Annexure-1

1. SCOPE OF SUPPLY:

Detailed engineering, preparation of isometrics, supply of SI pipeline segments with

free- issue instruments, erection with free- issue flow components and commissioning

of Super Insulated pipelines for Liquid Oxygen and Liquid Nitrogen service for stage

servicing at Semi Cryogenic Integrated Engine Test facility (SIET), ISRO Propulsion

Complex Mahendragiri, Tamil Nadu conforming to the specifications given in this

document.

Brief description of SIET facility:

Structural and Mechanical Systems (SMS)

It comprises Test Stand Structures, Flame Deflectors and Material Handling Systems.

Test stand structure is configured with twin bays namely, Stage Bay and Engine Bay.

Loading frames and Super Structure are the two major elements of test stand structure.

Loading frame is the main load carrying steel structure used for holding engine / stage

whereas Super Structure is a steel truss structure designed to house loading frames and other

essential ground systems needed in test stand. Super structure has platforms at 16 m, 20 m, 24

m, 28 m, 32 m & 44 m levels of stage bay and at 16 m, 20 m & 24 m levels of Engine bay for

supporting essential systems like fluid system, safety system, electrical system,

instrumentation system, etc.

Material Handling Systems comprise Electric Overhead Travelling (EOT) cranes, Moving

Platforms and Passenger cum goods lift. EOT cranes are provided in each bay for handling

engine and Turbo Pump whereas Moving Platforms are provided in each bay for assisting

working personnel involved in test article preparation activities. A Passenger cum goods lift

is provided beside Turbo Pump bay to facilitate movement of working personnel and goods

from ground level to platforms at different levels of super structure.

Fluids Servicing Systems

The Fluids Servicing System (FSS) is intended to supply propellants and service

fluids to the test articles and the associated facility systems. It is divided into Propellants

servicing system and Service fluids system. Propellants servicing system includes Isrosene

system and LOX system whereas Service fluids system includes GN2 system, GHe system,

LN2 system and Water system.

Isrosene run tanks and its associated systems are located at one side of test stand whereas

LOX run tanks and its associated systems are located at other side of the test stand. Both

LOX & ISROSENE systems are separated by a distance of approximately 120 m from each

other. Proper Dike walls are planned around Isrosene and LOX tanks to contain spillage.

Sufficient space is provided in the paved area for easy movement, maneouvering and parking

of the tankers and other material handling equipments such as cranes, forklifts etc. Stage

umbilicals will be installed at approx. 16m elevation in platform. Hence, SI pipelines (under the

scope of bidder/supplier) have to be taken up to 16m level platform. Bidder shall make a note of

this.

GEOGRAPHICAL LOCATION AND CLIMATIC CONDITION

Geographical Location of Mahendragiri

Mahendragiri is situated in Tirunelveli District, Tamil Nadu State, India. The nearest

major towns are Nagercoil, which is 25 km southward and Valliyoor, which is 15km

northward. IPRC, Mahendragiri is aside of Kanyakumari – Madurai National Highway

(NH7) at a distance of 25km Northward from Kanyakumari. The Major railway station

is at Nagercoil. The nearest International airport is at Thiruvananthapuram, which is 90

km away in South West direction. The nearest sea port is at Thoothukudi, which is 100

km away in North East direction. The nearest major sea port is at Chennai, which is

650 km Northward.

Location of SIET in Mahendragiri

Site for SIET is identified on a plain ground at an elevation of 144 m above Mean Sea

Level in the North West region of IPRC, Mahendragiri. The site is leveled and provided

with an approach road of width 5.5m having 1 m berms on either side.

Climatic Condition

The climatic condition at Mahendragiri is tropical and windy with gusts. Normal

monsoon period is June-July and October - November. The climatological data of

Mahendragiri is as follows:

Rainfall

Maximum daily rainfall : 50 mm

Maximum monthly rainfall : 120 mm

Average annual rainfall : 550 mm

Temperature

Maximum temperature in shade : 311 K (38o C)

Minimum temperature : 293 K (20o C)

Humidity

Maximum relative humidity : 80 %

Minimum relative humidity : 25 %

Type of climate : Tropical

(A) SUPER-INSULATED PIPE-LINES:

Type

Double wall pipelines with multi-layer insulation like

combination of Glass paper (Lydall) & Aluminum foil with

vacuum insulation compatible for oxygen service. Aluminized

mylar shall not be used for super insulation.

Size, schedule number

and MAWP

As per P&IDs & BOM given in Table 1 for inner pipe. The

size of outer pipe shall be specified by the Supplier; The outer

pipe shall be designed for 0.5 MPa (g) external overpressure

with full vacuum inside.

Length

Tentative lengths of pipelines are given in table 1. However,

actual quantity shall be estimated based on the detailed

engineering and preparation of isometrics to be done by the

Supplier. Changes in lengths of the SI circuits from those

given in table 1, due to detail engineering, should not have

any commercial implications whatsoever. The bidder shall

suitably consider this aspect while submitting the quote.

Material and

specifications for inner

and outer pipes

Material: ASTM A 312 TP 304L/316L / 321 or equivalent

Dimensional standard: ASME B 36.19

All inner pipes shall be of seamless construction

irrespective of size.

For the outer jacket pipes, Seamless pipes shall be

selected for straight lengths. Other outer jackets may be of

seam-welded type.

Bellows compensators: The thermal compensation of the inner pipes upon chill-down

shall be provided by bellows. Their material of construction shall be austenitic stainless

steel grade 321/ 316Ti/ Hastealloy C 276/ Inconel, etc. The bellows shall be provided with

stainless steel (SS 304L) sleeves both inside (to reduce fluid frictional pressure drop) and

outside (to provide axial guide). The bellows in the inner line shall be provided with

stopper arrangement with SS fasteners to prevent it from expanding axially more than the

stipulated value. Ferrite number for bellows shall be ≤ 8.

Permissible leakage rate 1E–09 Pa-m

3/s, from atmosphere to vacuum jacket and from

inner pipe to vacuum jacket.

Individual segment & it’s Outer Jacket of SI pipe lines Overall SI pipeline shall be divided in to individual segments. Each segment of SI pipelines

shall be of suitable length and provided with Vacuum valves and suitable safety device with

resealing feature. The exact segment length & Number of segments will be decided based on

straight run/ components etc and will be finalized during detail engineering. The segments

which can be fabricated in full at the factory shall be done at the Supplier’s site / factory

itself and rest of the segments will be partly fabricated at Supplier’s site and completed in

full at site. All the pre-fabricated segments shall be erected, installed & acceptance tested at

Department’s site.

