Professional Documents
Culture Documents
Vol-II of IV - Laying - HPCL
Vol-II of IV - Laying - HPCL
BID DOCUMENT
FOR
CONSTRUCTION OF 10" DIA. X 15 KM (APPROX.) & 8
DIA X 15 KM (APPROX.) STEEL PIPELINE, TERMINALS
AND ASSOCIATED FACILITIES FOR BAHADURGARH
TIKRIKALAN PIPELINE
OPEN DOMESTIC
COMPETITIVE BIDDING BASIS
E-Tender No. : 7280
TENDER NO.: 05/51/23LK/HPCL/001(i)
VOLUME - II OF IV
MECON LIMITED
SCOPE MINAR
13 & 15th Floor, North Tower
Laxmi Nagar District Centre
DELHI 110 092
th
DEC., 2009
MECON LIMITED
CONTENTS
LIST OF SPECIFICATION / STANDARDS
VOLUME-II OF IV
1.
MEC/S/05/21/01
2.
MEC/S/05/21/02
3.
MEC/S/05/21/03
4.
MEC/S/05/21/04
5.
MEC/S/05/21/05
6.
MEC/S/05/21/06
7.
MEC/S/05/21/07
8.
MEC/S/05/21/08
9.
MEC/S/05/21/10
10.
MEC/S/05/21/11
11.
MEC/S/05/62/12
12.
MEC/S/05/21/13
13.
MEC/S/05/21/15
14.
MEC/S/05/21/016A
15.
MEC/S/05/21/016B
16.
MEC/TS/05/21/016C
17.
MEC/S/05/21/19
18.
MEC/S/05/21/21A
19.
MEC/S/05/21/24A
20.
MEC/S/05/21/24B
Page 1 of 3
MECON LIMITED
21.
MEC/23LK/05/21/M/000/1092
22.
MEC/S/05/21/61
23.
MEC/S/05/21/65
24.
MEC/S/05/62/66
25.
MEC/S/05/21/69
26.
MEC/S/05/62/70
27.
MEC/S/05/21/74
28.
MEC/S/05/21/75
29.
MEC/TS/05/62/015, R-1
30.
MEC/S/05/21/025
31.
MEC/TS/05/62/059A
32.
MEC/TS/05/21/002
33.
MEC/TS/05/62/003, Rev-2
34.
35.
MEC/TS/05/21/009
36.
MEC/TS/05/21/010
37.
MEC/TS/05/21/081H
38.
MEC/TS/05/21/081K
39.
Deluge Valve
MEC/TS/05/21/081F/B
40.
Landing Valve
MEC/TS/05/21/081E
41.
Water Monitor
MEC/TS/05/21/081C/A
42.
Hose Cabinet
MEC/TS/05/21/081O
43.
Hose Pipe
MEC/TS/05/21/081C/B
44.
MEC/TS/05/21/081D/A
45.
MEC/TS/05/21/081D/B
Page 2 of 3
MECON LIMITED
46.
Fire Bucket
MEC/TS/05/21/081D/D
47.
MEC/TS/05/21/081C/C
48.
MEC/TS/05/21/081L
49.
MEC/TS/05/21/081P
50.
MEC/TS/05/21/081N
Page 3 of 3
Rev. : 0
Edition : 1
SPECIFICATION
FOR
MAINLINE CONSTRUCTION (ONSHORE)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/01
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
3.0
4.0
RIGHT-OF-WAY
5.0
6.0
TRENCHING
7.0
BENDING
8.0
LINING UP
9.0
LAYING OF PIPE
10.0
BACK-FILLING
11.0
TIEING-IN
12.0
13.0
14.0
15.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Jan. 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 1 of 41
MEC/S/05/21/01
REVISION : 0
EDITION : 1
1.0
SCOPE
1.1
This specification covers the minimum requirements for the various activities to be
carried out by CONTRACTOR for or about the construction of cross-country pipelines.
1.2
The various activities covered in this specification include the following works of
pipeline construction :
Trenching
Lining-up
Pipeline laying
Backfilling
Tieing-in
1.3
This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.
1.4
CONTRACTOR shall, with due care and vigilance, execute the work in compliance with
all laws, by-laws, ordinances, regulations etc. and provide all services and labour,
inclusive of supervision thereof, all materials, excluding the materials indicated as
"COMPANY Supplied materials" in the CONTRACT, equipment, appliances or other
things of whatsoever nature required in or about the execution of the work, whether of
a temporary or permanent nature.
1.5
CONTRACTOR shall take full responsibility for the stability and safety of all operations
and methods involved in the WORK.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
1.6
CONTRACTOR shall be deened to have inspected and examined the work area(s) and
its surroundings and to have satisfied himself so far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic conditions,
the extent and nature of the WORK and materials necessary for the completion of the
WORK, and the means of access to the work area(s).
1.7
1.8
CONTRACTOR shall, in connection with the WORK, provide and maintain at his own
costs, all lights, guards, fencing, watching etc., when and where necessary or required
by COMPANY or by any duly constituted authority and/ or by the authorities having
jurisdiction thereof for the protection of the WORK and properties or for the safety and
the convenience of public and/ or others.
2.0
2.1
Reference has been made in this specification to the latest edition of the following
codes, standards and specifications :
a)
ANSI B 31.8
b)
ANSI B 31.4
c)
API 1104
d)
API 1105
e)
Part 1992
Title 49
f)
Part 195
In case of differences between the requirements of this specification and that of the
above referred codes, standards and specifications, the requirements of this
specification shall govern.
2.2
For the purpose of this specification the following definitions shall hold:
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
3.0
DOCUMENT NO.
Page 3 of 41
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EDITION : 1
3.1
3.1.1
General
Pipelines which are constructed inside the area of high voltage lines may be electrically
influenced by the high voltage lines. The voltage caused by the influence may at times
be high enough to pose danger to personnel working on the pipeline. It is imperative
therefore, that the instructions given below should be strictly observed.
3.1.1.1
It is a necessity that all personnel working on the pipeline which is being laid in the
area influenced by the high voltage systems, be given clear instructions on measures
to be taken.
3.1.1.2
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
3.1.1.3
If its not impossible for plant and/ or materials to come within 50m of the centre of the
high voltage systems, special measures must be taken to prevent any approach
beyond that distance, unless article 3.1.2 is complied with.
3.1.1.4
3.1.1.5
3.1.1.6
Before a pipeline section is lowered into the trench the structure's earth electrodes
indicated in the drawings or determined with calculation method must have been
installed and connected both to the pipeline section already buried and to the section
which is about to be buried. The electrical connections which serve the purpose of
preventing dangerous voltages must have a min. area of 35mm2.
Said connections must not be interrupted until after the permanent safety earth
connections have been installed and connected to the entire uninterrupted pipeline.
3.1.1.7
The welded connection between the pipeline section and the section already buried
must be installed at a distance of at least 50m from the nearest point of a pylon base.
3.1.1.8
Personnel doing work inside the area of influence of the high voltage system must
wear electrically insulating foot-wear (e.g. rubber kneeboots) and wear insulating
rubber or plastic gloves.
3.1.2
Additional measures for work at less than 50m from the centre of the high
voltage system.
If work is done at less than 50m from the centre of the high voltage system, the
regulations below must be complied with in addition to the rules specified in clause
3.1.1.
3.1.2.1
The work must not be started until agreement has been reached with the authorities
which controls the high voltage system, about the implementation of the safety
measures specified in this section.
3.1.2.2
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
0
40
200
50 KV
200 KV 5m
380 KV 8m
DOCUMENT NO.
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EDITION : 1
3m
3.1.2.3
1.
2.
In the event that a vehicle, crane etc. should accidently come into contact with a live
cable of a high voltage system or flash-over of electrical charge occurs, the driver must
not leave his vehicle because this will pose a serious threat to his life.
The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE.
The driver must not leave his vehicle unitl be has managed to leave "the dangerous
area, or alternatively, when the Electricity Authorities have given notice that the
cable(s) have been put out of circuit. In case a serious fire starts in the vehicle, he is
permitted to jump from the vehicle, clearing it as far as possible, while the jump
should possible be to a dry spot.
4.0
RIGHT-OF-WAY
The CONTRACTOR is required to perform his construction activities within the width of
Right-of-way set aside for construction of pipeline, unless he has made other
arrangements with the land owner and/ or tenant for using extra land. Variation in this
width caused by local conditions or installation of associated pipeline facilities or
existing pipelines will be identified in the field or instructed to the CONTRACTOR by
COMPANY.
The ROW boundary lines shall be staked by the CONTRACTOR, so as to prepare the
strip for laying the pipeline. CONTRACTOR shall also establish all required lines and
grades necessary to complete the work and shall be responsible for the accuracy of
such lines and grades.
4.1
Staking
Prior to cleaning operations CONTRACTOR shall :
1)
Install Bench Marks, Intersection Points and other required survey movements.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 6 of 41
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EDITION : 1
2)
3)
4)
5)
Install distance markers locating and indicating special points, such as but not
limited to :
ROW markers shall be staked out at the boundary limits of Right-of-way wherever
possible. ROW markers shall be painted red with numbers painted in white. Number
shall be identical to centreline marker number with letters A (left side) and B (right
side) added, (looking, in flow direction). Reference markers shall also carry the same
information as its corresponding centreline markers.
Markers shall be of suitable material so as to serve their purpose and shall be coloured
distinctly for easy identification. CONTRACTOR shall be responsible for the
maintenance and replacement of the reference line markers until the permanent
pipeline markers are placed and the as-built drawings are submitted and approved.
Any deviation from the approved alignment shall be executed by CONTRACTOR after
seeking COMPANY approval in writing prior to clearing operations.
4.2
Monuments
All shrines, monument, border stones, stone walls and the like shall be protected and
shall be subjected to no harm during construction. Any violation of the above by the
CONTRACTOR shall be brought to the notice of the COMPANY and other concerned
authorities. Restoration of the above shall wholly be the responsibility of the
CONTRACTOR.
4.3
Fencing
Prior to clearing or grading of the Right-of-way or stringing of pipe, CONTRACTOR shall
open fences on or crossing the construction Right-of-way and install temporary gate of
sound construction made of similar materials and suitable quality to serve purpose of
original fence. Adjacent post shall be adequately braced to prevent slackening of the
remainder of the fence. Before such fences are cut and opened, CONTRACTOR shall
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 7 of 41
MEC/S/05/21/01
REVISION : 0
EDITION : 1
notify the land owner or tenant, and where practicable, the opening of the fences shall
be in accordance with the wishes of said owner and tenant. In all cases where
CONTRACTOR removes fences to obtain work route, CONTRACTOR shall provide and
install temporary fencing, and on completion of construction shall restore such fencing
to its original condition.
CONTRACTOR shall install temporary fencing on either side of ROW where in
COMPANY's opinion, it is considered essential to ensure safety and non-interference,
especially in areas like grasing lands, villages etc.
Fencing shall be removable type wherever necessary, to permit crossing of traffic. The
type of fencing must be suitable for the situation in accordance with user. The pole
distance shall not be greater than 6m. The minimum height of the fencing shall be
1.2m above grade. Fencing can consist of one or more rows of smooth wire and/ or of
barbed wire.
Fencing shall be continuously maintained and the thorough-ways inspected to be shut
during the execution of the work.
4.4
4.4.1
All stumps shall be grubbed for a continuous strip, with a width equal to trench top
width plus two metres on either side centred on the pipeline centreline. Further, all
stumps will be grubbed from areas of the construction Right-of-way, where Right-ofway grading will be required. Outside of these areas to be graded and the mentioned
trench strip, at the option of CONTRACTOR, the stumps may either be grubbed or cut
off to ground level. Any stump cut off must be left in a condition suitable for rubbertyred pipeline equipment traffic.
4.4.2
All grubbed stumps, timber, bush undergrowth and root cut or removed from the
Right-of-way shall be disposed of in a manner and method satisfactory to COMPANY,
land-owner and/ or tenant, and Government Authorities having jurisdication and as
soon as practical after the initial removal. In no case, it shall be left to interfere with
the grading and laying operations. Whenever stumps are grubbed and a hole is left in
the ground, CONTRACTOR shall back-fill the hole and compact it to prevent water
from gathering in it and creating a big hole.
4.4.3
CONTRACTOR shall grade the pipeline Right-of-way as required for proper installation
of the pipeline, for providing access to the pipeline during construction, and for
ensuring that the pipeline is constructed in accordance with the good engineering and
construction practices.
4.4.4
CONTRACTOR shall grade sharp points or low points, without prejudice to section 6.0
of this specification, to allow the pipe to be bent and laid within the limits set forth in
these specifications and drawings as regards the minimum elastic curvature permitted,
and shall drill, blast or excavate any rock or other material which cannot be graded off
with ordinary grading equipment in order to make an adequate working space along
the pipeline.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 8 of 41
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EDITION : 1
4.4.5
No temporary or permanent deposit of any kind of material resulting from clearing and
grading shall be permitted in the approach to roads, railways, streams, ditches,
drainage ditches and any other position which may hinder the passage and/or the
natural water drainage.
4.4.6
The Right-of-Way clearing and grading operations shall in no case involve embankment
structures of any type and class without prior approval of the authorities having
jurisdiction over the same.
4.4.7
In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other
fill materials, these shall be removed till stable natural ground level is reached so as to
ensure the construction of the pipeline ditch is in stable ground.
4.4.8
In the case of Right-of-Way clearing and grading on hillside or in steep slope areas,
proper barriers or other structures shall be provided to prevent the removed materials
from rolling downhill. The Right-of-Way crossfall shall not exceed 10%.
4.4.9
Wherever the pipeline Right-of-Way runs across plantations, alongside farmyards, built
up areas, groups of trees, horticultural spreads, gardens, grass-fields, ditches, roads,
paths, railways or any other area with restrictions of some kind, CONTRACTOR shall
grade only the minimum area required for digging and constructing the pipeline. In the
said places, CONTRACTOR shall carry out the works in such a way that damage done
from the pipeline construction is kept to a minimum.
4.5
Provision of Detours
CONTRACTOR shall do all necessary grading and bridging at road, water and other
crossings and at other locations where needed, to permit the passage of its men and
equipment. It is understood that the CONTRACTOR has recognised such restricctive
features of the Right-of-Way and shall provide the necessary detoors and execute the
works without any extra cost to COMPANY. Public travel shall not be inconvenienced
nor shall be wholly obstructed at any point.
CONTRACTOR at his own cost shall furnish and maintain watchman detours, lanterns,
traffic lights, barricades, signs, wherever necessary to fully protect the public.
CONTRACTOR shall be responsible for moving its equipment and men across or around
watercourses. This may require the construction of temporary bridges or culverts.
Temporary bridging or access to fording required for Right-of-Way crossing water
courses shall be constructed. CONTRACTOR shall ensure that such temporary works
shall not interfere with normal water flow, avoid overflows, keep the existing
morphology unchanged and shall not unduly damage the banks or water courses. No
public ditches or drains shall be filled or bridged for passage of equipment until
CONTRACTOR has secured written approval of the Authorities having jurisdiction over
the same. CONTRACTOR shall furnish COMPANY a copy of such approval.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
4.6
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 9 of 41
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EDITION : 1
4.7
5.0
5.1
General
The CONTRACTOR shall exercise utmost care in handling in pipe and other materials.
CONTRACTOR shall be fully responsible for all materials and their identification until
such time that the pipes and other materials are installed in permanent installation.
CONTRACTOR shall be fully responsible for materials, however, method of storage
shall be approved by COMPANY.
CONTRACTOR shall reimburse the COMPANY for the cost of replacement of all
COMPANY supplied materials damaged during the period in which such materials are in
the custody of the CONTRACTOR. It shall be CONTRACTOR's responsibility to unpack
any packing for the materials supplied by COMPANY.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
5.1.2
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 10 of 41
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EDITION : 1
5.2
5.2.1
Bare Pipe
CONTRACTOR shall unload, load, stockpile and transport the bare pipes using suitable
means and in a manner to avoid denting, flattening, or other damage to pipes. Pipe
shall not be allowed to drop or strike objects which will damage the pipe but shall be
lifted or lowered from one level to another by suitable equipment. Lifting hooks when
used, shall be equipped with a plate curved to fit the curvature of the pipe. In loading
pipe on trucks each length shall be lowered to position without dropping and each
succeeding length shall rest on special supports on the truck and shall be separated
from the adjacent pipes. After loading, suitable chains and padding shall be used to tie
the load securely to each bolster. Pipes, when stock piled, shall be placed on suitable
skids to keep them clear of the ground and flood water. The CONTRACTOR shall
provide all necessary timber or other materials required for the stock-piling. While
stacking, the number of allowable layers of bare pipes shall be calculated as per API
RP5L1 and shall be agreed with COMPANY. The stacks must be properly secured
against sliding and shall consist of pipes of the same diameter and wall thickness.
Adjacent stacks of pipes having different dimensional characteristics shall be clearly
separated.
Pipes which are damaged at the time of delivery or "taking-over" (when line pipe is
supplied by COMPANY), particularly those which are dented, buckled, or otherwise
permanently deformed, must be stacked separately and may be transported to the
sites only when these defects have been repaired or eliminated.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
5.2.2
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 11 of 41
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EDITION : 1
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 12 of 41
MEC/S/05/21/01
REVISION : 0
EDITION : 1
Coated Pipes stacked in open storage yards/dump yards shall be suitably covered on
top to decrease direct exposure to sunlight.
