ESPECIFICACIONES STANDAR DE TUBERIAS

105
TABLE OF CONTENTS Section No. Description No. of pages COVER SHEET 01 CONTENT SHEET 01 1 GENERAL TECHNICAL SPECIFICATION 40 2 DETAILED TECHNICAL SPECIFICATION 61 3 LIST OF TENDER DRAWINGS 03 4 TECHNICAL DATA SHEETS & SCHEDULES 12 5 PRICE SCHEDULES 05

description

ESPECIFICACIONES PARA TUBERIAS

Transcript of ESPECIFICACIONES STANDAR DE TUBERIAS

Page 1: ESPECIFICACIONES STANDAR DE TUBERIAS

TABLE OF CONTENTS

Section No. Description No. of pages

COVER SHEET 01

CONTENT SHEET 01

1 GENERAL TECHNICAL SPECIFICATION 40

2 DETAILED TECHNICAL SPECIFICATION 61

3 LIST OF TENDER DRAWINGS 03

4 TECHNICAL DATA SHEETS & SCHEDULES 12

5 PRICE SCHEDULES 05

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SECTION - 1 GENERAL TECHNICAL SPECIFICATIONTABLE OF CONTENTS

1.0.0 INTENT OF SPECIFICATION...................................................................................3

2.0.0 SCOPE OF WORK FOR ERECTION........................................................................3

3.0.0 TERMINAL POINTS..................................................................................................6

4.0.0 EXCLUSIONS FROM THE BIDDER'S SCOPE OF WORK........................................6

5.0.0 PERFORMANCE TEST............................................................................................7

6.0.0 PROJECT INFORMATION........................................................................................7

7.0.0 APPROVED SUB VENDORS/MAKES.......................................................................7

8.0.0 TAGGING..................................................................................................................7

9.0.0 PAINTING..................................................................................................................7

10.0.0 QUALITY ASSURANCE, TESTING AND INSPECTION.............................................7

11.0.0 DOCUMENTATION.................................................................................................10

ANNEX-1.1 PROJECT INFORMATION.......................................................................................14

ANNEX- 1.2 BILL OF MATERIAL................................................................................................17

ANNEX- 1.3 PIPING CLASSIFICATION.....................................................................................32

ANNEX - 1.4 LIST OF SUB-VENDOR...........................................Error! Bookmark not defined.

ANNEX- 1.5 PAINTING ...........................................................................................04 SHEETS

SECTION 1

GENERAL TECHNICAL SPECIFICATION 1.0.0 INTENT OF SPECIFICATION

1.1.0 This specification covers the minimum technical requirements and essential particulars for Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports Erection, Laying, inspection & testing at site, cleaning & painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc.

1.2.0 Services shall be rendered in conformity with proven design principles, taking into account the current technology. The requirements of the contract must be fulfilled in its entirety. The services shall be rendered inclusive of all appliances and interconnecting arrangements with other supplies, necessary for installation of all accessories, needed for proper and reliable continuous operation and for satisfactory maintenance and repair.

1.3.0 In so far as data on the execution of services as contained in drawings, but none in specification and vice versa, such data shall be deemed to be contained in both. Contradictions, if any, between drawings and specifications and within various sections of the specification shall be brought to the attention of the Purchaser/Consultant by the Bidder and the correct requirement shall be obtained.

1.4.0 It is mandatory for the bidder's to furnish along with the bid the deviations if any, whether major or minor in the „Schedule of Deviations' only. In the absence of the deviations listed in the „Schedule of Deviations', the offer shall be deemed to be in full conformity with the specification not withstanding anything else stated elsewhere in the offer, data sheet, etc. The hidden deviations or stated / implied deviations in the offer shall not be acceptable OR binding on the Purchaser.

1.5.0 All materials supplied under this contract shall be new and unused.

1.6.0 The Bidder shall furnish along with the Bid the necessary information meeting the above

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requirement.

2.0.0 SCOPE OF WORK FOR ERECTION

2.1.0 The scope of work covered under this specification include but not limited to preparation of relevant drawings, specifications, documents and getting them approved by the Consultant and statutory authorities for necessary clearances, Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc. as detailed in the scope of work.

2.2.0 Scope of supply

2.2.1 All handling equipment, machinery, tools, consumables etc., required for fabrication work tobe carried out at site.

2.2.2 All handling equipment, machinery, tools, consumables etc., required for erection of LPpiping.

2.2.3 Piping supports for the above ground piping complete with all accessories.

2.2.4 Consumables and chemicals required for the piping and fittings fabrication, erection, cleaningand testing works.

2.2.5 Temporary piping material and supports for piping system, cleaning and testing.

2.2.6 Gasket for all flanges and Hume pipe for Buried pipe.

2.2.7 Required hardware (like bolts, nuts, clamps, U- clamps etc.)

2.2.8 Painting of piping.

2.2.9 Wrapping and Coating tape for Buried piping.

2.3.0 Scope of services

2.3.1 Fabrication, Erection & Commissioning of LP Piping:

Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc... as detailed in the scope of work.

2.3.2 The Bidder shall be responsible for examining all the consignments and notify the ProjectManager immediately of any damage, shortage, discrepancy etc. The Bidder shall submit tothe Project Manager every week a report detailing all the receipts during the week. However,the Bidder shall be solely responsible for any shortages or damage in transit, handling and/orin storage and erection of the equipment/ material at the site. Any demurrage, wharf age andother such charges claimed by the transporters, etc shall be to the account of the Bidder.

2.3.3 The Bidder shall maintain an accurate and exhaustive record detailing out the list of allequipment / material received by him for the purpose of erection and keep such record openfor the inspection of the Owner/ Project Manager at anytime.

2.3.4 The equipment/material stored shall be properly protected and the same shall be moved tothe actual location at an appropriate time so as to avoid any kind of damage to them.

2.3.5 The Bidder shall ensure that all the packing materials, and protection devices used for thevarious equipment / material during transit and storage are removed before the same areinstalled. The packing materials and protection devices shall remain the property of theOwner and shall be handed over by the Bidder to the Owner after the completion of works.

2.3.6 The Bidder shall be responsible for making arrangement for suitable indoor storage facilitiesto store required equipment/ material. In general, all the electrical equipment/ material suchas motors, control gears and consumables like electrodes, lubricants etc. shall be stored inthe closed storage space. The Project Manager, in addition, may direct the Bidder to movecertain other materials that in his opinion will require indoor storage to the designated indoorstorage areas, which the Contractor shall strictly comply with.

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2.3.7 If the materials belonging to the Bidder are stored in areas not acceptable to the Owner, theProject Manager will have the right to get them moved to the area earmarked for the Bidder atthe Bidder's cost.

2.3.8 All the materials stored in the open or dusty location must be covered with suitable weatherproof and flame proof covering of material wherever applicable. Any damage or deterioration of the material while in the custody of the Bidder shall be recovered by the Owner from the Bidder.

2.3.9 The erection quantities involved are listed in Annex 1.2 this section of the specification.

2.3.10 The scope includes fabrication design of pipes & accessories which includes preparation offabrication and spool drawings. Time is the essence of contract in completing each phase ofthe work so that the plant can be in commercial operation on the specified date. The Bidderwill be required to submit drawings and engineering data in accordance with the schedule andrequirements specified herein to assure compliance with the overall construction andoperating schedule.

2.3.11 Obtaining necessary approvals from various agencies as applicable.

2.3.12 Providing all man power, material and complete erection equipment including cranes/hoists,tools and tackles, consumable, welding electrodes, filler wires, oxygen, acetylene, sequenceof erection, calibration & measuring instruments etc. to enable execution of job including finaltesting, calibration and handing over in a planned manner and within the schedule ofstipulated time.

2.3.13 After completion of job arrange to clear the area of work of all loose materials, scraps, toolsequipment etc. Also update Purchaser's construction drawings to incorporate all themodifications carried out and get same certified as 'as-built' drawings by the Project Manager.

2.3.14 Assisting the Purchaser in successful commissioning of the system by providingskilled/unskilled personnel, equipment & tools etc.

2.3.15 Participation in design conferences, as specified herein.

2.3.16 The onsite construction / erection / installation work shall be in accordance with therequirements specified in this specification.

2.3.17 All pre-commissioning and commissioning activities.

2.3.18 All the tests as specified in this specification.

2.3.19 Welding of pipes /flanges at terminal points shall be included under the scope of this packageand required to be done by the Bidder.

2.3.20 The Bidder shall allow not less than 30 days for mailing, processing, and Owner review ofdrawings and data in his Engineering Schedule and Procurement / Production / ShippingSchedule.

2.3.21 Field Supervision: The Bidder shall furnish the services of one or more construction / erectionsupervisors for resident supervision of all erection work, testing, and placing the piping intosuccessful operation. The erection supervisors shall be present during and shall supervise theunloading of equipment and materials from vehicles, hauling, storing, cleaning, erection, startup, and testing.

2.3.22 Technical Services: In addition to the resident field supervision specified herein before, theBidder shall furnish the services of one or more technical service representatives. The servicerepresentatives shall be technically competent; trained; experienced in the fabrication,erection and testing of the LP piping; and authorized to perform the work stipulated.

2.3.23 Design Conference: The Bidder's design engineer shall attend a design conference at a timeand place prescribed by the Owner to discuss matters relative to the execution of thisContract. The Bidder's design engineer shall attend additional design conferences as requiredby the Owner thereafter to expedite the work.

2.3.24 Quality Assurance and Quality Control: As specified in Cl.11.0.0 of this specification, theBidder shall submit a documented Quality Assurance and Quality Control program capable ofproviding assurance that all involved equipment, materials, and services meet requirementsof the contract documents.

2.3.25 Submission of Daily, Weekly, Monthly progress report including reconciliation statement offree issue materials at the end of the month.

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2.3.26 Any other activities found necessary for the successful completion of the job.

2.4.0 Drawings

2.4.1 Purchaser shall provide the following drawings & documents

a. Plot Plant.

b. Symbol and Legends.

c. P&ID Drawings.

b. Piping layout drawings.

d. Isometric / 2D drawings.

c. Standard piping support details.

d. Equipment layout drawings.

The list of drawings indicated above is furnished else where in this tender document. However these are tentative and indicative only. The final drawings will be made available to the contractor progressively after the award of contract.

2.4.2 Coordinating for approvals from the statutory authorities like Inspector of ExplosivesCCOE (if required) and for calibration from Weights & Measures Department etc. & others forthe system under their purview. This includes getting approval of the welders from the aboveauthorities, arranging for the Inspector to visit site and obtain necessary approvals andcertificates for the erected pipe work etc.

2.4.3 Location, type and details of support for lines will be indicated in the Piping / G.A. drawingsupport details wherever not shown in GA drawing, but required for the piping stability theContractor shall carry out supporting with the approval of Project Manager after developingnecessary support drawings.

2.4.4 All fabrication drawings for piping shall be developed by the Contractor and submit to theProject Manager for approval.

2.4.5 Any alteration in pipe routing / supporting required to suit the site condition shall be done bythe Contractor to the satisfaction of the Project Manager at no extra cost.

2.5.0 Consumables

Supply of all consumables required for commissioning and performance test shall be included in the scope and the same shall be supplied by the successful Bidder at appropriate time.

3.0.0 TERMINAL POINTS

3.1.0 Terminal point has been indicated in the P&I Drawings (All Terminal point details are preliminary only and which shall be finalised after award of the contract).

4.0.0 EXCLUSIONS FROM THE BIDDER'S SCOPE OF WORK 4.1.0 Mechanical

• Erection of Piping beyond battery limits.

All valves, expansion joints their counter flanges along with fastener and gaskets.

All instruments with their accessories.(required stubs and fitting to be provided by bidder

as indicated in the P & ID'S

Supply of pipes and fittings (other than fabricated from the plate material).

Plate for fabricated pipe and fittings.

Pipe Support materials.(structural materials only)

All specialties their counter flanges along with fastener and gaskets.

4.2.0 Civil

• All Civil Engineering works such as RCC foundation, buildings, roads, pipe racks/ pipe

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trenches etc.

• Encasement for the buried piping.

5.0.0 PERFORMANCE TEST

5.1.0 Guarantee requirements

In addition to compliance with the requirements of the Specification, the Bidder shall meet the specific guarantees of performance as required and as stated in the specification. All tests shall be carried out in accordance with the relevant international standards unless otherwise specified or approved by the Purchaser. Performance test will be carried out, within the appropriate time period as specified to demonstrate the achievement of guaranteed parameters.

6.0.0 PROJECT INFORMATION

Project Information is furnished in Annex 1.1 of this section of the specification. 7.0.0 APPROVED SUB VENDORS/MAKES

7.1.0 The makes of all material/equipment/ instruments under this specification shall be subject to Purchaser's approval in the event of order. Bidder shall furnish a list of makes/ sub-vendors/ sub-contractors along with his bid. Purchaser reserves the right to accept/ reject any make or sub-vendor or add new makes/ sub-vendors for the project, after award of contract. Approval, rejection or addition of makes shall not have any cost implication to the Purchaser after award of contract.

8.0.0 TAGGING

8.1.0 Components whose identity is important for operation and maintenance of the plant viz., all apparatus, motors, signal tapping points, instruments and control equipment, cubicles, as well as the terminal boards, etc., installed in the latter shall be provided with permanently attached tag bearing the Purchaser's coding together with relevant text clearly inscribed. The inscription shall be approved by the Purchaser/Consultant. The tag shall be of engraved plate of sufficient rigidity and figures and letters embossed and painted. Such nameplates or labels shall be of white non- hygroscopic material with engraved black lettering. The language of inscription shall be English. The method of implementation and labeling will be informed for all components after award of contract.

9.0.0 PAINTING

9.1.0 The painting specification for all the piping shall be as specified in Annex 1.5 of this specification.

10.0.0 QUALITY ASSURANCE, TESTING AND INSPECTION

10.1.0 Quality Assurance Programme

10.1.1 To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Bidder's works or at his Sub-Vendor's premises or at the Purchaser's site or at any other place of work are in accordance with the specifications, the Bidder shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programmes shall be outlined by the Bidder and shall be finally accepted by the Purchaser after discussions before the award of Contract. A quality assurance programme of the Bidder shall generally cover the following:

a) Bidders organisation structure for the management and implementation of proposed qualityassurance programme,

b) Qualification data of his key personnel,

c) The procedure for purchase of materials, parts, components and selection of Sub- Vendor'sservices including Vendor analysis, source inspection, incoming raw material inspection,verification of materials purchased, etc.,

d) System for shop manufacturing including process controls and fabrication and assemblycontrols,

e) Inspection and test procedure both for manufacture and field activities,

f) Control of calibration and testing of measuring and testing equipment,

g) System for indication and appraisal of inspection status,h) System for quality audits,

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i) System for handling, storage & delivery,

j) System for authorising release of manufactured product to the Purchaser,

k) System for maintenance of records, and

l) A quality plan detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component furnished.

10.2.0 Quality Assurance Documents

10.2.1 The Bidder shall be required to submit the following Quality Assurance Documents as required.

a) All non-destructive examination procedures, stress relief and weld/repair procedure actuallyused during fabrication.

b) Welder and welding operation qualification certificates.

c) Welder identification list, listing welder's and welding operator's qualification procedure andwelding identification symbols.

d) Material mill test reports on components as specified by the specification.

e) The inspection plan with verification, inspection plan check points, verification sketches, ifused, and method used to verify that the inspection and testing points, in the inspectionplan were, performed satisfactorily.

f) Sketches and drawings used for indicating the methods of traceability of the radiographs tothe location on the equipment.

g) Non-destructive examination result reports.

h) Stress relief time temperature charts.

i) Factory test results for testing required as per applicable codes and standards referred in the specification.

10.2.2 The Purchaser shall be given reasonable notice of all tests and shall have the right to witness alltests, and shall have access to the works of Bidder and Sub-Vendor at all times for the purposeof carrying out system audits, conducting quality surveillance witnessing of tests and inspectionsetc.

10.2.3 The Purchaser or his authorized representative may periodically check the work and theConstructor's method of operation to assure that quality control practices are being followed. Atthe time of Purchaser's visit all quality documentation pertaining to test, qualifications,inspections etc., shall upon request be made readily available.

10.2.4 All reports of tests and inspections as per Quality Control Practices and Quality Plans shall befurnished to the Purchaser.

10.3.0 General Requirements for Testing and Inspection

10.3.1 All equipment covered under these specifications shall be subject to inspection and tests bythe Purchaser/his authorized representative or third party during erection and commission.The approval of the Purchaser or passing of such inspection of test will not, however,prejudice the right of Purchaser to reject the equipment if it does not comply withspecifications when erected or does not give complete satisfaction in service. The cost of allsuch tests as well as third party inspectors shall be borne by the Bidder.

10.3.2 The Bidder shall furnish the quality plan for erection and commissioning activities indicatingstage wise all tests and inspections, procedures and acceptance norms to be adopted for eachpiece of equipment under this specification.

10.3.3 Testing/inspection procedures as detailed herein is to give a basic quality control programme tobe followed by the Bidder and are in no way comprehensive and in no way form a completequality assurance programme. Any other inspection stages not mentioned in these clauses butrequired as per the Bidder's quality assurance programme or the Purchaser shall be deemed tobe included. Any tests necessary from operation, safety and reliability point of view shall also beincluded. Such quality plan shall be subject to the approval of the Purchaser.

10.3.4 The cost of all inspections at site by other regulatory institutions shall be borne by Bidder and

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accordingly included in his lumpsum price in the Bid.

10.3.5 The Purchaser, his duly authorised representative shall have access at all reasonable times toinspect and examine the materials and workmanship of the works during its Fabrication orerection and if part of the works is being fabricated or assembled on other premises or works,the Bidder shall obtain for the Project Manager and for his duly authorised representativepermission to inspect.

10.4.0 Non-destructive Examination

10.5.0 All non-destructive examinations shall be performed in accordance with written procedure tomeet ASME Sec. 1 and Sec. V code requirements. The personnel shall be qualified withPractice SNT-TC-1A of the American Society of Non-destructive Testing or equivalent. Eachnon-destructive examination shall be recorded in a report which summarises methods andequipment used, results evaluation, date and identification of personnel employed.

10.6.0 Welding Procedure

10.6.1 All welding procedures adopted for performing welding work shall be qualified in accordancewith the requirements of Section IX of ASME code.

10.6.2 These welding procedures shall clearly state the type of material, thickness, the joint details, thepreheat temperature maintained, the post-weld heat treatment given, the welding current andvoltage used during qualification of welding procedures.

10.6.3 All records of the welding procedures, the welders qualifications, tests and welders performancedetails for the work performed under these specifications shall be maintained by the Bidder andbe made available to the Purchaser on request.

11.0.0 DOCUMENTATION

11.1.0 Drawings, data / documents to be submitted along with tender

11.1.1 Duly filled-in technical data and prices as per specified schedules.

11.1.2 List of drawings/documents attached.

11.1.3 Time schedule for erection, testing, and commissioning.

11.1.4 List showing auxiliary piping furnished for all equipments.

11.1.5 List of tests the Bidder proposes to carry out at site after installation including those pertainingto their sub-contractor.

11.1.6 A bar chart indicating fabrication, installation, testing and commissioning activities.

11.1.7 A comprehensive write-up or brochure on the details of facilities / man power available withthe Bidder.

11.2.0 Drawings, data / documents to be furnished by the successful Bidder

The following drawings, data / documents shall be submitted for the approval / review of the Purchaser / Consultant by the successful Bidder.

Description Category

11.2.1 Piping fabrication/spool piece details. I

11.2.2 Test procedures and details of test to be conducted. A

11.2.3 Technical data sheet and GA drawings for supply items I

11.2.4 Quality assurance document for erection of piping system A

11.2.5 Fabrication procedure for piping I

11.2.6 Final welding procedure for piping. A

11.2.7 Any other details if required by purchaser/Owner. A

11.2.8 Type and Routine Test certificates, material test certificates for major Acomponents.

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Note:

Category-A : For Approval

Category-I : For Information/Reference.

11.3.0 General

a. Contract network schedule

b. Detailed painting specification.

c. Detailed interface schedule for all terminal points identifying terminal point no., size,material, type of connection, design flow, pressure and temperature at the terminal points

d. QAP for all manufactured and sub contracted items.

e. Detailed write-up for shop tests

f. Test certificates for type/routine tests, standard acceptance tests and performance tests

g. Field Quality Plans

h. Storage instructions for all equipment

i. Installation drawings and manuals for all equipment/systems

j. Detailed write-up on all pre-commissioning and commissioning activities.

k. Detailed write-up for site performance tests

l. Integrated operation and maintenance manuals for the complete plant as well as for all

individual equipment m. As-built drawings for all equipment/systems supplied under this contract and works

executed under this contract incorporating all changes/modifications upto the time of

commissioning / handling over to the Purchaser/consultant, n. Drawings/data to be required/submitted to statutory authorities o. Documents as listed in respective sections of Technical specification.

11.4.0 Drawings/ Documents Submission

11.4.1 All drawings shall be made in latest Autocad version.

11.4.2 The contractor shall submit drawings/ documents as per the no. of copies listed below:

To PLL : 7 copies

To Consultant : 4 copies

11.4.3 All drawings submitted by the Contractor including those submitted at the time of bid shall bein sufficient detail indicating the type, size, arrangement, weight of each component forpacking and shipment, the external connection, fixing arrangement required, the dimensionsrequired for installation and interconnections with other equipment and materials, clearanceand spaces required between various portions of equipment.

11.4.4 Each drawing submitted by the Contractor shall bear a title block at the right hand bottomcorner with clear mention of the name of the Contractor/Purchaser, Title block to be issued byContractor after award of contract. If standard catalogue pages are submitted the applicableitems shall be indicated therein. All titles, notings, markings and writings on the drawing shallbe in English. All the dimensions shall be in metric units.

11.4.5 The furnishing of detailed engineering data and drawings by the Contractor shall be inaccordance with the time schedule finalised during pre-award meeting. The review of thesedocuments / data / drawings by the Contractor/Purchaser will cover only general conformanceof the data / drawings / documents to the specifications and contract, interfaces with theequipment provided by others and external connections of the dimensions as reviewed. Thereview and / or approval by the Contractor/Purchaser shall not relieve the Purchaser/Contractor of any of this responsibilities and liabilities under this contract.

11.4.6 After the approval of the drawings, further work by the Contractor shall be in strict accordancewith these approved drawings and no deviation shall be permitted without the written approval

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of the Contractor/Purchaser.

11.4.7 As Built Drawings

a) After final acceptance of individual equipment / system by the Contractor/Purchaser, theContractor will update all original drawings and documents for the equipment / system to"as built" conditions.

b) Drawings must be checked by the Contractor prior to submission to the Purchaser. Incase, drawings are found to be submitted without proper checking by the Contractor, thesame shall not be reviewed and returned to the Contractor for re-submission.

11.5.0 Engineering Information Submission Schedule

Prior to the award of Contract, a Detailed Engineering Information Submission Schedule shall be tied up with the Contractor. For this, the contractor shall furnish a detailed list of engineering information alongwith the proposed submission schedule. The list would be a comprehensive one including all engineering data / drawings / information for all bought out items and manufactured items. The information shall be categorised into the following parts.

i) Information that shall be submitted for the approval to the Contractor/Purchaser before proceeding further and

ii) Information and would be submitted for Contractor's/Purchaser's information only. The Engineering Information Schedule shall be prepared monthwise.

The schedule should allow adequate time for proper review and incorporation of changes / modifications, if any, to meet the contract without affecting the equipment delivery schedule. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performance and progress.