In the fabrication of every segment, after the fabrication of the core pipe, the multi layer

insulation materials shall be wrapped, spacers & suitable adsorbents placed at appropriate

locations and the jacket pipe fabricated. The manual vacuum valves and safety device shall

be welded suitably in every segment of the jacket. After leak test, the jacket shall be

evacuated with proper baking (by heating the outside surface of the jacket by electrical heater

tapes and by passing hot dry Air through the core pipe/vessel). After achieving stabilized

vacuum pressure, the jacket shall be sealed.

Configuration of spacer (to support inner pipe line within outer pipe line) & its material of

construction shall be provided by the Supplier during detail engineering review. Also the

location of fixed stoppers at discrete points in SI lines shall be finalized during DER.

Details of MLI materials, its layer density, properties like thermal conductivity, etc, shall be

provided by the Supplier during detail engineering.

Manual Vacuum valve : Every segment of the vacuum jacket of the SI pipe-lines shall be provided with a welded

manual vacuum valve size DN25/ DN40 (size to be decided during Detail Engineering)

for evacuation and another valve of size DN15 for vacuum measurement with brief

specifications given below.

Specifications:

Leak rate (Body, seat) < 1 x 10-9

Pa- m3/s

Type Bellow sealed manual valve

Pressure range 1 x 10-9

to 100 kPa ( absolute)

Service life ≥10000 cycles

Operating temperature 250 to 350 K

Materials of Construction

Body ASTM A182F 304 L/ 316L / 321

Bellows SS 321/316 Ti /Hastalloy /Inconel

Seat To be suitably selected and specified

by the bidder during DER

End connection DN 50 ISO KF for DN50 size

DN25 ISO KF for DN25 size &

DN15 ISO KF for DN15 size valve

15 KF with suitable end fittings like

centering ring, O rings, C clamps, SS

fasteners and mating flange

Vacuum gauges: Every individual segment of the vacuum jacket of the SI pipe-

lines shall be interconnected at site to form minimum common

segments to be limited by straight run/components which will be

finalized during detail engineering and those common segments shall be

fitted, by welding, with a 15 NB pipe line with 15 NB vacuum valve with 15 NB

KF end connector. Gauge heads shall be provided in those common segments.

The gauge head shall be with 15 NB KF. The gauge head shall be of

Pirani/Thermal conductivity type with a measurement range of 1E-01 kPa to

1E-05 kPa and an accuracy of ± 15% of the displayed value. Individual

cabling shall be laid by the Supplier between the gauge heads and the display

panel placed at the vacuum pump room (refer attached layout)) so that any

vacuum measurement can be read out from the vacuum pump room.

Maximum allowable heat in-leak rate: The maximum allowable heat in-leak rate

(referred to the condition of LN2 in inner pipe for straight segments excluding

end fittings) shall be as follows:

0.75 W/m for DN 25

1.0 W/m for DN 50

1.5 W/m for DN 100

2.0 W/m for DN 150

The SI pipe-lines shall, as far as possible, be fabricated at the Supplier’s factory

in such segments that they can be transported by sea and/or road. The jackets of

the fabricated segments shall be evacuated with proper baking (to facilitate de-

gassing through heating by wrapping flexible electrical tape heaters over the

jacket pipe and passing hot Air through the inner pipe) and stabilized vacuum

pressure attained at the Supplier’s factory itself.

1.0 Tests

a. Tests to be carried out for raw materials & bought out components required

for fabrication at Supplier’s site and Department’s site. Applicable for inner and

outer pipelines and also for pipes used as tappings for safety devices/vent valves/

pressure transmitters

A detailed Quality Assurance Plan shall be submitted during Detailed

Engineering Review. Preliminary QAP with minimum requirements to be

complied with is given in table -2.

1. Visual examination: All pipes shall be visually examined for workmen-like finish

against any scratches, dents and surface irregularities, etc.

2. Dimensional check: All the pipes shall be subjected to dimensional check.

3. Chemical analysis: One specimen from each heat shall be taken by TPIA and

subject to detailed chemical analysis as per ASTM A 751. This is in addition to

Manufacturer’s test certificate.

4. Mechanical tests: One specimen from each lot shall be taken by TPIA and subject to

tests for mechanical properties as per ASTM A 370.

5. Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with

Water as per ASTM A 999 at 1.5 times MAWP

6. Low temperature impact test at 77K: One sample per heat for those pipes

which are used for LOX/ LN2 service.

7. Ultra-sonic test: All the pipes of size ≥ DN 25 shall be subject to Ultra-sonic test

(100 %) by pulse echo or appropriate method as per ASTM E 213.

8. Eddy current test: All the pipes size ≤ DN 20 shall be subjected to Eddy

current/ultrasonic test as per ASTM E 426.

9. Flattening test: Pieces of pipes of length 63.5 mm (2.5”) cut from the ends of 5 % of

pipe lengths per lot shall be subjected to flattening test as per ASTM A 530 in 2 steps

to prove ductility and soundness.

10. Inter-granular corrosion test: One specimen per lot shall be subjected to inter-

granular corrosion test as per ASTM A 262 (practice E/A).

11. Etching Test: Etching test shall be made on a cross section from one end or both

ends of each pipe and shall show sound, reasonably uniform material free of

injurious laminations, cracks, and similar objectionable defects as per ASTM E

340.

12. Cleanliness: All the p ipes/pipe fittings shall be cleaned free of scale. The

pipelines shall be cleaned as per the following procedure. Additionally, all the

pipelines that are pre-fabricated at supplier’s/sub-contractor’s premises shall

be cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93 prior

to dispatch to Department’s site.

a. Mechanical cleaning: All the metallic surfaces with scales and newly welded

surfaces shall be cleaned by scrubbing with SS wire brush. The loose particles

generated by mechanical cleaning shall be removed by blowing with

compressed air, sucking or washing with water.

b. De-greasing: The oil and grease adherent to the surface shall be removed

by vapour phase de-greasing with Tri-Chloro Ethylene (TCE) or Per-Chloro

Ethylene (PCE), followed by liquid phase de-greasing with TCE or PCE. After

degreasing, the lines should be purged with GN2.

c. Pickling: In order to remove rusts and scales, the surfaces shall be washed

with water and pickled with a solution containing Hydro-fluoric acid (HF) and

Nitric acid (HNO3). The composition of the pickling solution and duration are

to be adjusted after trial test on a sample piece to remove uniformly less than 25

m thick material. Mostly, the composition is as follows:

HF : 5 % by mass

HNO3 : 15 to 20 % by mass

Water : Remainder

This is followed by rinsing with

water.

d. Passivation: All the inner surface of the pipe lines and external surface of

weld joints shall be passivated with a solution of the following composition:

HNO3 : 25 % by volume

Water : Remainder

Duration : 2 h

This is followed by rinsing with De-mineralised water and checking the pH

value to ensure the complete removal of acid. DM water required for pickling

and passivation will be provided by Department.

e. The external surface of the weld joints shall be pickled and passivated by

hand- mopping.

f. Preservation: The volume inside pipe lines shall be completely dried with GN2

or dry air and all open ends shall be blanked off during transportation, storage

and handling.