The ends of the pipes during handling and stacking shall always be protected with
bevel protecters.
The lorries/rail wagons shall be equipped with adequate pipe supports having as many
round hollow beds as the number of pipes to be placed on the bottom of the lorry bed.
Supports shall be provided for at least 10% of the pipe length. These supports shall be
lined with a rubber protection and shall be spaced in a manner as to support equal
load from the pipes. The rubber protection shall be free from all nails and staples
where pipes are in contact. The second layer and all subsequent layers shall be
separated from other layers with adequate number of separating layers of protective
material such as straw in plastic covers or otherwise to avoid direct touch between the
coated pipes.
All stachions of lorries/rail wagons used for transportation shall be covered by nonabrasive material like rubber belts or equivalent. Care shall be exerclsed to properly
cover the top of the stanchions and convex portions such as reinforcement of the
truck/rail wagon only, rivets etc. to prevent damage to the coated surface.
5.3
Stringing of Pipe
Pipes shall be unloaded from the stringing trucks and lowered to the ground by means
of by means of boom tractor or swinging crane or other suitable equipment using
lifting devices as mentioned earlier. Dragging or sliding of pipe shall not be permitted.
Special precaution shall be taken during stringing of corrosion corrosion coated pipe as
per the special requirements of previous para. Stringing of pipe shall only be carried
out in daylight and after clearing and grading operations have been completed. Pipes
shall not be strung along the ROW in rocky areas where blasting may be required, until
all blasting is completed and the area cleared of all debris.
The stringing of the pipe on the ROW shall be done in such a manner so as to cause
the least interference with the normal use of the land crossed and to avoid damage to
and interference with the pipes. The sequence of pipes must be interrupted at suitable
intervals, spaced to coincide with passages, roads, railwys, water crossings as well as
at other places if requested by landowner / tenants to permit use of land.
In case line pipe supply is by different manufacturers s, CONTRACTOR shall string all
line pipes of one manufacturer before commencing the stringing of line pipes of
another manufacturer.
When parallel pipelines are being constructed, bumping against and contact with the
strung sections of pipe shall be avoided, whether the stringing of the pipes for the
individual lines is carried separately or simultaneously.
The pipe lengths shall be properly spaced in order to make easier the handling during
the welding phase.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 13 of 41
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EDITION : 1
It shall be the responsibility of the CONTRACTOR to see that pipe is strung as per the
approved drawings for the proper placement of pipe by size, thickness, grade and
other specifications. Any additional handling of pipes due to failure to comply with the
requirements shall be at the CONTRACTOR's expense.
5.4
5.5
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 14 of 41
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EDITION : 1
kept permanently in store, supported above the ground in a dry place, protected
against the weather and transported for use only at the time and in quantities
necessary for immediate application. Deteriorated materials shall not be used and
replaced with no extra cost to COMPANY.
5.6
Identification
CONTRACTOR shall provide all pipes, bends, etc. greater than 2" with serial numbers
as soon as possible and measure their length and state is on the pipes, etc. Pipes to be
bent shall be measured prior to bending. Identification (i.e. letter, number and length)
shall be indelible.
All serial numbers shall be recorded in a list, which shall also state appurtenant pipe
numbers.
Beside recording the stamped - in pipe numbers, length of pipe and painted-on serial
numbers, the stamped-in numbers of T-pieces, bends, valves, etc. and the batch
numbers of bends, T-pieces, valves, etc. and the make of valves, shall also be
recorded in said list.
Before a pipe length, pipe end, etc. is cut the painted serial number and stamped-in
pipe number shall be transferred by CONTRACTOR in the presence of COMPANY to
either side of the joint which is to be made by cutting, and the changes shall be
recorded in the above mentioned list stating the (new) length. The results shall be
such that all pipes, pups, etc. of diameter greater than 2" bear clear marks painted on.
CONTRACTOR shall explicitly instruct his staff that parts which cannot be identified
must not be removed, except after permission by COMPANY.
As a general rule parts must be marked as described above before being moved. In no
conditions may unmarked parts be incorporated into the WORK.
6.0
TRENCHING
6.1
Location
CONTRACTOR shall, excavate and maintain the pipeline trench on the staked center
line of the pipeline taking into account the curves of the pipeline.
6.2
Excavation
6.2.1
CONTRACTOR shall, by any method approved by COMPANY, dig the pipeline trench on
the cleared and graded Right-of-Way. In cultivable land and other areas specifically
designated by the COMPANY, top 60mm of the arable soil on the pipeline trench top
and 500mm on either side shall be excavated and stored separately to be replaced in
original position after backfilling and compacting rest of the trench.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 15 of 41
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EDITION : 1
Suitable crossing shall be provided and maintained over the open ROW where
necessary, to pemit general public, property owners or his tenants to cross or move
stock or equipment from one side of the trench to the other.
Care shall be exercised to see that fresh soil recovered from trenching operation,
intended to be used for backfilling over the laid pipe in the trench, is not mixed with
loose debris or foreign material. The excavated material shall never be deposited over
or against the strung pipe.
6.2.2
In steep slope area or on the hillside, before commencing the works, proper barriers or
other protection shall be provided to prevent removed materials from rolling downhill.
6.2.3
On slopes where there is danger of landslide, the pipeline trench shall be maintained
open only for the time strictly necessary. Forever, the COMPANY may require
excavation of trench by hand, local route detours and limiting the period of execution
of the works.
6.2.4
In certain slope sections before the trench cuts through the water table, proper
drainage shall be ensured both near the ditch and the Right-of-Way in order to
guarantee soil stability.
6.2.5
All sewers, drains ditches and other natural waterways involved in the execution of the
works shall be maintained open and functional. The same applies to canals, irrigation
canals, pipelines and buried facilities crossed by the ditch for which temporary pipeline
shall be laid, if required, and proper temporary installations provided.
6.3
Blasting
Blasting for trenching and the related removal of scattered rock and debris caused by
the blasting from the Right-of-Way and/or adjacent property, shall be performed by
CONTRACTOR as part of his work.
Every possible precaution shall be taken to prevent injuries and damages to persons
and properties during blasting operations, which shall be performed in accordance with
Standard Rules for Blasting.
CONTRACTOR shall obtain necessary permits for storage and use of explosives and
comply with the laws, rules and regulations of the respective Governmental agencies
having jurisdiction thereof. No blasting will be allowed without prior and due notice
given by CONTRACTOR to COMPANY, Government authorities, land-owners, property
occupants, adjacent work crew, and other concerned parties.
CONTRACTOR shall employ only such workmen who are experienced in the type of
work to be performed, to supervise, handle and use explosives.
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REGD. OFF: RANCHI
834002
TITLE
6.3.1
MAINLINE CONSTRUCTION
(ONSHORE)
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EDITION : 1
Where blasting is to be carried out beyond 50 meters away from any existing
pipeline or structures (either above or below ground) the CONTRACTOR shall
submit his proposed blasting procedure and perform a trial blast for
COMPANY's approval.
b)
c)
6.3.2
All necessary precautions shall be taken to prevent stones from falling outside the
Right-of-way and in cultivated areas and to avoid any damage to the installation and
properties existing nearby.
6.3.3
Blasting and removal of debris shall be carried out prior to stringing the pipes.
6.3.4
Ground vibration due to blasting near the existing structures shall be continuously
monitored using certified instruments to be provided by CONTRACTOR and approved
by COMPANY and the peak particle velocities shall not exceed 50 mm/ sec.
COMPANY reserves the right to refuse blasting where possible danger exists to
property, existing utilities or other structures. In such locations other methods of
extracting rock shall be proposed by CONTRACTOR and shall be approved by
COMPANY.
6.4
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
Sl.
No.
DOCUMENT NO.
Page 17 of 41
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Location
EDITION : 1
a)
1.0
b)
Rocky Terrain
1.0
c)
1.5
d)
1.5
e)
1.5
f)
g)
2.5
h)
1.2
i)
Railroad Crossings
1.7
j)
1.0
k)
1.5
Notes :
In case pipeline is located within 1.5 m from any dwelling unit, the cover shall be
increased by 300 mm over and above that specified.
6.5
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 18 of 41
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EDITION : 1
Throughout the period of execution of such works, CONTRACTOR shall provide and
use warning signs, traffic lights or lanterns, barricades, fencing, watchman, etc. as
required by the local authorities having jurisdiction and/ or COMPANY.
For all roads, paths, walkway etc. which are open-cut, CONTRACTOR shall provide
temporary diversions properly constructed to allow the passage of normal traffic with
the minimum of inconvenience and interruptions.
The paving shall be restored to its original condition after the pipeline is installed.
6.6
6.7
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 19 of 41
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EDITION : 1
adopting the crumbling shoe and digging teeth of the trenching machines and by use
of a drag behind the trenching machines or manually dressing-up the same.
CONTRACTOR shall do such hand work in the trench as is necessary to free the
bottom of the trench from loose rock and hard clods and to trim protruding roots from
the bottom and side walls of the trench.
6.8
Padding
In all cases where rock or gravel or hard soil is encountered in the bottom of the
trench, COMPANY will decide the exact extent of trench padding, that will be required.
The thickness of the compacted padding shall not be less than 150mm. In those areas
that are to be padded, the trench shall be at least 150mm deeper than otherwise
required, and evenly and sufficiently padded to keep the pipe, when in place, at least
150mm above bottom of excavated trench.
Acceptable padding shall be placed under the pipeline before its installation, and
around after installation to establish at both sides and on top of the pipe a permanent
layer of padding. The thickness of compacted padding on top of pipe corrosion coating
shall be at least 150mm. Padding materials that are approved by COMPANY shall be
graded soil/ sand and/ or other materials containing no gravel, rock, or lumps of hard
soil. Sand used for padding shall pass through sieve size ASTM-10 or ISO-2.00.
When specified in the CONTRACT, rock shield may be used in place of or in addition to
sand padding as indicated above. Such rock shield shall be in accordance with the
specification issued for the purpose and shall be subject to COMPANY approval.
6.9
Protection of Trench
CONTRACTOR shall keep the trench in good condition until the pipe is laid, and no
claim is to be made to the COMPANY by reason of its caving either before or after pipe
is laid.
All lumber, sheet-piling jacks or other materials, that may be necessary to shore the
trench, in order to prevent caving are to be furnished and removed by CONTRACTOR.
CONTRACTOR shall dewater if necessary, using well point system or other suitable
systems, shore, or do what else might be required to excavate the trench, install the
pipe in it and backfill the trench in accordance with these specifications at no extra cost
to COMPANY.
6.10
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
6.12
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 21 of 41
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REVISION : 0
EDITION : 1
In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall
be drained to the extent and for the time required to make a visual inspection of the
ditch bottom. After this inspection, the presence of water will be allowed provided its
level does not cause sliding of the ditch sides and pipe floating before backfilling when
no concrete weighting is provided.
The water pumped out of the ditch shall be discharged into a natural water course.
Wherever up-floating of the pipeline after backfilling is to be reckoned with, antibuoyancy measures shall be provided by CONTRACTOR for areas indicated in the
drawings or as may be encountered during construction, using one or a combination of
the following methods :
The above provisions shall be in accordance with the relevant specifications and/ or job
standards/ drawings.
7.0
BENDING
CONTRACTOR shall preferably provide for changes of vertical and horizontal alignment
by making elastic bends. CONTRACTOR may provide cold field bends, at its option for
change of direction and change of slope. COMPANY at its option, may authorise
fabricated bends for installation at points where in COMPANY's judgement the use of
such bends is unavoidable.
Overbends shall be made in such a manner that the center of the bend clears the high
points of the trench bottom. Sag bends shall fit the bottom of the trench and side
bends shall conform and leave specified clearance to the outside wall of the trench.
7.1
Elastic Bends
The minimum allowable radius for elastic bends in the buried pipeline including that for
continuous concrete weight coated pipe shall be in accordance with relevant job
standards. The elastic bend shall be continuously supported over its full length. A
radius smaller than permitted in elastic bending shall require a cold bend.
7.2
7.2.1
The radius of cold field bends shall not be less than 40 times the pipe nominal
diameter for pipe diameter 18 inch and above and shall not be less than 30 times the
pipe nominal diameter for pipe diameter less than 18 inch.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
7.2.2
CONTRACTOR shall use a bending machine and mandrel and employ recognized and
accepted methods of bending of coated pipe in accordance with good pipeline
construction practice. However, bending machines shall be capable of making bends
without wrinkles, buckles, stretching and with minimum damage to the coating.
7.2.3
CONTRACTOR shall, before the start of the work, submit and demonstrate to
COMPANY a bending procedure which shall conform with the recommendations of the
manufacturer of the bending machine. The procedure shall include amongst other
steps - lengths, maximum degree per pull and method and accuracy of measurement
during pulling of the bend. This procedure and the equipment used shall be subject to
COMPANY's approval.
7.2.4
Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane
passing through the neutral axis of the bend which shall be installed positioning the
longitudinal weld in the upper quadrants. If horizontal deviations are to be achieved by
joining more adjacent bends, the bending of the pipe lengths shall be made by
positioning the longitudinal welds alternatively 70mm above and below the plane
passing through the neutral axis in such a way that the bends are welded with the
longitudinal welds displaced by about 150mm and situated in the upper quadrants. In
case of vertical bends formed from a number of pipe lengths, the longitudinal welds
shall be positioned on the plane passing through the neutral axis of the bend to the
right and left alternatively.
7.2.5
The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to
avoid damage to the pipe coating. Where applicable, fully retaining bending shoes shall
be used. Roller type bending machines are preferred.
7.2.6
The ends of each bent length shall be straight and not involved anyway in the bending.
The length of the straight section shall permit easy joining. In no event shall the end of
the bend be closer than 1.5m from the end of a pipe or within one meter of a girth
weld.
7.2.7
The ovalisation caused on each pipe by bending shall be less than 2.5% of the nominal
diameter at any point. Ovalisation is defined as the reduction or increase in the internal
diameter of the pipe compared with the nominal internal diameter. A check shall be
performed on all bends in the presence of COMPANY by passing a gauge consisting of
two discs with a diameter equal to 95% of the nominal internal diameter of the pipe
connected rigidly together at a distance equal to 300mm.
7.2.8
The wall thickness of finished bends, taking into account wall thinning at the outer
radius, should not be less than the design thickness. An indication of wall thinning as a
percentage is given by the following empirical formula :
50
Wall Thinning = --------------n+1
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 23 of 41
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EDITION : 1
Where n is the inner bend radius divided by pipe diameter. Pipes with measured wall
thickness greater than the nominal wall thickness (i.e. with +ve tolerance) shall
normally be used for making cold field bends.
7.2.9
Cold bent pipes on site shall have the corrosion coating carefully checked with the aid
of a holiday detector for cracks in the coating down to the pipe wall. It must also be
checked whether the coating has disbonded from the pipe wall during bending by
beating with a wooden mallet along the outer radius. Any defects or disbonding of the
coating caused during bending (also forced ridges in the coating) shall be repaired at
the CONTRACTOR's expense in accordance with COMPANY approved procedures.
7.2.10
When pipelines are laid in parallel, the horizontal bends shall be concentric.
7.3
8.0
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
8.1
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
8.1.1
Acceptability of defects in the pipe detected during inspection at the work site shall be
determined in accordance with latest edition of COMPANY's own material specification
or CODE ANSI B31.8/B 31.4 whichever is more stringent.
8.1.2
The maximum permissible depth of dents in pipes upto and including 123/4" OD is 5mm
and for pipes over 12 3/4" OD is 2% of the nominal pipe diameter.
8.1.3
Dents which contain a stress concentrator such as scratch, gauge, arc burn or groove,
and dents located at the longitudinal, spiral or circumferential weld shall be removed
by cutting out the damaged portion of pipe as a cylinder.
8.1.4
8.1.5
8.1.6
Repair of damaged pipe ends by hammering and/or heating is not allowed. If the
dented area is minor and at least 200mm away from the pipe end, and the steel is not
stretched, severed, or split in the COMPANY's opinion, the pipe may be straightened
with a proper jack.
8.2
8.2.1
When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings
approved by COMPANY shall be used. CONTRACTOR shall submit his method of
skidding and skid spacing for COMPANY's approval. A strip of soft material shall be
placed in between skid and pipe to protect the external coating of the pipe. The
material shall be approved by the COMPANY.
8.2.2
The maximum skid spacing is not allowed before the stringer bead and the top and
bottom reinforcements are completed, provided that the distance between the
incomplete weld and the skid shall not exceed 9 (nine) percent of the skid spacing.
8.2.3
Skids shall be atleast 1.20 meter long. For pipe with an O.D. of 12-3/4 inch and larger
the skids in contact with the pipe shall have a width of at least 200mm. For pipe with
an O.D. of less than 12 inch the skids in contact with the pipe shall have a width of
atleast 150mm. Pipe supports shall be stable, so that pipe movement will not cause
the supports to move. Skids shall not be removed under a string before lowering in.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
The welded pipe shall be maintained on skids at the minimum distance of 500mm
above ground. Crotches shall be installed at frequent intervals (atleast every 10th
support) with a greater number required at bends and undulation grounds.
8.3
Night Caps
At the end of each day's work or every time when joining and welding operations are
interrupted, the open ends on the welded strings of pipes shall be capped with a
securely closed metal cap or plug as approved by COMPANY so as to prevent the entry
of dirt, water, or any foreign matter into the pipeline. These covers shall not be
removed until the work is to be resumed. The caps/plugs used shall be mechanical
type and shall not be attached to pipe by welding or by any other means which may
dent, scratch or scar the pipe.
