not required 100 % on weld seam Class-3 Not required Spot Radiography on weld seam Liquid Penetrant Examination 100 % on root and final pass 100% on root and final pass 100% on root and final pass Intergranular Corrosion Test On one sample for each size per heat per heat treatment batch On one sample per heat treatment batch On one sample per heat treatment batch Product Analysis One sample from each size of each heat One sample on 10% of lengths or max. 10 lengths from each heat (max.no. of sizes to be covered) Required Delta Ferritic Determination Test One sample per production batch One sample per production batch One sample per production batch.

13 PAGE NO : 11 of 16 APPENDIX A: STANDARD QUALITY ASSURANCE PLAN FOR SEAMLESS PIPES Sl. No OPERATION NPC S INSPECTION SAMPLE INSPECTION A B C 1. Heat Analysis One sample from each Checking of manufacturer s test certificates. 2. Heat Treatment Each Pipe Checking of time temperature chart etc. 3. Product Analysis One sample from each Checking of manufacturer s test certificates. 4. Mechanical Tests YS, UTS, One sample from each As per material specification % Elongation 5. Intergranular Corrosion Test One sample from each per HT batch 6. Ultrasonic Test All class 1 pipes shall be tested in both transverse and longitudinal direction As per ASTM A 262 Practice A/E. As per Clause 5.2 of this specification 7. Checking for seamless One sample from each Macro etch test. 8. Liquid Penetrant Test on reworked areas 100% on repaired area of pipe. As per Clause 5.3 of this specification. 9. Hydrostatic Test Each pipe shall be tested Witness test operation at random 10. Pickling & Passivation Each Pipe As per clause 9 of this specification. 11. Surface inperfections All Visual 12. Dimensional check Each pipe shall be Witness the test operation checked 13. End Preparation and squareness All Random 14. Repair of Defect All repaired pipes Witness 15. Visual Inspection Test 10% random for each size 16. Marking & color coding Each pipe shall be marked 17. Checking of test certificates All certificates must be checked 18. Packing All pipes shall be suitably packed and ends protected. 19. Issue of third party inspection certificate and shipping release note A = Checking of Test Report B = Witnessing of Operation C = Hold Point Random checking of inside and outside diameter of pipes. Mill scale, degreased condition and dryness. Random checking Checking Checking

14 PAGE NO : 12 of 16 APPENDIX B: STANDARD QUALITY ASSURANCE PLAN FOR WELDED PIPES Sl. No OPERATION NPC S INSPECTION SAMPLE INSPECTION A B C 1. Heat Analysis One sample from each Checking of manufacturer s test certificates. 2. Heat Treatment Each Pipe Checking of time temperature chart etc. 3. Product Analysis One sample from each Checking of manufacturer s test 4. Welders Qualification, Procedure Qualification, Consumable Qualification ASME II C As per ASME Section IX certificates. As per ASME Section IX. Consumable qualification is required for class-i only. 5. Plate/Coil cutting of edge preparation Random Witnessing 6. Rolling (post bending) Template Checking Random Witnessing 7. Set up (Tack weld) Rootgap Alignment Random Witnessing 8. Mechanical Tests YS, UTS, % Elongation One sample from each As per material specification 9. Delta Ferrite analysis for welded pipes Table-2 As per Table Intergranular Corrosion Test One sample from each per HT batch As per ASTM A 262 Practice A/E % Ultrasonic Test on pipe or plate All class 1 pipes shall used for making pipe be tested in both transverse and longitudinal direction 12. Hydrostatic Test Each pipe shall be tested 13. Radiographic Test As per Table 2 of this specification 14. Liquid Penetrant Test on reworked areas/ 100% on root and final weld joints. pass of pipe weld/100% As per Clause 5.2 of this specification Witness test operation at random As per Clause 5.1 of this specification. As per Clause 5.3 of this specification. on repaired areas. 15. Repair of defects All repaired pipes As per ASME Code. 16. End Preparation and squareness All pipes As per ASME Code. 17. Pickling & Passivation Each Pipe As per clause 9 of this specification. 18. Dimensional checks. Each pipe shall be checked 19. Visual Inspection Test 10% random for each size 20. Marking & color coding Each pipe shall be marked 21. Checking of test certificates All certificates must be checked 22. Packing All pipes shall be suitably packed and ends protected. 23. Issue of third party inspection certificate and shipping release note A = Checking of Test Report B = Witnessing of Operation C = Hold Point Witness the test operation Random checking of inside and outside diameter of pipes. Mill scale, degreased condition and dryness. Random checking Checking Checking