11.6.0 Work Progress and Exception Report

11.6.1 The Contractor shall submit every month a work progress and Exception Report giving thestatus of work information including

a) A list of drawings / data which remains unapproved for more than four (4) weeks after thedate of first submission.

b) Drawings which were not submitted as per agreed schedule.

c) Master list of drawings (computer output).

11.6.2 The draft format for this report shall be furnished to the Contractor/Purchaser within four (4)weeks of the award of the contract, which shall then be discussed and finalized with theContractor/Purchaser.

11.7.0 Instruction Manuals

The Contractor shall submit to the Owner/Purchaser, draft Instruction Manuals for all the work covered under the Contract by the end of six (6) months from the date of his acceptance of the Letter of Award. The Instruction manuals shall contain full details required for erection, commissioning and testing. The manual shall be specifically compiled for this project and subject to approval by Purchaser. The Contract shall not be considered to be completed for purposes of taking over until the final Instructions manuals have been supplied to the Owner/Purchaser. The Instruction Manuals shall comprise of the following.

A) Erection Manuals

The erection manuals shall be submitted atleast three (3) months prior to the commencement of erection activities of particular equipment / system. The erection manual should contain the following as a minimum.

a) Erection strategy

b) Sequence of erection

c) Erection instructions

d) Critical checks and permissible deviation / tolerances

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e) List of tool, tackles etc.

f) Bills of Materials

g) Procedure for erection

h) Procedure for initial checking after erection

i) Procedure for testing and acceptance norms

j) Procedure / Check list for pre-commissioning activities

k) Procedure / Check list for commissioning of the system

l) Safety precautions to be followed in electrical supply distribution during erection.

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1.0 2.0 3.0

4.0

4.1 5.0

6.0

7.0

8.0

9.0

10.0

11.0

(a) (b) (c)

12.0 (a) (b) (c) (d) (e) (f)

(g)

13.0 (a) (b) (c) (d)

14.0

(a) (b) (c)

Owner

Project Title Location

Power station site Elevation above Mean Seal Level (MSL)

Latitude /Longitude Nearest Railway station

Nearest Town

Distance from Nearest State Highway

Nearest Airport

Nearest Sea Port

Road Approach

Seismic data

Seismic intensity Zone Importance factor

Temperature

Maximum / Minimum temperature

Daily maximum mean temperature

Daily minimum mean temperature Maximum Dry bulb temperature Minimum Dry bulb temperature Wet Bulb Temperature Design temperature for elec equipment/device/System

Relative Humidity

Monthly Maximum Relative Humidity Maximum mean Relative Humidity Monthly minimum Relative Humidity Minimum mean Relative Humidity Design relative humidity for Electrical equipment/Device/System Rain fall

Max. recorded

Average Annual rain fall

Period of Monsoon (Avg) Showers

FFL + 224.5 m TG hall

19°58'N/79°18 'E

Tadali Railway Station of Warora Branch of Central Railway and the distance is about 3.0 KM

Chandrapur (Maharashtra), India, 3.0 km

0.5 Km from SH-264

Nagpur

Visakhapatnam (East coast)

NH-3&NH-6, and SH-264

AsperIS-1893.

II

1.75 for tanks

48.3 0C and 2.8 0C 42.8 0C

12.8 °C

33.8 0C21.3 0C29 0C

50 °C

84% 65% 21% 46%

95%

1276.5mm.

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15.0 Wind data

Maximum wind speed 16.0 Climatic conditions

17.0 Auxiliary power supply

17.1 AC Motors above 160 kW

17.2 AC Motors 0.18 kW to including 160kW

17.3 AC Motors Below 0.18 kW

17.4 Plant lighting, utility power sockets,space heating panels and spaceheating of motors of rating 30kW andabove

17.5 Control Circuit of local panels (likecompressor control, crane control, etc.)and 415 V switchgear outgoing feedermodules controls.

17.6 For control of switchgear, switchyardequipment, DC emergency drives, DCemergency lights, switchyard andgenerator protection panels, etc.

17.7 For Instrumentation and Control

17.8 Unless otherwise specified all electricalfrequency variations:

17.9 AC system

(a) Voltage variations

(b) Frequency variationCombined Voltage and Frequency

(c) Variation

17.10 DC system

a) Voltage variation (220 V)

17.11 UPS

18.0 Electrical Voltage levels a. EHV System

44 m/s.

Unless otherwise specified, All auxiliary equipment to be supplied against this specification shall be suitable for operation on the following supply

6.6kV, 3 phase, 3 wire, AC supply (Medium resistance earthed)

400V, 3 phase, 4 wire, AC supply (Effectively earthed)

240V, 1 Phase, AC supply (Effectively earthed) 240V, 1 Phase, AC supply (Effectively earthed)

240V, 1 Phase, AC supply system (Derived from 415/240V step down transformer)

220V DC Supply

:

UPS supply 240V AC, Any other AC or DC voltage required shall be derived from the same.

system shall be designed for the following voltage and

± 10%

+ 5% to - 5%

± 10%

+ 10% to- 15% ±1%

400000 V (±)10% , 3 phase, 50 Hz (+)5% to (-)5%, solidly grounded system.

Page 14: ESPECIFICACIONES STANDAR DE TUBERIAS

b. MV System

c. LV System

d. Control Voltage

e. Auxiliary supply for lighting

f. Combined voltage & frequency variation

g. DC Voltage

h. UPS Voltage

19.0 Electric Equipment Voltage Rating

a. For motors above 160 kW

b. For motors from 0.18 upto 160 kW

c. For motors less than 0.18

d. For all MOV motors

20.0 Fault Level

a. 400,000 volts system

b. 6.6 kV system

c. 415 volts system

6600 V (±)10% volts, 3 phase, 50 Hz (+)5% to (-)5%, low resistance grounded system.

415 V (±)10% volts, 3 phase, 50 Hz (+)5% to (-)5%, solidly grounded system.

230 V (±)10% volts, 1 phase, 50 Hz. 240 V (±)10% volts, 1 phase, 50 Hz 10% (Absolute sum)

220 (+)10% to (-) 15% volts, ungrounded system

230 volts (±)10% volts, 1 phase, 50 Hz system

6.6 kV, 3 phase, 50 Hz low resistance grounded system

415 Volt, 3 phase, 50 Hz Solidly earthed 240 Volt, 1 phase, 50 Hz 415 Volt, 3 phase, 50 Hz

40 kA for 1 (One) second 40 kA for 3 (Three) second. 50 kA for one second

Page 15: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX-1.2 BILL OF MATERIAL

System : Instrument Air system

ITEM: PIPE

SL.No. MATERIAL ENDS REMARKS

1 150 168.30 Mild Steel -IS 1239 Part 1, ERW, Galvanised

Medium Grade 720 BW

2 100 114.30 Mild Steel -IS 1239 Part1, ERW, Galvanised

Medium Grade 120 BW

3 50 60.32 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 470 Threaded One end of pipe to be provided with Threaded full coupling threaded.

4 25 33.40 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 550 Threaded One end of pipe to be provided with Threaded full coupling threaded.

5 15 21.34 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 7 Threaded One end of pipe to be provided with Threaded full coupling threaded.

ITEM : 90° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 150 168.30 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 9 BW

2 100 114.30 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 16 BW

3 50 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 4 Threaded

4 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 28 Threaded

ITEM: EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 150 168.30 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 4 BW

2 100 114.30 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 4 BW

3 50 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 5 Threaded

4 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 5 Threaded

ITEM: CONCENTRIC REDUCER

SL.No. MATERIAL ENDS REMARKS

1 150X100 168.30X114.30 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 2 BW

2 100X50 114.30X60.32 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 5 BW

3 100X25 114.30X33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 3 BW

4 50X25 60.32X33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 3 Threaded

Page 16: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM : UN EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 150X100 168.30 X114.30 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 8 BW

2 100X50 114.30X60.3 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 2 BW

3 100X25 114.30X33.40 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 2 BW

4 50X25 60.30X33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 3 Threaded

5 50X15 60.30X21.34 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 4 Threaded

6 25X15 33.40X21.34 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 8 Threaded

ITEM : HALF COUPLING

SL.No. MATERIAL ENDS REMARKS

1 15 21.34 Mild Steel -IS 1239 Part 2, Galvanised A 105,

Galvanised

Heavy Grade / 3000#

2 Threaded

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, thickness and Quantity details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

Page 17: ESPECIFICACIONES STANDAR DE TUBERIAS

System : Service Air system

ITEM: PIPE

SL.No. MATERIAL ENDS REMARKS

1 80 88.90 Mild Steel -IS 1239 Part1, ERW, Galvanised

Medium Grade 500 BW

2 65 73.02 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 90 BW

3 50 60.32 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 435 Threaded One end of pipe to be provided with Threaded full coupling

threaded.

4 40 48.26 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 450 Threaded One end of pipe to be provided with Threaded full coupling

threaded.

5 25 33.40 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 1550 Threaded One end of pipe to be provided with Threaded full coupling

threaded.

6 15 21.34 Mild Steel -IS 1239 Part1, ERW, Galvanised

Heavy Grade 6 Threaded One end of pipe to be provided with Threaded full coupling

threaded.

ITEM: 90° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 80 88.90 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 16 BW

2 65 73.02 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 8 BW

3 50 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 6 Threaded

4 40 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 7 Threaded

5 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 40 Threaded

ITEM: EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 80 88.90 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 8 BW

2 65 73.02 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 3 BW

3 50 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 2 Threaded

4 40 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 2 Threaded

5 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 7 Threaded

Page 18: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM : UN EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 80X65 88.90 X 73.02 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 2 BW

2 80X50 88.90 X 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 1 BW

3 80X25 88.90 X 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 3 BW

4 50X40 60.32 X 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 1 SW

5 50X25 60.32 X 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 2 SW

6 40X25 48.26 X 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 4 SW

7 25X15 33.4X21.34 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 2 SW For Pressure I ndicator

ITEM: CONCENTRIC REDUCER

SL.No. MATERIAL ENDS REMARKS

NB OD in mm THK. Nos.

3 80X40 88.90 X 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 2 BW

4 80X50 88.90 X 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Medium Grade 2 BW

5 50X40 60.32 X 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 1 Threaded

6 50X25 60.32 X 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 5 Threaded

7 50X15 60.32X21.34 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 2 Threaded For Pressure I ndicator

8 40X25 48.26 X 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade 3 Threaded

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, thickness and Quantity details have been indicated preliminary and which shall be finalised later.

3 Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

Page 19: ESPECIFICACIONES STANDAR DE TUBERIAS

System - Potable Water System

ITEM : PIPE

SL.No. MATERIAL ENDS REMARKS

1 200 219.08 IS 3589 Fabricated from IS 2062 Gr.B

4.5 50 BE

2 80 88.90 Mild Steel -IS 1239 Part 1, ERW, Galvanised

Heavy Grade

880 BW

3 65 73.02 Mild Steel -IS 1239 Part 1, ERW, Galvanise

Heavy I Grade

1100 BW

4 50 60.32 Mild Steel -IS 1239 Part 1, ERW, Galvanise

Heavy I Grade

2 Threaded One end of pipe to be provided with full coupling

threaded.

5 40 48.26 Mild Steel -IS 1239 Part 1, ERW, Galvanise

Heavy I Grade

500 Threaded One end of pipe to be provided with full coupling

threaded.

6 25 33.40 Mild Steel -IS 1239 Part 1, ERW, Galvanise

Heavy I Grade

10 Threaded One end of pipe to be provided with full coupling

threaded.

7 15 21.34 Mild Steel -IS 1239 Part 1, ERW, Galvanise

Heavy I Grade

5 Threaded One end of pipe to be provided with full coupling

threaded.

ITEM : 90° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 200 219.08 A 234 Gr.WPB 4.5 2 BW

2 80 88.90 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

14 BW

3 65 73.02 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

23 BW

4 50 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

24 Threaded

5 40 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

27 Threaded

6 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

5 Threaded

ITEM : 45° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 65 73.02 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

2 BW

Page 20: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM : EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 200 219.08 A 234 Gr.WPB 4.5 2 BW

2 80 88.90 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

9 BW

3 65 73.02 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

2 BW

4 50 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

3 Threaded

5 40 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

2 Threaded

6 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

5 Threaded

ITEM : CONCENTRIC REDUCER

SL.No. MATERIAL ENDS REMARKS

1 80X65 88.9X73.02 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

3 BW

2 80X50 88.9X60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

7 BW

3 65X50 73.02 X 60.32 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

4 BW

4 50X40 60.32 X 48.26 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

11 Threaded

ITEM : END CAP

SL.No. MATERIAL ENDS REMARKS

1 25 33.40 Mild Steel -IS 1239 Part 2, Galvanised

Heavy Grade

5 Threaded End Cap for Drain and Ven

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system.

4 10% Margin has been considered for all piping & all Fittings.

Page 21: ESPECIFICACIONES STANDAR DE TUBERIAS

System : Service water system

ITEM : PIPE

SL.No. MATERIAL ENDS REMARKS

1 200 219.08 IS 3589 Fabricated from IS 2062 Gr.B

4.5 700 BE -

2 100 114.30 Mild Steel -IS 1239 Part 1, ERW

Medium Grade 350 BE -

3 80 88.90 Mild Steel -IS 1239 Part1, ERW

Medium Grade 800 BE -

4 50 60.32 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 30 BW

5 40 48.26 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 800 Plain End One end of pipe to be provide with socket welded full

coupling.

i

6 25 33.40 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 10 Plain End One end of pipe to be provide with socket welded full

coupling.

i

ITEM : 90° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 200 219.08 A 234 Gr.WPB 4.5 11 BW

2 100 114.30 Mild Steel- IS 1239 Part 2

Medium Grade 13 BW

3 80 88.90 Mild Steel- IS 1239 Part 2

Medium Grade 24 BW

4 50 60.32 Mild Steel- IS 1239 Part 2

Heavy Grade 4 BW

5 40 48.26 Mild Steel- IS 1239 Part 2

Heavy Grade 44 SW

6 25 33.40 Mild Steel- IS 1239 Part 2

Heavy Grade 5 SW

ITEM : 45° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 80 88.90 Mild Steel- IS 1239 Part 2

Medium Grade 2 BW

ITEM : EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 200 219.08 A 234 Gr.WPB 4.5 2 BW

2 100 114.30 Mild Steel- IS 1239 Part 2

Medium Grade 1 BW

3 80 88.90 Mild Steel- IS 1239 Part 2

Medium Grade 1 BW

4 50 60.32 Mild Steel - IS 1239 Part 2

Heavy Grade 4 BW

5 40 48.26 Mild Steel- IS 1239 Part 2

Heavy Grade 3 SW

6 25 33.40 Mild Steel- IS 1239 Part 3

Heavy Grade 5 SW

Page 22: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM : UNEQUAL TEE

SL.No. MATERIAL ENDS REMARKS

1 200X100 219.08X114.3 A 234 Gr.WPB 4.5 6 BW

2 100X80 114.3X88.90 Mild Steel- IS 1239 Part 2

Medium Grade 1 BW

3 100X40 114.3X48.26 Mild Steel- IS 1239 Part 2

Medium Grade 2 BW

4 80X50 88.90X60.31 Mild Steel- IS 1239 Part 2

Medium Grade 1 BW

5 80X40 88.90X48.26 Mild Steel- IS 1239 Part 2

Medium Grade 8 BW

ITEM : CONCENTRIC REDUCER

SL.No. MATERIAL ENDS REMARKS

1 200X100 219.08X114.3 A 234 Gr.WPB 4.5 3 BW

2 100X80 114.3X88.90 Mild Steel- IS 1239 Part 2

Medium Grade 2 BW

3 100X40 114.3X48.26 Mild Steel- IS 1239 Part 2

Medium Grade 3 BW

4 80X40 88.90X48.26 Mild Steel- IS 1239 Part 2

Medium Grade 4 BW

5 50x40 60.32X48.26 Mild Steel- IS 1239 Part 2

H eavy G rade 1 SW

ITEM : HALF COUPLING

SL.No. MATERIAL END REMARKS

1 25 33.40 Mild Steel -IS 1239 Part 2 / A 105

#3000 5 SW

ITEM : END CAP

SL.No. MATERIAL ENDS REMARKS

1 25 33.40 Mild Steel -IS 1239 Part 2

Heavy Grade 5 SW End cap for vent and drain.

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

Page 23: ESPECIFICACIONES STANDAR DE TUBERIAS

System : Plant water system

ITEM : PIPE

SL.No. MATERIAL END REMARKS

1 700 711.20 IS 3589 Fabricated from IS 2062 Gr.B

7.1 106 BE -

2 600 609.60 IS 3589 Fabricated from IS 2062 Gr.B

6.3 248 BE -

3 500 508.00 IS 3589 Fabricated from IS 2062 Gr.B

6.3 31 BE -

4 400 406.40 IS 3589 Fabricated from IS 2062 Gr.B

6.3 16 BE -

5 350 355.60 IS 3589 Fabricated from IS 2062 Gr.B

5.6 10 BE -

6 250 273.05 IS 3589 Fabricated from IS 2062 Gr.B

5 648 BE -

7 200 219.08 IS 3589 Fabricated from IS 2062 Gr.B

4.5 677 BE -

8 150 168.30 Mild Steel -IS 1239 Part 1, ERW

Medium Grade i 632 BE -

9 100 114.30 Mild Steel -IS 1239 Part1, ERW

Medium Grade i 23 BE -

10 80 88.90 Mild Steel -IS 1239 Part1, ERW

Medium Grade i 85 BE -

11 65 73.02 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 67 BE -

12 50 60.30 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 25 Plain End One end of pipe to be provide with socket welded full

coupling.

d

13 25 33.40 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 25 Plain End One end of pipe to be provide with socket welded full

coupling.

d

14 15 21.34 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 25 Plain End One end of pipe to be provide with socket welded full

coupling.

d

ITEM : 90° ELBOW 1.5D

SL.No. MATERIAL END REMARKS

1 700 711.20 Fabricated from IS 2062 Gr.B

7.1 5 BW Miter Bend

2 600 609.60 Fabricated from IS 2062 Gr.B

6.3 12 BW Miter Bend

3 500 508.00 Fabricated from IS 2062 Gr.B

6.3 6 BW Miter Bend

4 400 406.40 Fabricated from IS 2062 Gr.B

6.3 6 BW Miter Bend

5 350 355.60 Fabricated from IS 2062 Gr.B

5.6 2 BW Miter Bend

6 250 273.05 A 234 Gr.WPB 5 26 BW

7 200 219.08 A 234 Gr.WPB 4.5 19 BW

8 150 168.30 Mild Steel- IS 1239 Part 2

Medium Grade 29 BW

9 100 114.30 Mild Steel- IS 1239 Part 2

Medium Grade 7 BW

Page 24: ESPECIFICACIONES STANDAR DE TUBERIAS

SL.No. MATERIAL END REMARKS

10 80 88.90 Mild Steel- IS 1239 Part 2

Medium Grade 15 BW

11 65 73.02 Mild Steel- IS 1239 Part 2

Medium Grade 31 BW

12 50 60.30 Mild Steel- IS 1239 Part 2

Heavy Grade 10 SW

13 25 33.40 Mild Steel- IS 1239 Part 2

Heavy Grade 15 SW

ITEM: EQUAL TEE

SL.No. MATERIAL END REMARKS

1 250 273.05 A 234 Gr.WPB 5 1 BW

2 100 114.30 Mild Steel- IS 1239 Part 2

Medium Grade 6 BW

3 80 88.90 Mild Steel- IS 1239 Part 2

Medium Grade 6 BW

4 65 73.02 Mild Steel- IS 1239 Part 2

Medium Grade 5 BW

ITEM: UNEQUAL TEE

SL.No. MATERIAL END REMARKS

1 600 X 400 609.60X406.40 Fabricated from IS 2062 Gr.B

6.3 1 BW

2 250 X 200 273.05X219.08 A 234 Gr.WPB 5 1 BW

3 200X150 219.08X168.30 A 234 Gr.WPB 4.5 2 BW

4 150X100 168.30X114.30 Mild Steel- IS 1239 Part 2

Medium Grade 1 BW

5 100X80 114.30X88.90 Mild Steel- IS 1239 Part 2

Medium Grade 1 BW

ITEM : SORF FLANGE ( Header Flange)

SL.No. MATERIAL END REMARKS

1 80 - A 105 #150 4 Flat face Flange Code ASMEB16.5

2 65 A 105 #150 2 Flat face Flange Code ASMEB16.6

ITEM: GASKET

SL.No. MATERIAL END REMARKS

1 80 CNAF (Compressed Non asbestos fibre)

#150 4 3MM THICKNESS SELF CENTERING

FLAT RING

2 65 - CNAF (Compressed Non asbestos fibre)

#150 2 3MM THICKNESS SELF CENTERING

FLAT RING

-

ITEM : BLIND FLANGE( Header Flange)

SL.No. MATERIAL END REMARKS

1 80 - A 105 #150 4 Flatface Flange Code ASMEB16.5

2 65 - A 105 #150 2 Flat face Flange Code ASMEB16.5

ITEM: END CAP

SL.No. MATERIAL END REMARKS

1 50 60.30 Mild Steel -IS 1239 Part 2

Heavy Grade 15 Threaded

2 25 33.40 Mild Steel -IS 1239 Part 2

Heavy Grade 25 Threaded

Page 25: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM HALF COUPLING

SL.No. MATERIAL END REMARKS

1 50 60.30 Mild Steel -IS 1239 Part 2 / A 105

#3000 15 SW

2 25 33.40 Mild Steel -IS 1239 Part 2 / A 105

#3000 25 SW

3 15 33.40 Mild Steel -IS 1239 Part 2 / A 105

#3000 30 SW

ITEM DISHED END COVER

SL.NO. MATERIAL SCH/ THK.

QTYIN Nos.

END REMARKS

1 700 711.20 Fabricated from IS 2062 Gr.B

7.1 1 BW Torispherical

Note: 1 Pipe length, Pipe size and Pipe thickness details have been indicated preliminary and which shall be finalised later. 2 No Fittings, Fitting size and thickness details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

Page 26: ESPECIFICACIONES STANDAR DE TUBERIAS

System : DM Feed water system

ITEM : PIPE

SL.No. MATERIAL END REMARKS

1 50 60.30 A312TP304, ERW 40 35 Plain End One end of pipe to be provide with socket welded full

coupling.

2 25 33.40 A312TP304,ERW 40 10 Plain End One end of pipe to be provide with socket welded full

coupling.

3 15 21.30 A312TP304, ERW 40 16 Plain End One end of pipe to be provide with socket welded full

coupling.

ITEM : 90° ELBOW

SL.No. MATERIAL END REMARKS

1 50 60.30 A182Gr.F304 #3000 6 SW

2 25 33.40 A182Gr.F304 #3000 8 SW

ITEM : HALF COUPLING

SL.No. MATERIAL END REMARKS

1 25 33.40 A182Gr.F304 #3000 14 SW

2 15 21.30 A182Gr.F304 #3000 30 SW

ITEM : END CAP

SL.No. MATERIAL END REMARKS

1 25 33.40 A182Gr.F304 #3000 14 NPT

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. 3 10% Margin has been considered for all piping & all Fittings.