12. Marking: The pipes shall be marked as per ASTM A 700.

b. Applicable for bellows on inner and outer pipeline:

13. Bellows cyclic life test: One per batch of same size & type used in the SI pipelines

shall be subjected to cyclic life test or type test certificate for the specific model

number shall be provided. Bellows cyclic life shall be more than 5,000 cycles.

14. Pressure test for bellows: All the bellows shall be subjected to pneumatic test

with dry air or gaseous nitrogen at 1.1 times MAWP of the SI pipeline.

15. Relief pressure test for vacuum safety device:

One per lot of the same size shall be relief pressure tested as per relevant standards.

16. Welding joint test for bellows (wherever applicable)

a. All butt welding joints in the bellows shall be subjected to radiographic test to

2% equivalent sensitivity as per section IX ASME.

b. All welding joints shall be subjected to dye penetrant test.

c. Ferrite content test shall be conducted for the bellows and its welding. Ferrite

content measurement by magnetic flux/other suitable method is preferable

17. Cleanliness: All the interior flow surfaces of the bellows assembly shall be

degreased and cleaned to Oxygen Service Standards as per ASTM G-93 or CGA G

4.1

c. Tests to be carried out for all the Pre-fabricated segments of SI pipeline at

the manufacturer’s factory.

Welding process:

All the welding both in the inner pipe as well as in the outer vacuum jacket pipe

shall be performed by Gas purged tungsten arc welding (GTAW/TIG) with

gaseous Argon (better than 99.99% purity) purging.

All the weld joints in the fluid circuits shall be of Butt welded type and no Socket

weld type is permitted except in outer pipes of Insulated lines.

All the welding should be done only by qualified welders for both pipelines and

structural works. The welding procedure qualification and welder’s performance

qualification shall be done as per ASME Section IX.

1. Weld joints tests

For inner (core) pipes: All the butt weld joints shall be subjected to DP test at

the root pass as well as at the final pass.

All the butt weld joints shall be subjected to DP test at the root pass & final

pass and 100% radio-graphic test to 2% equivalent sensitivity. All the

radiography films shall be handed over to the Department.

For outer (jacket) pipes: All the weld joints shall be subjected to DP test at

the root pass as well as at the final pass.

For the radiographic tests on the piping segments at Supplier’s works

Department reserves the right to have full access to examine and verify the

radiographic films. All the radiographic films shall be handed over to the

Department. Copies of radio graphics film will be accepted only for weld joints

of equipment fabricated at Supplier’s shop for welding of all butt weld joints

in the pipelines carried out at site, original film shall be submitted.

2. Pressure test: All the inner piping segments fabricated at suppliers’ site shall

be subjected to pneumatic test at 1.1 times MAWP. There shall be no pressure

drop during the hold period. Extra care should be taken for preventing

expansion of bellows while testing.

3. Leak test: The leak tightness of all the segments and the leak rate across inner

pipe as well as outer jacket shall be tested with GHe Mass Spectrometer

Leak Detector (MSLD). The measured leakage rate at different stages shall be

finer than that given below.

i. Inner pipeline and its Individual joints/bellows of inner pipe before

vacuum jacketing

The weld joints in the inner line before providing vacuum jacketing, shall be

leak checked by sniffer probe method using He MSLD by providing a shroud

over the individual weld joints and charging the inner line with 20% GHe +

80% GN2 at its MAWP. Leak tightness shall be as follows

Inner pipe and its weld joints : ≤ 1x 10-9

Pa-m3/s

Bellows : ≤ 1x 10-9

Pa-m3/s

ii. Global leak of each pipeline segment after vacuum jacketing (each

vacuum cavity) by hood technique in vacuum mode:

Atmosphere to vacuum jacket : ≤ 1x 10-9

Pa-m3/s

Inner pipe to vacuum jacket : ≤ 1x 10-9

Pa-m3/s

While global leak testing the inner pipes, the internal volume shall be

charged to its MAWP with a mixture of 80 % GN2 + 20 % Gaseous

Helium and the annular volume between inner pipe and outer pipe be

evacuated and connected to MSLD.

iii. Outer jacket:

While leak testing the outer jackets, the exterior surface of the outer pipe

shall be shrouded by synthetic bag and charged to 0.15 MPa (a) with GHe

and the annular volume between inner pipe and outer pipe be evacuated

and connected to MSLD.

Leak test by detector probe or tracer probe technique is not acceptable for

global leak test.

4. Vacuum stabilisation test:

After evacuation of the jacket of SI pipelines / pressure vessel, the stabilised vacuum

pressure shall be periodically recorded over 1-week period. The permissible rise in

vacuum pressure shall not exceed the value predicted by the specified permissible leak

rate. There shall be no deterioration in vacuum level and it should stabilize at < 1 Pa (at

atmospheric temperature).

5. Cleaning: All the pipelines that are pre-fabricated at Supplier’s premises shall be

cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93 prior to dispatch

to Department’s site

Preservation: The ends shall be blanked off properly during transportation and storage.

The pipe-lines shall be kept pressurised with GN2 or dry Air at ~ 0.15 MPa (a) during

transportation and storage.

Note that collection and safe disposal of all chemical waste generated during execution of

this project outside the Department’s premise is the Supplier’s responsibility.

6. Cold shock test: All the piping segments shall be subjected to cold shock test with

LN2 to observe for any structural defects or sweating/ frosting on the jacket. MSLD

leak test specified in 1.c.3 shall also be carried out.

7. Inspection:

All the bought-out material, works during fabrication at the supplier’s factory and

fabrication & erection at the Department’s site shall be inspected by Third Party

Inspection (TPI) agency. Apart from inspection by TPI agency, the Purchaser‘s

representative(s) shall inspect the system at any stage of fabrication. Inspection

during commissioning activities at site shall be carried out by Department.