8.4
Temporary Caps
Whenever the welded strings of pipes are left open at intervals to be tied in later after
an appreciable time lag, under roads, railroads, rivers, marshy crossings, ets.,
temporary caps approved by COMPANY shall be welded to the ends of the pipe.
9.0
LAYING OF PIPE
9.1
Lowering In Trench
9.1.1
Lowering can start after removal from ditch bottom of all off cuts, pipe supports,
stones, roots, debris, stakes, rock projections below underside of pipe and any other
rigid materials which could lead to perforation or tearing of the coating. Sand padding
and / or rock shield shall be provided as required in accordance with clause 6.8 of this
specification.
9.1.2
Lowering shall follow as soon as possible, after the completion of the joint coating of
the pipeline. In the case of parallel pipelines, laying shall be carried out by means of
successive operations, if possible without interruption.
9.1.3
Before lowering in, a complete check by a full circle holiday detector for pipe coating
and for field joint coating shall be carried out and all damages repaired at
CONTRACTOR's cost. All points on the pipeline where the coating has been in contact
with either the skids or with the lifting equipment during laying, shall be carefully
repaired. If, after checking, it becomes necessary to place the pipeline again on
supports at the bottom of the trench, these must be padded in such a way as to
prevent damage to the coating, thus avoiding necessity for further repairs when the
pipe is finally raised and laid. Before the last operation, a check must be made of the
coating at points of contact with the supports.
9.1.4
Before lowering in, short completed sections of the pipeline shall be cleaned with
compressed air in order to remove all dirt, etc. from the inside of pipe sections.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
9.1.5
The pipeline shall be lifted and laid using, for all movements necessary, suitable
equipment of non-abrasive material having adequate width for the fragility of the
coating. Care shall be exercised while removing the slings from around the coated pipe
after it has been lowered into the trench. Any damage caused to the coating shall be
promptly repaired. Lowering in utilizing standard pipe cradles shall be permitted if
CONTRACTOR demonstrates that pipe coating is not damaged. No sling shall be put
around field joint coating.
9.1.6
Wherever the pipeline is laid under tension, as a result of an assembly error (for
example, incorrect positioning of bends, either horizontal or vertical), the trench shall
be rectified or in exceptional cases a new assembly shall be carried out, to be
approved by COMPANY, so that it fits the excavation and the laying bed.
9.1.7
Laying shall be carried out under safe conditions so as to avoid stresses and temporary
deformations of the equipments which may cause damage to the pipeline itself and to
the coating. In localised points where the right-of-way is restricted to the minimum
necessary for the transit of mechanical equipment, the laying shall be carried out using
other suitable means. The pipe shall be placed on the floor or the excavation, without
jerking, falling, impact or other similar stresses. In particular, care must be taken that
the deformation caused during the raising of the pipe work from the supports, does
not exceed the values for the minimum allowable radius of elastic curvature, so as to
keep the stresses on the steel and on the coating within safe limits. The portion of the
pipeline between trench and bank shall be supported by as many side-booms as
required and approved by COMPANY for holding the line in gentle S-curve maintaining
minimum elastic bend radius as specified in job standard. Lowering in and back-filling
shall preferably be carried out at the highest ambient temperature.
9.1.8
The pipeline must be laid without interruption for the whole or the length of section
available. Where water is present, no laying shall be permitted until the ditch has been
drained to the extent and for the time necessary to make visual inspection possible of
the bed on which the pipe is to be laid. Following such inspections, the presence of
water will be permitted, provided that it is not so high as to cause cave-in of the walls
of the trench or floating of the pipeline before backfilling, when weighting is not
provided for the pipe.
9.1.9
9.1.10
In laying parallel pipelines in the same trench, the minimum distances between the
pipeline indicated in the approved drawings shall be observed. Once the first pipeline
has been positioned, it shall in no way be disturbed by laying of the subsequent
pipeline.
At every seven meters along the trench sand/earth filled bags shall be placed between
the parallel pipelines so as to ensure maintenance of the minimum stipulated distance
between the parallel lines.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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9.2
9.2.1
The following works shall be completed before proceeding with the assembly and
laying of overhead pipelines :
-
9.2.2
The erection of the supports shall be carried out taking care that the elevation and
alignment is in accordance with the drawings.
In the case of metal work supports, prefabrication and/or assembly shall take into
account the maximum allowed free span and the supports shall not interfere with the
pipeline welds.
9.2.3
In case roller supports are used, the roller shall be lubricated, then checked for smooth
rotation and, in case of seizure, the defect shall be repaired or roller shall be replaced.
In the case of overhead section where the pipeline is slanting, the alignment of the end
supports shall be made after placing the pipeline in position. Before installation of the
pipe section, all the rollers shall be perfectly centered acting on the seat of the support
plates.
The above alignment operations shall be carried out before connecting the overhead
section with the ends of the buried section.
9.2.4
Lifting, moving and laying of the pipeline shall be carried out in accordance with the
provisions of clause 9.1.5.
An insulation sheet shall be installed to isolate the pipe from the support or support
from the earth.
The sheet shall be hard polyethylene at least 5mm thick.
9.2.5
9.2.6
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
(f)
(g)
DOCUMENT NO.
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10.0
BACK-FILLING
10.1
Backfilling shall not be done until the pipe and appurtenances have the proper fit and
the pipe is following the ditch profile at the required depth that will provide the
required cover and has a bed which is free of extraneous material and which allows the
pipe to rest smoothly and evenly. Before any such work is done, it shall be the
CONTRACTOR's responsibility to first secure the approval of COMPANY. If any
backfilling is done without COMPANY's approval, COMPANY will have the right to
require removal of the backfill for examination, and the cost of such uncovering and
refilling shall be borne by CONTRACTOR. Backfilling of trench in water courses shall be
carried out as per the relevant specifications issued for the purpose.
10.2
Backfilling shall be carried out immediately after the pipeline has been laid in the
trench, inspected and approved by the COMPANY, so as to provide a natural
anchorage for the pipeline, thus avoiding long exposure of coating to high
temperature, damaging actions of adverse weather conditions, sliding down of
trench sides and pipe movement in the trench. If immediate back filling is not
possible, a covering of atleast 200mm of earth, free of rock and hard lumps shall be
placed over and around the pipe and coating.
On no account the top soil from the ROW be used for this purpose. In general, the
trench shall be dry during backfilling. Deviations there of must have prior approval of
the COMPANY. The backfill material shall contain no extraneous material and/or hard
lumps of soil which could damage the pipe / coating or leave voids in the backfilled
trench. After the initial backfill has been placed into the trench to a level slightly above
the surrounding ground, CONTRACTOR shall compact the backfill material. The
surplus material shall be neatly crowned directly over the trench and the adjacent
excavated areas on both sides of the trench as per clause 6.2.1, to such a height which
will, in COMPANY's opinion, provide adequately for future settlement of the trench
backfill during the maintenance period and thereafter. The crown shall be high enough
to prevent the formation of a depression in the soil when backfill has settled into its
permanent position. Should depression occur after backfill, CONTRACTOR shall be
responsible for remedial work at no extra cost to COMPANY. Surplus material, including
rock, left from this operation shall be disposed of to the satisfaction of land owner or
authority having jurisdiction at no extra cost to the COMPANY.
For further requirements reference is made to Section of 14.0 "Clean-up and
Restoration of Right-of-Way" of this specification.
10.3
Rock, gravel, lumps of hard soil or like materials shall not be backfilled directly onto the
pipe unless 'padding' and/or rock shell has been provided as per Section 6.0 of this
specification. When "Padding" as described in Section 6.0 of this specification is to be
used, the following shall be applicable.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
Page 29 of 41
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REVISION : 0
EDITION : 1
Where rock, gravel, lumps of hard soil or like materials are encountered at the time of
trench excavation, sufficient earth, sand or select backfill materials shall be placed
around and over the pipe to form a protective cushion extending at least to a height of
150mm above the top of the pipe. Select backfill materials for padding that are
acceptable to COMPANY shall be soil, sand, clay or other material containing no gravel,
rock or lumps or hard soil. Whether such padding material would be taken from the
adjacent spoil bank or imported from elsewhere shall be directed by COMPANY. All
these works shall be carried out by CONTRACTOR at no extra cost to COMPANY. Loose
rock may be returned to the trench after the required selected backfill material has
been placed, provided the rock placed in the ditch will not interfere with the use of the
land by landowner, or tenant.
10.4
When the trench has been dug through drive ways or roads, all backfills shall be
executed with sand or a suitable material as approved by COMPANY and shall be
thoroughly compacted. In certain cases, special compaction methods, such as
moistening or ramming of the backfill in layers may be required by COMPANY.
COMPANY and any public or private authority having jurisdiction over a road, street or
drive way may require that the surface of the backfill be graveled with crushed rock or
some other purchased material and the road shall be repaved. In such instances,
CONTRACTOR shall comply with said requirements at no extra cost to COMPANY.
10.5
Trenches excavated in dykes which are the property of railways or which are part of
main roads shall be graded and backfilled in their original profile and condition. If
necessary, new and/or special backfill materials shall be supplied and worked-up. The
materials required may include gravel, special stabilization materials or stabilized
mixtures. However, special processing and/or compacting methods shall require the
approval of COMPANY and/or competent authorities.
10.6
The trench in irrigated and paddy fields shall be backfilled to within 300mm of the top,
then rammed and further backfilled until the trench is completely backfilled. Surplus
material remaining after the operation shall be spread over the ROW as specified in
Section 14.0 "Clean-up and Restoration of Right-of-Way", of this specification.
10.7
At the end of each day's work, backfilling shall not be more than 500 meters behind
the head end of lowered-in pipe, which has been padded and approved for backfill.
The backfill shall be maintained by CONTRACTOR against washouts etc., until the
completion and final acceptance of the work by COMPANY.
10.8
CONTRACTOR shall furnish materials and install breakers in the trench in steep areas
(slope generally 10% and more) for the purpose of preventing erosion of the backfill.
The type of breakers installed shall be as per the approved drawings. Breakers shall be
constructed of grout bags filled with a mixture of 4:1 Sand:Portland cement at
COMPANY's direction. CONTRACTOR may propose other methods such as foam dams
etc. which shall be subject to approval by COMPANY. Such works shall be at no extra
cost to COMPANY. CONTRACTOR shall pay attention to the direction of backfilling in
such steep areas.
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
10.9
When backfilling the trenches in sloping terrains or steep areas, where in the opinion
of the COMPANY, the backfill may be washed out of the trench, sheet piling or other
effective water breakers across the trench shall be provided by CONTRACTOR. This is
to divert the flow of water away from the trench into normal drainage followed before
laying the line. In no case, the water is to be drained via the trench or via channels
other than those followed before the line was laid.
10.10
CONTRACTOR shall leave the pipe uncovered at certain locations to allow COMPANY to
survey the center line of the pipe and the level of the pipeline in the backfilled trench.
Within 48 hours after backfilling, COMPANY shall have carried out such survey and
informed CONTRACTOR of any realigning, if required. Thereafter CONTRACTOR shall
compact the backfill.
The maximum allowable deviation from the centerline for land sections as staked out
by COMPANY and as referenced by CONTRACTOR after backfilling is limited to:
Pipeline dia upto and including 24"
200mm
300mm
10.11
Before backfilling of the trench, CONTRACTOR shall comply with the requirements of
Clause 6.12 of this specification.
10.12
Stabilization of backfill shall be carried out by the CONTRACTOR in sandy areas and
other such places to obtain consolidated cover as directed by the COMPANY.
CONTRACTOR shall carry out the stabilization over the pipeline at no extra cost to
COMPANY.
The backfill shall be stabilized preferably with 150mm layer of marl, mattresses of
gatch other than straw or other stable materials. The width of stablisation shall be
atleast 5.0 meters on either side of the pipeline, plus one meter for every 10 meters
height of dune (where the line passes through the dune areas).
10.13
Temporary workers shall be installed during backfilling and the survey as per clauses
10.10 to locate the pipeline axis. These markers shall then be replaced with permanent
pipeline markers.
10.14
11.0
TIEING-IN
11.1
The unconnected sections of the pipe line at various locations have to be tied in after
the sections are coated, lowered and backfilled. The sections to be connected shall
have at the ends, sections of over lapping, uncovered pipe of sufficient length to
absorb, without inducing excessive stresses in the steel, small displacements necessary
for perfect alignment and connection of the ends.
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TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
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11.2
11.3
11.4
The tie-in should be done in such a way as to leave a minimum of strain in the pipe. If
necessary, with respect to the trench, realigning of the pipe shall be done to eliminate
force or strain in the pipe by the CONTRACTOR at no extra cost to COMPANY.
11.5
If a pup end cannot be avoided for tie-in, the minimum length that shall be added is
1.0 meters and two or more such pups shall not be welded together. All cut-off lengths
greater than 1.0 meters shall be moved ahead in order to be welded into the pipeline
at a suitable location. Tie-in with two or more pups may be used provided that they
each have minimum length of 1.0 meter and are separated by an entire length of pipe.
In no case more than three (3) welds shall be permitted on a 10 meter length of
pipeline.
11.6
In connecting pipes, special items, fittings and equipment where different wall
thickness are to be welded, CONTRACTOR shall follow the procedures indicated in
ANSI B31.8/ANSI B31.4, as applicable. The required tapering shall be done by
CONTRACTOR at no extra cost to COMPANY.
11.7
For tie-in of adacent sections of pipeline already pressure tested, the pup used for tiein shall be of single length or off-cuts of pipe which have already been hydrostatically
tested. CONTRACTOR shall take care that sufficient number of pretested pipes with
different wall thicknesses are readily available.
12.0
12.1
General
12.1.1
In addition to constructing the pipeline, CONTRACTOR shall also install certain other
auxiliary facilities and appurtenances.
CONTRACTOR shall do all work necessary at each of the installations to provide
facilities which are complete in all respects and ready for operation.
Without limiting the generality thereof, the work required to complete the installations
shall, where applicable, include all site surveys, site preparation, filling, grading,
fencing, foundations, installation of block valves, side valves, pipework, pipe supports,
pressure gauges, mechanical facilities, civil work, painting, installation of all electrical
MECON LIMITED
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TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
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equipments, motors, cables, conduIt, wiring and fixtures and hooking up of same;
installation of all instruments, piping, valves and fittings; mount all instruments and
make all piping and electronic connections, etc.
On completion, all elements of each installation shall be checked our and tested for full
and correct operation in the presence of and to the satisfaction of COMPANY. All work
shall be carried our strictly in accordance with the appropriate codes, the approved
drawings, and this and other related specifications.
CONTRACTOR shall fabricate all piping and install valves and fittings as required by the
detailed engineering drawings prepared by him and approved by COMPANY.
Stainless steel lines will be "swaged" using permanent fittings installed with a hydraulic
device.
Cold bending for the fitting of 1/2" and 1/4" pipes is allowed when special bending
tools are used with guides to prevent flattening. The minimum radius allowed shall not
be less than R = 10 D where D is the outside diameter of pipe.
The bending tool shall be subject to COMPANY's approval.
CONTRACTOR shall ensure that the piping assemblies are not in a strain prior to the
final bolting or welding. CONTRACTOR shall also ensure that all equipment and piping
are thoroughly swabbed clean of all dust, refuse, welding-spatter, scale, or any
potentially detachable matter prior to the tie-in or final bolting.
12.1.2
Dimensional tolerances.
These tolerances apply to in line items and corrections for other lines. These tolerances
can be executed on items such as vents, drains, dummy supports, field supports,
temperature and pressure connections, where the deviation will not affect another
spool.
a)
b)
c)
d)
12.1.3
General dimension such as face to face, face or end to end, face or end to
center, and center to center : 3 mm.
Inclination of flange face from true in any direction: 4 mm per meter.
Displacement of branch connection from indicated location: 1.6mm. When
multiple branches are involved, the displacement of the branches shall not
exceed 3mm from a common point.
Rotation of flange bolt holes shall not exceed 1.6 mm.
Flanged connections.
CONTRACTOR shall ensure that all flange faces are parallel and centered, according to
standard practice, prior to final bolting. CONTRACTOR shall not use bolting forces as a
means for attaining alignment. A gasket of proper size and quality shall be installed
between the flanges at each joint.
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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Bolts shall be tightened in diagonal sequence and shall be centered with equal
amounts of thread visible on both sides. Bolts shall be uniformly tightened to produce
a leak-proof joint. Bolts that yield during tightening shall be remover and discarded. It
is mandatory that a torque wrench is used for bolt tightening.
12.1.4
Threaded connections.
Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.
CONTRACTOR shall properly align all threaded joints. Pipe entering unions shall be true
to centreline so the union will not be forced during tightening. The threaded pipe shall
not project through fittings to cause interference with valves or other operating
mechanisms.
Except for the threaded connections of instruments, which will require periodic testing
and maintenance, all threaded connections shall be seal welded. The latter joints shall
be made up without pipe joint compound and with a minimum of oil from the threaded
cutter. Seal welds should taper into the pipe with as little discontinuity as possible and
should cover all threads.
12.1.5
.
12.1.6
Welded connections
Where the Ends of the piping components being welded have an internal surface
misalignment exceeding 1.6mm, the wall of the component extending internally shall
be trimmed by machining so that the adjoining internal surfaces will be approximately
flush. All welding shall be performed in accordance with the specification " Specification
for welding of pipelines and related facilities".