Page 27: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM : PIPE

SL.No. MATERIAL END REMARKS

1 400 406.40 A312TP304, ERW 5S 35 BE -

2 250 273.00 A312TP304, ERW 10S 70 BE

3 200 219.10 A312TP304, ERW 10S 40 BE

4 150 168.30 A312TP304, ERW 10S 710 BE -

5 100 114.30 A312TP304, ERW 10S 435 BE

6 80 88.90 A312TP304, ERW 10S 20 BE -

ITEM: 90° ELBOW 1.5D

SL.No. MATERIAL END REMARKS

1 400 406.40 A 403 Gr. WP304 5S 6 BW

2 250 273.00 A 403 Gr. WP304 10S 9 BW -

3 200 219.10 A 403 Gr. WP304 10S 10 BW

4 150 168.30 A 403 Gr. WP304 10S 67 BW -

5 100 114.30 A 403 Gr. WP304 10S 30 BW -

6 80 88.90 A 403 Gr. WP304 10S 12 BW

ITEM : EQUAL TEE

SL.No. MATERIAL END REMARKS

1 400 406.40 A 403 Gr. WP304 5S 2 BW

2 200 219.10 A 403 Gr. WP304 10S 2 BW

3 150 168.30 A 403 Gr. WP304 10S 2 BW -

4 100 114.30 A 403 Gr. WP304 10S 1 BW

ITEM : UNEQUAL TEE

SL.No. MATERIAL END REMARKSNB OD in mm THK. Nos.(Rev.

0A)

1 400 X 250 406.40 X 273.00 A 403 Gr. WP304 5S 8 BW -

2 250 X 200 273.00 X219.10 A 403 Gr. WP304 10S 2 BW

3 250X150 273.00X168.30 A 403 Gr. WP304 10S 1 BW

4 150 X 100 168.30X114.30 A 403 Gr. WP304 10S 15 BW -

ITEM : CONCENTRIC REDUCER

SL.No. MATERIAL END REMARKS

1 250X150 273.00X168.30 A 403 Gr. WP304 10S 7 BW -

2 100X50 114.30X60.3 A 403 Gr. WP304 10S 2 BW

ITEM : SOFF FLANGE ( Header Flange)

SL.No. MATERIAL END REMARKS

1 400 - A182Gr. F304 #150 2 Flat face Flange Code ASME B16.5

2 250 - A182Gr. F304 #150 1 Flat face Flange Code ASME B16.5

3 200 A182Gr. F304 #150 2 Flat face Flange Code ASME B16.5

Page 28: ESPECIFICACIONES STANDAR DE TUBERIAS

4 150 - A182Gr. F304 #150 4 Flat face Flange Code ASME B16.5

ITEM : BLIND FLANGE

SL.No. MATERIAL END REMARKS

1 400 - A182Gr. F304 #150 2 Flat face Flange Code ASME B16.5

2 250 A182Gr. F304 #150 1 Flat face Flange Code ASME B16.5

3 200 - A182Gr. F304 #150 2 Flat face Flange Code ASME B16.5

4 150 - A182Gr. F304 #150 4 Flat face Flange Code ASME B16.5

ITEM : GASKET

SL.No. MATERIAL END REMARKS

1 400 - CNAF (Compressed Non asbestos fibre)

#150 2 3MM THICKNESS SELF CENTERING

FLAT RING

-

2 250 CNAF (Compressed Non asbestos fibre)

#150 1 3MM THICKNESS SELF CENTERING

FLAT RING

3 200 - CNAF (Compressed Non asbestos fibre)

#150 2 3MM THICKNESS SELF CENTERING

FLAT RING

-

4 150 CNAF (Compressed Non asbestos fibre)

#150 4 3MM THICKNESS SELF CENTERING

FLAT RING

Note:

5 Pipe size,Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 6 Fitting size, thickness and Quantity details have been indicated preliminary and wh ch shall be finalised later. 7 Flow transmitter flange details shall be covered in next revision. 8 10% Margin has been considered for all piping & all Fittings.

System : Effluent System

ITEM: PIPE

SL.No. MATERIAL ENDS REMARKS

1 300 323.80 IS 3589 Fabricated from IS 2062 Gr.B

6.3 1400 BE -

2 150 168.30 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 745 BE

3 65 88.90 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 2290 BE

4 50 60.32 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 1800 Plain End One end of pipe to be provided with socket welded full

coupling.

5 40 48.26 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 5319 Plain End One end of pipe to be provided with socket welded full

coupling.

6 25 33.40 Mild Steel -IS 1239 Part1, ERW

Heavy Grade 25 Plain End One end of pipe to be provided with socket welded full

coupling.

ITEM: 90° ELBOW 1.5D

SL.No. MATERIAL ENDS REMARKS

1 300 323.80 A 234 Gr.WPB 6.3 20 BW

2 150 168.30 Mild Steel- IS 1239 Part 2

Heavy Grade 30 BW

3 65 88.90 Mild Steel- IS 1239 Part 2

Heavy Grade 30 BW -

4 50 60.32 Mild Steel- IS 1239 Part 2

Heavy Grade 30 SW -

5 40 48.26 Mild Steel- IS 1239 Part 2

Heavy Grade 30 SW -

6 25 33.40 Mild Steel- IS 1239 Part 2

Heavy Grade 20 SW

ITEM: EQUAL TEE

SL.No. MATERIAL ENDS REMARKS

2 150 168.30 Mild Steel- IS 1239 Part 2

Heavy Grade 5 BW

3 65 88.90 Mild Steel- IS 1239 Part 2

Heavy Grade 5 BW

4 50 60.32 Mild Steel- IS 1239 Part 2

Heavy Grade 5 SW -

5 40 48.26 Mild Steel- IS 1239 Part 2

Heavy Grade 5 SW -

6 25 33.40 Mild Steel- IS 1239 Part 3

Heavy Grade 5 SW -

Page 29: ESPECIFICACIONES STANDAR DE TUBERIAS

ITEM: HALF COUPLING

SL.No. MATERIAL END REMARKS

1 25 33.40 Mild Steel -IS 1239 Part 2 / A 105

#3000 25 SW -

ITEM: END CAP

SL.No. MATERIAL ENDS REMARKS

1 25 33.40 Mild Steel -IS 1239 Part2

Heavy Grade 25 SW End cap for vent and drain.

Note:

1 Pipe size, Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 2 Fitting size, Thickness and Quantity details have been indicated preliminary and which shall be finalised later. , Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. 4 10% Margin has been considered for all piping & all Fittings.

Page 30: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX-1.3 PIPING CLASSIFICATION

PIPING CLASSIFICATION NON IBR CHART 1

Corrosion Allowance -1 mm Hydrotest Pressure Factor -1.5

Instrument Air Distribution System Service Air Distribution System

Description Design Press. (bar g ) Design Temp. °C Description Design Pres. (bar g ) Design Temp. °C

Instrument Air Distribution Lines 10.5 50 Service Air Distribution Lines 10.5 50

Pipes Nominal Diameter (NB) 15 20 25 32 40 50 65 80 100 150

Outside Diameter (mm) 21.34 26.67 33.4 42.16 48.26 60.32 73.02 88.9 114.3 168.3

Pipe Thickness (mm) 3.2 3.2 4 4 4 4.5 4.5 4.8 5.4 5.4

Standard IS-1239 ( Part -I)

End type THREADED END/ BUTTWELD

Material Mild Steel - IS 1239 (Heavy Grade / Medium Grade ), ERW, Galvanised

Flanges Material ASTMA105, Galvanised

End Type /Facing /Class THREADED END / RAISED FACE /Class 150

Standard ASMEB16.5

Bolts / Nuts

Type FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.)

Material /Class BOLTS A193Gr. B7, Galvanised & NUTS A194 Gr. 2H, Galvanised/Class 150

Standard ASMEB 16.5/ASMEB 18.2.1 /ASME B 18.2.2/ASME B1.1

Gaskets Type 3MM THICKNESS SELF CENTERING FLAT RING

Material /Class CNAF (Compressed Non asbestos fibre) / Class 150

Standard ASME B16.21

Fittings End type THREADED END//BUTTWELD

Class / Thick TO MATCH PIPE THICKNESS

Standard IS-1239 (Part- 2 )

Material Mild Steel IS -1239, Galvanised

Note: 1. * - Pressure & Temperature have been indicated preliminary and subject to change. 2. Pipe thickness details have been indicated preliminary and subject to change.

Page 31: ESPECIFICACIONES STANDAR DE TUBERIAS

PIPING CLASSIFICATION NON IBR CHART 2

Corrosion Allowance -1 mm Hydrotest Pressure Factor -1.5

Potable Water System Potable Water System

Description Design Press. (bar g ) Design Temp. °C Description Design Pres. (bar g ) Design Temp. °C

Plant Potable Water Pump suction lines 3.5 50 Colony Potable Water Pump suction lines 3.5 50

Plant Potable Water Pump discharge lines 12 50 Colony Potable Water Pump discharge lines 10 50

Potable Water Distribution lines 3.6 50

Pipes Nominal Diameter (NB) 15 20 25 32 40 50 65 80 100 150 200

Outside Diameter (mm) 21.34 26.67 33.4 42.16 48.26 60.32 73.02 88.9 114.3 168.3 219.08

Pipe Thickness (mm) 3.2 3.2 4 4 4 4.5 4.5 4.8 5.4 5.4 6.3

Standard IS-1239 ( Part -I) IS-3589

End type THREADED END/ BUTT END BUTT WELDED END /BEVELED END WITH ZINC RICH ELECTRODE

Material Mild Steel – IS 1239 (Heavy Grade), ERW, Galvanised IS 3589 Fabricated from IS 2062 Gr.B , Galvanised

Flanges Material ASTMA105, Galvanised

End Type /Facing /Class THREADED END / FLAT FACE / Class 150

Standard ASMEB16.5

Bolts / Nuts

Type FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.)

Material /Class BOLTS A193Gr. B7, Galvanised & NUTS A194 Gr. 2H, Galvanised/Class 150

Standard ASMEB 16.5/ASMEB 18.2.1 /ASME B 18.2.2/ASME B1.1

Gaskets Type 3MM THICKNESS SELF CENTERING FLAT RING

Material /Class CNAF (Compressed Non asbestos fibre) / Class 150

Standard ASME B16.21

Fittings End type THREADED END BUTT WELDED END /BEVELED END WITH ZINC RICH ELECTRODE

Class / Thick TO MATCH PIPE THICKNESS TO MATCH PIPE THICKNESS

Standard IS-1239 (Part-2) ASMEB 16.9

Material Mild Steel IS-1239, Galvanised ASTM A 234 Gr. WPB, Galvanised

Note: 1. * - Pressure & Temperature have been indicated preliminary and subject to change. 2. Pipe thickness details have been indicated preliminary and subject to change.

PIPING CLASSIFICATION NON IBR CHART 3

Corrosion Allowance - 0 mm Hydrotest Pressure Factor -1.5

DM Feed Water System DM Feed Water System

Description Design Press. ( Bar g ) Design Temp. °C Description Design Press. ( Bar g Design Temp. °C

DM Water Transfer Pump Suction line 3.5 50 DM Cooling Water Make up Pump Suction lines 3.5 50

DM Water Transfer Pump Discharge lines 3.5 50 DM Cooling Water Make up Pump Discharge lines 5.5 50

Hot Well Make up Pump Suction lines 3.5 50 Boiler Fill Pump Suction lines 3.5 50

Hot Well Make up Pump Discharge lines 5.5 50 Boiler Fill Pump Discharge lines 16.32 50

Page 32: ESPECIFICACIONES STANDAR DE TUBERIAS

Pipes Nominal Diameter (NB) 15 20 25 32 40 50 65 80 100 150 200 250 400

Outside Diameter (mm) 21.34 26.67 33.4 42.16 48.26 60.32 73.02 88.9 114.3 168.3 219.08 273.05 406.40

Pipe Thickness (mm) 40 10S 5S

Standard ASMEB36.19M

End type PLAIN END BUTT WELDED END / BEVELED END

Material STAINLESS STEEL ASTM A 312 TP 304, ERW

Flanges Material ASTMA 182Gr.F304

End Type /Facing /Class SOCKET WELDED / FLAT FACE / Class 150 SLIP ON / FLAT FACE / Class 150

Standard ASMEB16.5

Bolts / Nuts

Type FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.)

Material /Class ASTM A 193 Gr. B8M Cl.2 & A 194 Gr.B8M / Class 150

Standard ASMEB 16.5/ASMEB 18.2.1 /ASME B 18.2.2/ASME B1.1

Gaskets Type 3MM THICKNESS SELF CENTERING FLAT RI NG

Material /Class CNAF (Compressed Non asbestos fibre) / Class 150

Standard ASME B16.21

Fittings End type SOCKET WELDED END BUTT WELDED END / BEVELED END

Class / Thick Class 3000 TO MATCH PIPE THICKNESS

Standard ASMEB 16.11 ASMEB 16.9

Material ASTMA 182 Gr. F304 ASTMA403Gr.WP304

Note: 1. Design Pressure & Design Temperature have been indicated preliminary and subject to change. 2. Pipe thickness details have been indicated preliminary and subject to change.

PIPING CLASSIFICATION NON IBR CHART 4

Pipes Nominal Diameter (NB) 15 20 25 32 40 50 65 80 100 150 200 250 300 350 400 450 500 600 700 800 1000 1400 1200 1800 2200 2600

Outside Diameter (mm) 21.34 26.67 33.40 42.16 48.26 60.32 73.02 88.90 114.30 168.30 219.08 273.05 323.80 355.60 406.40

457.20 508.00 609.60 711.20 812.80 1016.00

1422.40 1219.20 1824.00 2224.00 2624.00

Pipe Thickness 3.2 3.2 4.5 4.5 4.8 5.4 5.4 6.30 6.30 6.30 6.30 6.30 6.30 6.30 6.30 6.30 7.10 10.00 12.00 10.00 12.00 12.00 12.00

Standard IS-1239 (Par t- I ) IS - 3589 AWWA C200 / AWWA M11

Page 33: ESPECIFICACIONES STANDAR DE TUBERIAS

Material Mild Steel - IS 1239 (Heavy Grade) , ERW IS 3589 Fabricated from IS 2062 Gr.B AWWA M11 Fabricated from IS 2062 Gr.B

Flanges

End Type / Facing /Class SOCKET WELDED / FLAT FACE / Class 150

SLIP ON/FLAT FACE/Class 150 SLIP ON/FLAT FACE / Class B or Class D

Standard ASMEB16.5 AWWA C 207

Bolts / Nuts

Material / Class BOLTS A193Gr. B 7 & NUTS A194 Gr. 2H/Class 150

Standard ASME B 16.5 / ASME B 18.2.1 / ASME B 18.2.2 / ASME B1.1

Gaskets

Material / Class CNAF (Compressed Non asbestos fibre /Class 150

Standard ASMEB16.21

Fittings End type SOCKET WELDED END BUTT WELDED END / BEVELED END

Class /Thick TO MATCH PIPE THICKNESS TO MATCH PIPE THICKNESS

Standard IS 1239 (Part-2) IS 1239 (Part-2) ASME B 16.9 AWWA C 208 / BS 534

Material Mild Stee - IS 1239 ld

Mild Ste

! -IS 1239 ASTM A 234 Gr. WPB

Fabricated From Mild Steel IS 2062 Gr.B

Note: 1. * - Pressure & Temperature have been indicated preliminary and subject to change.

2. * * - Pressure details shall be provided later

3. Pipe thickness details have been indicated preliminary and subject to change.

4. Miter Bends shall be used for size 300NB and above.

5. Epoxy coating shall be provided above 500NB pipe size for CW Piping system, ACW Piping system and Raw Water System

Page 34: ESPECIFICACIONES STANDAR DE TUBERIAS

SECTION - 2.0 DETAILED TECHNICAL SPECIFICATION

SECTION - 2.1

DETAILED TECHNICAL SPECIFICATION -FABRICATION, ERECTION, TESTING & COMMISSIONING

SECTION CONTENTS SHEET NO

2.1 TECHNICAL SPECIFICATION FOR

ERECTION OF LP PIPING 14

2.2 TECHNICAL SPECIFICATION-WELDING PROCEDURE 23

2.3 TECHNICAL SPECIFICATION - ERECTION OF 06BURIED PIPING

2.4 TECHNICAL SPECIFICATION - HYDRO TEST PROCEDURE 05

2.5 TECHNICAL SPECIFICATION - LP PIPING FLUSHING ANDCLEANING PROCEDURE 05

2.6 TECHNICAL SPECIFICATION-WRAPPING& COATING

OF BURIED PIPING 06

SECTION - 2.1

TECHNICAL SPECIFICATION ERECTION OF LP PIPING

TABLE OF CONTENTS

1.0.0 INTENT OF SPECIFICATION.........................................................................................................3

2.0.0 CODES AND STANDARDS............................................................................................................3

3.0.0 SCOPE OF WORK.........................................................................................................................4

4.0.0 EXCLUSIONS.................................................................................................................................6

5.0.0 LAYOUT, CUTTING AND FITTING UP...........................................................................................6

6.0.0 ERECTION......................................................................................................................................9

7.0.0 BURIED PIPING............................................................................................................................10

8.0.0 INSTALLATION AND ASSEMBLY................................................................................................10

9.0.0 ERECTION OF VALVES...............................................................................................................11

10.0.0 ERECTION OF SUPPORTS.........................................................................................................12

11.0.0 ERECTION OF INSTRUMENTS...................................................................................................12

12.0.0 LINE MOUNTED FILTERS, SIMPLEX/DUPLEX FILTERS, MIXERS & FLEXIBLE

HOSES........................................................................................................................................12

13.0.0 INSPECTION................................................................................................................................13

14.0.0 MATERIAL IDENTIFICATION.......................................................................................................13

15.0.0 HYDROTEST................................................................................................................................14

16.0.0 INSTRUMENT CONNECTIONS....................................................................................................14

17.0.0 RECORDS....................................................................................................................................14

Page 35: ESPECIFICACIONES STANDAR DE TUBERIAS

SECTION 2.1

TECHNICAL SPECIFICATION ERECTION OF LP PIPING

1.0.0 INTENT OF SPECIFICATION

This specification covers the minimum requirements and guidelines to be adhered by the Bidder for the Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Fabrication of Supports (Support material will be free issued by owner), Laying, Erection, inspection & testing at site, cleaning & painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping, valves, supports and specialties etc.

The LP piping Erection comprises the following:

• Instrument Air Distribution System

• Service Air Distribution System

• Service Water Distribution System

• Potable Water Distribution System.

• DM Feed Water System

a) DM Water Transfer Pumps all suction, discharge and recirculation lines.

b) Hot Well Make up Pumps all suction, discharge and recirculation lines.

c) DM Cooling Water Make up Pumps suction, discharge and recirculation lines.

d) Boiler Feed Pumps suction, discharge and recirculation lines (Condensate Makeup line).

• Plant Water System -I

a) Raw Water System.

b) APH Wash pumps all suction and discharge lines.

c) Ash Water Tank Fill pumps suction and discharge lines.

d) Service Water Pumps suction and discharge lines

e) DM plant pumps suction lines.

f) AHS Seal Pumps suction lines.

• Plant Water System - II

a) Plant Potable Water pumps all suction and discharge lines.

b) Colony Potable Water pumps all suction and discharge lines.

• CW Blow down System.

• Wash Water System.

• Effluent System.

• Sludge Water system.

• All pipe line headers.

• All tanks external down comer pipe lines, over flow lines, vent pipe lines and draw ofsump lines.

• DM Cooling Water Supply & Return Line for Main Plant compressor & Ash Handlingcompressor.

• SSF Backwash line.

Page 36: ESPECIFICACIONES STANDAR DE TUBERIAS

2.0.0 CODES AND STANDARDS

The erection and testing of piping, valves, specialities and flash vessels, shall comply with the requirements of latest edition of ASME B31.1. The following standards shall be followed in particular.

• ANSIB31.1 Power Piping

• ANSI B 2.1 Pipe threads

• ANSI B16.9 Wrought steel Butt Welding Fittings.

• ANSI B 16.20 Ring joint gaskets and grooves for steel pipe flanges

• ANSI B 16.25 Butt welding ends

• IS:803 Code for design, testing and erection of mild steel storage tanks.

• ASME BPVC Sec V Non destructive Examination

• ASME BPVC Sec VII Pressure Vessels

• ASME BPVC Sec IX Welding and Brazing qualifications.

• MSS-SP-55 Visual inspection & testing

• MSS-SP-53 Magnetic particle testing

• MSS-SP-54 Radiographic testing

• AWWA-M11 Steel Pipe - A guide for Design and Installation.

• AWWA-C206 Standard for Field Welding of Steel Water Pipe.

• AWWA-C208 Dimension for fabricated steel water pipe fittings.

• AWWA-C200 Standard for Steel Water Pipe 6 in.(150mm) and larger.

Page 37: ESPECIFICACIONES STANDAR DE TUBERIAS

3.0.0 SCOPE OF WORK

• The scope of work covered in this document include but not limited to the following.

• Supply and receipt of materials, unloading, handling, identification, Prefabricationincluding cold bending of pipes, erection of complete piping, valves and specialities, allfield welding of pipes and fabrication of pipes, fittings & supports, heat treatment, pre-qualification of welding procedures and welders (WPS, PQR), NDT examinations as perASME sec IX, flushing, Hydro testing, cleaning including steam blowing as per thespecification given hereinafter. The quantity of piping and equipment to be fabricated,erected, installed and tested shall be as per the erection drawings.

• Erection of all rod hangers and supports including auxiliary structures as required.

• Execution of field engineering, modification during execution, hydro testing etc. TheTenderer shall supply all required piping / supports etc on take back basis afterdismantling the same.

• Supply and application of coating and wrapping for all buried piping.

• Supply and application of grouting material including non-shrinkable cement and erectionof grouting.

• Supply and application painting for above ground piping.

• Supply and application of cathodic protection for all buried piping.

• The Purchaser/Consultant will furnish isometric drawings for all LP lines above 2".Tenderer shall prepare isometrics for lines below 2" based on site routing and get theapproval of the Purchaser/ Consultant during the time of erection.

• The Tenderer shall prepare the erection drawings for all LP piping lines.

• Providing all labour, material, consumables and equipment as necessary for fabrication,manufacture and testing at site as required.

Broad Guidelines for Erection and Installation of Low Pressure Piping

• All fittings like "T” pieces, weld neck flanges, reducers, etc., shall be suitably matched withpipes for welding. The valves shall be checked, cleaned, or overhauled in full or in partbefore erection, after chemical cleaning, and during commissioning.

Adjustments such as removal of ovailties in pipes, and opening or closing the fabricated bends of high-pressure piping to suit the layout shall be considered part of the work and the Contractor is required to carry out such work, which shall include specified heat treatment procedures, etc., wherever required.

Certain adjustments in length may be necessary while erecting high-pressure pipelines and the Contractor shall remove the extra lengths / add extra lengths to suit the final layout after preparing edges afresh and adopting specified heat treatment procedures.

Suspension for piping, pressure parts, etc., shall be supplied in running lengths which shall be cut to suitably sizes and adjusted as required.

All the valves, lighting equipment, actuators, power cylinders. etc., shall be serviced and lubricated before erecting the same and also during precommissioning. Even after commissioning the equipment, if there are problems in the operation, these shall be attended to by the Contractor.

Welding or jointing of extension spindle for valves to suit the site conditions and operational facility shall be part of erection work.

All tubes and pipes shall be cleaned and blown with compressed air before erection. Bigger size pipes shall be cleaned with flexible wire brush, wherever necessary.

Fine fittings, drain piping, oil systems, and other small bore piping have to be routed according to site conditions and hence shall be done only in position. As such, layout of small bore piping shall be done in accordance with site requirement. There is a possibility of slight change in routing the above pipelines even after completion of erection. Work shall also include fabrication of small bends at site from straight lengths to suit the site conditions.

No temporary supports shall be welded on the pressure parts. Welding of temporary

Page 38: ESPECIFICACIONES STANDAR DE TUBERIAS

supports, cleats, etc., on the building columns shall also be avoided.

(a) All pipes shall be grouped wherever practicable and shall be routed to present a neatappearance.