The broad scope of inspection shall be generally as follows. However, the

detailed scope of inspection shall be given in the QAP to be provided by the

supplier. Tentative QAP is given in table-2

a. Bought-out Materials

1. Review of the material test certificates.

2. Witnessing/review of tests given in QAP of specification of

individual components

3. Issue of inspection report and release note.

4. Stamping of all items.

b. Fabrication of SI pipe segments at the Supplier’s factory

1. Review and approval of the design calculations and fabrication

drawings.

2. Identification of raw materials and review of the material test

certificates for compliance with the relevant requirements.

3. Witnessing of welding procedure qualification and welder’s

performance qualification tests. If the welder already possesses the

performance qualification certificate, the TPI agency shall review

and authorize the same.

4. Witnessing / review of tests given in specification of these items

5. Review of X-ray films of radio-graphic tests to find out the defects in

the weld joints.

6. Inspection at any stage of fabrication to ensure that the

methodology employed for the fabrication is in compliance with the

requirements of standards/ codes, practices, contract specification

and the approved documents.

7. Witnessing of Hydro/ Pneumatic pressure test, leak test and

cleanliness test .

8. Verification of health check of instruments installed in the SI piping.

9. Issuance of Pre-Delivery Inspection (PDI) certificate and stamping.

c. Fabrication & Erection at Department site

1. Identification of the materials such as pipes, pipe fittings, etc and review of the

test certificates for compliance with the contract specification.

2. Verification of health check of instruments installed in the SI piping.

3. Witnessing of welding procedure qualification and welder’s performance

qualification tests. If the welder already possesses the performance

qualification certificate, the Department will review and authorize the same.

4. Review of X-ray films of radio-graphic tests to find out the defects in the weld

joints.

5. Inspection at any stage of fabrication to ensure that the methodology employed

for the fabrication is in compliance with the requirements of standards/ codes,

practices, contract specification and the approved documents.

6. Witnessing of Hydro/ Pneumatic pressure test, leak test and cleanliness test of

the system during fabrication and erection.

PAINTING

All the SI pipe-lines (over the jacket pipe) shall be painted with identification bands

of 100 mm width at 2 m span based on the colour code scheme as follows:

LOX: Black; LN2: Olive Green

Prior to painting, the surfaces shall be suitably prepared. The painting shall comprise

2 coats of primer (like red oxide) and 2 coats of synthetic enamel. Line number shall

be clearly marked on the outer jackets. The weld joints of the outer jackets shall also

be painted.

TECHNICAL SPECIFICATION OF INSTRUMENTATION

1. The Department on free of cost will issue the required fluid temperature sensor (500 Ω RTD), surface temperature sensor (500 Ω RTD) and flow meters (turbine) to the supplier. The bidder shall install these instruments in the Super Insulated (SI) piping segments of CFTS. Necessary arrangements shall be made in the

SI pipeline to mount the temperature sensors and sensor pigtail shall be properly protected. The vacuum feed through connectors with the matting connectors shall be the scope of Supplier.

2. The supplier shall fabricate all the adapters, interface elements, etc., required for integration of these instruments with SI pipelines. The fabrication drawings of adaptors & interfaces and wiring diagram connecting temperature sensors with vacuum feed through are to be prepared by supplier & shall be submitted to Department for approval before starting fabrication.

3. The specification of Vacuum feed through (VFT) for temperature sensors/flow meters shall be as follows: Specification of 20/10-Pin vacuum feed through connector Make : Insulator seal INC, USA or equivalent

Application : Instrumentation, Low power

Leak tightness Tightness : <1E-8 m3.Pa/s Type : UHV Connector (Air side plug) Type : MIL-DTL-26482 Voltage : 500 VDC Contact amps : 5 A/Contact AWG of contacts : 18/20 No. of contacts : 10/20-Pins

Material Body : SS 304 Temperature range :-125 to +55˚C Contact type : Crimp type, gold plated Insulator :Alumina ceramic

Socket Type : MIL-DTL-26482 Voltage :500 VDC No. of contacts :10/20-Pins Material Body : SS 304 Contacts :Alumel Installation : NW 35 CF Temperature range : -40 to +125˚C Contact vacuum side : Gold plated crimp contact with

Ceramic spacer Crimp tool - Suitable for the Air and Vacuum side crimping shall be provided

Note: Approval for specification & make of the vacuum feed through connectors shall be obtained from Department during detail engineering review (DER).

9. DEPARTMENT’s RESPONSIBILITY

9.1 Basic Engineering Design: The Department has done the Basic Engineering Design of

the Fluid system. Process and Instrumentation Diagrams (PIDs) of super insulated

piping process is given in annexure-C. Equipment layout and tentative piping layout are

attached as annexure-D.

9.2 a) Free-Issue Material (FIM) at Supplier’s factory: The Department will free- issue

the in-line instruments such as surface & fluid temperature sensors and flow meters of

required quantity to the bidder. Bidder shall arrange to collect the materials from

Department’s Stores at Mahendragiri (after submission of Bank Guarantee for

equivalent amount) and transport the materials to their factory. If any free-issued

material is damaged due to the bidder, the value of it shall be recovered by

Department from the bidder. However, replacement for damaged material will be

provided by Department. Details are given in section 8 above. The list of free-issue

materials and the cost details are given in following table

Sl. No.

Item Quantity Unit Price

(Rs.) Total Price

(Rs.)

1 Turbine Flow Meter - LOX - 4"

4 3,80,000.00 15,20,000.00

2 Turbine Flow Meter - LOX - 2"

1 2,80,000.00 2,80,000.00

3 Turbine Flow Meter - LOX - 1"

1 2,20,000.00 2,20,000.00

4 Flow Pre-amplifier 6 55,000.00 3,30,000.00

5 RTD - Probe Type 27 80,000.00 21,60,000.00

6 RTD - Surface Pasting Type

12 2,000.00 24,000.00

Grand total

45,34,000.00

b) Free-Issue Material (FIM) at IPRC site: The Department will free-issue the flow

components of required sizes and quantity as clearly indicated and delineated in the

P&ID enclosed.

9.3 Process Fluids: The Department will provide, free of cost, the process fluids such as,

LOX, LN2, GHe and GN2 for commissioning. The quantity of fluids shall be reviewed

and mutually agreed during detail engineering review.

9.4 Electrical Power Supply: The Department will provide temporary electrical power

supply for onsite construction/ fabrication/ erection activities on chargeable basis at

prevailing rate. Department shall not be responsible for interruptions in power supply from

the power grid. Supplier shall make alternative power supply arrangements like Diesel

Generator as may be required for execution of site works on time.