Tie - ins between fixed points shall be made at maximum ambient temperature.
Civil Work
Civil work shall be provided in accordance with Specifications issued for the purpose.
12.1.7
Painting
All exposed surfaces like piping, valves, structures, and miscellaneous appurtenances
shall be painted in accordance with the specifications issued for this purpose. The
corrosion coating on pipe surface will end approximately 0.3 meter above the finish
grade and it will be necessary for CONTRACTOR to provide a clean interface at the
junction of the protective coating and the paint.
12.1.8
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(ONSHORE)
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a report used alongwith all the test certificates. Only after obtaining written approval
from the COMPANY, CONTRACTOR shall commence the work of coating.
12.1.9
Clean-up
After all required tests have been concluded satisfactorily CONTRACTOR shall clean up
the site as laid down in the specifications issued for the purpose. The Site finish shall
be graded in accordance with the approved drawings.
12.2
12.2.1
Block and sectionalising valve stations shall be installed as shown on the approved
drawings. It is CONTRACTOR's responsibility to have the units completely assembled,
tested and made fully functional including all related instruments etc.
12.2.2
The civil and structural work shall be carried our in accordance with the relevant
specifications issued for the purpose and in accordance with the approved drawings as
directed by COMPANY. This work as a minimum shall include clearing, grading,
fencing, foundations, etc, as required. All above ground structures shall be painted as
per the specification and color code given by the COMPANY.
12.2.3
12.2.4
Valves with flow arrows shall be installed according to the normal flow in the pipeline.
During, welding, the valves shall be in fully open position. In addition all
manufacturer's instructions shall be followed.
Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.
12.2.5
For valves and piping installed below ground and/or above ground, the anti-corrosion
coating/painting shall be as per the requirements of the relevant specifications issued
for the purpose. The anti-corrosion coating below ground shall extend upto 300mm
above grade at the lowest point.
12.2.6
12.2.7
All valves shall always be handled using equipment and methods to avoid impact,
shaking and other stresses. In particular, the equipment and tools for lifting and
handling shall never be done through handwheel, valve stem, joints and other parts
which may suffer damage.
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
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12.2.8
All sectionalizing valve and any other inline assemblies shall be prefabricated and
tested hydrostatically ex-situ as per applicable specification. All such assemblies shall
be installed at the locations shown in the drawings only after successful completion of
the hydrostatic test and dewatering. Thereafter the ends of the assembly shall be
closed off. CONTRACTOR shall carry out necessary excavation, cutting, bevelling and
welding of the tie-ins required for the installation of such assembly. The tie-in joints
shall be radiographically examined over 100% length and also 100% ultrasonically
examined prior to backfilling. All works shall be executed in accordance with the
relevant specifications issued for the purpose.
12.3
12.3.1
Scraper stations shall be fabricated and installed as per the approved drawings and
whenever applicable as per the requirements of clause 12.2 of this specification. It is
CONTRACTOR's responsibility to have the units completely assembled, tested and
made fully functional including all instruments & related piping.
12.3.2
The civil and structural works for the scraper stations shall be carried out as per the
relevant specifications, in accordance with the drawings and as directed by the
COMPANY. The work as a minimum shall include site survey, site preparation, clearing,
grading, fencing, foundations, etc. as required.
12.3.3
12.3.4
The painting for the scraper stations shall be carried out as per "Specifications for
Painting". The underground sections shall be coated as specified for the pipeline upto
atleast 300mm above grade.
12.3.5
The hydrostatic testing of the scraper stations shall be executed after installation in
accordance with the relevant specification issued for the purpose.
12.4
12.4.1.1
12.4.2
Handing and installation of the insulating joints shall be carried out with all precautions
required to avoid damage and excessive stresses and that the original pup length is
not reduced.
12.4.2
The insulating joints and the welded joints shall be protected by external coating as
per relevant specifications issued for the purpose.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
12.4.4
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
The in-line inserting shall be made on the buried pipeline; care shall be taken to
operate at an external temperature as close as possible to the pipeline operating
temperature.
The joints shall be inserted on straight sections and laid on a fine sand bed.
12.4.5
During the execution of the in-line connection welding, the propagation of heat shall be
avoided. To achieve this, the joint shall be kept cold by means of nags continuously
wetted.
12.4.6
Insulating joints shall be electrically tested before welding into the pipeline. The
electrical conductance test shall be carried out using a Megger. Measurement of the
insulation resistance across the joints shall be approx. one (1) Mega Ohm. The tests
shall be repeated after installation and welding of the joint into the pipeline to verify
that the assembly is undamaged.
13.0
30 Kms
05 Kms
The above limitations do not apply to point spreads such as continuous rock blasting,
river crossing, etc.
Any deviations from the above shall require prior approval of COMPANY. COMPANY
reserves the right to stop the work, in case the approved spread limitations are
exceeded and CONTRACTOR shall not be paid any compensation for stoppage of work.
14.0
14.1
CONTRACTOR shall restore the ROW and all sites used for the construction of
pipelines, water crossing and other structures in accordance with COMPANY's
instructions, and deliver them to the satisfaction of COMPANY.
14.2
Surplus Materials
The following stipulations shall apply in case CONTRACT provides for supply of line
pipe, bare and/or corrosion coated, by COMPANY.
All surplus and defective materials supplied by COMPANY shall be collected by
CONTRACTOR and delivered to designated stockpile areas.
All Pipe-ends shorter than 1.0m shall be returned to COMPANY being scrap, all pipes
longer than 8.0m shall be reconditioned (bevels, coating, provided with pipe letter,
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REGD. OFF: RANCHI
834002
TITLE
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(ONSHORE)
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EDITION : 1
Disposal
14.3.1
All surplus and defective materials supplied by CONTRACTOR and all trash, refuse and
spoiled materials shall be collected and disposed of by CONTRACTOR.
14.3.2
The ROW shall be cleared of all rubbish, broken skids, empty cans, card board, sacks,
stamps, trash, and leftover construction material. All burnable matter shall be burned,
but only after obtaining appropriate permits for such burning. If burning is not allowed,
CONTRACTOR shall haul the clean-up material to approved dumping area. All scrap
metal and unburnable material shall be disposed of, in an appropriate manner, but
never be buried in the ROW.
14.3.3
Surplus soil can only be removed from the Owner's plot after authorisation by
COMPANY.
14.3.4
All dumping fees connected with the disposal of materials shall be to the account of
CONTRACTOR.
14.3.5
All loose stones and rock exposed by the construction operations and scattered over
the ROW or adjacent grounds shall be removed by CONTRACTOR and be transported
to a location considered suitable by the authorities having jurisdiction, for satisfactory
disposal. For stones, gravel or other hard material which may be buried in the trench
the provisions of the specifications shall apply with the understanding that the use of
the land by the land-owner and/or tenant will not be interfered with.
14.4
Temporary Structures
All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which
were erected or installed by CONTRACTOR as temporary measure, shall be removed.
However, it may be necessary to remove the fence of ROW during the maintenance
period.
14.5
Repair of Damage
Damages to roads, bridges, private property shall be repaired by CONTRACTOR. All
fences and other structures which are damaged during construction shall be restored
to original condition.
Slopes, water course sides or banks which have been partially or totally demolished
during the execution of the works shall be properly consolidated and restored without
waiting for their natural consolidation and settling.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
All boundary stones which have been moved or removed during the work must be
reset in their original location to the satisfaction of the landowner concerned.
14.6
On completion of clean-up, the ROW shall be restored to such stable and usable
condition as may be reasonably consistent with the condition of the ROW prior to
laying the pipeline. The COMPANY shall be completely indemnified and held harmless
by CONTRACTOR from any and against all claims, demands, losses, expenses etc. that
may arise in this behalf or the COMPANY may anyway suffer or sustain, relative to,
arising out of, or in connection with same. The COMPANY may require from the
CONTRACTOR signed Releases
from land owners regarding satisfactory
indemnification and restoration of their lands.
14.7
Special precautions shall be taken near slopes prone to erosions and land slides. All
necessary steps shall be taken to ensure the rapid growth of grass by providing wicker
barriers and by regulating the drainage of surface waters.
14.8
All cadastral or geodetric markers which may have been removed during the execution
of the works shall be restored in their exact position.
14.9
Ditches for which no instructions for restoration have been issued, or restoration
cannot be done according to existing banks because of the absence of it, shall be
restored as instructed by COMPANY. The bed of ditches crossed by the pipeline, shall
be cleaned over the full width or the ROW, also outside the ROW if necessary. This
restoration might involve the supply and installation proper materials for backfill and
protection, sodding or other precautions to prevent erosion or guarantee the stability.
Work has to be done after deliberation and acceptance of the authorities and
COMPANY. Other field drains have to be restored by hand and/or special equipment to
be used for that purpose as soon as possible and if necessary, also outside the ROW.
14.10
Any subsidence, cave-ins, wash-outs, which have been caused during the pipeline
construction and maintenance, caused by whatever reason within the edge of ditches
and open drains, shall be repaired by CONTRACTOR immediately or at first notice
given by COMPANY.
14.11
After the clean-up, the ROW of pastures has to remain fenced and to be removed
during the maintenance period. When agricultural and other traffic (requested by
tenant) have to cross the ROW the cross-overs have to be fenced with the same
material as the ROW. If necessary, special materials have to be used to allow traffic on
the cross-over. Fencing of the right-of-way as specified shall not be removed until
CONTRACTOR has obtained written permission by COMPANY. In general this has to be
done during the maintenance period.
14.12
All openings in or damage to the fence or enclosures shall be repaired by installing new
fencing of quality which shall be at least equal to the parts damaged or removed.
Provisional gates shall be removed and replaced with new fencing. All repairs to fences
and enclosures shall be carried out to the complete satisfaction of COMPANY, land
owner and/or tenant.
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REGD. OFF: RANCHI
834002
TITLE
MAINLINE CONSTRUCTION
(ONSHORE)
DOCUMENT NO.
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EDITION : 1
14.13
If, in the opinion of COMPANY, the sod in pasture land has been damaged by vehicles
and wheel tracks are visible, the ROW shall be tilled with a disc-harrow or rotary
cultivator several times. The damaged sod shall be firmly cut up and thoroughly mixed
through the top-soil. In general the ROW has also to be ripped. After this procedure
no closed-in layers must be found and sufficiently loose top-soil 25 to 30cm thick must
be present. The whole procedure has to be approved by COMPANY. Subsequently, the
entire ROW which is part of pasture land, shall be prepared for seeding and fertilized
according to the instructions of COMPANY.
14.14
In crop fields the tillage shall consist of passing over the land several times with a disc
harrow, cultivating with a spading machine, or plow, to a depth of approx. 20 cm. In
general the ROW has also to be ripped. After this cultivation process no closed-in
layers must be found in the ROW. The equipment used and methods adopted shall
require the approval of COMPANY. Ripping, has to be done with rippers with a distance
of 50 cm between the ripper blades. The type to be used shall be approved by
COMPANY.
14.15
A sapling of any plant/tree uprooted or cut during construction shall be planted along
the route as per the direction of the COMPANY and in accordance with the Forest
Preservation Act, 1981. The cost of sapling and its plantation shall be to
CONTRACTOR's account.
14.16
The ROW and the backfilled trench in particular has to be finished in such a way that
after settlement of the soil the fields are at their original level.
If during the maintenance period certain parts of the ROW are lower than the original
level, COMPANY can order CONTRACTOR to bring these parts to the original level. If
the level of the ROW for clean-up is ordered by COMPANY, risk of above mentioned
additional restoration shall not be to CONTRACTOR's account.
In cases where heavy damage has occurred to the structure of the subsoil as a result
of special circumstances, COMPANY reserves the right to order CONTRACTOR to carry
out special work. Said special work can include:
-
If during clean-up operations, soil shortages become apparent outside the trench,
CONTRACTOR shall supplement said soil shortage using suitable materials, approved
by COMPANY.
If site and/or climatic conditions should render this necessary, COMPANY shall have the
right to order CONTRACTOR to suspend certain parts of the WORK related to the
clean-up and postpone it to a later date.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
14.17
MAINLINE CONSTRUCTION
(ONSHORE)
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Soil Surplus
If on site, as a result of the work and after careful backfilling and compacting, a subsoil surplus exists, this shall be worked up by grading and compacting below the subsoil top layer and as a rule this shall be done in the same plot of land. It shall not be
permitted to remove the surplus from the plot concerned, unless it concerns rejected
soil which has to be removed. Working up surplus soil or removal of rejected soil shall
be considered to pertain to the WORK.
To work a soil surplus into the ground CONTRACTOR shall remove an additional strip
of top soil beside the trench. Next the upper layer of sub-soil shall also be removed.
Both soil types shall be stored separately across a width depending on the size of the
soil surplus. The soil surplus shall then be distributed across the trench thus widened,
after which it shall be graded and compacted and subsequently the top layer of subsoil and the top-soil shall be replaced in the correct order, in accordance with the
Specifications.
In case COMPANY has given prior permission for mixed excavation of the sub-soil as
well as in cases where COMPANY deems mixed excavation permissible, the above
provision of separate storage of the upper layer of sub-soil shall not apply to the
working up of the soil surplus.
In cases where the soil surplus can be worked up in other plots where soil shortages
have arisen due to the WORK, this shall only be done after prior permission by landowner, land-user and COMPANY.
14.18
Soil Shortages
If due to unforeseen circumstances during backfilling and compacting there isn't
enough soil to fill the trench properly, or to install the crown height as stipulated,
CONTRACTOR shall supply the necessary backfill material.
Soil shortages shall be supplemented and applied before the top-soil is replaced.
The soil to be supplied shall be worked up in those locations and into those layers
where a soil shortage has been established. The quality of the supplemented soil shall
be equal to that of the shortage.
15.0
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REGD. OFF: RANCHI
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TITLE
MAINLINE CONSTRUCTION
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occur during the Defects liability Period and which arise either:
a)
b)
from any act or omission of CONTRACTOR done or omitted during the said
period.
If such defect shall appear or damage occur, COMPANY shall forthwith inform
CONTRACTOR thereof stating in writing the nature of the defect or damage.
If any such defect or damage be not remedied within a reasonable time, COMPANY
may proceed to execute the work at CONTRACTOR's risk and expense, provided that
he does so in a reasonable manner. Such defect or damage can be, but is not limited
to:
-
Short-circuit in casings
etc.
Company reserves the right to have the required Computerised Potential Logging Test
executed during the DEFECTS LIABILITY PERIOD and whenever conditions are more
favorable for this job. The work shall at or as soon as practicable after the expiration of
the Defects Liability Period be delivered to COMPANY in the conditions required by the
CONTRACT, fair wear and tear excepted, to the satisfaction of COMPANY.
CONTRACTOR shall finish the work, if any outstanding, at the date of completion as
soon as possible after such date and shall execute all such work.
Rev. : 0
Edition : 1
SPECIFICATION
FOR
WELDING OF ONSHORE GAS PIPELINES
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/02
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
01.0
SCOPE
02.0
03.0
MATERIAL SPECIFICATIONS
04.0
WELDING CONSUMABLES
05.0
06.0
WELDING PROCESSES
07.0
08.0
09.0
WEATHER CONDITIONS
10.0
WELDING
11.0
HEAT TREATMENT
12.0
13.0
REPAIR OF WELDS
14.0
15.0
ULTRASONIC INSPECTION
16.0
17.0
RADIOGRAPHY
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Jan. 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
01.
DOCUMENT NO.
Page 1 of 51
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REVISION : 0
EDITION : 1
SCOPE
This specification stipulates requirements for fabrication of all types of welded joints of
carbon steel main pipeline systems covering the pipeline and its facilities, which will
include the following:
All line pipe joints of the longitudinal and circumferential butt welded and socket
welded types.
Branch connections
Attachments of smaller connections for vents/ drain pipes and tappings for
instrumentation.
Note: Any approval accorded to the Contractor shall not absolve him of his
responsibilities and guarantees.
02.
03.
Code for Gas Transmission and Distribution Piping System (ANSI B31.8).
Specification for welding Electrodes and Filler Materials (ASME Sec. II C).
MATERIAL SPECIFICATIONS
The CONTRACTOR will keep a record of test certificates of all the materials for the
reference of the welding engineer.
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
04.
DOCUMENT NO.
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EDITION : 1
WELDING CONSUMABLES
The CONTRACTOR shall provide at his own expenses all the welding consumbles
necessary for the execution of the job such as electrodes, oxygen, acetylene etc. and
the same shall be approved in advance by the Purchaser/ Consultant.
The welding electrodes/ filler wires supplied by the CONTRACTOR shall conform to the
class specified in the welding specification chart. The materials shall be of the make
approved by the COMPANY.
The electrode shall be suitable for the welding process recommended and base metal
used. Physical properties of the welds produced by an electrode recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal unless otherwise specified in Welding Specification Chart
and shall correspond to the physical properties of the class of electrode adopted. The
choice of electrode shall be made after conducting the required tests on the electrodes
as per relevant standards, and shall be the sole prerogative of the COMPANY.
The CONTRACTOR shall submit batch test certificates from the electrode
manufacturers giving details of physical and chemical tests carried out by them for
each batch of electrode to be used.
Electrode Qualification test records shall be submitted as per Annexure-I with respect
to the electrodes tested by the CONTRACTOR and submitted for approval of the
COMPANY, f or each batch of electrode.