(b) The piping shall be arranged to provide clearance for the removal of equipment formaintenance and for easy access to valves, instruments, and other pipingaccessories required for operation and maintenance.

(c) Piping shall be generally routed above ground but, where specifically indicated /approved, piping may be arranged in trenches or buried.

(d) Overhead piping shall generally have a minimum overhead clearance of 2.3 metersabove walkways and working areas and 6 metres above roadways.

(e) Drains shall be provided at all low points and vents at high points in accordance withactual layout regardless of whether the same have been shown in the respectivedrawings or not. The pipelines shall be sloped towards the drain points.

(f) For field run piping, the Contractor shall fabricate and erect all hangers and supportsas required with due regard to general arrangement and layout of other pipes,hangers, cable trays, ducting, structural members etc.

All drips and drains for piping and equipment whether shown on the drawings or not shall terminate on the ground floor at the station drain unless otherwise noted. Leading such drains to the station drainage is also the responsibility of the Contractor.

4.0.0 EXCLUSIONS Mechanical:

• Erection of Piping beyond battery limits.

• All valves their counter flanges along with fastener and gaskets.

• All specialties their counter flanges along with fastener and gaskets.

• All instruments with their accessories.

• Supply of pipes and fittings (other than fabricated from the plate material).

• Plate for fabricated pipe and fittings.

• Pipe Support materials.

Civil:

• All Civil Engineering works such as RCC foundation, buildings, roads, pipe racks/ pipetrenches etc.

• Making opening in the walls for routing of pipes

• Encasement for the buried piping.

5.0.0 LAYOUT, CUTTING AND FITTING UP 5.1.0 Cutting and fitting-up

• Pipes shall be cut to required length in accordance with piping layout drawings and/orspool drawings.

Preparation of pipe ends shall preferably be done by any combination of turning and grinding. When oxygen or arc cutting is resorted to then the cut shall be reasonably smooth and true and all slag is cleaned from the flame cut surfaces.

Preparation of butt welding joints shall be as per ASME B 31.1/as per enclosed figure elsewhere in this tender document, unless otherwise approved by the Engineer.

• The ends of piping components to be joined shall be aligned as accurately as ispracticable within existing tolerance on diameters, wall thickness and out-of-roundness.

Internal radial misalignment exceeding 1.6 mm shall be taper trimmed as per enclosed figure elsewhere in this tender document, after getting approval from Engineer.

5.2.0 Branch Connections

Page 39: ESPECIFICACIONES STANDAR DE TUBERIAS

• Openings for branch connections shall preferably be made by drilling. Oxygen or arccutting is acceptable only if the cut is reasonably smooth and true and all slag is cleanedfrom the flame cut surfaces.

• End preparation of branch and runner pipe shall be as per the relevant clause ofASME B31.1. Edge Preparation details for branch connection joints shall be subjected toapproval of Consultant/ Purchaser.

5.3.0 Minimum Distance between Longitudinal Welds

The distance between two longitudinal weld shall be staggered suitably. 5.4.0 Flanged Connections

Flange bolt holes shall straddle the established center-lines (horizontal or vertical) unless otherwise shown.

5.5.0 Threaded Connections

Taper pipe threads shall be used in accordance with ANSI B.2.1 "Pipe Threads" for threaded pipe joints.

5.6.0 Bending

Hot bending is not permitted except for non- pressure piping such as drain and vent lines. Cold bending is only permitted and no hot bending is envisaged at site.

5.7.0 Mitre Bends

Mitre bends shall be fabricated in accordance with "Piping Standard Drawing" unless otherwise specified in piping GA drawing. Single cut mitre are not allowed.

5.8.0 Threaded Joints

When threaded couplings or nipples are welded to the pipe spools, the thread must be checked for fit and roundness after welding.

5.9.0 Heat Tracing

Wherever applicable pipes should be installed along with heat tracer pipes as per the details given in the piping layout drawings. Heat tracer pipes shall be of non-cementing type with the main pipe line.

5.10.0 Layout

• For laying out headers, tees, laterals and other irregular details, templates shall be usedto ensure accurate cutting and proper fit-up.

• All cutting shall follow the outline of the template.

• Machine cut bevels to form the welding groove are preferred in carbon steel pipe.However, smooth, clean, slag free, flame cut bevels using flame bevel cutting machines.

• All buried piping shall be as per the specification given in Section 2.4.5.11.0 Dimensional Tolerances

The dimension tolerances generally acceptable are as follows

a. Face to face/center to face : ± 3 mm (max)

b. Lateral translation in any

direction : ± 1.5 mm (max)

c. Rotation : ±1.5 deg (max)

d. Out of alignment measured

across the diameter : ±1 mm

e. Flattening measured as difference between maximum and minimum OD at any CrossSection.

i. For pipe with external

Page 40: ESPECIFICACIONES STANDAR DE TUBERIAS

pressure : 3% (max)

ii. For pipe with internal

pressure : 8% (max)

Tenderer shall be responsible for working to the dimensions shown in the drawing. However, there may be slight variations due to minor variation in the location of equipment, insert etc. Field welds (F.W) to be provided to take care of these. An extra pipe length of 100 mm over and above the dimension shown in the drawing may be left on one side of the pipe at each end of field weld. During erection the pipe end with extra length of each field weld may be cut to obtain proper dimension. The Tenderer shall provide adequate number of field welds. Wherever omissions/ errors occur in drawings and bill of materials, it shall be the responsibility of the Tenderer to notify the Purchaser prior to fabrication and erection.

5.12.0 Pipe Joints

Pipe joints shall be generally welded or as indicated in Piping drawings. In general, BW joints shall be used for 65 NB and above and SW/Threaded/BW joints shall be used for sizes 50 NB and below as specified in piping drawings. However, BW joints may be used after getting prior approval from Purchaser/Consultant in place of SW/Threaded connections in long runs of piping. This is applicable for non-galvanised piping and piping without lining. All welding shall be as per the welding procedure specified.

Flanged joints shall be used at connections to vessels, equipment and where required for ease of erection and maintenance as indicated in drawing.

5.13.0 Piping Alignment

The pipes to be jointed by welding shall be aligned correctly with the existing tolerances on diameters, wall thickness and out of roundness. The same alignment shall be preserved during welding. For the internal misalignment due to difference in wall thickness of the mating components exceeding 1.5 mm, the component with the higher wall thickness shall be internally machined ground so that the adjoining surfaces are approximately flushed.

5.14.0 Cleaning of Piping

On completion of fabrication, all pipes and fittings shall be cleaned inside and outside by suitable means (Mechanical tools, wire brush etc.) before erection to ensure that assembly is free from all loose foreign material such as scale, sand, weld spatter particles, cutting chips etc.

All field fabricated piping shall be cleaned at the conclusion of the fabrication. All burrs, welding circles and weld spatter shall be removed by any suitable means (mechanical tools, wire brush etc.)

Field fabricated piping shall be blown out with compressed air at the termination of cleaning and capped.

5.15.0 Quality Control For Welding

5.15.1 Welding Machines

1. DC Machines only to be used.

Inspection and Maintenance of Welding Machines.

Welding machines shall be periodically inspected at least once a month for maintenance.

This inspection and maintenance shall be done mainly for quality control purpose and shall be periodically recorded in a list showing the location and conditions of the welding machines being used.

5.15.2 Installation

a) Location of welding machines and the switch boards to be connected with them shall bedecided in consultation with Engineer to prevent them for disturbing other work as well asto prevent overloading of the switchboards, cables and electrical power sources. Properearthing to be provided for welding machine.

b) Electric cables, switches and connections for welding machines shall be carefullychecked and repaired atleast once a month and before operating the welding machines.

c) Portable power cables used with welding machines shall be carefully examined and

Page 41: ESPECIFICACIONES STANDAR DE TUBERIAS

repaired as necessary every day.

d) Proper earthing of the welding machines shall be ensured by the Tenderer.

5.16.0 Welding

5.16.1 General

a) All welding and heat treatment shall be performed in accordance with the weldingrequirements detailed in ASME B31.1.

b) No welding shall be done if there is impingement of any rain, or high winds on the weldarea except when suitable protection or shield against the rain or wind is provided.

c) Before welding, the ends shall be cleaned by wire brushing, filing or grinding. Each weld-run shall be cleaned of slag before the next run is deposited.

d) Welding shall be done by certified welders only. Welding procedure and welderqualification records shall be maintained for reference of Purchaser/Consultant at anytime.

e) Welding at any joint shall be completed uninterrupted. If this cannot be followed for somereason, the weld shall be completely removed and a new joint shall be made.

f) Welding shall be done by manual shielded metal arc process and TIG welding asapplicable. Automatic or semi-automatic welding processes may be done only with thespecific approval of Purchaser/ Consultant.

5.16.2 Welding Procedure

For detailed welding procedure refer Section -2.3 enclosed along with this section. 6.0.0 ERECTION

6.1.0 All piping shall be routed and located as shown in piping drawings keeping in view the piping specifications. No deviations from the arrangement shown shall be permitted without the approval of the Engineer.

6.2.0 For erection of piping, use of davits, welding of temporary supports on adjacent equipment / structure, use of existing foundation or steel structure shall be allowed only after approval of Engineer-in-charge. In each case, maximum allowable load and erection procedure shall be as directed by the Engineer-in-charge.

6.3.0 Location and design of pipe supports shown in support drawings should be strictly adhered to. Pipe supports have been designed and located to effectively sustain the piping system for weight and thermal offsets.

6.4.0 Erection and fabrication or supports i.e. restraints such as guides, stops and anchors must be made in such a manner that they will not over stress a line while protecting a weaker or more sensitive component e.g. turbine, pump compressor, vessel nozzles, etc.

6.5.0 Flanged connections at the pump, turbines, compressors and other equipment shall be made in such a way as not to induce any stresses due to misalignment, excessive gap etc. The final tightening shall be redone when the machines are aligned completely and specifically authorised by the Engineer. Pipes shall not be pulled and connected to equipment as well as during welding. Temporary protective covers shall be provided at all flanged connections of pumps, compressors, turbines and other similar equipment until the piping is finally connected.

6.6.0 Slopes specified for various lines in the drawings shall be maintained by the Tenderer. In case the Tenderer is unable to maintain the indicated slope he shall check the sagging of the pipe with a precision spirit level and maintain a difference in levels higher than that. Vents and drains are shown in the isometric of each line and these are intended for releasing the trapped air during hydrostatic test and draining out the test fluid after testing. Valved vents and drains are also shown wherever required. The Tenderer shall provide vent and drain connections even when these are not shown in the drawings and are found necessary by the Engineer. The details for the type of connections to be adopted shall be as per enclosed drawings.

6.7.0 After the piping is erected in final position, it shall be cleaned, tested for tightness and kept dry wherever instructed, as described in this specification.

7.0.0 BURIED PIPING

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Buried piping shall be as per detailed procedure enclosed as Annexure-3.2.0 along with this section.

8.0.0 INSTALLATION AND ASSEMBLY

8.1.0 General

a) Installation and assembly of fabricated spool and piping components shall be made so that the completely installed piping system conforms to the requirements of relevant drawings and specifications.

b) Care shall be taken to prevent damage to equipment nozzle caused by the weight and moment of fabricated spools or piping components. Permanent or suitable temporary pipe supports shall be installed prior to installation of such a piping.

8.2.0 Connection to Equipment Nozzles

a) Faces of flanges and the bolt holes shall accord reasonably to those of equipment nozzleflanges.

b) Lines connected to rotating machinery shall be aligned so as to meet the followingrequirements.

i) Flange faces which connect piping to the primarily aligned machinery shall be strictly parallel with the clearance between them equal to the thickness of the gasket so that alignment of the machinery after tightening the flanges will be within the allowable tolerances specified. No load shall be transferred to the connected equipment.

ii) Off-center of bolt holes shall be minimised so that the bolt can pass smoothly through the bolt holes.

The alignment of the piping shall be checked after completion of piping fabrication with flanges disconnected and witnessed by the Engineer.

8.3.0 Installation of Spools and Piping Components

a) Care shall be taken to protect/prevent tack welds at both weld ends from any damagecaused by weight and the moment of piping components.

b) For installation of angle, blow-down, check and needle valve, control valve and pressurerelief valve, the direction of those shall conform to the flow direction shown on pipingdrawings.

c) Direction of the pressure balancing hole for gate valves, if drilled, shall conform to pipingdrawings.

d) Care shall be taken that the faces of companion flanges for flanged cast iron componentsshall be parallel with the required clearance for gasket thickness and that the flange boltsshall not be off-centre.

8.4.0 Bolting Procedure

8.4.1 Anti galling compound shall be applied on all flanges bolts in order to prevent seizing.

8.4.2 All flanged joints shall be fitted so that the faces of the flange meet evenly with the gasket,and then the bolts shall be tightened in a sequence to ensure uniform bolt stress.

8.4.3 In bolting flanged joints, the bolt shall be tightened in a proper manner to compress the gasketto build up a compression suitable for the type of gasket used.

8.4.4 Steel-to-cast iron flange joints shall be assembled with care to prevent damage of the castiron flange.

8.4.5 All bolts shall extend completely and uniformly through their nuts.

Bolt loads shall be in accordance with the manufacturer's recommendation.

8.5.0 Threaded Piping

8.5.1 Teflon seal tape shall be used for all threaded piping. No lead based component shall beused.

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9.0.0 ERECTION OF VALVES

9.1.0 Erection and testing of the valves shall be in accordance with the applicable standards.

9.2.0 Valve spindle positions are shown in the arrangement drawings and the Tenderer shall be required to follow them. He shall, however, bring it to the notice of the Engineer in case he encounters some difficulty in installing them.

9.3.0 Where practicable and except when otherwise shown on the drawings, valve stems shall be installed in a vertical direction and shall not be installed with stems below the horizontal.

9.4.0 For Safety valves, Pressure relief valves, Rupture discs and other safety devices against excess pressure the directives of the Appendix II of the code ANSI B 31.1. "Non mandatory rules for design and safety valve installations" shall apply.

9.5.0 All globe valves shall be installed with the pressure on the bottom of the disc.

9.6.0 Globe valve, check valve, control valves etc. shall be installed in the correct sequence and direction as shown in P&I diagram and piping drawings.

10.0.0 ERECTION OF SUPPORTS 10.1.0 Welding

Pipe supports which are welded to the pressurised pipe directly, shall be welded by qualified pipe welders.

10.2.0 Fabrication

All supports shall be properly levelled and plumbed as per pipe support drawings. Shims and wedges may be employed for levelling and alignment of the supports on the grade. Rigid temporary wooden frames or other suitable devices may be used for supporting piping before installation of pipe supports.

10.3.0 Supports Permitting Pipe Movement

Supports permitting pipe movement shall be assembled to allow the necessary movement of pipes as caused by thermal expansion and contraction in accordance with the piping drawing and stress analysis reports giving details of movements at individual support locations.

10.4.0 Bracing

10.4.1 The first nipple and valve of small connections including instrument connections to piping,vessel or equipment shall be braced if required.

10.4.2 For 2" and smaller piping, additional pipe supports may be installed to improve the stability ofthe piping after approval of the Engineer.

11.0.0 ERECTION OF INSTRUMENTS

11.1.0 All in-line instruments shall be installed only after final flushing of the line and when the line is ready for commissioning.

11.2.0 The limits of piping Tenderer are clearly shown in the drawings provided (such as upto first block valve, nozzle and flange, taps etc.). In addition to this, he shall install all the in-line instruments such as orifice flanges including orifice plates, with valves, venturi control valves, flow integrators, positive displacement meters with strainers, pressure relief/safety valves, rotameters, rupture/bursting discs etc.

11.3.0 For installation of all in-line instruments, reference may be made to relevant clause of the chapter for pressure testing inspection procedures.

11.4.0 Care shall be exercised and adequate precautions to be taken to avoid damage to the instruments while transportation, installation etc. protection cover shall be used at control valves, flow meter etc. to avoid contamination with dust and foreign matter.

12.0.0 LINE MOUNTED FILTERS, SIMPLEX/DUPLEX FILTERS, MIXERS & FLEXIBLE HOSES

12.1.0 Installation of line mounted filters with by-pass arrangements, or any other arrangements, if any, duplex filters, mixers, ejectors including installation of all types of supports will be done by the Tenderer as part of piping erection work.

12.2.0 Installation of temporary strainers as per requirements either during finishing or start-up, its cleaning and up-keeping shall be part of the piping erection work and no separate payment shall

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be made on this account.

12.3.0 Flexible hoses shall be installed on the suction of naphtha and distillate unloading pump as indicated in relevant piping layout maintaining necessary slope.

12.4.0 Bolts, Nuts

12.4.1 During erection of the piping, the Tenderer shall install proper number and size of bolts andnuts as per drawings and specifications.

12.4.2 Grease and Graphite shall be supplied by the Tenderer.

12.4.3 All bolts shall extend completely through their nuts. Only bolts of adequate length, requireddie, specified material and machining quality shall be used. The number, material shall bereadable for all the same side. Hexagonal bolt heads shall be all at the same side withhorizontal flanges at the top. Threaded ends with machine bolts shall protrude adequatelythrough the nuts. Bolts/stud threads and compressed asbestos gaskets shall be treated withgraphite oil before assembly or as per the specification.

13.0.0 INSPECTION

13.1.0 General

13.1.1 Purchaser's/Consultant's inspector shall have free access to all places where the work isbeing done or any other place concerned with the work.

13.1.2 Purchaser is entitled to send his own inspector or his representative to field where pre-fabrication and erection of pipe lines are being done, with the following functions but notlimited to:

i. To check that the execution of welding and welding equipment used on the job are suitable and conform to relevant standards.

ii. To supervise welding procedure qualification, iii. To supervise welder performance qualification.

iv To check whether welding is conforming to relevant specification and the procedure followed and is in accordance with good pipeline construction practice.

v. To check any other activity to ensure quality of work.

13.1.3 Tenderer shall notify inspection dates sufficiently in advance with all facilities necessary forcarrying out his work at no extra cost to the Purchaser.

13.1.4 Approval from the Purchaser's inspector shall not relieve the Tenderer partially or fully of hisresponsibilities and guarantees under this Work order.

13.2.0 Details of inspection and defect acceptance norms its repair and removal shall be as per this tender document.

14.0.0 MATERIAL IDENTIFICATION

Specification of all materials shall be as per the relevant piping drawings and piping service sections.

14.1.0 Material Check

a) All the materials before usage the materials shall be identified by means of stencil and/orcolour identification or other marking.

14.2.0 Thickness and Pressure Temperature Rating

a) Thickness and pressure temperature rating of piping components to be used shall bechecked by stencil or other marking and measurement referring to the material shown onpiping drawing and piping service classes.

b) Markings on pipe stencilled by manufacturer shall be left until final use of the pipe and betransferred by painting on to the length to be cut off prior to cutting.

15.0.0 HYDROTEST

Hydrotest shall be as per Section 2.5 of this tender document. 16.0.0 INSTRUMENT CONNECTIONS

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16.1.0 Stubs with root valves shall be provided for all pressure connections and half couplings shall be provided forthermowells.

17.0.0 RECORDS

Fabrication details and results of inspection of piping shall be recorded on the piping drawings for records.

SECTION - 2.2

TECHNICAL SPECIFICATION WELDING PROCEDURE

TABLE OF COTNENTS

1.0.0 INTENT OF SPECIFICATION........................................................................................................3

2.0.0 APPLICABLE CODES AND STANDARDS....................................................................................4

3.0.0 BASE METAL.................................................................................................................................4

4.0.0 GENERAL STORAGE OF WELDING CONSUMABLES.................................................................4

5.0.0 EQUIPMENT AND ACCESSORIES...............................................................................................5

6.0.0 WELDING PROCESS.....................................................................................................................5

7.0.0 EDGE PREPARATION..................................................................................................................5

8.0.0 ALIGNMENT& SPACING..............................................................................................................6

9.0.0 WELDING TECHNIQUE.................................................................................................................7

10.0.0 WELDING PROCEDURE QUALIFICATION....................................................................................8

11.0.0 WELDER'S QUALIFICATION.........................................................................................................8

12.0.0 WELD HEAT TREATMENT PROCEDURES...................................................................................8

13.0.0 INSPECTION AND TESTING.........................................................................................................9

14.0.0 SAFETY REQUIREMENTS..........................................................................................................13

ANNEX- A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS...............................................15

ANNEX-B: FORMAT FOR PROCEDURE QUALIFICATION RECORD...................................................17

ANNEX - C : FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR

QUALIFICATION TESTS......................................................................................................19

ANNEX - D : FORMAT FOR STRESS RELIEF HEAT TREATMENT PROCEDURE

SPECIFICATION..................................................................................................................20

ANNEX-E: RADIOGRAPHIC TECHNIQUE LOG.....................................................................................21

ANNEX- F: WELDER'S IDENTIFICATION CARD....................................................................................22

ANNEX-G: LIST OF APPROVED ELECTRODE MANUFACTURER.......................................................23

SECTION 2.2 TECHHNICAL SPECIFICATION - WELDING PROCEDURE

1.0.0 INTENT OF SPECIFICATION

This specification shall be followed for the fabrication of all types of welded joints of carbon steel / mild steel LP piping system within the battery limits of the plant.

• Instrument Air Distribution System

• Service Air Distribution System

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• Service Water Distribution System

• Potable Water Distribution System.

• DM Feed Water System

a) DM Water Transfer Pumps all suction, discharge and recirculation lines.

b) Hot Well Make up Pumps all suction, discharge and recirculation lines.

c) DM Cooling Water Make up Pumps suction, discharge and recirculation lines.

d) Boiler Feed Pumps suction, discharge and recirculation lines (Condensate Makeup line).

• Plant Water System -I

a) Raw Water System.

b) APH Wash pumps all suction and discharge lines.

c) Ash Water Tank Fill pumps suction and discharge lines.

d) Service Water Pumps suction and discharge lines

e) DM plant pumps suction lines.

f) AHS Seal Pumps suction lines.

• Plant Water System - II

a) Plant Potable Water pumps all suction and discharge lines.

b) Colony Potable Water pumps all suction and discharge lines.

• CW Blow down System.

• Wash Water System.

• Effluent System.

• Sludge Water system.

• All pipe line headers.

• All tanks external down comer pipe lines, over flow lines, vent pipe lines and draw ofsump lines.

• DM Cooling Water Supply & Return Line for Main Plant compressor & Ash Handlingcompressor.

(Instrument Air System / Service Air System / Potable water system pipes (upto 150NB) are of threaded ends, hence it will not come under the purview of this document).

The welded pipe joints shall include the following:-

a. All pipe joints of the longitudinal and circumferential butt welded and socket welded types.

b. Attachments of forgings, flanges and other supports to pipes.

c. Welded manifold headers and other sub-assemblies.

d. Welded branch connections with or without reinforcing pads.

e. Joints in welded / fabricated piping components.

f. The attachments of smaller connections for vents, drain drips and other instrumenttappings.

Any approval granted by the Engineer-in-Charge or Owner's inspector, shall not relieve the Contractor of his responsibilities and guarantee.

2.0.0 APPLICABLE CODES AND STANDARDS

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All welding works, equipments for welding heat treatment other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the following acceptable standards and procedures unless otherwise specified in the welding specification chart. In case of conflicting requirements, the requirements mentioned in welding specification chart/Technical notes shall be applicable.

Since this section covers welding procedure for LP piping all IBR related procedure may be ignored.

ANSIB31.1 Power piping

ANSI B16.9 Wrought steel Butt Welding Fittings

IBR Indian Boiler Regulations

In addition, the following codes and specifications referred in the relevant code of fabrication shall be followed for the welding qualifications, consumable qualifications and non-destructive test procedures.