(B) BIDDER’S/SUPPLIER’S SCOPE

1. The supplier shall carry out detailed engineering of SI lines the with respect to

P&ID enclosed and shall include the following:

a. GA drawings: Overall dimensioned General Arrangement (GA) drawings of pipelines

showing the assembled view along with all accessories shall be provided.

b. The foundation details of the pipelines, indicating the forces and moments acting on the

foundation due to static and dynamic loading of the pipelines shall be provided. The

calculations for arriving at the forces and moments acting on the foundation due to the

aforesaid factors shall also be provided.

c. A detailed Quality Assurance Plan (QAP) shall be provided complying with tentative

QAP given in table 2

d. Design of safety systems including sizing of safety relief valves and rupture disks for

the pipelines shall be carried out by the Supplier and the design calculations and

specifications for the safety systems shall be provided.

e. Static earthing scheme.

f. Pipeline layout: The detailed piping layout (top view) drawings (indicating skeletal

dimensions and to scale) of the pipelines of the process fluid circuits shown in the P&IDs,

vacuum circuits for jacket evacuation of pipelines and impulse tubes of instrumentation

system shall be made while preparing piping layout. The drawings shall be made on latest

AutoCAD-based software and provided in Compact Discs (CDs).

g. Pipeline isometrics: The 3-dimensional isometric drawings of the individual pipeline

segments shall be made. The drawings shall be fully dimensioned to scale and show the

locations of the fittings, flanges, flow components, instruments, bellows compensators,

pipe supports, etc. Each isometric drawing shall contain the detailed Bill of Materials

(BOM). The drawings shall be made on latest AutoCAD-based software and provided in

Compact Discs (CDs).

Flexibility Analysis: All the cryogenic pipelines shall be provided with bellows to

compensate for thermal contraction and other forces upon chill-down. Supports at end

terminals like interfaces with tanks, tanker, test article, etc. shall be configured as rigid

supports and flexibility analysis is to be carried out based on isometrics.

h. Estimation of temperature rise based on the pipeline layout and isometric drawings.

i. Design of joints: The details of the welded joints including drawings shall be provided.

j. Super Insulation: In case of SI circuits, after fabrication of the core pipe, the multi-layer

shall be wrapped, suitable adsorbents placed at appropriate locations and the jacket pipe

fabricated. The vacuum pump-out port cum seal-off valve and vacuum gauge head shall be

welded on the jacket pipe. After leak test, the jacket shall be evacuated with proper baking

(by heating the outside surface of the jacket pipe by electrical heater tapes and by passing

hot Air through the core pipe). After achieving stabilised vacuum pressure, the jacket shall

be sealed. All tests & cleaning shall be carried out for each segment.

k. Tappings in the SI lines at different locations in the circuit as shown in the P&ID to

facilitate mounting of safety valves/GA ports/vent valves (which will be Free-issued at

site) shall be provided. Mounting/erection of free-issued components shall be under the

scope of the bidder.

2. Structural Works: The structural works to be done by the supplier shall include design,

supply of materials, fabrication, assembly and erection of all types of structures like pipe

supports, structural bridges, structural crossover staircases etc. Design shall be submitted to

Department for approval.

The total weight of structural materials is anticipated to be approximately 10MT. Bidder

shall quote for this quantity. However, actual quantity shall be estimated based on the

detailed engineering to be done by the Supplier. Payment will be made for actual

quantity supplied.

3. Minor Civil Works

The minor civil works shall be done by the supplier with Plain Cement Concrete (PCC),

Reinforced Cement Concrete (RCC), brick masonry, grouting, anchor bolts, breaking &

disposal of PCC/RCC and breaking of brick masonry as required. The minor civil works are

required for

a. Grouting of equipments, pipe supports, structural works, etc

b. Breaking and making holes across walls for laying pipelines

c. Excavation and leveling of ground wherever required for laying the pipelines and

providing pipe supports. In some locations, it may be required to break and

excavate already laid PCC/ RCC pavements for grouting etc.

d. Plastering and applying 2 coats of white washing of the concrete surfaces.

e. RCC foundation/pedestal for pipelines and valves of sizes ≥ DN100 and PCC

foundation for sizes < DN100.

4. Supply of consumables for erection and commissioning shall be under the scope of the

bidder.

5. SHOP FABRICATION

As far as possible, the pipeline segments shall be fabricated at the Bidder’s/ Sub-

contractor’s factories to such an extent that they can be transported by sea/ air/ road.

6. PACKING, TRANSPORTATION, STORAGE AND HANDLING OF

MATERIALS

The bidder shall be responsible for packing, transportation, storage and handling of

materials as per following

6.1 DELIVERY

6.1.1 PACKING

All the components, pipes, pipe fittings, instruments, etc shall be blanked off at

ends by dust-tight plugs/ closures. The materials shall be packed and crated for

delivery by sea/ air / road in a manner suitable for safe transportation to

Mahendragiri, which has tropical humid climate, in accordance with

internationally accepted practices and in such a manner as to protect them from

damage and deterioration during the transportation. The bidder shall be held

responsible for all damages due to improper or inadequate packing. The packing

specification shall be mutually agreed upon in advance before delivery.

Phytosanitary certificate: As per “Plant Quarantine (Regulation of Control into

India) Order”, articles packed with packaging material of plant origin viz hay,

straw, wood shavings, wood chips, saw dust, wood waste, wooden pallets,

dunnage mats, wooden packages, coir pith, peat or sphagnum moss, etc will be

allowed entry by Customs (Department of India) only with a “Phytosanitary

certificate”. Therefore, the Supplier shall ensure that any imported consignment is

accompanied by such a certificate issued by the Plant Quarantine authority in the

country of origin, if any of the above-mentioned packaging materials is used. In

case of delay/ denial in customs clearance (in India), the entire responsibility

including additional expenditure shall solely rest with the bidder.

6.1.2 DELIVERY TERM

All the materials under the Contract shall be delivered on “DAP Mahendragiri”

basis as per INCOTERMS 2010.

The ultimate consignee shall be as follows:

Purchase & Stores Officer, Stores Section,

ISRO Propulsion complex, Indian Space research Organization,

Department of Space, Government of India,

Mahendragiri 627133,Tirunelveli District, Tamil Nadu State, India.

Marking: The bidder shall ensure that the consignments are legibly and properly

marked with Contract Number, Destination and other details for correct

identification. One copy of the packing list giving details such as dimensions,

gross mass, net mass, content of each package, etc shall be enclosed in each

package. The bidder shall be liable for any additional expense or demurrage due

to improper identification. The bidder shall email the complete delivery

documents immediately upon dispatch.