All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers (except cellulosic coated
electrodes) shall be kept in holding ovens at the temperature recommended by the
electrode manufacturer. Ovens shall be used for low hydrogen electrodes only. Out-ofthe oven time of electrodes, before they are consumed, shall not exceed the limits
recommended by the electrode manufacturer. The electrodes shall be handled with
care to avoid any damage to the flux covering.
The electrodes used shall be free from rust, oil grease, earth and other foreign matter
which affect the quality of welding.
Different grades of electrodes shall be stored separately. Cellulosic electrodes used
shall however be used as per specific recommendations of manufacturer.
04.01
Shielding Gas
The composition and purity of shielding gas when required by the welding processes
other than shielded metal arc welding, when permitted by the COMPANY, shall have
prior approval of the COMPANY. Where appropriate, gases or gas mixture of the
following quality shall be used.
a)
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b)
c)
When a gas mixture is used which has specified additions, e.g. 2% O2, 5% CO2 the
variation of such addition shall not exceed 10% of that stated. Moisture content shall
correspond to a dew point of - 30C or lower.
05.
5.1
The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedule.
5.2
All the equipment for performing the heat treatment including transformers,
thermocouples, pyro-meters, automatic temperature recorders with suitable calibration
arrangements, etc. shall be provided by the CONTRACTOR, at his own expenses and
these shall bear the approval of the COMPANY. Adequate means of measuring current
and voltage shall be available.
5.3
06.
WELDING PROCESSES
6.1
Welding of various materials under this specification shall be carried out using Shielded
Metal Arc Welding process (SMAW) with the approval of the COMPANY.
6.2
6.3
6.4
Double jointing of two pipe lengths using Submerged Arc Welding (SAW) process in a
specially laid pipe welding yard is also permitted.
Any deviation desired by the Contractor shall be obtained through the written consent
of the Company.
6.5
The welding procedure adopted and the consumables used shall be specifically
approved.
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6.6
The welding processes to be employed are given in the welding specification chart. Any
deviation desired by the CONTRACTOR shall be obtained through the express consent
of the COMPANY.
6.7
Automatic process shall be employed only with the express approval of the COMPANY.
The welding procedure adopted and consumables used shall be specifically approved.
6.8
07.
08.
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Seam orientation of welded pipe shall be selected to ensure that at the circumferential
welds, the longitudinal welds shall be staggered in the top 90 of the pipeline, or
250mm whichever is the lesser. A longitudinal joint shall pass an appurtenance of a
structural element at a minimum distance of 50mm. Should a section of the line
containing uncompleted welds fall from the skids, the CONTRACTOR shall immediately
inform COMPANY.
Every effort shall be made to reduce misalignment by the use of the clamp and
rotation of the pipes to obtain the best fit. For pipe of same nominal wall thickness offset shall not exceed 1.6mm. The off set may be checked from outside using dial
gauges. Any branch connection, sleeve, etc. shall be atleast 150mm from any other
weld. The welds for fittings shall be so located that the toe of the cold dressing is
permissible only in cases of slight misalignment and may only be carried out with a
bronze headed hammer. Hot dressing shall not be permitted. When welding pipes of
different wall thickness (as directed by COMPANY) a special transition piece shall be
used. This shall have a minimum of 1:4 taper. The welds shall be subject to both
ultrasonic and radiographic inspection.
The root gap shall be accurately checked and shall conform to the qualified welding
procedure. The use of internal line-up clamps is mandatory for pipe diameters 10" and
above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe 10"
etc.) where it is impossible to use internal clamps, an external line-up clamp may be
used.
The internal line-up clamp shall not be released before the entire root pass has been
completed.
When as external line-up clamp is used, all spaces between bars or atleast 60% of the
first pass shall be welded before the clamp is released and the pipe remaining
adequately supported on each side of the joint.
Segments thus welded shall be equally spaced around the circumference of the pipe.
Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
09.
WEATHER CONDITIONS
The parts being welded and the welding personnel shall be adequately protected from
rain and strong winds. In the absence of such a protection no welding shall be carried
out. The completed welds shall be suitably protected in case of bad weather
conditions.
10.0
WELDING
10.1
Root Pass
a)
Root pass shall be made with electrodes/ filler wires recommended in the
welding specification chart attached along with other project data sheets. The
size of the electrodes used shall be as per the approved welding procedure.
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10.2
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b)
Position or roll welding (for yard double jointing) may be permitted. Separate
procedures shall be submitted and qualified for up hill, down hill, vertical down
and roll welding. The vertical up method of welding shall be used for the root
pass of the tie-ins, special crossings, fittings and special parts, filled welds,
repairs and when an external line up clamp is used. The down hill welding may
be used for root run welding of tie-ins and special crossings when (a) the edges
are machined or have equivalent preparation (b) line up clamps are used and
the fit up is geometrically and mechanically similar to one of the oridinary line
welding without misalignment or uneveness.
c)
The root pass of butt joints shall be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
pipe shall not exceed 1.6 mm wherever not specified by the applicable code.
d)
Any deviation desired from the recommended welding technique and electrodes
indicated in the welding specification chart shall be adopted only after obtaining
express approval of the COMPANY.
e)
f)
g)
While the welding is in progress care shall be taken to avoid any kind of
movement of the components, shocks, vibration and stresses to prevent
occurance of weld cracks.
h)
Fillet welds shall be made by shielded metal arc welding process irrespective of
the thickness and class of piping. Electrode size shall not exceed 3.25mm
diameter for socket joints. Atleast two passes shall be made on socket weld
joints
i)
Root pass of fillet weld for branch connection can also be made by GTAW
process. However other pass shall be made by SMAW process as mentioned
above (point h).
j)
Joint Completion
In case of manual welding, the first pass shall be carried out by a minimum of two
welders, working simultaneously and so placed as to cause minimum distortion of the
pipe.
The number of welders and the allowable welding sequences shall be as those laid
down in the qualified welding procedure specification. Once the deposit of the first
pass has been started, it must be completed as rapidly as possible, reducing
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interruptions to the minimum. The welding and wire speed shall be approximately
same as that established in the Qualified Welding Procedure Specification (QWPS).
The pipe shall always be adequately supported and must not be pumped or shaken
during welding. The clamp shall be removed, as indicated in clause 8.0 above. Before
starting the second pass, the first pass shall be cleaned and flattened with rotating
grinders.
The interruption between completion of the first pass and starting the second pass
shall be as stated in the procedure specification.
For crack prevention a top and bottom reinforcement of at least one electrode shall be
applied before lowering the pipe on the skid.
The welding speed selected shall enable production of a bead which is sufficiently thick
and which shows no undercutting.
The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or
following passes, welding operations may be suspended, so allowing the joint to cool
down, provided that the thickness of the weld metal deposited is equal to at least 50%
of the pipe thickness. Upon restarting, depending on the materials, wall thickness and
welding process, a preheating to atleast 100C shall be carried out. Subsequent passes
up to weld completion shall be protected to avoid rapid cooling, if meteorological
conditions so dictate. Cleaning between passes shall be done carefully so as to reduce
the possibility of inclusions.
Electrodes starting and finishing points shall be staggered from pass to pass. Arcstrikes outside the bevel on the pipe surface are not permitted. Arc - strike or arc-burn
on the pipe surface outside the weld, which are caused accidentally by electrical arcs
between the electrodes, electrode holder, welding cable shall be removed by grinding
in accordance with a procedure approved by COMPANY and the repair checked by
ultrasonic, radiographic, magnetic particle or dyepenetrant tests which the COMPANY
feels necessary. The pipe wall thickness after grinding shall not be less that the
minimum thickness limit permitted for the pipe. Repair of arc-strikes by welding is
prohibited.
The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc.
These requirements apply not only to completed welds but also to the bare strip at
least so wide so as to allow full skid examination at both ends of the pipe to allow a
good ultrasonic inspection when it is required.
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11.0
HEAT TREATMENT
11.1
Preheating
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11.2
a)
Preheating requirements for the various materials shall be as per the welding
specification chart.
b)
c)
Preheating shall extend uniformly to atleast three times the thickness of the
joint, but not less than 50mm, on both sides of the weld.
d)
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 by the CONTRACTOR to check the temperature.
Post weld heat treatment, wherever required for joints between pipes and
fittings, pipe body and supports shall be carried out by the CONTRACTOR at his
expense as per the relevant specifications, applicable standards and the
instructions of the COMPANY.
b)
The heat treatment of welded joints shall be carried out as per the
requirements laid down in ANSI B31.8 and other special requirements
mentioned in welding specification chart.
c)
The CONTRACTOR shall submit for the approval of the COMPANY, well before
carrying out actual heat treatments the details of the post weld heat treatment
procedure, as per Annexure-II attached, that he proposes to adopt for each
of the materials/ assembly/ part involved.
d)
e)
While carrying out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the portion
being heat treated. Care shall be taken to ensure that width of heated band
over which specified post weld heat treatment temperature is attained is atleat
as that specified in the relevant applicable standards/ codes.
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The width of the heated band centered on the weld shall at least be equal to
the width of weld plus 2" (50mm). The temperature gradient shall be such that
the length of the material on each side of the weld, at a temperature exceeding
half the heat treatment temperature, is atleast 2.5 rt where is the bore radius
and t is the pipe thickness at the weld.
f)
Throughout the cycle of heat treatment, the portion outside the heat band shall
be suitably wrapped with insulation so as to avoid any harmful temperature
gradient on the exposed surface of pipe. For this purpose temperature at the
exposed surface of the pipe shall not be allowed to exceed 400C.
g)
h)
i)
j)
Each joint shall bear an identification number which shall be maintained in the
piping sketch to be prepared by the CONTRACTOR. The joint identification
number shall appear on the corresponding post weld heat treatment treatment
charts. The same identification numbers shall also be followed for identification
on corresponding radiographic films. The chart containing the identification
number and piping sketch shall be submitted to the COMPANY in suitable
folders.
k)
Vickers hardness/ Brinnel hardness of the heat affected zone as well as of the
weld metal, after heat treatment shall be measured using a suitable hardness
tester and shall not exceed the maximum hardness specified in the welding
specification chart. The weld joint shall be subjected to reheat treatment, when
hardness measured exceeds the specified limit, at the CONTRACTOR's own
expense.
l)
The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the
COMPANY.
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12.0
12.1
General
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a)
The COMPANY's Inspector shall have free access to all concerned areas, where
the actual work is being performed. The CONTRACTOR shall be also provide
the COMPANY's inspector all means and facilities necessary to carry out
inspection.
b)
The COMPANY is entitled to depute its own inspector to the shop or field where
pre-fabrication and erection of pipelines are being done, with (but not limited
to) the following objectives :-
c)
12.2
DOCUMENT NO.
i.
ii.
iii.
iv.
v.
b)
COMPANY's inspector will review, check and approve the welding procedure
submitted and shall release the procedure for procedure qualification tests. The
procedure qualification test shall be carried out by the CONTRACTOR under
field conditions at his own expense. A complete set of test results in format as
per Annexure-III & Annexure-IV (attached) shall be submitted to the
COMPANY's Inspector for approval immediately after completing the procedure
qualification test and atleast 2 weeks before the commencement of actual
work. Standard tests as specified in the code shall be carried out in all cases. In
addition to these, tests, other tests like radiography, macro/ micro examination,
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EDITION : 1
12.4
Welder's Qualification
a)
Welders shall be qualifed in accordance with the API 1104 and other applicable
specifications by the CONTRACTOR at his expense. The butt weld test pieces of
the qualification test shall meet the radiographic test requirements specified in
Clause 12.5 and 16.0 of this specification. The COMPANY's Inspector shall
witness the test and certify the qualification of each welder separately. Only
those welders who have been approved by the COMPANY's Inspector shall be
employed for welding. CONTRACTOR shall submit the welder qualification test
reports in the standard format as shown in Annexure-V and obtain express
approval, before commencement of the work. It shall be the responsibility of
CONTRACTOR to carry out qualification tests of welders and obtain written
approval, before commencement of works.
b)
The welders shall always have in their possession the identification card as
shown in Annexure-VII and shall produce it on demand by the COMPANY's
Inspector. It shall be the responsibility of the CONTRACTOR to issue the
identity cards after it has been duly certified by the COMPANY.
c)
d)
Visual Inspection
Inspection of all welds shall be carried out by COMPANY as per the latest editions of
the applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity of welds,
shrinkage, cracks, under-cuts, dimensions of the weld, surface porosity and other
surface defects. Undercutting adjacent to the completed weld shall not exceed the
limits specified in the applicable standard/ code.
12.5
12.5.1
Radiographic examination of one hundred percent (100%) girth welds will be required
by the COMPANY.
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On the first 100 welded joints corresponding to each automatic GTAW / and
Semi-automatic FCAW welding procedure used.
b)
When 20mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 20mm to assure no
lamination exist.
c)
d)
e)
f)
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In addition, Radiography inspection may be required for certain critical welds of the
pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY
discretion. All fillet and groove welds, other than those AUT examined, shall be
subjected to Dye-Penetrant /MP testing followed by manual Ultrasonic testing.
The non-destructive testing system used for inspecting welds must by approved by the
COMPANY.
All other welds made of FCAW and SMAW processes and the Tie-in joints having API
bevel shall be examined by Radiography. When Radiography is used, the provisions
stated in this para shall be applicable.
-
Welds shall meet the standards of acceptability as set forth in API 1104 and as well as
the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the Radiography examination
of work covered by the specification at his expense.
The COMPANY will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the COMPANY shall be final and binding
in this regard.
All the requirements mentioned in the specification shall be arranged and executed by
the CONTRACTOR through his own resources. In addition, Ultrasonic inspection is
required in the following cases as per clause no. 15.0 of this specification:
a)
b)
c)
On the first 10 welded joints corresponding to each automatic GMAW and semiautomatic FCAW welding procedures used.
When welds are repaired.
When in the opinion of COMPANY, Ultrasonic inspection is required to confirm
or clarify defects indicated by Radiography.
In addition, Ultrasonic inspection may be required for certain critical welds of the
pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY
discretion. All fillet and groove welds, other than those are subjected to Radiography,
shall be subjected to Dye-Penetrant/MP inspection. The non-destructive testing system
used for inspecting welds must by approved by the COMPANY.
Acceptance Criteria
Weld quality is judged on the basis of the acceptability criteria mentioned below:
Any weld which as a result of radiographic and/ or ultrasonic examination in the
opinion of COMPANY exhibits imperfections greater than the limits stated in API-1104
latest edition or as superseded in this specification shall be considered defective and
shall so be marked with an identification point marker.
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In addition to the API-1104 requirements, the welds containing cracks including crater
cracks regardless of size of location are unacceptable.
1.
2.
3.
Any length of inadequate penetration of the root bead as defined by API1104 is not acceptable except that root concavity is allowed as per API 1104.
Any amount of incomplete fusion at the root of the joint as detailed in API
1104 is considered unacceptable.
Unrepaired burn through areas are unacceptable.
Destructive Testing
The COMPANY has the authority to order the cutting of upto 0.1% of the total number
of welds completed for destructive testing at no extra cost of COMPANY. The
destructive testing of weld joints shall be made as per Clause 14.0.
In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. The sampling and the re-execution of welds shall be carried out by
the CONTRACTOR at his own expense. If the results are unsatisfactory, welding
operations shall be suspended and may not be restarted until the causes have been
identified and the CONTRACTOR has adopted measures which guarantee acceptable
results. If it is necessary in the COMPANY's opinion the procedure shall be re-qualified.
The weld joint represented by unsatisfactory welds shall stand rejected unless
investigation prove otherwise.
13.0
REPAIR OF WELDS
13.1
With the prior permission of COMPANY, welds which do not comply with the standards
of acceptability shall be repaired or the joint cut out and re-welded.
A separate welding procedure specification sheet shall be formulated and qualified by
CONTRACTOR for repair welds simulating the proposed repair to be carried out.
Separate procedures are required to be qualified for (a) thorough thickness repair (b)
external repair and (c) internal repair. Welders shall be qualified in advance for repairs.
The root pass, for repairs opening the root, shall be done by the vertical uphill
technique. The procedure shall be proven by satisfactory procedure tests to API 1104
including the special requirement of the specification, and shall also be subject to
metalographic examination, hardness surveys and Charpy tests to determine the
effects of repair welding on the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root defects
shall be ground thoroughly and welded with a minimum of two passes. However, while
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grinding for repairs, care shall be taken to ensure that no grinding marks are made on
the pipe surface anywhere.
The repair shall be subjected, as a minimum requirement to the same testing and
inspection requirements as the original weld. The re-radiography of repaired weld shall
be limited to 6 weld length on either edge of the repaired area. A 100% ultrasonic
test shall be done at the repaired area externally. Any repaired area that is wide,
irregular or rough shall be rejected and a full cut out shall be done. Single pass repairs
shall be subjected to 100%, Dye-Penetrant / MP testing.
Repairs are limited to a maximum of 30% of the weld length. Not more than two
repairs are permitted on the same location. A report of all repairs shall be maintained
by CONTRACTOR and submitted every day to the Company / Consultant.
13.2
14.
14.1
Preparation
Having passed the visual and the non-destructive-inspection the test weld shall be
subject to mechanical test.
After satisfactory completion of all visual and non-destructive testing the test weld shall
be set aside for a period not less than 24hours. No further work on the test weld and
no cutting of test specimens from the weld shall be performed until a period of at least
24 hours has expired. Having passed the visual and the nondestructive inspection, the
test weld shall be subjected to mechanical test.