15 PAGE NO : 13 of 16 APPENDIX C: STANDARD QUALITY ASSURANCE PLAN FOR WELDED PIPES FOR OPRD SYSTEM Sl. No. OPERATION NPC S INSPECTION SAMPLE INSPECTION A B C 1. Heat Analysis One sample from each Checking of manufacturer s test certificates. 2. Heat Treatment Each Pipe Checking of time temperature chart etc. 3. Product Analysis One sample from each Checking of manufacturer s test 4. Welders Qualification, Procedure Qualification, Consumable Qualification ASME II C As per ASME Section IX certificates. As per ASME Section IX, Consumable qualification is required for class-1 only. 5. Plate/Coil cutting of edge preparation Random Witnessing 6. Rolling (post bending) Template Checking Random Witnessing 7. Set up (Tack weld) Rootgap Alignment Random Witnessing 8. Mechanical Tests YS, UTS, One sample from each As per material specification % Elongation 9. Guided Weld Bend Test Material Specification As per material specification 10. Delta Ferrite analysis for welded pipes Table-2, class 1 As per Table-2 Class 1 requirements. requirements. 11. Intergranular Corrosion Test One sample from each per HT batch As per ASTM A 262 Practice A/E % Ultrasonic Test on pipe or plate All class 1 pipes shall used for making pipe be tested in both transverse and longitudinal direction 13. Hydrostatic Test Each pipe shall be tested 14. Radiographic Test As per class 1 requirement of Table 2 of this specification As per Clause 5.2 of this specification Witness test operation at random As per Clause 5.1 of this specification. 15. Repair of defects All repaired pipes As per ASME Code. 16. Liquid Penetrant Test on reworked areas/ 100% on root and final As per Clause 5.3 of this specification. weld joints. pass of pipe weld / 100% on repaired area. 17. End Preparation and squareness All pipes As per ASME Code. 18. Pickling & Passivation Each Pipe As per clause 9 of this specification. 19. Dimensional check. Each pipe shall be Witness the test operation checked 20. Visual Inspection Test 10% random for each Random checking of inside and outside size diameter of pipes. Mill scale, degreased 21. Marking & color coding Each pipe shall be marked 22. Checking of test certificates All certificates must be checked 23. Packing All pipes shall be suitably packed and ends protected. 24. Issue of third party inspection certificate and shipping release note A = Checking of Test Report B = Witnessing of Operation C = Hold Point condition and dryness. Random checking Checking Checking

16 PAGE NO : 14 of 16 Notes:- 1. The lot number, heat number, coil number, mill test certificate number and its quantity shall be identified at raw material stage for ladle analysis, check test analysis and for product analysis. Random samples for various testing as required by QAP and code / material specification shall be drawn by QA representative and stamped. 2. Original test certificate of raw materials shall be required for review at the time of First Stage Inspection. 3. The material test laboratory shall be approved by NPCIL. 4. The heat treatment furnaces shall be in good condition and shall have temperature recorder and checked for calibration by NPCIL QA / Third party QA and the related certificate shall be submitted. The validity of calibration shall not be more than 6 months. The agency for heat treatment shall be approved by NPCIL. 5. The loading and unloading of items in the furnace may be witnessed by NPCIL QA / Third party representative. Heat treatment chart shall be submitted for review. 6. All items shall be identified to avoid mixing and proper identification during inspection and examination. 7. Vendor shall carry out 100 % dimensional check on all pipes. 8. All items shall be visually examined for any imperfections and defects. 9. All NDE examinations (UTE, LPE, Eddy current testing, radiography, etc.) shall be carried out as per NPCIL approved procedures. The selection of appropriate technique(s) / method(s) shall be approved by NPCIL. Work shall be taken up after approval of procedures. 10. NPCIL QA representative / Third party shall witness 100 % UT examination and 100 % liquid penetrant examination. 11. On removal of surface defects after LPE (particularly on class-i components) thickness checking shall be carried out by ultrasonic gauging. The UT instrument shall have reference master thickness gauge of required contour and capable of measuring the least count accuracy as required.

17 PAGE NO : 15 of Suitable Go - NO GO gauges and fixtures may be used for dimensional inspection. 13. Material traceability report (indicating material, size, item description, lot no., heat no., NDE report nos., check test certificate, vendor s final certificate no., etc.) shall be submitted. 14. Colour coding, bin card and proper tagging along with entry in proper registers shall be maintained to identify the location of material at any point during manufacturing and to avoid mixing of materials. 15. All items shall be stamped by vendor s name / monogram apart from item description, size, serial no., class, material code, rating, grade, etc. and meeting NPCIL specification. The pipes confirming to NPCIL specification shall be colour coded as mentioned in specification. 16. The history docket containing all test certificates, inspection reports, approved procedures, QAPs along with shipping release shall be submitted in properly bound document along with soft copy on CD. 17. In case, manufacturer intends to use On line UTE or eddy current examination or hydro test facility, the required system details shall be submitted for approval for on line witnessing and extent of witnessing. 18. Calibrated instruments shall be used for inspection, examination and testing. 19. Non destructive examinations shall be carried out by personnel qualified to level-1 of ASNT/ISNT and evaluated by ASNT/ ISNT level-ii. 20. The portion at the end of pipe which is not examined by Ultrasonic Examination is to be discarded. 21. The visual examination and dimensional check shall cover outer diameter, wall thickness, workmanship, root face, end beveling, end squareness, outer and inner surface finish, out of roundness, straightness, dents on inside / outside surfaces, length, weight, marking, color coding, stamping, stenciling, processing / rolling marks on internal surface, etc. 22. After repair by grinding on parent material up to minimum wall thickness, the repaired area should be blended smoothly to the surrounding surface.

18 PAGE NO : 16 of Check and ensure consistency and repeatability of detection in ultrasonic examination. 24. QA representative shall stamp the inspected items. 25. Vendor shall submit guarantee certificate.