6.1.3 STORAGE AND HANDLING

Upon receipt of the consignment, the bidder shall unload and store the materials

at the Department’s site. It shall be the bidder’s responsibility to construct

temporary sheds/ buildings for proper storage of the materials to protect them

from the vagaries of nature. The bidder shall be responsible for safe and secure

custody of the materials until final acceptance at IPRC.

Upon completion of the work, the Supplier shall hand over all unused, surplus, scrap and

spare materials to the Department at identified location (store, dump yard, etc) inside the

Department’s premise with proper listing.

7 INSPECTION

All the bought-out material, works during fabrication at the Supplier’s factory and

erection at the Department’s site shall be inspected by one of the following reputed Third

Party Inspection (TPI) agencies:

Lloyds Register Industrial Services Pvt. Ltd (LRIS)

Det-Norske Veritas (DNV)

Technischer Uberwachungs Verein (TUV)

The detailed scope of inspection is given in the tentative QAP in Annexure - 1.

8 FABRICATION

8.1 Shop fabrication

SI piping in segments shall be fabricated at the Supplier’s/ factory to the extent

possible. Considering P&ID, equipment layout, piping layout and isometric

drawings.

All the weld joints in the fluid circuits shall be of Butt welded type and no

Socket weld type is permitted except for outer pipes of Insulated lines. Only

qualified welders and procedures as per code shall be employed. All the Butt

welded joints in the inner lines of SI segments fabricated at Supplier’s factory

shall be radiographed with X-ray to 2% sensitivity. The fabrication, testing,

inspection, etc. of SI pipes at manufacturer’s factory shall be as per the technical

specification

9. SITE WORKS:

The Supplier shall transport, unload and store the pre-fabricated SI pipeline segments

safely at Department’s site. The erection of pre-fabricated SI pipeline segments,

completion of fabrication of SI piping circuits by carrying out field-welded joints,

providing supports and inspection & quality control shall be the Supplier’s responsibility.

9.1. Erection & Site fabrication:

All the works applicable to erection and fabrication at Department’s site shall be carried

out by the Supplier. All the technical requirements delineated above for fabrication & testing

(Weld joint test, Pressure test, leak test & vacuum retention test, etc) at Supplier’s premises

shall also apply to the works done at Department’s site. Before installation, all the pipelines

and flow components shall be visually inspected for any entry of foreign particles. The

pipelines shall be purged to remove the foreign particles. All piping circuits shall be

connected, if required by welding and installed by the supplier at site as per approved layout.

All the machineries required for erection such as welding equipments, grinding machine,

drilling machines, radiographic equipments, etc, consumables such as Gaseous Argon,

Gaseous Argon – Nitrogen(2-3%) mixture, hacksaw blades, etc and tools & tackles, etc. shall

be arranged by the supplier. During erection at the Department’s site, the pre-fabricated

segments shall be joined (by welding) and vacuum jacket (joint box) to be made around the

joint. Inspection at Department’s site: a. During Erection and fabrication

All Inspection and Quality control of works to be carried out during erection and

fabrication of SI pipelines at Department’s site shall be carried out by TPI agency

arranged by the Supplier.

b. During Acceptance tests

The necessary Inspection works during acceptance tests at Department’s site shall be

done by Department’s Quality Control Division.

9.2. Internal Surface oil contamination test:

The cleanliness of the pipeline for LOX service during welding at the Department site will

be checked by taking sample using calico cloth wetted in Iso-Propyl Alcohol/ Heptane and

the contamination must be less than 200 mg/m2.

9.3. Acceptance Tests:

The acceptance tests for the commissioning are to be carried out after the completion of

final fabrication & erection at Department site as following

GN2, LN2 and GHe required for acceptance test will be supplied by the Department.

1. Weld joint test: As per section 1.c.1

2. Pressure test: As per section 1.c.2

3. Leak test: As per section 1.c.3.

4. Vacuum stabilisation test: As per section 1.c.4

5. Cleaning: As per section 1.c.5.

6. Pressure test with LN2 and Leak tightness test: All the SI piping assembly

shall be subjected to pressure test with LN2/cold GHe at its MEOP. Before &

after this test, the vacuum pressure in the jacket shall be measured.

7. Global leak test after pressure test with LN2: The leak tightness across inner

pipe and as well as outer jacket in all SI pipeline assembly shall be tested with

GHe MSLD as per section 1.c.3. The measured leakage rate shall be finer than

given in section 1.c.3.

8. Performance test with actual fluids:

i. Chilling & filling of the SI pipelines with the respective working

fluids, conducting flow test at nominal flow rates and working pressure to

verify conformance with thermal, structural and functional specification.

ii. To verify performance and integrity of all instruments with respect to

specification.

There shall be no sweating/frosting on the outer pipe surface. Detailed procedure

for performance test shall be prepared by the Supplier and provided to the

Department for approval. Supplier shall follow strictly the approved procedure

during performance test

10. COMMISSIONING

After completion of erection and testing of all the fluid circuits at ambient

temperature, the acceptance tests for commissioning shall be carried out. The bidder

shall prepare the systems and generate the operating procedure. The Department shall

review operating procedures, preparation of system and test results. Process

operations for commissioning shall be executed jointly by supplier’s and the

Department’s personnel.

11. Pre-Qualification Criteria:

The Bidder’s capability shall be evaluated based on the following Pre-Qualification

(PQ) criteria. The Bidders shall suitably fill-up the information solicited in “Item

specification” and submit as part of the Techno-Commercial Bid (TCB). Those

Bidders who comply with the PQ criteria only will be screened-in for opening and

evaluation of Price Bid. The information to be submitted in the TCB shall be complete

in all respects substantiated by attached documents and there shall not be any further

opportunity for the Bidders to submit any information or document unless the

Purchaser solicits so at their own discretion. Any lack of information or incomplete/

ambiguous information or false information or information non-compliant with the

PQ criteria shall be treated as sufficient cause to summarily reject such Bids.

1. The Bidder must be manufacturer/supplier of vacuum insulated or super insulated

pipelines. Manufacturer shall submit a self-declaration to that effect. If the bidder is a

subsidiary of their foreign principal, the credential of their principal may also be

accepted provided that there is an agreement of technical support from their principal.

2. The average annual financial turnover of the bidder or their principal during the last 3

years ending 31/03/2019 must be at least Rs. 2.9 crore. The claim shall be substantiated

by audit annual report/Income tax return statement/balance sheet.