Weld specimens shall be taken from the positions indicated in Fig. 1 of this
specification from areas as free from defects as possible; for this reason it is necessary
to take the previous non-destructive tests into account. The minimum number of tests
to be carried out is given in Table-1 of this specification.
The tests shall be carried out in laboratories approved by the COMPANY. The
specimens shall be prepared in accordance with the figures given in the paragraphs
which refer to the individual tests.
14.2
Tensile Strength
Specimens shall be taken from the position indicated in Fig. 1 & 1A of this
specification. Two ISO type specimens and two API - type specimens shall be taken.
The ISO test specimen are shown in Fig. 2 of this specification.
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14.2.1
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Method
The test shall be carried out in accordance with ISO:375.
Table-1
Type and Number of Test Specimens for
Procedure Qualification Test & Production Welds
Pipe Size,
Out Side
DiamterInches
Number of Specimens
Tensile
API
Tensile
ISO
Nick
Break
Root
Bend
Face
Bend
Side
Bend
Macro
Bend
Hardness
Impact
Total
2-3/8 to 4 incl.
Over 4-
less than
12.75
12
24
24
44
Over 4-
less than
12-3/4
12
24
12-3/4 and
over
24
44
14.3
Nick-Break Test
14.3.1
Preparation
Specimens for Nick-break test with notches thus worked can break in the base metal,
instead of in the fusion zone; therefore an alternative test piece may be used after
authorisation by the COMPANY with a notch cut in the reinforcement of outside weld
bead to a maximum depth of 1.5mm measured from the surface of the weld bead.
14.4
Macroscopic Inspection
14.4.1
Preparation
Specimens shall be taken from the positions indicated in Fig. 1 of this specification and
shall be prepared in accordance with ASTM E2 and E3.
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The width of the macrosection has to be at least three times the width of the weld.
The section is to be prepared by grinding and polishing and etched to clearly reveal the
weld metal and heat affected zone.
14.4.2
Method
Specimens shall be carefully examined under the microscope, with a magnification of
atleast 25 times (25:1). The COMPANY may ask for a macrograph with 5 times (5:1)
magnification for DOCUMENTATION purposes.
14.4.3
Requirements
Under macroscopic examination, the welded joints shall show good penetration and
fusion, without any defect exceeding the limits stated in the evaluation criteria of the
nick break test.
14.5
Hardness Test
14.5.1
Preparation
The prepared macrosection is to be used for hardness testing using the Vickers
method with 10 kg load Indentations are to be made along traverses each
approximately 1mm below the surface on both sides of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses are
to be made. The HAZ indentations are to be made along the traverses for
approximately 0.5mm each into unaffected materials, and starting as close to the
fusion line as possible.
One indentation on each side of the weld along each traverse is to be made on parent
metal. Refer Fig.3. The indentations are to be made in the adjacent regions as well on
the opposite sides of the macrosection along the specified traverses.
14.5.2
Method
The test shall be carried out in accordance with Recommendation ISO R81, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO R146
and using a diamond pyramid penetrator set at 2.37 rad (136) with a load of 10 kg.
14.5.3
Requirements
Hardness value shall not exceed the limit specified in welding Specification chart. In
case of a single reading having a slightly (+10 HV) higher value than the specified
limit, further indentations shall be made to check if the high value was an isolated
case.
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All the hardness values contained from the heat affected zone shall not exceed 100 HV
with respect to the average hardness of the values obtained for the base metal. If
these additional tests give a hardness within the specification limit the slightly higher
value may be accepted.
14.6
14.6.1
Specimens shall be taken from the position indicated in Fig. 1 of this specification. The
test specimens will be prepared in accordance with ISO R148. Charpy V-notch
specimens shall have dimensions as given in Fig. 3 of this specification.
Three test specimens shall be taken from each sample and they shall be cut and
worked so that their length is transverse and perpendicular to the weld bead with the
notch position as shown in Fig. 4 of this specification. The notch shall be perpendicular
to the roller surface. The test specimen width shall depend upon the pipe wall nominal
thickness as following :
Sl.
No.
1.
2.
3.
4.
14.6.2
Test Method
The test shall be carried out as indicated in ISO R148 "Beam impact test V-notch".
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall then be placed in the testing machine
and broken within 5 seconds of their removal from the bath. The test temperature
shall be as mentioned in Special conditions of the Contract.
14.6.3
Requirements (Note-1)
The impact energy shall be as follows :
Sl.
No.
Test Specimen in
mm
"Average of three
Specimens (Note-2)
Joules (Min.)
Minimum Single
Value (Note-1)
Joules
1.
2.
3.
4.
10.0
7.5
5.0
2.5
27.0
21.5
18.5
10.0
22.0
17.0
15.0
8.0
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Note :
1)
2)
14.7
Only one value is permitted to be lower than average value upto the value
specified.
These values are specified for resistance to brittle fracture only, where
additional requirements are specified in project data sheet. (Ex. pipeline
materials with arrest properties i.e. a higher upper shelf charpy V-energy for
resistance against propagating ductile fractures) the same shall be followed.
:
:
:
2t
3 t + 1.6mm
50.8mm
The acceptance criterion on shall however be as per para 2.643 and 2.653 of API 1104
nineteenth edition Sept. 1999.
Note : t = thickness of specimen
15.
ULTRASONIC INSPECTION
In addition to the radiographic inspection, ultrasonic inspection is required as per
conditions listed in paragraph 12.5 of this specification. This section concerns manual
ultrasonic inspection. However ultrasonic by automatic equipment may be used if
approved by the COMPANY.
15.1
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The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.
The CONTRACTOR appointed to carry out ultrasonic inspection shall supply all the
instruments necessary for their execution on site.
15.2
15.3
15.4
Test Procedure
Circumferential welds shall be inspected from both sides using angled probes.
The surface with which the probes comes into contact shall be free of metal spatter,
dirt, iron oxide, and scales of any type; therefore it shall be necessary to clean a strip
at least 50mmwide on both sides of the weld with steel wire brushes and anyhow the
cleaned strip must be atleast wide enough to allow full skip examination.
If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam transducer
in order to check whether any manufacturing defects are present which could have
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The characteristics of the above - listed instruments and equipment shall guarantee:
a)
b)
continuous operation
All the instruments and equipment shall be approved by the COMPANY before
being used. The COMPANY has the authority to reject any item which is
considered unsuitable. The decision of the COMPANY is final. The
CONTRACTOR appointed to carry out ultrasonic inspections shall also ensure
the operational efficiency and maintenance of the instruments and equipment,
and shall immediately substitute any item rejected by the COMPANY.
All the instruments and equipment necessary for carrying out ultrasonic
inspection on site shall satisfy the requirements laid down by the public boards
of institutions which regulate `safety at work'.
15.5
Ultrasonic Instruments
The Ultrasonic Instruments shall satisfy the following:
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15.6
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Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to
the type of steel, the diameter, the thickness of the pipe and to the joint design.
15.7
depth : 1 0.1mm
breadth (measured parallel to the 150mm side) : 1 01mm
Length (measured parallel to the 50mm side) not less than 30mm
In addition, the calibration piece shall have a hole, 2mm in diameter, passing through
its thickness and positioned so that during calibration the echoes returning from the
two grooves do not interfere with those returning from the hole.
15.8
Calibration
For a precise check of the sound paths necessary for a full inspection of the weld joint,
the probe shall be moved (half skip and full skip distance) until internal and external
notches on the test piece are detected (See Fig. 5 of this specification).
The relevant defect limits the path lengths on the time base. The calibration of
reference sensitivity is obtained by utilising the through - drilled test hole in the
thickness of the reference block to draw the distance - amplitude correction curve
relevant to the test probe.
Calibration shall be carried out according to the following procedure ; place its internal
vertex until the maximum height of echo is displayed on the screen ; this echo is
adjusted to 80% of full screen height by means of the sensitivity adjuster set in dB.
Without varying the amplification, the probe placed at full skip distance from the hole
is moved to detect the external vertex of the hole until the maximum height of echo is
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obtained. The straight line connecting the peaks of the two echoes obtained by the
above procedure, represents 100% reference level, while the one connecting the two
points at half height of the same echoes represents "50% reference level".
The two straight lines shall be marked on the screen with a pen. Calibration shall be
repeated each time tests are re-started ; at intervals not longer than 30 minutes during
normal operations; each time the conditions fixed in advance are altered. This
calibration is applicable provided that the crystal of the probe is 8 x 9mm size. Should
this size of the crystal be different, the value of the sensitivity obtained from the
calibration by a crystal of a different size shall be brought to the value of sensitivity
obtained from the calibration by a 8 x 9mm crystal. The sensitivities of the two
different size probes shall be compared through the echoes obtained on the notch of
the test piece with the probe position at half skip of the distance.
15.9
15.10
15.11
15.12
Other Equipment
The use of rules calibrated in centimeters, attached if possible to the probe, for the
precise location of the position of welding defects, is recommended. Defect location is
effected by measuring the projection distance between the probe output and the
reflecting surface.
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The operators carrying out the tests shall have besides the probing instrument, tools
for cleaning the pipe surface (files, brushes, etc.), as well as, the coupling liquid or
paste appropriate for the temperature of the section to be examined.
16.0
INTRODUCTION
The specification shall be applicable for Automated Ultrasonic Testing (AUT) system
suitable for pipeline girth welds. The system shall be based on focused pulse-echo,
tandem or through transmission methods enhanced with mapping image and
augmented by Time Of Flight Diffraction (TOFD) technique.
REFERENCE DOCUMENTS
ASTM E 1961-98 Standard Practice for Mechanized Ultrasonic examination of Girth
Welds using Zonal Discrimination with Focused Search Units. The inspection system
shall meet and exceed the requirements of ASTM E 1961-98.
Appendix-E, Automated Ultrasonic Girth Weld Testing, OS-F101, Submarine Pipeline
Systems, January 2000.
API Std. 1104 Welding of Pipeline and Related Facilities.
APPROVED AGENCIES
Automated Ultrasonic Testing (AUT) systems and agencies who have proven track
record and have done a single project of diameter 20 or above and minimum length
of 50 km and also have inspected a cumulative length of 500 km or above on large
diameter Pipe lines in the last ten years shall be accepted. The agency should have
been approved by the reputed inspection agencies. The track record shall be submitted
to the COMPANY for approval prior to engagement.
AUT SYSTEM
The system shall meet and exceed the requirements of ASTM E1961-98.
The system shall provide an adequate number of examination channels to ensure the
complete volumetric examination of the weld through the thickness in one
circumferential scan. The evaluation zones should be of maximum 2.0mm height. The
instrument linearity should be such that the accuracy is within 5%.
Each examination channel should be selective for pulse-echo or through transmission
mode gate position and length for a minimum of two gates and gain.
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COUPLING
The coupling shall be obtained by using a medium suitable for the purpose. It shall be
suitable for the temperature used. No residue shall remain on the pipe surface. A
method should be employed to determine that constant coupling is achieved during
examination. An examination of the test piece with its surface wiped dry should
produce a record showing an absence of the couplant recording signal.
SEARCH UNITS
The search unit shall meet all the requirements specified in Para 6.4 of ASTM E196198.
CALIBRATIONS
Reference standards shall be manufactured from a section of unflawed project specific
line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the
reference standard design to the COMPANY before manufacturing. No design changes
in the reference standard shall be made without the prior approval. Annexure A3 of the
standard ASTM E1961-98 provides an example for minimum requirements for
reference standards.
The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E
1961-98. Static and Dynamic calibration shall be done and the approved procedure
shall clearly state the gain setting fixed for each channel.
The reference standard should be used to verify the scanning sensitivity at the start of
each shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds.
A re-calibration shall be carried out if :
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a)
b)
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The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration i) after a weld repair, ii) after equipment breakdown.
In case the calibration differs from the initial setting, outside the given tolerances, the
applicable probe(s) and coupling shall be checked. If the calibration has to be changed,
the welds before this calibration upto the previous calibration will be re-examined.
The reference standard design for calibration shall be approved separately. The
procedure for calibration and verification shall be same as given above.
PROCEDURE
A detailed AUT procedure shall be prepared and qualified for each wall thickness and
joint geometry to be examined prior to the start of any NDT work. Repair procedure
shall be separately qualified for each joint geometry. All the requirements of ASTM
E1961-98 should be met. The procedure as a minimum shall include the following:
-
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Mapping channels in the root will be used to identify the position of the root
penetration for pattern recognition purpose. The sensitivity as a minimum shall be
equal to the related pulse-echo channels, increased with additional gain to ensure
proper detection.
The lateral wave of the TOFD channel sensitivity is set at 80% FSH.
2.
INTERPRETATION OF RESULTS
General
With the transit distance measurements and with the information from the mapping
and TOFD channels visible on the result presentation, indications shall be judged
whether they are from the weld geometry or from the defects. The coupling channels
will check for coupling loss; in case of coupling loss, a re-scan shall be carried out.
Inspection Result
The inspection result should be evaluated and/or reported as follows:
Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below.
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This shall be performed in parallel and rejection against either of these criteria shall be
cause for rejection of the weld. The exceptions to this are described in the following
notes:
1.
2.
3.
4.
All indications in the pulse echo channels should be evaluated which exceed the
threshold level of 20% FSH.
Defect length shall be measured for the pulse-echo channels from the point
where the signal exceeds 20% FSH to the point the signal falls below. The
largest height assessed with TOFD or the greatest measured amplitude with
pulse-echo shall be assumed to apply over the whole defect length.
If the indication cannot be resolved by TOFD i.e. the upper and lower flaw
diffraction tips cannot be separately distinguished, no measurement can be
made to determine the defect height. In this case, the signal from the pulseecho channels will be solely used to determine that particular area of the scan.
Defects shall be assessed for interaction as follows:
a)
Horizontal interaction
If the distance between two adjacent defects is less than the length of
the smaller of the two defects, then the defect shall be treated as a
single defect.
b)
5.
Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the
distance between the two adjacent defects is less then the height of the
shorter of the two defects, than the defect shall be treated as a single
defect. Where the individual defects cannot be resolved by TOFD for
the vertical interaction, then the defects are assumed to interact and
shall be treated as a single defect.
The maximum allowable accumulated defect length shall be as per the criteria
given in welding specification.
ACCEPTANCE CRITERIA
Weld quality shall be judged on the basis of the acceptability criteria mentioned in
welding specification.
17.0
RADIOGRAPHY
17.1
Scope
This covers the radiographic inspection of all types of welded joints of the main
pipeline.
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17.2
i.
Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii.
Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.
iii.
iv.
Terminal Piping
Applicable Standards
This specification shall apply in conjunction with the following (all latest edition):
i.
ii.
ANSI B31.8, Code for Gas Transmission and Distribution Piping Systems.
iii.
iv.
v.
vi.
17.3
Procedure
17.3.1
17.3.2
Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.
ii.
iii.
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17.3.3
The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior
to use.
17.3.4
17.3.5
All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved
format. The details of the radiographs all alongwith the joint identification number shall
be duly entered in a register and signed by the CONTRACTOR and submitted to the
COMPANY for approval.
17.3.6
When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each
exposure shall not exceed the values given in Table-4 of API 1104. The minimum film
overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on
nominal pipe sizes of 2 inch and smaller provided that the source of film distance used
is a minimum of 12 inch.
17.3.7
Three copies of each acceptable radiographic procedure (as per Annexure-VI) and
three copies of radiographic qualification records, shall be supplied to COMPANY. One
set of the qualifying radiographs on the job shall be kept by the CONTRACTOR's
authorised representative to be used as a standard for the quality of production
radiographs during the job. The other two sets shall be retained by COMPANY for its
permanent record.
17.3.8
Three copies of the exposure charts relating to material thickness, kilo voltage, source
of film distance and exposure time shall also be made available to COMPANY by the
CONTRACTOR.
17.3.9
The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) welder's number (3) approximate chainage of weld location, (4) whether
or not the welds meet the specified acceptance standards and (5) the nature and
approximate location of unacceptable defects observed. It must be possible to relate
back to a particular butt weld and welder on piping drawing and pipe line alignment
drawing.
17.3.10
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17.3.11
The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room
with controlled temperature, film viewer etc. to enable the COMPANY to examine the
radiographs.
17.3.12
17.3.13
COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.
17.3.14
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
17.4
Radiation Source
17.4.1
17.4.2
Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360C).
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40mm at the ends of
each film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
17.5
Level of Quality
The quality level of Radiographic sensitivity required for radiographic inspection shall
be at least equivalent to the values in Fig. 6
17.6
Penetrameters
The image quality indicator (abbreviation : IQI) shall be used for the qualification of
the welding procedure and during normal line production. Radiographic sensitivity shall
be measured with the wire image quality indicator (Penetrameter). The penetrameter
shall be selected according to DIN54109 or ISO1027. For radiographs made with the
source on the outside, a penetrameter shall be placed on each side of the film with the
smaller wiere of the penetrameter turned towards the end of the film itself. When a
complete weld is radiographed in a single exposure using a source inside the piping,
four penetrameter approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source side
and on the film side. The sensitivity obtained with IQI on the source side shall not be
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17.8
17.8.1
All unexposed films shall be protected and stored properly as per the requirements of
API 1104 standard and ASTM E.94.
17.8.2
The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging
radiation prior to and following the use of the film for radiographic exposure.
17.9
Re-radiography
17.9.1
17.9.2
All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
in the same manner as that followed for the original welds. In addition, the repaired
weld areas shall be identified with the original identification number plus the letter R to
indicate the repair.
17.9.3
When evaluating repair film, radiographers shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original defect
removed.