ASME BPVC Sec.IX Welding and Brazing Qualifications

ASME BPVC Sec.V Non destructive examination

ASME Sec.II Part C Material specifications; welding rods, electrodes and filler metals.

IS: 2825 Code for Unfired Pressure Vessels

MSS-SP-55 Visual inspection and testing

MSS-SP-53 Magnetic particle testing

MSS-SP-54 Radiographic testing

3.0.0 BASE METAL

Base metal shall be as detailed in Welding Specification chart. 4.0.0 GENERAL STORAGE OF WELDING CONSUMABLES

The welding electrodes and filler wires supplied shall confirm to the class specified in the welding specification chart.

Electrode qualification test record have to submitted in the enclosed format.

Batch test certificates has to be submitted from the electrode manufactures, giving details of physical and chemical tests carried out has to be submitted by them.

All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration.

Welding rods shall be stored indoors free from moisture. The package of the welding rods shall not be opened until immediately buffer use.

Drying of welding rods

Welding rods shall be baked in a heating cabinet in accordance with the manufacturer's recommendation. Welding rods not consumed in a day shall be baked by the same method with only two rebakings permitted. Portable ovens shall be utilized to maintain a temperature of 80°C at actual site locations.

Handling of welding rods being used

During welding work welding rods shall not be laid down directly on the ground or any other humid place to ensure that rods are not damaged by moisture.

5.0.0 EQUIPMENT AND ACCESSORIES

5.1.0 All the equipments for performing the heat treatment, including transformers, thermo-couples, pyro-meters, automatic temperature recorders with suitable calibration certifications shall be provided duly approved by Engineer.

5.2.0 The make & type of radiographic equipments, radiographic films, and all the equipments/materials required for carrying out the dye-penetrant/magnetic particle test shall be subjected to approval of Engineer in charge. All statutory regulations shall be adhered to (including qualification of personnel) for radiographic equipments & personnel.

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6.0.0 WELDING PROCESS

6.1.0 Welding of various materials under this specification shall be carried out at site using one or more of the following processes with the approval of the Engineer-in-charge.

Shielded Metal Arc Welding Process (SMAW) Gas Tungsten Arc Welding Process (GTAW)

6.2.0 The welding processes to be employed are given in the Welding Specification Chart. Any deviation desired shall be done through the consent of the Engineer-in-charge.

6.3.0 Automatic and semi-automatic welding processes shall be employed only with the approval of the Engineer-in-charge. The welding procedure adopted and consumables used shall be specifically approved.

6.4.0 A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-charge.

7.0.0 EDGE PREPARATION

7.1.0 The edges to be welded shall be prepared to meet the joint design requirements by any of the following methods recommended. Edge shall conform to B31.1

a) Carbon Steel

Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides shall be removed by chipping or grinding.

b) Low Alloy Steels (containing upto 2/4% Chromium) (Not applicable for LP piping)

Gas cutting, machining or grinding, methods shall be used. After gas cutting, machining or grinding shall be carried out on the cut surface.

c) High alloy steels, cupro-nickel, nickel alloys, and aluminium alloys:

Plasma cutting, machining or grinding methods shall be used. After plasma cutting, cut surfaces shall be machined or ground smooth.

7.2.0 Cleaning

7.2.1 The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides,sand, earth and other foreign matter. The ends shall be completely dry before the weldingcommences.

7.2.2 On completion of each run, craters, welding irregularities, slag etc., shall be removed bygrinding and chiseling. Wire brushes used for cleaning stainless steel joints shall havestainless steel wires and the grinding wheels used for grinding stainless steel shall be of asuitable type. Suitable grinding wheels and wire brushes should be used for carbon steelsand stainless steels.

8.0.0 ALIGNMENT & SPACING

8.1.0 Components to be welded shall be aligned and spaced as per the requirements laid down in applicable code. Special care must be taken to ensure proper fitting and alignment when the welding is performed by GTAW process. Flame heating for adjustment and correction of ends is not permitted unless specifically approved by the Engineer-in-charge.

8.2.0 A wire spacer of suitable diameter may be used to maintain the weld root opening while tacking, but it must be removed after tack welding and before laying the root bead.

8.3.0 For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in position with the aid of couplers, yokes and 'C clamps, to maintain perfect alignment. Yokes shall be detached after the completion of weld, without causing any surface irregularity. Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the Engineer-in-charge.

8.4.0 Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified welders. Since the tack welds become part of the final weldment they shall be executed carefully and shall be free from defects. Defective tack welds must be removed prior to the actual welding of the joints.

8.5.0 Tacks should be equally spaced. Minimum number of tacks shall be

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2 tacks - for 2/4" and smaller dia pipes

4 tacks - for 3" to 12" dia pipes

6" tacks - for 14" and larger dia pipes.

8.6.0 Engineer-in-charge shall check and approve the fit-up and alignment of pipe joint prior to the commencement of welding.

8.7.0 Dimensional tolerances generally acceptable are as follows.

8.7.1 Face to Face/Center to Face : ±3mm (Max)

8.7.2 Lateral translation in any : ±1.5 mm (Max)direction

8.7.3 Rotation : ±1 .5degMax

8.7.4 Out or alignment measured

across the diameter : ± 1 mm

9.0.0 WELDING TECHNIQUE 9.1.0 Root Pass

a) Root pass shall be made with electrodes/filler wires recommended in the weldingspecification chart. For fillet welding shall be done with consumables recommended forfiller passes. The preferable size of the electrodes is 2.5 mm diameter (12 SWG) but inany case not greater than 3.25 mm (10 SWG).

b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.

c) The root pass of butt joints should be executed so as to achieve full penetration withcomplete fusion of the root edges. Weld projection inside the pipe shall not exceed1.6 mm.

d) Any deviation desired from the recommended welding technique and electrodes indicatedin the welding specification chart should be adopted only after obtaining approval of theEngineer-in-charge.

e) Welding shall be uninterrupted.

f) While the welding is in progress care should be taken to avoid any kind of movement ofthe components, shocks, vibrations and stresses to prevent occurrence of weld cracks.

g) Penning shall not be used.9.2.0 Joint completion

a) Joint shall be completed using the class of electrodes, recommended in the WeldingSpecification Chart. Size of the electrode shall not exceed 4 mm in diameter for stainlesssteels and alloy steels used for low temperature applications.

b) Two weld beads shall not be started at the same point in different layers.

c) Butt joints shall be completed with a cover layer that would effect good fusion at the jointedges and a gradual notch free surface.

d) Each weld joint should have a workman like finish.

e) Weld identification work shall be stamped clearly at each joint, just adjacent to the weld.Metal stamping shall not be used as a standard. Suitable paint shall be used on thin wallpipes for identification.

f) No painting shall be done until the weld joint has been approved.

g) All welded joints are subjected to acceptance by Engineer-in-charge.9.3.0 Dissimilar Welds

Where welds are to be produced between carbon steels and alloy steels, preheat and postweld Heat Treatment requirements shall be to those specified for corresponding alloy steels and electrodes shall correspond to AWS E-7016 / 7018 type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatment shall be those specified for higher alloy steel and electrodes used shall correspond to those specified for steel of lower alloy content.

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For carbon steel or alloy steel to stainless welds, use of electrodes E-309/E-310/E NiCr Fe-2 shall be made. The welding procedure, electrodes/filler wires to be used shall be approved by the Engineer-in-charge.

Following shall be generally adopted to ensure proper welding: i) Relation of welding rods matches with parent material, ii) Preheating to the required value of the parent material before welding, iii) Quality & brand of the welding rods approved by owner, iv) Overhead welding should be avoided to the extent possible. 10.0.0 WELDING PROCEDURE QUALIFICATION

Welding procedure qualification shall be carried out in accordance with the relevant requirements of ASME Sec.IX latest edition or other applicable codes and the job requirements. The welding procedure specifications in format as per enclosed Annex - A should be submitted.

Purchaser's inspector will review, check and approve the welding procedure submitted and shall release the procedure for qualification tests. A complete set of test results in format as per enclosed Annex - B shall be submitted to the Purchaser's inspector for his approval immediately after completing the procedure qualification test. Standard tests as specified in the code shall be carried out in all cases. In addition to these tests, other tests like macro/micro examination, hardness tests, dye penetrant examination, charpy V-notch and U-notch impact tests etc. shall be carried out on specimens depending upon the type of base material, operating conditions and requirements laid down in the detailed drawings and specifications.

11.0.0 WELDER'S QUALIFICATION

11.1.0 Welders shall be qualified in accordance with the ASME Section - IX or other applicable codes. The Purchaser's inspector shall witness the test and certify the qualification of each welder separately. Only those welders who have been approved by the Engineer in charge shall be employed for welding. The welder qualification test reports shall be submitted in the format enclosed as Annex - C and obtain express approval before commencement of the work.

11.2.0 The welders shall always have in their possession the identification card as shown in enclosed Annex- F and shall produce it on demand by the Engineer in charge.

11.3.0 No welder shall be permitted to work without the possession of identity card duly certified by the inspector.

11.4.0 If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder.

12.0.0 WELD HEAT TREATMENT PROCEDURES

12.1.0 Preheating

12.1.1 No welding shall be performed without preheating the joint to 10°C (50°F) when ambienttemperature is 10°C and below.

12.1.2 Preheating requirements for the various materials shall be as per the welding specificationchart attached.

12.1.3 Preheating shall be performed using resistance or induction heating methods. Preheating bygas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with neutral flame may alsobe carried when permitted by the Engineer-in-charge.

12.1.4 Preheating shall extend uniformly to atleast three times the thickness of the joint, but not lessthan 50 mm, on both sides of the weld.

12.1.5 Preheating temperature shall be maintained over the whole length of the joint during welding.Temperature indicating crayons or other temperature indicating devices shall be provided tocheck the temperature.

12.2.0 Postweld Heat Treatment

12.2.1 Post weld Heat Treatment, wherever required for joints between pipes, pipes and fittings, pipebody and supports shall be carried out as per the welding specification chart, applicablecodes standards and the instructions of the Engineer-in-charge.

12.2.2 The details of the post weld Heat Treatment procedure (as per Annex - D attached), that isproposed to adopt for each of the materials/assembly/part involved shall be submitted for theapproval of the engineer - in - charge well before carrying our actual heat treatment.

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12.2.3 While carrying out local post weld Heat Treatment, technique of application of heat mustensure uniform temperature attainment at all points of the portion being heat treated. Careshall be taken to ensure that width of heated band over which specified post weld HeatTreatment temperature attained complies with relevant applicable standards/codes.

12.2.4 Throughout the cycle of Heat Treatment, the portion outside the heated band shall be suitablywrapped under insulation so as to avoid any harmful temperature gradient at the exposedsurface or pipe.

12.2.5 The temperature attained by the portion under heat treatment shall be recorded by means ofthermocouple pyrometers. Adequate number of thermocouples should be attached to the pipedirectly at equally spaced location along the periphery of the pipe joint. The minimum numberof thermocouples attached per joint shall be 1 upto 6" dia, 2 upto 10" dia and 3 for 12" dia andabove. However the Engineer-in-charge can increase the required minimum number ofthermocouples to be attached if found necessary.

12.2.6 Automatic temperature recorders which have been suitably calibrated should be employed.The calibration chart of each recorder should be submitted to the Engineer-in-charge prior tostarting the Heat Treatment operations and his approval should be obtained.

12.2.7 Immediately on completion of the Heat Treatment, the post weld Heat TreatmentCharts/records alongwith the hardness test results on the weld joints, wherever required asper the welding specification chart, shall be submitted to Engineer-in-charge for his approval.

12.2.8 Each joint shall bear an identification number which shall be maintained in the piping sketch.The joint identification number should appear on the corresponding post weld heat TreatmentCharts. The chart containing the identification numbers and piping sketch shall be submittedto the Engineer-in-charge in suitable folders.

13.0.0 INSPECTION AND TESTING

13.1.0 General

13.1.1 Purchaser's/Consultant's inspector shall have free access to all places where the work isbeing done or any other place concerned with the work.

i. To check that the execution of welding and welding equipment used on the job are suitable and conform to relevant standards.

ii. To supervise welding procedure qualification, iii. To supervise welder performance qualification.

iv. To check whether welding is conforming to relevant specification and the procedure followed is in accordance with good pipeline construction practice.

v. To check any other activity to ensure quality of work.

13.1.2 Inspection dates shall be notified sufficiently in advance with all facilities necessary forcarrying out his work at no extra cost to the Purchaser.

13.1.3 Approval from the Purchaser's inspector shall not relieve the Tenderer partially or fully of hisresponsibilities and guarantees under this work order.

13.2.0 Visual Inspection

13.2.1 Inspection of all welds shall be carried out as per ASME - B31.1. Finished welds shall bevisually inspected for parallel and axial misalignment of the work, cracks, incompletepenetration, under cut on surface, weld reinforcement and lack of fusion, unrepaired burn-through, dimensions, and other surface defects.

13.2.2 Inspection before welding

a) Dimension and orientation of spool assembly and installed spool and/or pipingcomponents shall be checked with the piping drawings.

b) Width of root space, bevel angle and alignment of components shall also be checked oneach joint fitted up.

c) Surfaces to be welded shall be checked to assure that they are clean and free fromforeign material such as grease, oil, paint, scale, or others for a distance of at least25 mm from the bevel ends.

Page 52: ESPECIFICACIONES STANDAR DE TUBERIAS

13.2.3 Inspection During Welding

Crack in tack welds, welding slag on inter passes, welding current conditions, and finish after back chipping shall be checked.

13.2.4 Inspection of Welds

Bead appearance under cut, overlap, spatter, crater, reinforcement of weldment and size of fillet weld shall be checked.

13.3.0 Radiography

1. All piping above 51 kg/sq cm (g) shall have 100% Radiography. All alloy steel and SSwelding shall have 100% Radiography. However, SS lines used for services like bearinglubrication oil supply shall be tested as per the instruction of Engineer-in-charge.

2. All other IBR piping (steam) shall be tested as per regulation 360 of IBR or Table-Awhichever is higher.

3. Gamma ray with Iridium-192 source is acceptable for carrying out radiography.

4. Plate fabricated pipes & specials forCW/ RW/ CLW service shall have 10% radiography.

5. All fuel lines shall have minimum 50% radiography.

13.3.1 Radiographic Examination

Radiographic examination shall be performed in accordance with the following requirements.

13.3.2 Random Examination

a) Radiographic testing and acceptance shall be in accordance with MSS-SP-54.

b) Random radiographic examination shall be applied to the entire circumference of aspecified percentage of the girth butt welds as designated in Table A.

c) The welds to be examined shall be selected to ensure that the work product of eachindividual welder is included.

d) The extent of radiographic examination shall be as per Table-A.

e) Conducting radiographic test outside the Purchaser's premises should be performed onlyon approval of Engineering - in - charge.

13.3.3 Identification of Radiographs

Identification marks shall be marked on every radiograph and radiographs of repaired welds shall be marked separately.

13.4.0 Liquid Penetrant or Magnetic Particle Examination

a) Socket welds in piping system shall be liquid penetrant or magnetic particle examined inaccordance with Table A.

b) All completed girth butt and socket welds of carbon steel to Austenitic steel shall besubjected to 100% liquid penetrant examination.

c) Liquid penetrant or magnetic particle examination shall be performed in accordance withsection V ASME code.

d) All fuel lines shall have for 100% LP/MP tested on welded joints.

TABLE - A PIPING WELDING DETAILS FOR ERECTION - NON IBR (LP IPING)

SERVICES : COOLING WATER, CIRCULATING WATER, RAW WATER, CLARIFIED WATER, EFFLUENT LINES AND EXHAUST PIPING TO ATMOSPHERE

Sl. No.

Material Combination AWS SpecificationSpecn. P.No. Gr. Specn. P.No Gr.

No.Root Run

Further Run

Page 53: ESPECIFICACIONES STANDAR DE TUBERIAS

1 IS 3589/ IS 1239/ IS 2062

P1 1 Any combination P1 1 E6013* E6013*

Note: WPS shall be qualified (PQR) by the respective quality department of erection groups (FQA) prior to welding.

Page 54: ESPECIFICACIONES STANDAR DE TUBERIAS

13.5.0 Acceptance Standards

The following acceptance standards shall be used unless otherwise specified.

13.5.1 X-Ray Acceptance Standard

No cracks or lack of penetration are permitted.

Elongated slag or tungsten inclusions with lengths greater than the following are not permitted:

1/2 in. for Tup to 3/4 in. 2/3 T for T from 3/4 in . to 2-1/4 in. 1-1/2 in. fort over2-1/4 in. where T is the thickness of the weld.

Groups of slag inclusions in line that have an aggregate length greater than T in length of 6T are not permitted.

The through thickness of slag inclusions shall not exceed 1/4 of the thickness of the thinner member being joined.

Porosity in excess of that specified in the following table shall not be permitted.

MAXIMUM PERMISSIBLE POROSITY IN 6 INCH LENGTH OF WELD

(inches) Pore AreaLess than

1/8 t/4 8(t/4)1/8 1/32 0.0881/4 1/16 0.0301/2 1/8 0.0603/4 3/16 0.0901 ¼ 0.120

IV)

¼ 0.2403 ¼ 0.360

13.5.2 Magnetic Particle and Liquid penetrant Acceptance standards

Linear MP and LP indications up to 1/2 T where T is the weld thickness or 1/4 inch in length, whichever is smaller, and which are not visible cracks, are acceptable.

The cumulative length of linear magnetic particle or liquid penetrant indications shall not exceed T in any 12T length of weld.

13.5.3 Ultrasonic Acceptance Standards

Indications are unacceptable if the amplitude exceeds the reference level established by the basic calibration block for ultrasonic examination of welds as stipulated in ASME Boiler and Pressure Vessel Code, section V, Article 5, and the lengths exceed the following:

1/2 in. for Tup to 3/4 in. 2/3T for T from 3/4 in. to 2-1/4 in. 1-1/2 in. for T over 2-1/4 in. where T is the thickness of weld.

Where indications are interpreted as cracks or lack of penetration, they are unacceptable regardless of length.

13.5.4 Visual Acceptance Standards

The visual acceptance standards shall be as follows:

Cracks -None

Linear Indications - None

Undercuts - (Including Burnback) - None for component thickness up to 1/8 in. include. 1/32 in max. for component thickness over 1/8 in.

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Reinforcement - 1/16 in max. for component thickness up to 3/16 in include. 1/8 in max. for component of 3/16 in. max. for component thickness over 1/2 in.

Appearance - Welds shall have a workmanship appearance with minimum variations in width and size of weld, and absence of sharp notches at undercuts and surface ripples. Spatter and projections from welding and any remaining tack welds shall be removed.

All arc strikes in the base metal are unacceptable. Any blending in the base metal shall not exceed the undercut allowance.

13.6.0 Repair and removal of visual defects

13.6.1 Defects which are not within the acceptable limits shall be removed from the joint completelyby chipping or grinding.

13.6.2 When the whole joint is found unacceptable, the weld and the ends of the joints shall berestored.

13.6.3 No repair shall be carried out without prior approval of the Engineer.

13.6.4 Traces of jigs removed, undercutting, craters and beads shall be ground and weld metaldeposited.

13.6.5 Repairs of weld reinforcement and overlap shall be ground and weld metal deposited.

13.6.6 Repairs of weld reinforcement and overlap shall be ground smooth.

Spatter and slag shall be removed by a hammer or a brush. A crack found visually shall be removed and examined by a magnetic particle or liquid penetrant test until assured no defect remains.

14.0.0 SAFETY REQUIREMENTS

Utmost care shall be taken during welding and gas cutting process to avoid fire hazard.

Oxygen & Acetylene gas cylinders shall be stored and maintained properly including its valves, regulators, etc.

Gas cutting torches shall be lighted by means of friction lighter and not with matches.

The welding sets shall be earthed properly and properly insulated cables shall be used for welding purposes.

For carrying out welding work in plant area necessary work permit shall be obtained from the Engineer - in - charge and after ensuring from him that the environment is quite safe for welding purpose the work shall be commenced.

The wearing of safety by the gas cutters, grinders and welders, such as handgloves, safety goggles, welding glass, helmet, etc. should be observed strictly.

Overhead work

While carrying out the work in elevated positions, care should be taken to ensure that tools and materials are not left in position from where they can fall on the persons below. No tools, tackles and materials shall be dropped from any height which may endanger anybody.

While working on elevated position use of safety belt shall be ensured which has to be periodically checked for its suitability to provide safety.

Wherever necessary ladder and scaffolding shall be used to carry out work at elevated positions.

Scaffolding and ladders should be maintained in good conditions.

ANNEX -A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS

QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boiler and pressure Vessel Code)

Company Name

________________________________

Welding Procedure Specification No._Revision No

________________________________

_By:_

Date

_Supporting PQR No (s)_

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Welding Process (es)__Type(s)_

(Automatic, Manual, Machine, or semi-Auto)

JOINTS (QW-402) Details. Joint Desiqn

(Refer to both backing and retainers.) | | Metal | | Nonfusing Metal I | Nonmetallic | | Other

Sketches, Production Drawings, Weld Symbols or Written Description Should show the general arrangement or the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified

(At the option of the Mfgr, sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g. for notch toughness proce-dures, for multiple process procedures, etc.)

* Base Metals (QW-403) P Nn Grmip No. to P.No Group No

OR

OR Hhpm Analysis and Mpnh Prnp

Thickness Range: Paso M°tar nrnnvo Fillet

Other

• FILLER METALS 9QW-404

Weld Metal Thickness Range : Groove

Fillet

Electrode-Flux (class)

Flux Trade Name

Consumable Insert

Other

" Each base metal.filler metal combination should be recorded individually

Page 57: ESPECIFICACIONES STANDAR DE TUBERIAS

POSITIONS (QW-405) Position (s) of Groove Welding Progression: Up Position (s) of Fillet

Down QW-482 (Back)

WPS No.

POSTWELD HEAT TREATMENT (QW-407)

Temperature Range ___________________

Time Range __________________

PREHEAT (QW-406) Preheat Temp. Min.

Interpass Temp. Max.

(Continuous or special heating where applicable should be recorded)

GAS (QW-408)

Shielding

Trailing

Backing

Percent Composition Gas (es) (Mixture)

Flow Rate

ELECTRICAL CHARACTERISTICS (QW-

Current AC or DC_______________Polarity

Amps (Range)

(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information maybe listed in a tabular form similar to that shown below.)

Tungsten Electrode Size and Type________________________________________________________

(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW

(Spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range

TECHNIQUE (QW-410)

String or Weave Bead ___________________

Orifice or Gas Cup Size ___________________

Initial and Interpass Cleaning (Brushing, Grinding, etc.)

Method of Back Gouging

Oscillation

Contact Tube to Work Distance

Multiple or Single Pass (per side)

Multiple or Single Electrodes

Travel Speed (Range)

Peening _______________

Other

Weld Layer (s) Process Filler Metal

Class

Dia. Type Polar

Current Amp. Range

Volt Range

Travel Speed Range

Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch angle, Etc.

ANNEX - B : FORMAT FOR PROCEDURE QUALIFICATION RECORD

QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)

(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)

Record Actual Conditions used to Weld Test Coupon.

Company Name

Procedure Qualification Record No

WPS No. _______________

Welding Process (es)

Types (Manual, Automatic, Semi-Auto)

Date

Rev.