3. The company must have made profit in at least 3 years out of 5 years ending 31/03/2019 as per audited balance sheets. The Bidder shall attach audited balance sheet/ Annual report for prior turnover and profit/ loss.

4. The price of similar works successfully completed during last 7 years ending 31/05/2019 must be as follows:

1 similar completed work costing not less than Rs 1.5 crores OR

2 similar completed works costing not less than Rs 98 lakhs each OR

3 similar completed works costing not less than Rs 78 lakhs each.

“Similar completed works” shall primarily involve any one of the following system:

i) Engineering, Procurement and Construction of Cryogenic process piping system with vacuum insulation or super-insulation.

ii) Construction of cryogenic process piping system.

iii) Engineering and Construction of Cryogenic tanks/equipments with vacuum-insulation or super-insulation.

Note:

(a) Engineering shall comprise design, detail engineering and analysis.

(b) Procurement shall comprise purchase of materials, quality control and project management service.

(c) Construction shall comprise fabrication (offsite/ onsite), erection, testing & commissioning.

5. The Bidder shall mention, in the techno-commercial bid, whether they propose to

execute the Contract on their own OR they propose to engage sub-contractor(s) for (i)

Engineering AND/ OR (ii) Construction.

6. Group/ Parent/ subsidiary company of the Bidder may also be engaged as

subcontractor. The Bidder shall not be permitted to change the Subcontractor upon

award of Contract, till the completion of work, without permission of the Department.

7. The Bidder shall give full information about their credentials/ subcontractor’s

credentials substantiated by valid documents (Work completion/ Final acceptance

certificate issued by the Client in favor of the Bidder/ subcontractor or Inspection

release note by Third Party Inspection agency/ Consultant) to comply with criteria

mentioned above. Experience shall pertain to works completed within 7 years ending

on 31-05-2019.

8. The Bidder and their subcontractor(s) must possess adequate & suitably qualified and

experienced in-house personnel at all levels such as managerial, supervisory &

tradesmen level and in the area of design, procurement, fabrication & erection to

execute the works given in this document. The details shall be provided along with

the techno-commercial bid.

9. The Bidder and their subcontractor(s) must possess adequate facilities (hardware &

software) for design & analysis. The details shall be provided along with the techno-

commercial bid.

10. Bidder and their subcontractor(s) must possess adequate in-house facilities such as

equipments, machineries, testing facility and other infrastructure to carry out factory

fabrication and required facilities for onsite erection. The details shall be provided

along with the techno-commercial bid.

List of SI pipelines

Inner pipeline

Inner & outer

pipeline

Table-1

Sl.

No.

Pipe

Size

(mm

)

Schedule

number

Nominal

Wall

thickness(

mm)

Material Service

Max.

Flow

rate

(kg/s)

Insulati

on

Type

Tentative

Length, (m)

Spare

(m)

Total

(m)

1 25 40S 3.38 ASTM 312 TP

304L LOX 5 SI 30 6 36

2 50 10S 2.77 ASTM 312 TP

304L LN2 5 SI 100 12 112

3 100 10S 3.05 ASTM 312 TP

304L LOX 15 SI 180 12 192

4 100 40S 6.02 ASTM 312 TP

304L LOX 20 SI 75 6 81

5 150 10S 3.4 ASTM 312 TP

304L LOX 20 SI 40 6 46

TYPICAL QUALITY ASSUARANCE PLAN – SI PIPELINES

Table - 2

Description of test, checks Kind of test/checks Extent of test Applicable code* Acceptance document

Inspection

Test

performed

by

Test

witness

ed by

Record

reviewed

by

1 2 3 4 5 6 7 8

1 I. Check of drawings

1.1 Analysis of project detailed drawings

ASME B31.3 Design documents and

drawings Vendor

Review and analysis

by TPIA and

Purchaser

2

II. Certification of welding processes and the personnel

2.1 WPQ Each welder 100% ASME Section IX RF certificate Vendor TPIA TPIA/

Purchaser

2.2 PQR Each procedure 100% ASME Section IX PQR certificate

Vendor TPIA

TPIA/

Purchaser

2.3 Welding process alignment Each procedure 100% Technical procedure Welding process alignment

certificate Vendor TPIA

TPIA/

Purchaser

3 III. Incoming inspection of materials quality

3.1a

1. Austenitic steel plates

Visual inspection, 100% Product spec

Product spec Vendor TPIA

TPIA/

Purchaser

3.1b

Chemical analysis Each heat/

As per code Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.2

Mechanical properties Each heat

/

As per code Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.3

Impact bending test at

T=-196º C Each heat

As per code Manufacturer's check test

report & MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.4 Ultrasonic test of austenitic Each pipe As per code Mill test certificate Vendor TPIA/

steel plates

(100%) Purchaser

3.5

2. Austenitic steel bars

Chemical analysis

Each heat

As per code Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.6

Mechanical properties

As per code

Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.7

Impact bending test at

T=-196º C Each heat

As per code Manufacturer's check test

report & MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.8 Ultrasonic test, visual

inspection

Each bar

As per code Mill test certificate Vendor

TPIA/

Purchaser

3.9

3. Austenitic steel forgings

Chemical analysis Each heat

As per code Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.10

Mechanical properties Each heat

As per code Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.11 Impact bending test at

T=-196º C Each heat As per code

Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.12

Ultrasonic test, visual

inspection

Each bar

As per code Mill test certificate Vendor TPIA/

Purchaser

3.13

4. Austenitic steel seamless pipes

Visual check 100 % Product spec Manufacturer's check test

report Vendor

TPIA/

Purchaser

3.14 Dimentional check One sample of

the lot

Product spec

ASME B 36.19

Manufacturer's internal

inspection report Vendor

TPIA/

Purchaser

3.15 Chemical analysis Each heat As per code

Mill test certificate &

MTC Manufacturer's

internal inspection report

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.16 Mechanical properties

(including impact test)

Each heat

As per code

Mill test certificate &

MTC

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.17 Hydraulic test @1.5 times

MAWP. 100% As per code Mill test certificate Vendor

TPIA/

Purchaser

3.18 Flattening test 5% pipes of lot As per code Mill test certificate

Vendor

TPIA/

Purchaser

3.19 Intergranular corrosion test Each heat As per code Mill test certificate

Vendor

TPIA/

Purchaser

3.20 Ultrasonic test 100%

As per code Mill test certificate Vendor

TPIA/

Purchaser

3.21

Etching test/

Macro & micro structure

examination

As per code Test report

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.22 Low temperature impact

test at 77K

One sample per

heat

As per code Test report

Sample taken by

TPIA; test performed

by Vendor in Govt.