17.9.4
The COMPANY will review prior to any repair of welds, all the radiographs of welds
which contain, according to the CONTRACTOR's interpretation, unacceptable defects.
The final disposition of all unacceptable welds shall be decided by the COMPANY.
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17.10
Qualification of Radiographers
17.10.1
17.10.2
Certification of all the radiographers, qualified as per 16.10.1 above, shall be furnished
by the CONTRACTOR to the COMPANY before a radiographer will be permitted to
perform production radiography. The certificate record shall include :
i.
ii.
iii.
iv.
v.
17.10.3
The radiographers shall be required to qualify with each radiographic procedure they
use, prior to performing the work assigned to him in accordance with the specification.
17.11
Preservation of Radiographs
17.11.1
The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographs shall be presented in suitable folders for
preservation alongwith necessary documentation.
17.11.2
17.12
17.12.1
CONTRACTOR shall make necessary arrangement at his own expense, for providing
the radiographic equipment, radiographic film and all the accessories for carrying out
the radiographic examination for satisfactory and timely completion of the job.
17.12.2
For carrying out the mainline radiographic examination the CONTRACTOR shall be
equipped with suitable mobile/ stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and
suitably controlled to allow viewing film densities upto 4.0 without damaging the film.
17.13
Radiation Protection
17.13.1
17.13.2
17.13.3
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set forth by Atomic Energy Commission or any other Government agency of India in
this regard and COMPANY shall not be responsible and shall be kept indemnified by the
CONTRACTOR for default (s) of whatever nature by the CONTRACTOR. Safety
equipment as considered adequate by the COMPANY for all necessary personnel shall
be made available for use and maintained for immediate and proper use by the
CONTRACTOR.
17.14
17.14.1
The safety provisions shall be brought to the notice of all concerned by display on a
notice board at a prominent place at the work spot. The person responsible for the
"safety" shall be named by the CONTRACTOR.
17.15
17.15.1
17.16
17.16.1
CONTRACTOR shall maintain first aid facilities for its employees and sub-contractors.
17.16.2
CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. shall be posted
prominently in CONTRACTOR's field office.
17.16.3
All critical industrial injuries shall be reported promptly to the COMPANY and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.17
No Exemption
17.17.1
Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from
the operation of any other act or rules in force.
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B.
ANNEXURE-I
Sheet 1 of 3
Date :
Manufacturer's Name
Brand Name
Code of Reference
(used for testing)
Pre-heat temp.
Visual Examination
Sl.No.
1.
2.
Identification No.
U.T.S.
Yield Point
Elongation
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ANNEXURE-I
Sheet 2 of 3
Test Temperature
Notch in :
Type of Specimens
(Charpy)
Size of Specimens :
Specimen No.
Impact Valve
Average
Batch No.
%C
E.
Page 37 of 51
Sl.No.
1.
2.
3.
4.
5.
6.
D.
DOCUMENT NO.
%S
%P
%SI
%Mn
Base Materials
1)
2)
3)
%Cr
%Ni
%Mo
Other
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F.
1.
2.
Remarks
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ANNEXURE-I
Sheet 3 of 3
In combination with
Position of Welding
Preheat Temperature
Radiography
Identification No.
U.T.S.
Fracture in
Remarks
Conclusion :
ID No.
1.
2.
3.
4.
5.
:
Remarks
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ANNEXURE-II
Sheet 1 of 2
STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
Name of the Heat-Treater :
Name of the Project :
1.
2.
General Details
Name of the Equipment
Material
Furnace Details
Type of Heating
Capacity (Size)
:
:
Maximum Temp.(C) :
3.
Method of Temp.
Measurement
Atmosphere Control
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ANNEXURE-II
Sheet 2 of 2
4.
Soaking Temp. C
Mode of Cooling
Notes :
The following documents shall be furnished alongwith the specifications :
i.
Material Test Certificates
ii.
Assembly/ Part Drawing.
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ANNEXURE-III
Sheet 1 of 3
FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
________________________________________________________________________________
Company Name ________________________ By __________________________________
Welding Procedure Specification No. _____________ Date __________ Supporting PQR No. (S)
_________ Revision No. ________________ Date ________________
Welding Process (es) _________________________ Type (s) _____________________________
(Automatic, Manual, Machines or Semi Auto)
________________________________________________________________________________
JOINTS
Joint Design ____________________________________________________________
Backing (Yes) _________________________________________(No) ___________________
Backing Material (Type) _________________________________________
Sketches Production Drawings. Weld Symbols Written
Description should show the general arrangement of the parts to be welded. Where applicable, the
root specing and the details of weld groove may be specified.
(At the option of the Manufacturer sketches may be attached to illustrate joint design weld layers
and bead sequence e.g. for notch toughness procedures, for multiple process procedures, etc.)
________________________________________________________________________________
BASE METALS
P.No. ____________ Group No. ____________ to P. No. ____________ Group No. ___________
OR
Specification type and grade _______________________________________________________
to Specification type and grade ________________________________________________
OR
Chern. Analysis and Mech. Prop. ____________________________________________________
to Chern. Analysis and Mech. Prop. ___________________________________________
Thickness Range :
Base Metal: Groove ____________________________________ Fillet ________________
Deposited Weld Metal: Groove ___________________________ Fillet ________________
Pipe Dia Range : Groove : _____________________________________ Fillet ________________
Other ______________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
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ANNEXURE-III
Sheet 2 of 3
FILLER METALS
GAS
Shielding Gas (es) ___________________
Percent Composition (mixtures) _________
___________________________________
Flow Rate __________________________
Gas Backing ________________________
Trailing Shielding Gas Composition _______
ELECTRICAL CHARACTERISTICS
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 ______________________________________________
(Pure Tungsten, 2% Ceriated, etc)
Mode of Metal Transfer for GMAW ______________________________________________
(Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range _________________________________________________________
_______________________________________________________________________________________
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ANNEXURE-III
Sheet 3 of 3
TECHNIQUE
String or Weave Bead ___________________________________________________________
Orifice or Gas Cup Size___________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) _________________________________
________________________________________________________________________________
Peening _____________________________________________________________________________
Other _______________________________________________________________________________
_____________________________________________________________________________________
Weld
Layer(s)
Process
Filler Metal
Class
Dia
Current
Type
Amp.
Polarity
Range
Volt
Range
Travel
Speed
Range
Others
e.g.
Remarks,
comments,
Hot wire
Addition,
Technique
Torch Angle,
etc.
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ANNEXURE-IV
Sheet 1 of 3
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON
________________________________________________________________________________________
Company Name __________________________________________________________________________
Procedure Qualification Record No. _____________________________________ Date _________________
WPS No. _____________________________
Welding Process (es) _____________________________________________________________________
Types (Manual, Automatic, Semi-Auto) _______________________________________________________
JOINTS
Groove Design of Test Coupon
(For combination qualification the deposited weld metal thickness shall be recorded for each Filler metal or process weld)
________________________________________________________________________________________
BASE METALS
Material Sepc.
____________________________
Type of Grade
____________________________
P.No. __________ to P.No. _____________________
Thickness of Test Coupon _____________________
Diameter of Test Coupon _____________________
Other __________ ___________________________
FILLER METALS
Weld Metal Analysis A No. _____________________
Size of Filler Metal ___________________________
Filler Metal E.No. ___________________________
SF A Specification ___________________________
A WS Classification ___________________________
Other __________ ___________________________
GAS
Type of Gas on Gases _____________________
Composition of Gas Mixture _________________
Other ___________________________________
________________________________________
________________________________________
________________________________________
POSITION
Position of Groove ___________________________
Weld Progression (Uphill, Downhill) ______________
Other __________ ___________________________
ELECTRICAL CHARACTERISTICS
Current _________________________________
Polarity _________________________________
Amps. _________________________________
Tungsten Electrode Size ___________________
Other __________________________________
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ANNEXURE-IV
Sheet 2 of 3
PREHEAT
Phreheat Temp.
Interpass Temp.
TECHNIQUE
___________________________ Travel Speed ___________________________
___________________________ String or Weave Bead ______________________
Oscillation _______________________________
Multipass or Single Pass (per side) ___________
Single or Multiple Electrodes ________________
Other __________________________________
Result
TOUGHNESS TESTS
Specimen
Notch
Notch
Test
Impact
No.
Location
Type
Temp.
Value
Lateral Exp.
% Shear
Mils
Drop Weight
Break
No Break
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
DOCUMENT NO.
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EDITION : 1
ANNEXURE-IV
Sheet 3 of 3
Test Conducted by _______________________ Laboratory Test No. _______________________
We certified that the statements in this record are correct and test welds were prepared, welded and tested in
accordance with the requirements of Section IX of the ASME Code.
Date : ___________
Manufacturer : ____________________
By : _____________________________
(Detail of record of tests are illustrative only and may be moulded to conform to the type and number of tests
required by codes and specifications).
MECON LIMITED
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DOCUMENT NO.
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EDITION : 1
ANNEXURE-V
Sheet 1 of 2
FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING OPERATOR
QUALIFICATION TESTS
Welder Name ________________ Check No. __________________ Stamp. No. __________________
_____________________________________________________________________________________
Using WPS No. ________________ Rev. ________________
The above welder is qualified for the following ranges
Variable
Qualification Range
Process
__________________
__________________
Process Type
__________________
__________________
Backing (metal,
Weld metal, flux, etc)
__________________
__________________
Material Spec.
_________ to _________
_________ to _________
Thickness
Groove
Filler
__________________
__________________
__________________
__________________
Diameter
Groove
Filler
__________________
__________________
__________________
__________________
Filler Metal
Spec. No.
Class
F. No.
__________________
__________________
__________________
__________________
__________________
__________________
Position
__________________
__________________
Weld Progression
__________________
__________________
Gas Type
__________________
__________________
Electrical Characteristics
Current
Polarity
________________
__________________
__________________
__________________
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DOCUMENT NO.
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EDITION : 1
ANNEXURE-V
Sheet 2 of 2
Guided Bend Test Results
Type and Fig. No.
Result
Organization __________________
By ___________________________
(Details of record tests are illustrative only and may be modified to conformation to the type &
number of tests required by the Code).
Note: Any essential variables in addition to those above shall be recorded.
MECON LIMITED
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DOCUMENT NO.
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EDITION : 1
ANNEXURE-VI
Sheet 1 of 1
RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD
FOR PIPE WELDING
1.
Location
2.
Date of Testing
3.
4.
4.A
5.
6.
7.
Radiation Source:
8.
9.
Geometric Relationship:
10.
11.
12.
Exposure Time:
13.
Processing:
14.
Density:
15.
Sensitivity:
16.*
Type of penetrameter:
(Source side)
17.*
Type of penetrameter:
(Film side)
Signature of Contractor / Agency with Seal
*
*
Ref. Para regarding recommended practice on placement of penetrameters Article 22, SE 142, ASME
Sec. V.
For "Random Radiography" lines placement of penetrameters as per Article 2, ASME, Sec. V is
permitted.
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DOCUMENT NO.
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EDITION : 1
ANNEXURE-VII
Sheet 1 of 1
WELDERS IDENTIFICATION CARD
Name
Identification
Date of Testing
Process
WPS No.
Valid Till
Approved by :
Photograph
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DOCUMENT NO.
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EDITION : 1
ANNEXURE-VIII
Sheet 1 of 1
Type of Source and Films to be used for RADIOGRAPHY
NOMINAL WALL
THICKNESS (T) IN mm
T> 19
8T< 19
<8
All Materials
Carbon Steel
All other
materials
Carbon Steel
Other than
Inspection
Class IV *
All other
materials and
Carbon Steel
of Inspection
Class IV *
IN-SITU WELDS
SOURCE
FILM : CEN Class
Gamma Ray
C5
Gamma Ray
C4
Gamma Ray
C3
Gamma Ray
C3
Gamma Ray
X-Ray
C4
C3/C1
Films slower than the above may have to be used, if required radiographic sensitivity is not achieved
consistently.
* Piping classes where 100% RT is specified. Refer Std. Spec. No. ____________.
COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS
CEN Classification
--C5
C4
C3
C2
CI
---
KODAK
CX
AA400
T200
MX125
M100
DR50
SR**
AGFA
D8
D7
D5
D4
D3
D2
---
FUJI
--IX 100
IX80
IX50
--IX25
---
FITTINGS
FLANGES
OTHERS
BASE METAL P NO
WELDING PROCESS
ASTM A106 GR.B, API 5L GR B PSL2, API 5L X52 PSL2, API 5L GR X-65
PSL2, API 5L GR X-70 PSL2, IS-1239 (BLACK) ASSORTED PIPES
ASTM A105, ASTM A234 GR.WPB, ASTM A234 RG.WPB-W, MSS SP-75
GR.WPHY-52, MSS SP-75 GR.WPHY-65
ASTM A105, ASTM A694 GR.F-52, ASTM A694 GR.F-65, ASTM A694
GR.F-70, ASTM A516 GR.70
-
1
GROOVE JOINTS SINGLE SIDE BEVEL
BUTT
OTHER THAN BUTT
ROOT PASS :
FILLER PASS :
ROOT PASS :
FILLER PASS : SMAW
GTAW
GTAW/SMAW
GTAW
FILLET JOINTS / SOCKET JOINTS : SMAW
GROOVE JOINTS
WELDING MATERIAL
ROOT PASS :
ER70S-2
BUTT
FILLER PASS
ER70S-2/ER80S-D2
E7018-1/E8018-G
GASES
PURGING :
SHIELDING : Argon
GAS COMPOSITION
PURGING :
SHIELDING : 99.995%
PREHEATING
PREHEAT TEMP: 1000C MIN
POST HEATING :
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP :
HOLDING TIME :
POST WELD HEAT
RATE OF HEATING:
MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING :
RATE OF COOLING :
MECHANICAL
PROPERTY
REQUIREMENTS
CODE OF FABRICATION :
MIN: 27 J
AVERAGE :
TECHNICAL NOTES :
MECON Limited
Specification No. :
Mec.WPC_AG01
Rev.
0
WELDING PROCESS
1
GROOVE JOINTS SINGLE SIDE BEVEL
BUTT
OTHER THAN BUTT
ROOT PASS :
FILLER PASS :
ROOT PASS :
FILLER PASS : SMAW
GTAW
GTAW/SMAW
GTAW
FILLET JOINTS / SOCKET JOINTS : SMAW
GROOVE JOINTS
BUTT
WELDING MATERIAL
ROOT PASS :
ER70S-2
FILLER PASS
ER70S-2/ E7018-1
2/ E7018-1
GASES
PURGING :
SHIELDING : Argon
GAS COMPOSITION
PURGING :
SHIELDING : 99.995%
PREHEATING
PREHEAT TEMP: 1000C MIN
POST HEATING :
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP :
HOLDING TIME :
POST WELD HEAT
RATE OF HEATING:
MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING :
RATE OF COOLING :
MECHANICAL
PROPERTY
REQUIREMENTS
CODE OF FABRICATION :
MIN: 27 J
AVERAGE :
TECHNICAL NOTES :
MECON Limited
Specification No. :
Mec.WPC_AG02
Rev.
0
WELDING PROCESS
ROOT PASS :
SMAW
GROOVE JOINTS
BUTT
OTHER THAN BUTT
FILLER PASS :
ROOT PASS : N.A.
FILLER PASS : N.A.
SMAW
FILLET JOINTS / SOCKET JOINTS : N.A.
GROOVE JOINTS
BUTT
WELDING MATERIAL
ROOT PASS :
E6010
Hot Pass
:E8010G/E9010 G
FILLER PASS
E8010G/ E9010G
GASES
PURGING :
SHIELDING :
GAS COMPOSITION
PURGING :
SHIELDING :
PREHEATING
PREHEAT TEMP: 1000C (MIN)
POST HEATING :
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP :
HOLDING TIME :
POST WELD HEAT
RATE OF HEATING:
MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING :
RATE OF COOLING :
MECHANICAL
PROPERTY
REQUIREMENTS
CODE OF FABRICATION :
MIN: 27 J
AVERAGE :
1.
MECON Limited
Specification No. :
MEC.WPC _ML01
Rev.
0
24, 30 & 36
MATERIAL
SPECIFICATIONS
BASE METAL P NO
WELDING PROCESS
1
GROOVE JOINTS SINGLE SIDE BEVEL
BUTT
OTHER THAN BUTT
ROOT PASS :
FILLER PASS : FCAW ROOT PASS : N.A.
FILLER PASS : N.A.
SMAW
FILLET JOINTS / SOCKET JOINTS : N.A.
GROOVE JOINTS
BUTT
FILLER PASS
WELDING MATERIAL
ROOT PASS :
E6010
HOT PASS: E8010G
E71T8GJ/
E81T8GJ/E81T8
Ni2J
GASES
GAS COMPOSITION
PREHEATING
PURGING :
SHIELDING : Argon +CO2 Mixture
PURGING :
SHIELDING :75-80% Argon,20-25% CO2
PREHEAT TEMP: 1000C MIN (INDUCTION
POST HEATING :
HEATING)
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP :
N.A.
HOLDING TIME :
POST WELD HEAT
RATE OF HEATING:
N.A.
MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING :
N.A.
RATE OF COOLING :
WIRE SPEED
CHARPY
V
NOTCH
VALUE
:
MIN:
27 J
AVERAGE :
MECHANICAL
0C or Design Temperature whichever is less
PROPERTY
AT TEMPERATURE :
REQUIREMENTS
HARDNESS :
CODE OF FABRICATION :
TECHNICAL NOTES :
1.