Volts (Range)

Page 58: ESPECIFICACIONES STANDAR DE TUBERIAS

JOINTS (QW-402)

Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filter metal or process used)

BASE METALS 9QW-403) Material Spec

POSTWELD HEAT TREATMENT (QW-407) Temperature

P.No to P.No. Thickness of Test Coupon

GAS (QW-408) Percent Composition Gas (es) (Mixture) Flow Rate

FILLER METALS (QW-404) SFA specification

ELECTRICAL CHARACTERISTICS (QW-409) Current

Amps. Volts Tungsten Electrode Size

POSITION (QW-405) Position of Groove

TECHNIQUE (QW-410) Travel Speed

PREHEAT (QW-406) Preheat Temp

QW-483 (Back) Tensile Test (QW-150|

Specimen No.

Width Thickness Area Ultimate Total Load Ib

Ultimate Unit Load Psi

Type of Failure & Location

Guided-Band Tests (QW-160)

Toughness Tests (QW-170)

Specimen No.

Notch Location

Area Test Temp

Impact Values

Result________Satisfactory: Yes

Macro —- Results

No Fillet-Weld Test (QW-180)

Penetration into Parent Metal: Yes

No

Other Tests

Type of Test Deposit analysis Other

Welder's Name ______________________________________________ Clock No.

Tests conducted by : _________________________________________________________

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer

______Stamp No.

Page 59: ESPECIFICACIONES STANDAR DE TUBERIAS

DateBy

(Detail of record of tests are illustrative only and may be modified to confirm to the type and number of tests required by the Code.)

Page 60: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX - C : FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR QUALIFICATION TESTS

QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR

WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW-301, Section IX, ASME Boiler and Pressure Vessel Code

Welder's name _________________________Clock number ________________________________Stamp no. ______

Welding process(es) used ___________________________________________Type____________________________

Identification of WPS followed by welder during welding of test coupon ________________________________

Base material(s) welded____________________________________________________________________Thickness

Manual or Semiautomatic Variables for Each process (QW-350) Actual Values Range Qualified

Backing (metal,weld metal, welded from both sides, flux, etc.) (QW-402) ______________________ _________________

ASMEP.No. _____________toASMEP.no. (QW-403) ______________________ _________________

() Plate () Pipe (enter diameter, if pipe) ______________________ _________________

Filler metal specification (SFA):____________Classification (QW-404) ______________________ _________________

Filler metal F-no. ______________________ _________________

Consumable insert for GTAW or PAW ______________________ _________________

Weld deposit thickness for each welding process ______________________ _________________

Welding position (1G, %G, etc.) (QW-405) ______________________ _________________

progression (uphill/downhill) ______________________ _________________

Backing gas for GTAW, PAW, or GMAW; fuel gas for OFW (QW-408) ______________________ _________________

GMAW transfer mode (QW-409) ______________________ _________________

GTAW welding current type/polarity ______________________ _________________

Machine Welding Variables for the process Used (QW-360) Actual Values Range Qualified

Direct/remote visual control ______________________ _________________

Automatic voltage control (GTAW) ______________________ _________________

Automatic joint tracking ______________________ _________________

Welding position (1G, 5G, etc.) ______________________ _________________

Consumable insert ______________________ _________________

Backing (metal, weld metal, welded from both sides, flux, etc) ______________________ _________________

Guided Bend Test Results

Guided Bend Test Type () QW-462.2 (Side) Results () QW-462.3 (a) (Trans. R&F) Type () QW-462.3(b) (Long, R&F) Result

Radiographic test results (QW-304 and QW-305) _________________________________________________________________________________________

(For alternative qualification of groove welds by radiography)

Fillet Weld _____________Fracture test ________________________________Length and percent of defects ______________________________ ii

Macro test fusion __________________________Fillet leg size _________________in. X ____________in. Concavity/convexity_____________________ ii

Welding test conducted by __________________________________________________________

Mechanical tests conducted by __________________________________________________________Laboratory test no. ________________________

We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Organization __________________________________________________________

Date ______________________________________ By

ANNEX - D : FORMAT FOR STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION.

STRESS RELIEF/HEAT TREATMENT PROCEDURE SPECIFICATION

Name of the project Specification

Name of the HeatTreater

Page 61: ESPECIFICACIONES STANDAR DE TUBERIAS

1 General Details Name of the

Other Details Type of Heatinq : Elec.Res:/ Induction

Equipment: (Tick mark)

Name of the Assembly/Part

Capacity (size)

Assembly/Part Drawinq No.

Maximum Temp.CC)

Material Method of Temp.

Thickness Atmosphere Control

3 Heat Treatment Cycle Details Charqinq Temp °C

Rate of heatinq °C/Hr

Soakinq Temperature °C

Soakinq time, Hrs

Rate of Coolinq 7Hr

Mode of Coolinq

4 Other details, if any

5 Hardness test A.S C.S

Page 62: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX - E : RADIOGRAPHIC TECHNIQUE LOG

RADIOGRAPHIC TECHNIQUE LOG

1 Location2 Date of Testing

3 Name of the Contractor and welder

4 Material: Carbon steel/Alloy Steel/Stainless

Steel

5 Diameter & Thickness

6 Type of Weld Joint

7 Radiation Source

8 Source strength

9 Screen

10 Screen thickness

11 Focus film distance

12 Limit of Film coverage

13 Film type and make

14 Exposure Time

15 Processing

16 Density

17 Sensitivity

18 Penetrameter thickness (Source

Side)

17 Penetrameter thickness

(Film slide)

18 Shim thicknessSignature of Contractor

with seal

Approval of Inspector

ANNEX - F : WELDER'S IDENTIFICATION CARD

WELDER'S IDENTIFICATION CARD

1 Name : Photograph

2 Identification :

3 Date of Testing :

4 Valid until :

5 Process :

6 Material :

7 Thickness :

8 Diameter :

9 F.No. :

Page 63: ESPECIFICACIONES STANDAR DE TUBERIAS

10 Approval of welding :

11 Position :

Approved by: Employee's Signature with seal

Page 64: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX - G : LIST OF APPROVED ELECTRODE MANUFACTURER

LIST OF APPROVED ELECTRODES AND MANUFACTURERS

Accepted manufacturers of 6010, 7018 and 6013 electrodes are given below:-

Root - run - Philips (ESAB) 31 CS E6010

7016/7018

- Supercito - Advani Oerlikon

- Philips 36 H - ESAB

- Supertherm - D & H

- Tenacito - Advani

- Ferro Weld 2 - ESAB-Modi 7018-MODI

6013 - Overcord S, Oerlikon

- Vordian Esab/IOL

ANNEX-A

QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boiler and pressure Vessel Code)

Company Name

______________________________

Welding Procedure Specification No._ Revision No

_By:_

Date _ Date

Supporting PQR No (s)_

Welding Process (es)__Type(s)_

Page 65: ESPECIFICACIONES STANDAR DE TUBERIAS

(Automatic, Manual, Machine, or semi-Auto)

JOINTS (QW-402) Joint Design

Details.

(Refer to both backing and retainers.)|______| Metal |____| Nonfusing Metal|______| Nonmetallic | | Other

Sketches, Production Drawings, Weld Symbols or Written Description Should show the general arrangement or the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified

(At the option of the Mfgr., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g. for notch toughness proce-dures, for multiple process procedures, etc.)

* Base Metals (QW-403) P Nn Grnup Nn tn P Nn firnur OR

No.

OR Chem. Analysis and Mech. Prop

to Chem. Anaysis and Mech. Prop.

Thickness Range: Base Metal: Groove Fillet

Pipe Dia. Range: Groove Fillet

Other

* FILLER METALS 9QW-404

Weld Metal Thickness Range : Groove

Other

* Each base metal.filler metal combination should be recorded individually

POSITIONS (QW-405) Position (s) of Groove Welding Progression: Up Position (s) of Fillet

Down QW-482 (Back)

WPS No.

POSTWELD HEAT TREATMENT (QW-407)

Temperature Range _________________

Time Range _________________

PREHEAT (QW-406)

Preheat Temp. Min.

InterpassTemp. Max.

(Continuous or special heating where applicable should be recorded)

GAS (QW-408)

Shielding

Trailing

Backing

Percent Composition Gas (es) (Mixture)

Flow Rate

ELECTRICAL CHARACTERISTICS (QW-409)

Rev.

Page 66: ESPECIFICACIONES STANDAR DE TUBERIAS

Current AC or DC______________Polarity _________

Amps (Range) _______________Volts (Range)__________

(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form similar to that shown below.)

Tungsten Electrode Size and Type Mode of Metal Transfer for GMAW

(Pure Tungsten, 2% Thoriated, etc.)

(Spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range

TECHNIQUE (QW-410)

String or Weave Bead __________________

Orifice or Gas Cup Size __________________

Initial and Interpass Cleaning (Brushing, Grinding, etc.)

Method of Back Gouging

Oscillation

Contact Tube to Work Distance

Multiple or Single Pass (per side)

Multiple or Single Electrodes

Travel Speed (Range)

Peening ______________

Other

Weld Layer (s) Process Filler Metal

Class

Dia. Type Polar

Current Amp. Range

Volt Range

Travel Speed Range

Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch angle, Etc.

Page 67: ESPECIFICACIONES STANDAR DE TUBERIAS

\\

ANNEXURE B

QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)

(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)

Record Actual Conditions used to Weld Test Coupon.

Company Name

Procedure Qualification Record No

WPS No.\

Welding Process (es)

Types (Manual, Automatic, Semi-Auto)

Date

Page 68: ESPECIFICACIONES STANDAR DE TUBERIAS

JOINTS (QW-402)

Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filter metal or process used)

BASE METALS 9QW-403) Material Spec

POSTWELD HEAT TREATMENT (QW-407) Temperature

P.No to P.No. Thickness of Test Coupon

GAS (QW-408) Percent Composition Gas (es) (Mixture) Flow Rate

FILLER METALS (QW-404) SFA specification

ELECTRICAL CHARACTERISTICS (QW-409) Current

Amps. Volts Tungsten Electrode Size

POSITION (QW-405) Position of Groove

TECHNIQUE (QW-410) Travel Speed

PREHEAT (QW-406) Preheat Temp

QW-483 (Back) Tensile Test (QW-150)

Specimen No.

Width Thickness Area Ultimate Total Load Ib

Ultimate Unit Load Psi

Type of Failure & Location

Guided-Band Tests (QW-160)

Toughness Tests (QW-170)

Specimen Notch Area Test Impact

Result_______Satisfactory: Yes

Macro — Results

No Fillet-Weld Test (QW-180)

Penetration into Parent Metal : Yes

No

Page 69: ESPECIFICACIONES STANDAR DE TUBERIAS

Other Tests

Type of Test Deposit analysis Other

Clock No.

Welder's Name _______________________________________

Tests conducted by : ________________________________________

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer

Date ______________________________________________________

(Detail of record of tests are illustrative only and may be modified to confirm to the type and number of tests required by the Code.)

______Stamp No.

By

Page 70: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX -C

QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR

WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW-301, Section IX, ASME Boiler and Pressure Vessel Code

Welder's name ________________________Clock number _______________________________Stamp no. ______

Welding process(es) used _________________________________________Type__________________________

Identification of WPS followed by welder during welding of test coupon ______________________________

Base material(s) welded_________________________________________________________________Thickness

Manual or Semiautomatic Variables for Each process (QW-350) Actual Values Range Qualified

Backing (metal,weld metal, welded from both sides, flux, etc.) (QW-402) _____________________ ________________

ASME P.No. ____________to ASME P.no. (QW-403) _____________________ ________________

() Plate () Pipe (enter diameter, if pipe) _____________________ ________________

Filler metal specification (SFA):___________Classification (QW-404) _____________________ ________________

Filler metal F-no. _____________________ ________________

Consumable insert for GTAW or PAW _____________________ ________________

Weld deposit thickness for each welding process _____________________ ________________

Welding position (1G, %G, etc.) (QW-405) _____________________ ________________

progression (uphill/downhill) _____________________ ________________

Backing gas for GTAW, PAW, or GMAW; fuel gas for OFW (QW-408) _____________________ ________________

GMAW transfer mode (QW-409) _____________________ ________________

GTAW welding current type/polarity _____________________ ________________

Machine Welding Variables for the process Used (QW-360) Actual Values Range Qualified

Direct/remote visual control _____________________ ________________

Automatic voltage control (GTAW) _____________________ ________________

Automatic joint tracking _____________________ ________________

Welding position (1G, 5G, etc.) _____________________ ________________

Consumable insert _____________________ ________________

Backing (metal, weld metal, welded from both sides, flux, etc) _____________________ ________________

Guided Bend Test Results

Guided Bend Test Type () QW-462.2 (Side) Results () QW-462.3 (a) (Trans. R&F) Type () QW-462.3(b) (Long, R&F) Result

Radiographic test results (QW-304 and QW-305)

____________________________________________________________________________________________________________________________

(For alternative qualification of groove welds by radiography)

Fillet Weld ____________Fracture test ______________________________Length and percent of defects _____________________________ in.

Macro test fusion ________________________Fillet leg size ________________in.X ___________in. Concavity/convexity____________________ in.

Welding test conducted by ________________________________________________________

Mechanical tests conducted by ________________________________________________________Laboratory test no.

____________________________________________________________________________________

We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Organization

______________________________________________________________________

Page 71: ESPECIFICACIONES STANDAR DE TUBERIAS

Date ____________________________________ By

ANNEX-D

STRESS RELIEF/HEAT TREATMENT PROCEDURE SPECIFICATION

Name of the project

Name of the Heat Treater 1 General Details

Name of the Equipment:

Name of the Assembly/Part

Assembly/Part Drawing No.

Material Thickness

Specification Reference No.

Other Details Type of Heating :

Capacity (size)

Maximum Temp.(°C)

Method of Temp. Measurement

Atmosphere Control

Elec.Res:/ Induction (Tick mark)

3 Heat Treatment Cycle Details

Charging Temp °C ____

Rate of heating °C/Hr ____

Soaking Temperature °C_____

Soaking time, Hrs ____

Rate of Cooling °/Hr ____

Mode of Cooling ____

4 Other details, if any

5 Hardness test A.SC.S

Page 72: ESPECIFICACIONES STANDAR DE TUBERIAS

ANNEX-E

RADIOGRAPHIC TECHNIQUE LOG

1 Location

2 Date of Testing

3 Name of the Contractor and welder

4 Material: Carbon steel/Alloy Steel/Stainless Steel

5 Diameter & Thickness

6 Type of Weld Joint

7 Radiation Source

8 Source strength

9 Screen

10 Screen thickness

11 Focus film distance

12 Limit of Film coverage

13 Film type and make

14 Exposure Time

15 Processing

16 Density

17 Sensitivity

18 Penetrameter thickness (Source Side)

17 Penetrameter thickness (Film slide)

18 Shim thickness

Approval of Inspector Signature of Contractor with seal

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WELDER'S IDENTIFICATION CARD

1 Name Photograph

2 Identification

3 Date of Testing

4 Valid until

5 Process

6 Material

7 Thickness

8 Diameter

9 F.No.

10 Approval of welding

11 Position

Approved by: Employee's Signature with seal

ANNEX -G

LIST OF APPROVED ELECTRODES AND MANUFACTURERS

Accepted manufacturers of 6010, 7018 and 6013 electrodes are given below:-

Root - run - Philips (ESAB) 31 CS E6010

7016/7018

- Supercito - Advani Oerlikon

-Philips 36 H - ESAB-Supertherm - D& H

- Tenacito - Advani

- Ferro Weld 2 - ESAB-Modi 7018-MODI

6013 - Overcord S, Oerlikon -Vordian Esab/IOL

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TECHNICAL SPECIFICATION -ERECTION OF BURIED PIPING

TABLE OF CONTENTS

1.0.0 INTENT OF SPECIFICATION................................................................................................................................................................3

2.0.0 CODES & STANDARDS.................................................................................................................................................................3

3.0.0 EXCAVATION FOR PIPE TRENCHES.................................................................................................................................................................3

4.0.0 LAYING OF UNDERGROUND PIPING.................................................................................................................................................................4

5.0.0 VENT AND DRAINING.................................................................................................................................................................5

6.0.0 RECORDS.................................................................................................................................................................6

7.0.0 BACKFILLING.................................................................................................................................................................6

8.0.0 CLEAN UP OF SURROUNDINGS.................................................................................................................................................................6

SECTION-2.3

TECHNICAL SPECIFICATION ERECTION OF BURIED PIPING

1.0.0 INTENT OF SPECIFICATION

This specification covers the minimum requirements and guidelines to be adhered by the bidder for the erection of complete underground piping of LP piping which includes excavation, laying and backfilling of buried pipe.

2.0.0 CODES & STANDARDS

Piping design, reinforcement of branch connection, materials, and fabrication

Flanges: rating, facing, and drilling for 24 inches (609 mm) and smaller

Flanges: rating, facing, and drilling for larger than 24 inches (609 mm)

Pipe specification

Field applied external coatings for underground piping

Repair of damaged field applied coatings for underground piping

Dimensional checks

Steel structure painting council, (SP-I solvent cleaning and SP-10 near white blast cleaning).

Recommended Practice, High Voltage Electrical

Inspection of pipeline coating prior to Installation.

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AWWA C200 and AWWA M11

ANSI B16.5, Class 150 or AWWA C207 Class B, D, or E as indicated in the specification

AWWA C207, Class B, D or E as indicated in the specification

AWWA C200 / IS 3589 / IS 1239 /ANSI

B31.1

AWWA C203/IS 10221

AWWA C209, Section 3.4

AWWA C200, C208 and other applicable AWWA standards

SPC-SPI&SP10

NACE RP-02-74

3.0.0 EXCAVATION FOR PIPE TRENCHES

3.1.0 The trench shall be cut true to the line leveled with the help of sight rails provided at every 30M, at change of direction, gradient and at any suitable distance as directed by the owner's project manager.

3.2.0 If the trench is excavated below the required level indicated in the drawing, the extra depth shall be filled with concrete or approved equivalent material as directed by the owner's project manager at no extra cost to Owner.

3.3.0 The trench shall be excavated so as to provide an average cover of 1000 mm or equal to the diameter of the largest pipe to be laid in the trench unless otherwise shown in drawings. The minimum average cover will be reckoned from top of the pipe of the largest diameter to be laid in the trench, to the finished grade. The width of the trench, shall be sufficient to give free working space on each side of the pipe. The free working space shall conform to IS: 783. Generally it shall not be less than 150 mm on either side or 1/3 of dia of pipe whichever is greater.

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3.4.0 No excavated material shall be deposited within 1.5 meters from the excavated trench.

3.5.0 In case of road cutting, all material i.e. metal, bricks, etc. shall be taken out carefully and kept separately for reuse and road work shall be redone upto the original level prior to cutting the road with the excavated road materials after laying & testing of the pipeline within 10 days from the date of starting the work at the cost of the Bidder. The Bidder shall provide suitable signs and barricades to prevent accidents. He shall also provide reasonable by pass at his own cost when a road is cut for laying pipeline. The dykes etc. affected due to laying of the pipes, shall be redone conforming to the original specifications by the Bidder at his own cost.

3.6.0 During excavation if some obstacle is met with, same shall be reported to the owner's project manager and dealt with as instructed by him.

3.7.0 The Bidder shall dewater, shore or do whatever might be required to excavate the trench, install the pipe in it and backfill the trench, in accordance with the specifications at no extra cost to the Owner. Dewatering shall be done in advance of the laying of the pipe to allow adequate inspection of padding of the bottom if required and dewatering shall be continued throughout during laying of the pipe and backfilling of the trench.

3.8.0 In muddy/slushy ground, the bed shall be provided with a layer of a sand or lean concrete as directed by the owner's project manager.

3.9.0 The trench shall follow the gradient of pipeline as specified in the drawing. The Bidder shall keep the trench in good condition, until the pipe is laid and tested. No extra claim shall be entertained due to its caving or setting down either before or after the pipe is laid. All materials to shore the trench in order to prevent caving are to be furnished and removed by the Bidder at no extra cost to the Owner.

3.10.0 In case pipe is lowered in caved trench and back-filled before being inspected by the owner's project manager, the Bidder shall re-excavate the trench for inspection and backfill it at his own cost.

4.0.0 LAYING OF UNDERGROUND PIPING 4.1.0 General

After prefabrication, coating and wrapping and trenching the Tenderer shall lay the underground piping in accordance with the following clauses and as per the approved piping arrangement drawings. The Tenderer shall be responsible for correct layout and gradient of the line. Errors, if any, shall be rectified by the Tenderer at his own cost.

4.2.0 Lowering & Laying

The pipes shall be lowered either by mechanical methods or by hand when the trench is ready and bottom of the trench is graded as per required pipe laying conditions and specifications.

4.2.1 By machine

The shop coated pipe, already transported to the pipe laying site/convenient length of pipe assembly coated and wrapped near the trench after hydrostatic testing shall be placed on clean square cut skids suitably spaced so as to keep the pipe away from touching the ground. The pipe may be lowered down in the trench by the launcher cranes, with sufficient care to protect the coating and wrapping of the pipeline. Bare cables, chains hooks etc. shall not be permitted to come in contact with the coating.

At tie in welds and other places, the Tenderer shall clean, prime, coat and wrap manually. Also short sections of pipelines which are impracticable to shop treat may be hand treated but only on the prior written approval of the Engineer-in-charge.

4.2.2 By Hand

The pipe may be lowered with the help of tripods and chain pulleys blocks into the trench immediately after the coating and wrapping. However if in the opinion of the Engineer-in-charge that the temperature condition do not allow direct lowering, then the pipe shall be set down on clean square cut skids. The skids shall be so spaced as to keep the pipe away from touching the ground.

4.3.0 Method & Time of lowering pipe

4.3.1 Under favorable temperature, conditions and using methods which will not damage coatingthe pipe may be lowered into the trench.

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4.2.0 Pipe previously set on skids, because of unfavorable temperature conditions shall be loweredinto the trench normally in the cool of the morning and only when the temperature of the pipeis below the softening point of the coating materials.

4.3.0 All skid marks and other places of damages shall be thoroughly examined to ensure properpatching where necessary, before the pipe is finally lowered into the trench.

4.4.0 Handling of Coated Pipes

4.4.1 Coated pipes shall not be placed in trench until cave in plugs, hard clods, stones, skids,welding rods etc. have been removed there from. Where the trench has a hard or jaggedbottom sufficient fine dirt or sand shall be placed therein, before the pipe is lowered.

4.4.2 Coated pipe shall not be handled or moved by means of cable or chains or by prying withskids or bars. It shall be tied and lowered by using lowering in belts of a standard width anddesigns for the size of pipe being handled.

4.4.3 Coated pipe shall not be dragged along the ground or otherwise handled in a manner that willbe detrimental to the coating.

4.5.0 Lining up & Welding

4.5.1 The ends of the pipe line shall be kept securely closed to prevent entry of any foreignmaterial/ moisture after lowering into the trench.

4.5.2 Before making joints the pipe shall be carefully laid so as to be perfectly aligned in both planand profile and the end closures provided shall be removed.

4.5.3 Tie-in shall be made in the coolness of the morning or when the ambient temperature is notexceeding 29°C or softening temperature of the coating material whichever is less. Allbeveling, aligning and welding shall be in accordance with the welding specifications.

4.5.4 Free access shall be provided for the welding of the circumferential joints by increasing thewidth and depth of the trench at these points. There should be no obstruction to the welderfrom any side so that a good welded joint is obtained.

5.0.0 VENT AND DRAINING

5.1.0 All lines and equipment shall be completely drained after the hydrostatic test of a system has been completed. High point vents shall be open to prevent excessive vacuum and permit complete draining.

5.2.0 If it becomes necessary to leave a system filled with the testing medium from any abnormal length of time, suitable arrangement such as venting shall be made to provide for possible liquid expansion with change in ambient temperature.