approved laboratory

TPIA/

Purchaser

3.23 Bellows cyclic life test One per batch As per code

Type test certificate Vendor TPIA/

Purchaser

3.24

Pressure test for bellows

with dry air or GN2 at 1.1

times MAWP and

Ferrite test for bellow & its

weld

100%

Ferrite No.

shall be less

than or equal to

8

As per procedure

Manufacturer's check test

report Vendor

TPIA/

Purchaser

3.25

Relief pressure test for

vacuum pump out port cum

seal off valve

One per lot of

the same batch

As per relevant

standard Manufacturer's check test

report Vendor

TPIA/

Purchaser

3.26

Welding joint test for

bellows: 1. RT at 2%

equivalent sensitivity for

butt welded joints

2. DP test for socket welds

100%

ASME Section IX

Manufacturer's check test

report Vendor

TPIA/

Purchaser

3.27 5. Welding materials Chemical analysis 100 %

As per code Manufacturer's certificate Vendor

TPIA/

Purchaser

4 IV. Manufacture of pipeline’s parts and assembly units

4.1 Inner pipe

Dimensional check and

visual check

100%

Product spec

ASME B 36.19

Manufacturer's check test

report

Vendor TPIA/

Purchaser

4.2 Jacket

Dimensional check and

visual check

100%

Product spec

ASME B 36.19 Manufacturer's check test

report Vendor

TPIA/

Purchaser

5 V. Check of pipeline’s welded joints

5.1 Fit-up Dimensional check and

visual check

Each welded

joint

Drawings

Drawings

Manufacturer's check test

report Vendor TPIA

TPIA/

Purchaser

5.2 Welding flow sheet, welding Approval Each procedure As per procedure Manufacturer's check test Vendor TPIA/

procedure report

Purchaser

5.3

Welds testing (on coupons) & Heat

affected zone

1. Static tensile test

2.Static bending test

3. Impact bending test at

T=-196 deg.C

One test for

each pipe lot

As per procedure

Manufacturer's check test

report

Vendor TPIA/

Purchaser

5.4 Nondestructive test of all welds of

inner pipe a) RT/ UT (ultrasonic

testing)/

b) Dye Penetrant test (DPT)

to be done after root run,

final runs

a)100%

b)100%

As per ASME Section

V

Manufacturer's check test

report

Vendor TPIA/

Purchaser

5.5 Nondestructive test of all welds of

outer jacket

a)25%

b)100%

As per ASME Section

V

Manufacturer's check test

report

Vendor TPIA/

Purchaser

6 VI. Cleaning, pickling, passivation

6.1 Inner pipe

Picking, passivation and

cleaned to oxygen service

standards

100%

ASTM G93/ CGA 4.1

Manufacturer's check test

report

Visual inspection,

Cleanliness particle

analysis / Luminescent

testing;

Mechanical particles

determination

Vendor TPIA TPIA/

Purchaser

7 VII. Pneumatic tests.

7.1 Pneumatic tests of inner pipe at 1.5 of

design pressure

Pneumatic test for strength

and leak

100%

As per procedure Manufacturer's check test

report

Vendor TPIA TPIA/

Purchaser

7.2 Pneumatic tests of outer pipe Pneumatic test for strength

and leak

100%

As per procedure Manufacturer's check test

report Vendor TPIA

TPIA/

Purchaser

8 VIII. Final dimensional & visual check

8.1 Final dimensional & visual check of

inner pipe Final dimensional & visual

check

Basic overall

dimensions and

dimensions of

all welds

(100%)

As per procedure

ASME B 36.19 Manufacturer's check test

report

Vendor TPIA TPIA/

Purchaser

8.2 Final dimensional & visual check of

outer jacket

As per procedure

ASME B 36.19 Vendor TPIA TPIA/

Purchaser

9 IX. Vacuum tests

9.1 Leak tests of inner pipe before

vacuum jacketing

Leak test of inner pipe and

its joints by charging GHe

inside and using sniffer

probe .

All welds

Leak should be less

than 1 x 10-9 Pa-m3/s

Manufacturer's check test

report

Vendor TPIA/

Purchaser

9.2 Outer jacket

Exterior surface of the outer

pipe shall be shrouded by

synthetic bag and charged to

0.15 MPa (a) with GHe and

100%

Leak should be less

than 1 x 10-9

Pa-m3/s

Manufacturer's check test

report

Vendor TPIA TPIA/

Purchaser

the annular volume between

inner pipe and outer pipe be

evacuated and connected to

MSLD

9.3

Global leak of each pipeline segment

after vacuum jacketing (each vacuum

cavity)

Hood technique-MSLD in

vacuum mode, helium

charged at MAWP inside

inner pipe, outer pipe

shrouded by synthetic bags

and charged with helium.

100%

Leak should be less

than 1 x 10-9

Pa-m3/s

Manufacturer's check test

report Vendor TPIA

TPIA/

Purchaser

9.4 Vacuum stability tests of HIS Vacuum retention test Each HIS

Vacuum rise

measurement

Manufacturer's check test

report

Vendor TPIA TPIA/

Purchaser

9.5 Check of residual pressure in HIS Instrumental inspection

Each HIS

As per code Manufacturer's check test

report Vendor TPIA

TPIA/

Purchaser

10 X. Cold Shock Test

10.1 Cold Shock Test & MSLD leak test Cold shock test with LN2 at

manufacturer’s factory

Post cold shock test-

Leak should be less

than 1 x 10-9

Pa-m3/s

Vendor TPIA TPIA/

Purchaser

11 XI. Final operations.

11.1

Check of documentation

completeness

Check

100%

As per code

Manufacturer's check test

report

Prepared

by Vendor

TPIA/

Purchaser

Notation conventions:

RT - Radiography (X-ray)

WPQ - Welders qualification

PQR - Welding procedure qualification

HIS – Heat/Vacuum insulation space

MTC – Material test certificate from Government approved laboratory

TPIA - Third Party Inspection Agency

Note; *- Applicable codes:

Impact Test - ASTM E23, ISO 21028 & ISO 148, EN10028 Macro Etching Test - ASTM E340

Chemical Analysis -ASTM A751 Intergranular Test - ASTM A262 practice E/A

Mechanical Properties - ASTM A370 Hydraulic Test - ASTM A999

Ultrasonic Test - ASTM E213 Flattening test - ASTM A530

Eddy Test - ASTM E426