6.0.0 RECORDS

6.1.0 Records in triplicate shall be made by the Tenderer for each piping system as follows:

6.2.0 In case of underground piping, layouts giving actual elevations of pipeline as laid.

6.3.0 Test certificates containing date of test, identification of the piping system, date of flushing & approval by Purchaser's Inspector.

7.0.0 BACKFILLING

7.1.0 Aftertesting and inspection of the pipeline to the entire satisfaction of the Engineer-in-charge, the trench shall be backfilled with the same material as the pipe bed above the top of the pipe. No trench shall be backfilled without the approval of Engineer-in-charge.

7.2.0 Backfilling with the excavated material shall be done in layers of 100 mm, well watered and rammed to avoid any settling afterwards.

7.3.0 The Tenderer shall place soil over the trench to such a height as to provide adequately for future settlement of the trench backfill.

If due to exigencies of the work, some portion of the pipeline is backfilled without approval of the Engineer-in-charge, the Engineer-in-charge shall have the right to order uncovering of the pipe for examination and the cost of such uncovering shall be borne by the Tenderer.

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7.4.0 The backfill material shall be free from stone pieces.

7.5.0 Surplus excavated soil or rubbish material shall be removed by the Tenderer at his own cost to a place designated by the Engineer-in-charge.

7.6.0 When the trench has been dug through roads all backfill shall be thoroughly compacted. In certain cases, special compaction methods may be required by the Engineer-in-charge. This shall be done by the Tenderer at no extra cost to the Purchaser.

7.7.0 When the trench has been dug through unlined ditches the backfill shall be thoroughly compacted in 150 mm layers for a distance of 1.50 m beyond the outside banks of the ditch on either side. The banks of the ditch shall also be compacted in 150 mm layers at no extra cost to the Purchaser.

7.8.0 After the roads have been already graded, if they are trenched or otherwise disturbed by the Tenderer during laying of the pipelines. The Tenderer shall restore the road to its original level and condition. In the event, the Tenderer is required to place extra fill, gravel, or other special material it shall be borne by him without any extra cost to the Purchaser.

8.0.0 CLEAN UP OF SURROUNDINGS

As soon as the backfill is completed, the Tenderer shall immediately clean up the adjoining area by removing all surplus and defective material and dispose of all refuse such as spurs, sheet iron, broken skids etc. to the complete satisfaction of the Engineer-in-charge.

Exclusions: CIVIL:

1. Excavation and backfilling.

2. Valve and drain pits.

3. PCC, RCC, supports for buried pipes.

SECTION - 2.4

TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE

TABLE OF CONTENTS

1.0.0 GENERAL.........................................................................................................................3

2.0.0 CODES AND STANDARDS...............................................................................................3

3.0.0 LINE CHECKS BEFORE PRESSURE TEST......................................................................3

4.0.0 TESTING...........................................................................................................................4

SECTION-2.4

TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE

1.0.0 GENERAL

This specification covers the general requirements related to the hydrotesting of LP piping system.

2.0.0 CODES AND STANDARDS

2.1.0 The Hydrotest of piping, valves and specialties comply with the requirements of latest edition the ANSI / Indian Standard or relevant standards.

3.0.0 LINE CHECKS BEFORE PRESSURE TEST 3.1.0 General

After completion of the fabrication and installation works and prior to pressure test, line checks shall be carried out for all works to ensure that the works have been performed properly and that the quality of work is adequate.

3.2.0 Check Points

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This shall include the following confirmation of overall and individual workmanship, but not be limited to these items:

a) Lines and components

i) Piping layout is in accordance with the applicable drawings including P&I diagrams.

ii) Size, dimension, rating and material specification are in accordance with the applicable drawings.

iii) Bend, tee, reducer and other fittings are in accordance with the applicable drawings.

iv) Drain, vent, thermal expansion, header and other components are in accordance with applicable drawings.

v) Valve, flange, blind, etc. are in accordance with applicable drawings and flange connection is properly made with correct use of bolts and gaskets.

vi) Orientation and direction of piping components are in compliance with piping drawings.

vii) Tightness and projection of flange bolts are adequate.

viii) Thread connections are not damaged and free from weld spatter, slag etc.

ix) All shipping and erection stoppers, welding jigs and temporary support attachments are removed.

x) Welding quality and other workmanship complies with the applicable specifications.

xi) Applicable examination or inspection and the heat treatment (if applicable) has been satisfactorily completed and accepted.

xii) Piping (including all components and attachments) is sufficiently cleaned, xiii) Slope is maintained as indicated in relevant drawings, b) Pipe Supports

i) All pipe supports such as anchors, guided restraints, bands, hangers, etc. are to permit free expansion and contraction of piping in the specified direction and are assembled as indicated on support drawings.

ii) Spring supports are to be properly set in cold position with setting pins.

iii) Enough and adequate temporary supports are to be provided wherever necessary to keep the piping stable.

iv) Supports, guides and anchors for piping shall be fabricated and provided as shown in the drawings. No anchors on piping shall be used except at locations shown in the drawings. The pipe shall be secured firmly at anchor supports.

v) Fabrication and erection of supporting elements and structural fixtures wherever required and pointed out by the Engineer-in-charge, whether indicated in drawing or not to prevent vibrations, excess sag etc. shall be carried out by the Contractor.

vi) Spring hangers shall be erected with springs locked in cold set position. The tie rods shall be selected that the pipe center line with slope can be maintained in cold position. The springs shall be released after hydrotesting and before passing steam. When the hanger are released they shall be checked for cold set values and if there is any disturbance, the series of hangers nearby shall be adjusted using the turn buckle to activate the cold set load in all hangers.

4.0.0 TESTING

4.1.0 General

4.1.1 All pipes shall be tested for leakage to a hydrostatic test pressure of 1.5 times the designpressure.

4.1.2 The testing shall be carried out in convenient sections as approved by Owner/Owner'sEngineer.

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4.1.3 If some defect is noticed during the hydrostatic testing, the same shall be brought to thenotice of Owner/Owner's Engineer. Joints, if leaking shall be rectified as per weldingspecifications and instructions of Owner/Owner's Engineer at no extra cost. If leakage is onthe threaded joints, necessary inert chemical bonding material shall be applied to arrest theleak.

4.1.4 The Owner /Owner's Engineer shall be notified in advance by Contractor of all testing. Thehydrostatic testing / flushing of all piping shall be carried out by the Contractor at his own cost.

4.1.5 Contractor shall make his own arrangements for flushing at suitable points as per theinstructions of the Owner /Owner's Engineer. Any extra work / modification on this accountshall be done by the Contractor at his own cost.

4.2.0 Test Medium

4.2.1 Soft water shall generally be used as the testing medium for the hydrostatic testing of pipingsystem.

4.2.2 In situation where water cannot be used air is used as a testing medium. Air testing shall becarried as per ASME B31.1 or relevant Indian standard.

4.3.0 Cleaning

4.3.1 All systems shall be cleaned and flushed free of all dirt, debris and loose foreign material aftertesting

4.3.2 Flushing and Pressure Test

a) The piping system shall be sufficiently flushed with the pressure test medium in thepresence of Owner/Owner's Engineer.

b) Care shall be taken during flushing that no foreign material can enter into equipmentwhich is connected to the test section.

c) After flushing and testing, water shall be drawn off by opening all drain valves and vents.The piping system shall be dried internally to the satisfaction of the Owner /Owner'sEngineer.

4.4.0 Temporary Blinds

4.4.1 Open ends of piping systems such as at pumps or wherever equipment has been removed ordisconnected prior to hydrostatic testing or at termination point of piping branch connectionsshall be blinded off by temporary blind flange made our of M.S. plate of suitable thickness.

4.5.0 Venting

4.5.1 All piping system and equipment shall be properly vented to remove air from the systemduring filling.

4.6.0 Pressurizing

4.6.1 Pressure shall be applied by means of a suitable test pump which shall not be connected tothe system until it is ready to test. A pressure gauge shall be provided at the pump dischargefor guidance in bringing the system upto pressure. The pump shall be attended to constantlyduring the test by authorized operator. The pump shall be disconnected immediately after thetest pressure is reached.

The test pressure is to be maintained for sufficient time to permit complete inspection of the system under test. Test shall be considered complete only when approval is given by Owner / Owner's Engineer.

4.7.0 Test Gauges

4.7.1 Contractor's own gauge shall be installed as close as possible to the lowest point in thesystem being tested. Calibration of test gauges shall be the responsibility of the Contractor.

SECTION - 2.5

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TECHNICAL SPECIFICATION -LP PIPING FLUSHING AND CLEANING PROCEDURE

TABLE OF CONTENTS

1.0.0 INTENT OF SPECIFICATIONS..............................................................................................3

2.0.0 CODES AND STANDARDS...................................................................................................3

3.0.0 INSPECTION.........................................................................................................................3

4.0.0 CLEANING METHODS..........................................................................................................3

5.0.0 FLUSHING.............................................................................................................................5

SECTION - 2.5

TECHNICAL SPECIFICATION -LP PIPING FLUSHING AND CLEANING PROCEDURE

1.0.0 INTENT OF SPECIFICATIONS

This specification covers the general requirements for inspection, cleaning & flushing of piping, valves and specialties for LP piping system.

2.0.0 CODES AND STANDARDS

The following codes and standards shall be followed for the work covered by this contract in addition to the detailed specifications of the contract.

• Swedish standard Institution - SIS-05 5900-1967 (Surface preparation standards forpainting steel surfaces).

■ Steel structures painting council, U.S.A. (Surface Preparation Specifications(SSPC-SP).

■ British Standards Institution (Surface Finish of Blast cleaned steel for painting) BS-4232.

■ National Association of Corrosion Engineers, U.S.A. (NACE).

■ IS:1477-1971 (Part - I) - code of practice for painting of Ferrous metals in buildings (Part1, pre-treatment).

■ Various international standards equivalent to Swedish standard for surface preparationare given in Table-1.

■ ASME B31.1 - power piping

The Contractor shall arrange, at his own cost, to keep a set of latest edition of the above standards and codes at site.

3.0.0 INSPECTION

During various stages and after completion of fabrication and erection, the piping system shall be inspected by the Engineer-in-charge to ensure that :-

• Proper piping material has been used.

• Piping has been erected as per drawings and instructions of Engineer-in-charge.

• All supports have been installed correctly.

• Test preparations mentioned in this specification have been carried out.

4.0.0 CLEANING METHODS 4.1.0 General

The Piping components shall be mechanically and /or chemically cleaned during the following stages of the Contract.

• Cleaning in workshop

• Cleaning before painting and/or corrosion protection (application of prime coat)

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• Cleaning before erection and after installation.

Cleaning of fabricated component items shall be carried out after fabrication and final heat treatment or welding at manufacturer's works or at site, as appropriate.

For cleaning in workshop and before painting mechanical cleaning as opposed to alternative chemical cleaning is the preferred method for works cleaning except where this is precluded by design or access considerations.

Machined surfaces shall be protected during the cleaning operations.

In the event of the surfaces not being cleaned to the purchaser's satisfaction, such parts of the cleaning procedures or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the contractor sole expense.

For recleaning small areas, hand cleaning by wire brushing by puffing method may be permitted. Wire brushes of austenitic steel bristles shall only be used.

Austenitic stainless steels, copper and aluminium alloys, cast iron, bimetallic and metallic/plastic items, and components fabricated by spot welding or riveting shall not be chemically cleaned. All weld areas shall be suitably stress relieved before chemical cleaning.

1Any cleaning work on piping shall be commenced only when erection activities are completed in all aspects and after the system tests have been completed and clearance for taking up painting work is given by the Engineer, who may, however, at his discretion authorise in writing, the taking up of surface preparation or painting work in any specific location, even prior to completion of system test.

All tools, brushes, rollers, spray guns, blast material, tarpaulin sheets for covering the areas to be sandblasted ,hand power tools for cleaning and all equipment shall be arranged by the Contractor at the site in sufficient quantity at his own cost.

4.2.0 Mechanical Cleaning

Mechanical cleaning shall preferably be carried out by abrasive blasting. The Purchaser is prepared to consider alternative methods provided they achieve the necessary surface condition.

4.3.0 Surface condition

The Metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any other deleterious matter.

Where metal surfaces are to be painted the surface profiles shall conform with the painting specification requirements.

Where this does not apply surfaces shall have a surface texture not coarser than Grade 80 abrasive paper.

4.4.0 Abrasives

Abrasives containing silica, silicates or slag residues shall not be used for water/steam side surfaces of plant except for cleaning sand castings, where hydro blasting with sand may be used.

For austenitic materials only, abrasives containing 98% or more of aluminia, Al2 O3, shall be used.

4.5.0 Removal of abrasive and debris

After cleaning, abrasive and debris shall be thoroughly removed from components.

4.6.0 Alternative Chemical Cleaning

The procedure shall comprise both pretreatment and acidic treatment and preservation of the system applicable only for fuel oil system.

5.0.0 FLUSHING

Flushing of all lines shall be done before pressure testing.

Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign material.

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Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure for air flushing the line / system will be pressurised by compressed air at the required pressure which shall be 50 psi maximum. The pressure shall then be released by quick opening of a valve, already in line or installed temporarily for this purpose. This procedure shall be repeated as many times as required till inside of the pipe is fully cleaned.

In line instruments like control valves, orifice plates, rotometers, safety valves and other instruments like thermowells which may interfere with flushing instrument shall not be included in flushing circuit.

From oil permanent strainers the screens / meshes shall be removed before flushing. Screen / meshes shall be reinstalled after flushing but before testing.

During flushing temporary strainers shall be retained. These shall be removed, cleaned and reinstalled after flushing but before testing.

In case on equipment such as column, vessel, exchanger etc. forms part of a piping circuit during flushing, this shall be done with the approval of Engineer-in-charge. However equipments thus included in the circuit, shall be completely drained and dried with compressed air, after flushing is completed.

During flushing discharge of water / air shall be drained to the place directed by the Engineer-in-charge. If necessary, proper temporary drainage shall be provided by the contractor.

Care shall be taken during flushing so as not to damage / spoil work of other agencies. Precautions shall also be taken to prevent entry of water / foreign matter into equipments, electric motors, instruments electrical installations etc. in the vicinity of lines being flushed.

The contractor shall carry out all the activities required before, during and after the flushing operation, arising because of flushing requirements, such as but not limited to the following:

Dropping of valves, specials distance pieces, inline instruments and any other piping part before flushing. The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-in-charge. These flanges shall be provided with temporary gaskets at the time of flushing.

After flushing is completed and approved the valve distance pieces, piping specials etc. shall be reinstalled by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where isolation is required during testing only temporary gaskets shall be provided.

Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing done in standard format. Contractor shall submit procedure for flushing and cleaning in detail based on the above for Engineer's approval.

SECTION-2.6

TECHNICAL SPECIFICATION -WRAPPING & COATING OF BURIED PIPING

TABLE OF CONTENTS

1.0.0 INTENT OF SPECIFICATIONS..................................................................................3

2.0.0 CODES AND STANDARDS.......................................................................................3

3.0.0 COATING THICKNESS..............................................................................................3

4.0.0 TECHNICAL REQUIREMENT....................................................................................3

5.0.0 PROCEDURE FOR COATING AND WRAPPING.......................................................4

6.0.0 EXTENT OF APPLICATION.......................................................................................5

7.0.0 INSPECTION..............................................................................................................5

8.0.0 REFERENCE DOCUMENT.........................................................................................6

9.0.0 BOQ FOR COATING AND WRAPPING OF BURIED PIPELINES..............................6

SECTION-2.6

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TECHNICAL SPECIFICATION - WRAPPING & COATING OF BURIED PIPING 1.0.0 INTENT OF SPECIFICATIONS

This specification covers the procedure for coating and wrapping of corrosion protection coating for buried pipes and fittings using polymeric protection prefabricated tape including, inspection and testing.

2.0.0 CODES AND STANDARDS

a) AWWA C-203-91 AWWA standard for coal tar protective coatings and linings for steelwater pipe lines enamels and Tape-Hot applied.

b) SSPC-SPI & SP 10 Steel structure painting council, (SP-I solvent cleaning and SP-10near white blast cleaning).

c) NACE RP-02-74 Recommended Practice, High Voltage Electrical Inspection of pipelinecoating prior to Installation.

d) IS 10221 Code of practice for coating and wrapping of underground mild steel pipelines.

3.0.0 COATING THICKNESS

The polymeric tape thickness is 2 mm and two layers shall be provided over the buried pipe.

4.0.0 TECHNICAL REQUIREMENT 4.1.0 General

The coating and wrapping of pipes shall be from a polymeric corrosion protective tape with mix of coaltar, rubber & other polymers. 2 mm thick tape is used and two layers of 2mm thick are to be applied one over the above on the pipes. The sequence of coating and wrapping of pipes shall consist of following operations.

i) Surface Preparation

ii) Application of First Layer of Primer

iii) Application of first Layer of Membrane tape

iv) Application of Second Layer of Primer

v) Application of Second Layer of Membrane tape

vi) Tape Coating of Field Joints

All appurtenances and equipment to be used for cleaning, priming, coating and wrapping and testing shall be approved by the Engineer-in-charge.

4.2.0 Materials

The materials required for application of anticorrosive polymeric tape are as below, a. Wire Brush to remove all foreign debris

b.Coat of fibre, coal tar and solvent based primer of density 0.92 gms/cm3 and viscosity of 1000-2000 cps. @ 150 gms/sqm (Primer) recommended by tape manufacturer.

c.Anticorrosive multilayered polymeric tape of 4 mm or 2 mm thick. Application should be with recommended over laps and in accordance with manufacturer's specification.

d. The material shall confirm to ASTM / DIN codes. 5.0.0 PROCEDURE FOR COATING AND WRAPPING 5.1.0 Surface Preparation

If the pipe surface is free from oil and grease then wire brush shall used to remove all foreign debris otherwise, all oil and grease on the pipe metal surface shall be thoroughly removed by flushing with a suitable solvent (such as xylene or 1,2,2 trichlorethane) and wiped with clean rags. The solvent cleaning shall be as per SSPC-SP-1. The degreased pipe metal surface shall be wire brushed / power brushed. The pipe surface after cleaning by wire brush shall be cleaned with dry cloth thoured.

After being cleaned the pipe shall be protected from and be maintained free of oil, grease and dirt that might fall on the pipe before it has received its final coat. Preferably priming shall be done within four hours of completion of wire brushing.

5.2.0 Application of First Layer of Primer

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Primer is to be applied on pipes immediately after cleaning. Primer is a cold applied primer and is applied by brush @ minimum 150 gms/sqm. After application, it is allowed to dry until the surface becomes tacky. This primer is applied so as to produce effective bond between metal and pipe coating membrane tape prior to application, primer shall be stirred in drums so that it is mixed properly.

After application the primer coat shall be uniform and free from floods, runs, sags, drips, or bare spots. Any bare spots shall be recoated with an additional application of primer. All runs, sags, or drips shall be removed by scraping and cleaning, and the cleaned area shall be retouched or remedied by reblasting and repriming. Suitable measures shall be taken to protect the wet primed pipe from contact with rain, fog, mist, spray, dust or other foreign matter until tape is applied.

The minimum and maximum drying times of the primer or the period of between application of primer and application of membrane tape shall be in accordance with instructions issued by the manufacturer.

The cleaning and priming operation may be carried out in the Bidder's workshop or on site. The entire pipe length shall be cleaned but the ends of the pipes shall be left without coating and wrapping for a distance of 150 to 200 mm for joints, which shall be coated and wrapped manually on site after laying, field welding and testing the pipes.

5.3.0 Application of first Layer of Membrane tape (used for 2 mm thick tape application)

After the surface is primed, membrane tape is applied over the pipe in spiral fashion under slight tension by thermofusion process. A LPG torch or other heat source is applied onto the inner face of the membrane tape till the polymeric mix attains a shiny appearance and tape compound is softened. The membrane tape is then adhered to the primed coated surface. Overlaps are maintained as per specifications with a minimum of 15 to 20 mm. The overlaps are doubly sealed by thermofusion on the exterior for additional security.

5.4.0 Application of Second Layer of Primer

The second layer of primer is applied over the first layer of tape by brushing or spraying @ minimum 150 gms/sqm. The primer is allowed to dry for 15 minutes before commencement of application of second layer of tape.

5.5.0 Application of Second Layer of Membrane Tape (used for 2 mm thick tape application)

Second layer of membrane tape is wound over the wet second layer of primer. This is a cold process, which does not involve thermofusing. Care is taken that the overlap of the second layer does not coincide with the overlap of the first layer. Once again overlaps are maintained at minimum 15 mm. However, overlaps are double sealed by thermofusion as for the first layer.

5.6.0 Tape Coating of Field Joints (common for all thickness of tape)

Incase of site coated pipes the welded joints shall be coated. Primer shall be applied with brushes after cleaning the pipe thoroughly.

The primer and tape coating materials shall be the same as used for yard coating the pipe.

The welded field joints and uncoated areas shall be cleaned and dried in accordance with the procedure indicated above. Primer shall be applied on the clean area. Primer shall be applied on adjacent tape coating also. Over the primed surface tape shall be applied in accordance with above section. Tapes shall overlap the coating on each side of the field joint to form a continuous external coating free of defects. Overlaps on each side of the weld joints shall be 50 mm.

No wrinkling in the wrapper shall be allowed. If coating and wrapping is found unsatisfactory to the Engineer-in-charge the same area shall be recoated and wrapped with above procedures.

6.0.0 EXTENT OF APPLICATION

All buried piping of water and utility service shall be applied with above type of coating & wrapping method.

Whenever buried pipe extents above the ground the coating of tape shall be applied as a minimum length of 500 mm above ground level.

7.0.0 INSPECTION 7.1.0 General

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Contractor shall test the coating and any repair subsequently made to it. The testing shall be carried out prior to laying of pipes in the trench.

7.2.0 Holiday Detection

i) All coated and wrapped pipes shall be subjected to a test with an electric holiday detector as specified in AWWA-C-203-91.

ii) The holiday detector shall be supplied, correctly operated and always maintained in good working condition along with adequate supply of spare parts. Any delay caused by the incorrect functioning of the holiday detector will not be entertained.

iii) The operating voltage of the detector shall be determined by NACE RP-02-74.

iv) Any pipe having three (3) or more holidays shall be rejected. Similarly any pipe having any one holiday bigger than 0.1 square metre shall be rejected. Any defective places shall be plainly marked with chalk immediately after they are detected visually or by the holiday detector.

v) For pipe with pre-fabricated tape, the test voltage which the pipe should pass with holiday detector kit at voltage 15 kV for 4 mm thickness coating.

7.3.0 Measuring coating thickness

i) All pipes shall be tested for thickness as per AWWA-C-203-91.

ii) The thickness shall be measured by pushing the point of an approved pit depth gauge or microtester through the coating and wrappers.

iii) The specified minimum thickness shall be present both at the pipe or any other point. 7.4.0 Testing and adhesion of the coating

i) Atleast two tests a day shall be carried out on finished coating after 12 hours from completion of coating. The test shall be carried out as per AWWA-C-203-91 Sec.7.8 / IS 10221 Section B-3.3.1 / 3.3.3/3.3.3.

ii) The areas where the coating has been removed for testing by the inspector shall be repaired by the CONTRACTOR at his own expense.

8.0.0 REFERENCE DOCUMENT

For material of construction, handling and storage of coated pipes, lowering of pipes, trenching & backfilling refer Section - 2.3 Technical specifications - Erection of Buried piping.

9.0.0 BOQ FOR COATING AND WRAPPING OF BURIED PIPELINES

Material: Anticorrosive 2 layered polymeric tape with primer required for the following length of pipe to be coated & wrapped.

Pipe Size( NB) Buried Pipe Length (m)

Note: Pipe Size and Buried pipe length details will be provided during details engineering.

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SECTION - 3 LIST OF TENDER DRAWINGS

SECTION - 3 LIST OF TENDER DRAWINGS

Sl.No. Drawing No. Title

1 DP-00CE-01-003 Symbols& Legends

2 DP-00SC-22-074 P&ID for Instrument Air Distribution System

3 DP-00SC-22-074 P&ID for Service Air Distribution System

4 DP-00GC-22-075 P&ID for DM Feed Water System

5 DP-00GH-22-072 P&ID for Plant Water System

6 DP-00PA-22-071 P&ID for CW and ACW System

7 DP-00GH-22-073 P&ID for Potable Water Distribution System

8 DP-00GH-22-077 P&ID for Service Water Distribution System

9 DP-00UE-01-002 Plot Plan

10 DP-00GH-35-166 Piping Layout - Raw Water Pump House Area

11 DP-00GB-35-167 Piping Layout - Clarified Water Pump House Area (Will be submitted later)

12 DP-00GC-35-168 Piping Layout - DM Water System (Will be submitted later)

13 DP-00PA-35-169 Piping Layout - CW Make up Water System

14 DP-00GH-35-170 Piping Layout - Service & Potable Water System (Will be submitted later)

15 DP-00MM-35-171 Piping Layout - Service & Instrument air system( Will be submitted later)

16 DP-00GC-35-172 Piping Layout - DM Make up & Condensate System (Will be submitted later)

17 DP-00PA-35-173 Piping Layout - CW blow down system

18 DP-00GB-35-174 Piping Layout - Effluent collection to ETP (Will be submitted later)

19 DP-00SC-35-176 Piping Layout- Main Plant Air Compressor & Closed Cycle Cooling Water System (Will be submitted later)

20 DP-00BQ-35-179 Piping Layout - Pipe rack

21 DP-00GH-31-190 Isometric - Raw water system (Will be submitted later)

22 DP-00GC-31-191 Isometric - DM water system (Will be submitted later)

23 DP-00PA-31-192 Isometric - CW makeup system (Will be submitted later)

24 DP-00PA-31-193 Isometric - CW blowdown system (Will be submitted later)

25 DP-00GH-31-194 Isometric - Service water system ( Will be submitted later)

26 DP-00GK-31-195 Isometric - Potable water system ( Will be

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Sl.No. Drawing No. Title

submitted later)

27 DP-00MM-31-196 Isometric - Instrument air system ( Will be submitted later)

28 DP-00MM-31-197 Isometric - Service Air system ( Will be submitted later)

29 DP-00GH-31-198 Isometric - Plant Water System ( Will be submitted later)

30 DP-00GB-31-199 Isometric - Effluent collection system ( Will be submitted later)

31 DP-197-39-210 Piping support - Typical pipe supports (Will be submitted later)

NOTE:

The above list of drawings is tentative and indicative only. Final drawings will be furnished progressively to the bidder after the award of the contract.

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SECTION - 4 TECHNICAL DATA SHEETS & SCHEDULES

TABLE OF CONTENTS

SCHEDULE 4.1

SCHEDULE 4.2 SCHEDULE 4.3 SCHEDULE 4.4 SCHEDULE 4.5 SCHEDULE 4.6 SCHEDULE 4.7 SCHEDULE 4.8 SCHEDULE 4.9 SCHEDULE 4.10

TECHNICAL DATA SHEET FOR LP PIPING - FABRICATION,ERECTION& COMMISSIONING.............................................................3

ERECTION/COMMISSIONING................................................................4

DEVIATION SCHEDULE - TECHNICAL...................................................5

DEVIATION SCHEDULE-COMMERCIAL..............................................6

DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS....7

CONCURRENT COMMITMENTS OF THE BIDDER................................8

SCHEDULE OF SUB-CONTRACTOR......................................................9

PROPOSED SITE MANPOWER DEPLOYMENT...................................10

QUALITY ASSURANCE PLAN...............................................................11

UTILITY CONSUMPTION LIST..............................................................12

SECTION 4

TECHNICAL DATA SHEETS & SCHEDULES [Duly filled in by the Bidder]

SCHEDULE 4.1 TECHNICAL DATA SHEET FOR LP PIPING - FABRICATION, ERECTION & COMMISSIONING

Bidder shall submit a detailed Technical data sheet for the following.

1. Receipt of material from site stores, Handling at site.

2. Fabrication of piping & fittings (above 300NB / the plate will be free issued byowner).

3. Fabrication of Supports (structural material only by owner).

4. Hume pipes / Encasement for Buried line.

5. Wrapping and Coating for Buried piping.

6. Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Site Supervision,Calibration and Commissioning at site for LP piping, valves, specialties andsupports etc.

SCHEDULE 4.2 ERECTION/COMMISSIONING

We hereby confirm the completion schedule for the various milestone activities indicated below:

Sl.No Description Completion schedule from date of LOI in (months)

1.0 Establishment of site office

2.0 Mobilisation of site staff

3.0 Delivery of Material at site from store (Completion)

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4.0 Fabrication of Pipes, Fittings and Flange etc.

5.0 Piping erection (Completion)

6.0 Testing

7.0 Trial operation

8.0 Commissioning / Performance Test and handing over

Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.

SIGNATURE OF BIDDER

NAME ______

COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.3 DEVIATION SCHEDULE -TECHNICAL

Sl.No. Tender References Deviation Taken Reasons for deviation takenCl.No./Page No./

Section No. / Volume No.

Description as specified

We confirm that above are the only deviations from the bid document. Notes:

1. Additional sheets of similar size and format may be used as per Bidder's requirement andshall be annexed to this schedule.

2. Deviations to tender documents, if any, shall be indicated only in this schedule.

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3. Deviations listed elsewhere will be summarily rejected and shall be ignored.

SIGNATURE OF BIDDER

NAME ______

COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.4 DEVIATION SCHEDULE - COMMERCIAL

Sl.No. Tender References Deviation TakenCl.No./Page No./

Section No. / Volume No.

Description as specified

We confirm that above are the only deviations from the bid document. Notes:

1. Additional sheets of similar size and format may be used as per Bidder's requirement andshall be annexed to this schedule.

2. Deviations to tender documents, if any, shall be indicated only in this schedule.

3. Deviations listed elsewhere will be summarily rejected and shall be ignored.

SIGNATURE OF BIDDER

NAME

COMPANY SEAL DESIGNATION_ DATE

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SCHEDULE 4.5 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS

Sl.

No

Full postal address of client

& name of Officer-in-charge

with Telex/Tel.No./ Fax

No.

Description of the work (shall

indicate parameters & major scope)

Value of contract

Date of commen -Cement of

work

Schedule Completion

Period

Actual completion

period

Reasons for delay, if any

Operating Hours

Logged

1 2 3 4 5 6 7 8 9

Certified that documentary proof for above information is enclosed.

Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.

SIGNATURE OF BIDDER

NAME

COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.6 CONCURRENT COMMITMENTS OF THE BIDDER

Sl.

No

Full postal address of client & name of Officer-in-charge

with Telex/Tel.No./ Fax No.

Description of the work (shall

indicate parameters & major scope)

Value of contract

Completion Time as stated in

order

Date of commen-cement of

work

% completion as on date

Expected date of

completion

1 2 3 4 5 6 7 8

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Certified that documentary proof for above information is enclosed.

Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.

SIGNATURE OF BIDDER

NAME ______

COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.7 SCHEDULE OF SUB-CONTRACTOR

Sl.

No

Equipment/ Item Sub-Vendor/Sub-Contractor

Place Experience Details

Note: This statement shall be furnished section wise separately for each volume of the bid specification.

SIGNATURE OF BIDDER

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NAME

COMPANY SEAL DESIGNATION_ DATE

SCHEDULE 4.8 PROPOSED SITE MANPOWER DEPLOYMENT

The Bidder shall also indicate here in proposed site organisation for timely execution of work. It is understood that this will be augmented from time to time depending on the requirements for timely completion of work, as directed by the Engineer.

Sl.

No

Designation of Personnel Qualification & Experience of Personnel

No. of Personnel

Remarks

Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.

SIGNATURE OF BIDDER

NAME

COMPANY SEAL DESIGNATION_DATE _______

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SCHEDULE 4.9 QUALITY ASSURANCE PLAN

SL. NO.

COMPONENT CHARACTERISTIC CHECKED

CLASSIFI-CATION

TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORM

FORMAT OF

RECORD

INSPECTION BY REMARKS

P W V

1 2 3 4 5 6 7 8 9 10 11

LEGENDS : P-PERFORMANCE, W-WITNESS, V-VERIFY.

SIGNATURE OF BIDDER

COMPANY SEAL NAME

DESIGNATION_

DATE

SCHEDULE 4.10 UTILITY CONSUMPTION LIST

ITEM NO.

No. Equipme Mode (KW) (NM3/HR) (M3/HR)

kg/cm2 (g) kg/cm2 (g)

C I C I C I C I

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Any items are not covered in the above table, Bidder shall include and give their details.

C - Continuous I - Intermittent

SIGNATURE OF BIDDER

COMPANY SEAL NAME

DESIGNATION_

DATE

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SECTION - 5 PRICE SCHEDULES

(TO BE FILLED AND SUBMITTED BY THE BIDDER WITH OFFER)

TABLE OF CONTENTS

SCHEDULE-5.1 SUMMARY OF PRICE PROPOSAL - FABRICATION,

ERECTION, TESTING & COMMISSIONING.........................................3

SCHEDULE- 5.2 SCHEDULE OF PRICE FOR FABRICATION, ERECTION AND

COMMISSIONING..................................................................................4

SCHEDULE - 5.3 PRICE BREAK-UP FOR SPECIAL TOOLS & TACKLES........................5

SECTION-5 PRICE SCHEDULES

SCHEDULE-5.1 SUMMARY OF PRICE PROPOSAL - FABRICATION, ERECTION, TESTING & COMMISSIONING

Details Rs. in lakhs

1.0 Erection & Commissioning: Total lumpsum price towards

1. Receipt of material from site stores, Handling at site.

2. Fabrication of piping & fittings (above 300NB / The plate material will be free issued by owner).

3. Fabrication of Supports (structural material only by owner).

4. Hume pipe for buried line. 5. Wrapping and Coating for Buried piping.

6. Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Site Supervision, Calibration and Commissioning at site for LP piping, valves, specialties and supports etc. as detailed in the scope of work (as per Schedule 5.2 inclusive of all taxes and duties).

TOTAL PRICE

COMPANY SEAL SIGNATURE OF BIDDER

NAME

DESIGNATION _ DATE

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SCHEDULE-5.2 SCHEDULE OF PRICE FOR FABRICATION, ERECTION AND COMMISSIONING

SL. DESCRIPTION BASIC PRICE

TAXES & DUTIES

INSURANCE TOTAL PRICE REMARKS

1.0 Fabrication, Erection & Commissioning:

Total lumpsum price towards

1. Receipt of material from site stores, Handling at site.

2. Fabrication of piping & fittings (above 300NB / The plate material will be free issued by owner).

3. Fabrication of Supports (Structural material will be free issued by owner).

4. Hume pipe for buried line. 5. Wrapping and Coating for Buried piping.

6. Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Site Supervision, Calibration and Commissioning at site for LP piping, valves, specialties and supports etc. as detailed in the scope of work.

Note: Any items are not covered in the above table, Bidder shall include and give their details.

COMPANY SEAL SIGNATURE OF BIDDER

NAME

DESIGNATION

DATE

PRICE BREAK-UP FOR SPECIAL TOOLS & TACKLES

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Sl. No.

DESCRIPTION OF THE EQUIPMENT/

ITEM

QTY. UNIT PRICE EX-WORKS (DULY

PACKED)

TOTAL PRICE EX-WORKS (DULY

PACKED)

EXCISE DUTY

(%)

SALES TAX

%

OTHER CHARGES

INSURANCE CHARGES

TRANSPORT ATION

CHARGES

TOTAL PRICE

(1) (2) (3) (4) (5)=(3)x(4) (6) (7) (8) (9) (10) (11)

GROSS TOTAL

Note: Any items are not covered in the above table, Bidder shall include and give their details.

SIGNATURE OF BIDDER

NAME

DESIGNATIONCOMPANY SEAL DATE

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2x300 MW Chandrapur Thermal Power Project Technical Specification

load. The hoist hook shall be provided with safety locking arrangement to provide accidental unhooking.

Provision shall be made for lubrication of all moving parts and bearings while the hoist is in service except where life lubricated bearings are used. All exposed bearings shall be suitably sealed or shielded.

Bridge girder for the crane shall be of plate welded box type construction fabricated from tested steel plates. Box section shall be adequately reinforced by internal diaphragms and ribs. Box girder shall be provided with end plates for sealing. Diaphragms shall be provided to transmit the trolley wheel loads to the web piates.

Trolley / crab runway rails shall be standard rail section as per IS:3443 or equivalent. The rails shall be accurately aligned, levelled and properly fixed to bridge girder. End stops and curved wheel stoppers on crab/ trolley runway rails on both end of each bridge girder shall be provided in approved construction. The rail section shall be sufficient to cover the whole runway length and shall be adequate for maximum permissible trolley travel. The trolley frame shall be built up from heavy steel sections welded together to form a rigid piece frame adequately braced to resist vertical, lateral and torsional strain and support all loads without undue deflection. Trolley frame shall be provided with equaliser sheaves and spring bumper at each side for safe operation of the crane assembly. Manually operated hoisis shall be of spur gear chain pulley block type. It shall be suspended from the trolley by a hook. The design of the hoist shall conform to IS:3832. The load hook shall be swivelling type fitted with a locking device. AN manually operated hoists, unless stated otherwise, shall be trolley suspended type. The trolley of hoists shall be manually operated.

Electric hoist shall be electric wire rope trolley suspended type. The design, operation, testing of electric hoist shall conform to IS:3938 {Specification for electric wire rope hoist. 3.25. PAINTING PROTECTION

3.25.1. General

The requirements for shop and field application of protective painting/coatings and linings are described in this clause. Each painting/coating system shall provide an optimum life expectancy of 10 years from the time of original painting, considering the corrosive saline atmosphere at project site. The optimum life of a painting/coating system shall be considered the time until first maintenance painting/touch up should occur before active rusting begins. Surfaces which are inaccessible after assembly shall be protected for the life of the equipment.

The tables included at the end of this section provide recommendations for painttng/coating systems at various locations and substrates found in the power station. The Bidder shall review the life expectancy and exposure requirements and propose complete painting/coating systems for the Owner's considerations. Coating material and application shall conform to the regulations of the air quality management agency having jurisdiction. Materials shall contain not greater than 0.06 percent lead or chromium in the dried film.

Ferrous metal surfaces shall be cleaned, prepared, and painted/coated in accordance with the painting/coating manufacturer's instructions and Steel Structures Painting Council Paint Application Specification No. 1 "Shop. Field, and Maintenance Painting."

3.25.2. Shop Coating

Equipment manufacturers' standard painting/coating systems shall be applied in lieu of those specified provided the system complies with the life expectancy requirements. All primers shall contain rust inhibitors.

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2x300 MW Chandrapur Thermal Power Project

Surfaces to be painted shalt be filled to provide a uniform substrate and shall be prepared for painting in accordance with the appropriate surface preparation specifications.

No paint shall be applied to surfaces within 75 mm of field welded connections. These surfaces shall be painted/coated wfth a consumable preservative and masked.

3.25.3. Mechanical Equipment

Mechanical equipment includes pumps, compressors, valves, valve operators, external piping surfaces, pipe hangers, and other similar equipment etc. At the Bidder's option, the primer shall be applied in the shop and the finish coats shall be applied in the field.

If equipment shall operate at temperatures above 60° C and shall not be insulated, a high temperature painting/coating system designed for the operating temperatures shad be applied. For those surfaces that shall be insulated, painting/coating system shall be applied that has been designed for application below thermal insulation.

Steel plate pipes shall be lined with a two pack cold cured Isophthalic Polyester acrylic co-polymer glass flake filled coatings, both internally and externally to provide long term corrosion protection. Coating thickness for the internal of the pipeline shall be 1.0 mm average and for external shall be 0.5 mm average.

The vertical water pumpsets surfaces particularly in respect of volute casing, suction elbow etc shall be lined with a two pack cold cured Isophthalic polyester acrylic co-polymer with glass flake filled coating at 1.5 mm thickness for providing corrosion protection. The surface preparation shall be by light sand blasting. The internals of the large sized butterfly valves handling water shall be coated with a two pack cold cured Isopthalic polyester acrylic co-polymer with flake glass coating at thickness of 1.0 mm average. The external surfaces of the valves shall be applied with a base coat of two pack epoxy compound incorporating a rust converter, inhibitor and passivator with leafing platelets + top coat of polyamine cured high solids, two pack glass fiake filled epoxy with good gloss and chemical resistance .

3.25.4. Structural Steel and Miscellaneous Metals

Structural steel and miscellaneous metals including steel fabricated items such as plates and shapes, ladders, handrails, stair stringers, ducts, equipment and pipe supports, and similar fabrications, shall be abrasive blast cleaned in accordance with SSPC-SP10, Near White Metal Blast Cleaning. Profile depth shall be 40 to 50 microns. The primer shall be inorganic zinc with a total of 85 percent zinc in the dried film applied to a minimum dry film thickness of 75 microns.

The fabricated steel structures in contact with water shall be coated with a two pack cold cured Isopthalic Polyester acrylic co-polymer with flake glass. The coating thickness shall be 1.0 mm average.

Metal Wall Panels

Wall paneis shall be finished with a three coat system consisting of a urethane primer and two fluoropoiymer topcoats. The first topcoat shall be coloured and the second topcoat shali be clear.

3.25.5. Touch-up Paint

Touch-up paint shall be provided for repair painting of at least 25 percent of shop finish painted equipment surfaces. The touch-up paint shall be the same type and colour as the shop applied material, Surface preparation and application instructions shad be provided.

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3.25.6.

Rust-Preventive Compounds

Machined surfaces and other ferrous surfaces which should not be coated, but are subject to corrosion, i shall be protected with rust-preventive comp

ounds. Additional

Page 103: ESPECIFICACIONES STANDAR DE TUBERIAS

protection shall be provided for equipment and materials which shall be exposed to the atmosphere for extended periods. Rust-preventive compounds shall be checked every two months while in transit and in site storage and renewed as required to maintain adequate protection.

Rust-preventive compounds which are used to protect surfaces of equipment and piping that are exposed to feedwater or steam shall be completely water soluble.

Machined surfaces of weld-end preparations shall be coated with consumable rust-preventive compounds which shall not affect the quality of the weld.

3.25.7. Galvanizing

Structural steel members and steel assemblies particularly outdoor switchyard structures and metallic surfaces in the open atmosphere to be galvanized shad be pickled after completion of fabrication process. Pickling shall remove scale, rust, grease, and other impurities. Steel shall be hot-dip galvanized in accordance with ASTM A123 or equivalent.

For bolted connections, where either member to be boltsd is galvanized, erection and structural bolts shall be galvanized in accordance with ASTM A153.

3.25.8. Field Paintings/Coatings and Linings

All surfaces of erected equipment, piping, tanks, structures and building components shall be finish painted. Surfaces of connections, field weids, and damaged areas shall be cleaned, prepared, and primed before application of the finish system.

The final topcoat for interior metai surfaces shall be a high solid polyamide epoxy applied to a minimum dry film thickness of 125 microns. The final topcoat for exterior metal surfaces shall be a high soiids aliphatic polyureihane applied to a minimum dry film thickness of 50 microns. Shop primers shall be touched up and barrier/universal coats shali be applied to a minimum dry film thickness of 50 microns to provide a suitable base for topcoat application.

3.25.9. Immersion Service

Interior surfaces of shop fabricated and field erected tanks shall be cleaned and lined with materials designed for the specific application. Cleaning shall be in accordance with SSPC-SP5, White Metal Blast Cleaning.

3.25.10. Architectural Components

Interior non-metallic architectural components, including concrete block/ cement plastered brick walls, in neutral environments shall be painted with low gloss water-borne materials. Finishes for metallic architectural components, including doors and frames, shall provide a smooth, semi-gioss, and durable surface.

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3.25.11.

Colours

Colours for the identification of pipelines, ventilation ducts, electrical conduits, and related services shall be in accordance with the requirements of

BS 1710 and its appendices. Pipelines shall be identified with the name of the fluid or gas and the direction of flow.

Finish colour of mechanical equipment shall match the colour of the system of which it is a part.

Finish colour of high temperature surfaces shall be deep grey.

Finish colour of exterior surfaces of electrical cabinets and panels shall be light grey.

Interior surfaces shall be gloss white.

3.25.12. Documentation

Engineering submittals shall identify the painting/coating and lining systems to be applied_______in the shop and the field. D^ta to be provided shall include the surfaces to be painted, the

Page 105: ESPECIFICACIONES STANDAR DE TUBERIAS

painting/coating system manufacturer's name and product designation, the degree of surface preparation, dry film thickness of each coating, finish colour, and Material Safety and Data Sheets (MSDS). 3.26. PLANT LAYOUT

This section describes the philosophy which shall be used in the development of the general arrangement drawings. Plot Plan drawing (LII-GEOE09043-G-00010-00), Genera! Arrangement drawings for different floors (LII-GEOE09043-203-W-102,103,104) and Cross-section drawings (LII-GEOE09043-203-W-101,) are attached with this specification as a guideline for the bidders. Bidders shall develop their recommended drawings based on the guidelines provided ensuring cost effectiveness, ease of operation and maintenance.

3.26.1. General

The power plant shall make optimum use of land and facilities to minimize total life cycle costs but not at the cost of flexibility of maintenance and future expansion. Major external functional systems shall be so oriented that any maintenance work as well as subsequent construction work can be carried out without any interference and/or hindrance to the adjacent unit.

The main power plant building shall be functionally subdivided into the turbine-generator area, steam generator area including Mill bay area, the auxiliary bay area, and the electrical equipment area. Similarly, unit control rooms shall be so located that turbine and steam generator areas of the units shall be easily accessible. Passenger-cum-goods-elevators shall be provided for each unit as indicated in the ground Moor plan drawing (LII-GEOE09043-203-W-103)

The turbine generator floor levels shall be same for both the units and have the same EOT crane serving the TG of two units.

3.26.2. Equipment Arrangement

The layout of the major equipment shall be shown on the bidder's general arrangement drawings to be enclosed with the bid indicating the overall internal arrangement of the plant building as well as the setting dimensions and orientation of all significant equipment. The overall building configuration including internal and external walls and column rows, floor outlines, stairways, access-ways and hatches, and major obstructions, such as the turbine foundation, shall be shown to determine that such items satisfy equipment installation, access, operation, and maintenance requirements even when other units are under construction/ operation and are inline with the layout enclosed with this specification.

The optimum arrangement of equipment shall be determined by considering functional requirements, economy of piping and electrical cables, economy of equipment supports, installation and maintenance access requirements, ventilation requirements, and equipment generated noise and vibration level. Equipment location shall be determined keeping in mind the overhead Travelling Crane clearance & approach required.

3.26.3. Maintainability

The primary objective shall be to maximize the generation of kilowatt-hours. To achieve this goal, a secondary objective shall be to minimise the complexity and time required for maintenance. The following general criteria shall be followed to achieve this objective:-

a) Equipment shall be of a low maintenance design and shall be easily maintainable.Special alloys shali be used which can withstand highly erosive coal S ash.

b) Equipment shall be designed to be maintained in place, if possible, with minimumdisassembly of surrounding equipment and minimum usage of temporary scaffolding