2.
Root & Hot Pass Welding will be carried out by SMAW process. Fill and cap passes will be carried out by
semi-automatic FCAW process.
For Tie-ins and crossings, either SMAW or semi-automatic FCAW welding process is permitted.
Specification No. :
MEC.WPC_ML02
Rev.
0
Rev. : 0
Edition : 1
SPECIFICATION
FOR
HYDROSTATIC TESTING OF ONSHORE
PIPELINE
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/03
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
3.0
GENERAL
4.0
5.0
TEST PRESSURE
6.0
7.0
PROCEDURES
8.0
ACCEPTANCE
9.0
TERMINATION
10.0
TEST REPORT
11.0
MEASUREMENTS
12.0
CALCULATION
13.0
14.0
PRESERVATION OF PIPELINE
TABLES
TABLE A
FIGURES
FIG.1
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Nov. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 1 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
1.0
SCOPE
1.1
This specification covers the minimum requirements of supply, works and operations to be
performed by CONTRACTOR for hydrostatic testing of cross-country steel pipelines
transporting hydrocarbons in liquid or gaseous phase under high pressure. This specification
does not cover the requirements of drying/precommissioning of the tested pipelines. This
specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between COMPANY and CONTRACTOR.
2.0
2.1
Reference has been made in this specification to the latest edition/ revision of the following
codes, standards and specifications.
a)
b)
c)
d)
e)
ANSI B 31.8
ANSI B 31.4
API RP 1110
ASME Sec. VIII Div-1
OISD 226
2.2
In case of conflict between the requirements of this specification and that of the above
referred coded, standards, and specifications, the requirements of this specifications shall
govern.
2.3
For the purpose of this specification the following definitions shall hold:
-
the words 'Should', 'May', and 'Will' are non-mandatory, advisory or recommended.
3.0
GENERAL
3.1
Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall
be performed in accordance with approved Hydrostatic Test Diagrams for each test section.
The maximum length of each test section shall not exceed 50 kms.
3.2
For pipeline sections which in COMPANY's opinion, once installed would require an inordinate
amount of effort for repair in case of a leak, a provisional pre-test shall be conducted.
However, after installation, such pretested sections shall be tested again alongwith the entire
pipeline.
3.3
Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all
welds have been accepted and the pipeline has been laid and backfilled according to the
specifications. Hydrostatic test shall include those sections which have been previously tested,
viz. Rail/ road crossing, major water crossings including test on banks and in place after
installation, and scraper traps at the terminals. CONTRACTOR shall perform all works required
for hydrostatic testing after obtaining prior written approval from the COMPANY.
MECON LIMITED
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TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 2 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
3.4
The pipeline shall be tested in accordance with the requirements of the latest edition of ANSI
B 31.8 or ANSI B 31.4, OISD 226 as applicable, and requirements laid down in this
specification.
4.0
For the systems to be tested, a diagram indicating all fittings, vents, valves, temporary
connections, relevant elevations and ratings. The diagram shall also indicate injection
locations and intake and discharge lines.
b)
c)
d)
The type and sequence of pigs and the pig tracking systems for cleaning and removal
of air pockets. Pig inspection procedures, including procedure to be followed in case
the calliper pig indicates damage.
e)
Procedures for levelling and stabilization after filling and for pressurization and to allow
for temperature stabilization.
f)
g)
h)
Procedure for dewatering the pipeline section(s) after testing, including a complete
description of all proposed equipment and instruments, (including spares), their
location and set-up, the type and sequence of pigs and the pig tracking system along
with the pig specifications.
i)
5.0
5.1
The duration of hydrostatic test shall be a minimum of 24 hours after stabilization and the test
pressure shall be as indicated in the approved hydrostatic test diagram.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
5.2
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 3 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
Unless specified otherwise in the CONTRACT, the hydrostatic test pressure shall be as follows :
For pipeline handling hydrocarbon in gaseous phase :
6.0
a)
1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 31.8.
b)
1.4 times the design pressure for pipeline located in Class-3 and Class-4 locations as
per ASME B 31.8.
Cleaning pigs with spring loaded steel wire brushes except for internal coated pipes. In
this case pigs to be provided with nylon / polyurethane brushes.
Calliper pigs with gauge plate diameter equal to 95% of the heavy wall pipe in the pipe
sections. Gauging pig fitted with gauge plate.
Fill pumps : The CONTRACTOR shall determine the type and number of fill
in order to guarantee the following :
pumps
d)
Two positive displacement meters to measure the volume of water used for filling
the line. These meters shall be provided with a callibration certificate not older than
one month.
e)
Portable tanks of sufficient size to provide a continuous supply of water to the pump
during pressurizing.
f)
MECON LIMITED
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TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 4 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
g)
Dead weight testers with an accuracy of 0.01 bar measuring in increments of 0.05 bar
provided with a calibration certificate not older than one month.
h)
Two 48 hours recording pressure gauges tested with charts and ink gauges tested with
dead weight tester prior to use. These shall be installed atp the test heads.
i)
j)
k)
l)
m)
Means to measure the volume of water necessary to drop the line pressure by 0.5 bar
(container on scales or graduated cylinder).
n)
Injection facilities to inject additives into the test medium in the required proportions.
o)
p)
The temporary scraper traps shall be installed according to the testing sections fixed in
the test procedure manual. Proper piping and valuing arrangements shall be available
to allow launching and receiving of each pig independently.
The test heads shall be sized in conformity with ASME specification Section VIII,
Division 2 with particular reference to Appendices 4 and 5.
q)
Thermocouples for assuring the temperature of the pipe wall shall be installed on the
pipeline to be tested:
The spacing may be increased to maximum 5000 metre depending on the terrain and nature
of sub soil along the alignment of test section.
Thermocouples shall be attached on the external surface of the pipe after removal of external
coating and shall be adequately protected and COMPANY's coating instructions shall be
followed.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 5 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
7.0
PROCEDURES
7.1
Equipment and/or parts which need not or must not be subjected to the test pressures, must
be disconnected or separated from the pipeline to be tested.
7.2
If the difference of minimum and maximum atmosphere temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps and
above ground pipeline shall be properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz.
Aerial lengths on piers, suspension bridges, etc., which shall be tested separately.
7.3
The test medium shall be soft non-aggressive water furnished by the CONTRACTOR. The
water to be used shall be filtered, shall not be contaminated, and free from sand or silt.
CONTRACTOR shall submit laboratory test reports of water used for testing. The possible use
of sea water shall be subject to its degree of cleanliness, the possibility of obtaining a pre
determined salinity neutralization and the use of corrosion inhibitors, this at the sole discretion
of COMPANY. CONTRACTOR shall provide COMPANY approved corrosion inhibitors, oxygen
scavengers and bactericides to be added to the test water. The CONTRACTOR shall furnish
and install all temporary piping which may be necessary to connect from source of water to its
pumps and manifolds/ tankage.
7.4
Before filling operation the CONTRACTOR shall clean the pipeline by air driven pigs provided
with spring loaded bushes and chisels to remove all mill scale rust/ sand from the inside of
pipe section. For this purpose temporary headers for air cleaning shall be attached to the
pipeline. The number of pig runs is depending upon the cleaning results and shall be
determined by the COMPANY at site.
7.5
After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried
out by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter
of the heaviest wall pipe in the test section. While computing the ID of heaviest wall pipe,
pipe manufacturing tolerance shall not be considered. A 10mm thick aluminium plate shall be
used for making gauge plate.
After receipt of gauging pig at the other end, the gauge plate shall be inspected in the
presence of Company representative. A deformed, bent or severally nicked plate or damaged
pig shall be evidence of gauging pig run failure and the same is not acceptable to company.
In such cases the Contractor shall repair and rectify the line and repeat the gauging pig run to
the satisfaction and approval of the Company Representative. Any obstruction and/ or faults
such as dents, buckles, flat spots, etc. analysed and noted during gauging pig run shall be
located and any necessary repair work shall be performed to rectify the same to the
satisfaction of the Company. A written approval shall be obtained from Company regarding
successful completion of gauging pig run.
After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pig shall be welded to test Section.
Un-inhibited water equal to 10% of the volume of test section shall be introduced in front of
the first pig. The first pig shall be launched by introducing about 1.5 km un-inhibited water.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 6 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
Then the second pig shall be launched by pumping the inhibited water till the second pig is
received at the other end. The thermal stablisation and pressurisation can now the started.
7.6
Thermal Stabilization
After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked through the
thermocouples installed on the pipeline.
Temperature readings shall be made at 2 hours-intervals. Thermal stabilization shall be
considered to have been achieved when a difference not higher than 1C is attained between
the average values of the last two readings. Thermal stabilization completion shall be
approved by COMPANY.
7.7
Pressurisation
Pressurisation shall be performed in the presence of COMPANY at moderate and constant rate
not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel with the
dead weight tester. Volume required to reach the test pressure shall be recorded periodically
throughout the pressurization as follows:
-
each 5 bar increments up to 80% of test pressure as recorded by the dead weight
tester;
each 2 bar increment between 80% to 90% of test pressure as recorded by the dead
weight tester;
each 0.5 bar increment between 90% of test pressure to full test pressure as recorded
by the dead weight tester.
b)
c)
d)
e)
During the pressurization to each test pressure, two tests shall be carried out for the
calculation of air volume in the pipeline under test.
In case, during the hold pressure periods indicated above, a decrease in pressure is observed,
the operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the CONTRACTOR has isolated and eliminated the cause for
the lack of water tightness.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
7.8
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 7 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.
1.06).
If the air found in the pipeline is within the above established tolerance, then the pressurizing
can continue. If the ratio V1 / Vp exceeds 1.06, the hydrostatic testing cannot go on and
additional pig passages shall be performed to remove the air pockets.
The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurizing can then continue, to reach the value of test pressure.
7.9
Testing
After the section has been pressurized and the air volume test has given acceptable results the
test pressure shall be held for a minimum of 24 hours after stabilization. After temperature
and pressure has stabilized, the injection pump shall be disconnected and all connections at
the test heads shall be checked for leakage. The pressure recorders shall then be started with
the charts in a real time orientation for continuous recording throughout the test.
During the testing period the following measurements shall be recorded :
-
All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded.
Bleed-off water shall be accurately measured and recorded.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 8 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
8.0
ACCEPTANCE
8.1
The hydrostatic test shall be considered as passed if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such change shall
be evaluated as described under clause 12.2 of this specification.
The pressure change value as a function of temperature change shall be algebraically added to
the pressure value as read on the meters. The pressure value thus adjusted shall be compared
with the initial value and the test shall be considered as acceptable if the difference is less
than or equal to 0.3 bar. In case of doubt the testing period shall be extended by 24 hours.
8.2
If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shall
determine by search the location of leakage or failure. All leaks and failures within the pipe
wall or weld seam shall be repaired by replacement of entire joint or joints in which leakage or
failure occurs. In circumferential welds the method of repair shall be determined by the
COMPANY. CONTRACTOR shall comply with instructions of the COMPANY whether to replace
a section of the line pipe that includes the line leak or whether to repair the circumferential
weld. This repair should however meet the requirements of 'Specification for Welding Pipelines
and Related Facilities'. Where failure occur in pipeline field bends, bends shall be replaced with
same degree of bends. After completion of repairs, the hydrostatic test shall be repeated in
full, as per this specification.
8.3
The cost of repairs or replacements, followed by refilling and repressurizing the line, due to
poor workmanship, shall be borne by the CONTRACTOR. In the event of leaks or failures
resulting form faulty COMPANY furnished materials, CONTRACTOR shall be reimbursed for
furnishing all labour, equipment, materials, except those materials furnished by the COMPANY,
and transportation necessary to repair and repressurize the section of the pipeline to the
pressure at the time of recognition of leak or line failure. CONTRACTOR shall be entitled for
compensation as per the provisions of the CONTRACT. All work of reinstalling line pipe, to
replace pipe failures shall be done in accordance with the relevant specification included in the
CONTRACT.
8.4
CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations
designated by the COMPANY. All cracks and splice resulting from failures shall be coated with
an application of grease to preserve the characteristics of failures from corrosion. Joint of
failed pipes shall be marked with paint, with a tag indicating failure details, date and location
of failure and pressure at which failure occurred.
9.0
TERMINATION
After the positive results of testing and collection of all data the test shall be terminated upon
written approval given by the COMPANY.
9.1
CONTRACTOR shall dewater the tested line as per the following requirement after test
acceptance.
The dewatering shall be carried out by using four cup pigs and foam pigs driven by
compressed air. The detailed dewatering procedure shall be developed by the CONTRACTOR
MECON LIMITED
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DOCUMENT NO.
Page 9 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
in such a way as to provide adequate control of pigs during dewatering. Pigs and equipment
required for dewatering the line shall be furnished by CONTRACTOR and shall be approved in
advance by the COMPANY. Four cup pigs shall first be passed through the line to displace the
water. Foam pigs shall then be passed in order to complete the line dewatering.
CONTRACTOR shall use a number of foam pigs, each in different colors/ numbered for this
purpose. The line shall be considered dewatered when a negligible amount of water is flushed
out by the last foam pig and approval is given by the COMPANY.
9.2
During dewatering, care shall be taken to properly dispose the discharging water in order to
avoid pollution, damages to fields under cultivation and/or existing structures and interference
with the traffic. Before start of dewatering and disposal of hydrotest water, a procedure for
treatment of inhibited water to prevent pollution shall be submitted by contractor to owner/
consultant for review and approval.
9.3
Upon completion of the testing and dewatering operation, any provisional traps for pigs and all
other temporary installation relating to the test shall be removed. Subsequently the individual
sections of the line already tested shall be joined in accordance with the requirements of
relevant specifications issued for the purpose.
10.0
TEST REPORT
A complete report signed by CONTRACTOR and the COMPANY
completion of the hydrostatic test for each test section.
This report shall contain as a minimum:
a profile of the pipeline that shows the test sites, all instrument and injection
connections;
pig specifications;
MECON LIMITED
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TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 10 of 17
MEC/S/05/21/03
REVISION : 0
environmental data;
11.0
MEASUREMENTS
11.1
EDITION : 1
The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used). In the calculation,
as per clause 12.1 of this specification, use shall be made of the geometrical volume of the
section in question.
11.2
Pressure Measurement
Pressure shall be measured with a dead weight tester with an accuracy of 0.01 bar that shall
permit readings of at least 0.05 bar.
During the test the pressure shall be recorded by means of a pressure recorder featuring the
following specifications:
Accuracy
Recording
Feed
Recording
The pressure recorder shall be checked by means of dead weight tester at the beginning,
during and at the end of the hydrostatic test.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 11 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
A pressure gauge tested with dead weight tester shall be connected in parallel to the dead
weight tester at the test head.
11.3
Temperature Measurements
Water temperature shall be taken at every 2 hours through the thermocouple that have been
installed on the pipe wall along the section under test on the pipe wall.
Further the temperature measurement shall be taken :
-
The thermocouples sensitivity shall enable temperature readings with an accuracy of 0.2C.
b)
- 10 to + 40 C
Recording:
Feed
c)
d)
- 0 to + 60 C
Recording:
Feed
12.0
CALCULATIONS
12.1
The theoritical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
MECON LIMITED
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TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 12 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
The theoretical water amount that is necessary for pressurizing the section shall be calculated
by means of the following formula:
Vp = (0.884 r i/t +A) x 10-6 x Vt x P x K
Where:
Vp =
Vt =
t =
A =
K =
12.2
The pressure change due to a water temperature change shall be calculated by the following
formula:
B
P = -------------------------- T
0.884 r i/ t +A
Where,
P = pressure change resulting from a temperature change (bar)
T
algaebrical difference between water temperature at the beginning of the test and
water temperature as measured at the end of the test (C).
B=
value of the difference between the thermal expansion of water at the pressure and
temperature as measured at the end of the test and that of steel (C-1) x 106
(Refer table A)
A=
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
13.0
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
ri=
t =
DOCUMENT NO.
Page 13 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
13.1
Provision shall be made for the installation of no-admittance signs to unauthorized personnel
from the roads to the R.O.W.
13.2
Signs stating "PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed
where the pipeline is uncovered, and particularly where the provisional traps and stations are
located. Such areas shall be suitably fenced in such a way as to prevent access of
unauthorized personnel. No unauthorized personnel shall be closer than 40 m to the pipeline
or equipment under test.
13.3
Provisional scraper traps shall be installed in compliance with methods and suitable locations
so that their rupture cannot cause any injuries to the personnel or third parties.
13.4
The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.
13.5
Once dewatering is over, the sectionalizing valves and other valve assemblies tested
previously, shall be installed at locations shown in the drawings and in accordance with the
procedures contained in the relevant specifications. All thermocouple installed in the pipeline
shall be removed and damaged corrosion coating shall be repaired using COMPANY approved
materials and procedure.
14.0
PRESERVATION OF PIPELINE
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration,
CONTRACTOR shall completely fill the pipeline with water, with sufficient quantity of corrosion
inhibitors depending upon quality of water and the period of conservation, at a pressure to be
agreed upon with the COMPANY at a later stage. CONTRACTOR shall obtain necessary
approval from the COMPANY of the procedure and the type and quantity of the inhibitors
used before commencement of the works.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 14 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
TABLE - A
0
C
Bar
0.981
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
-98.62
-95.55
-92.15
-88.74
-85.32
-81.90
-78.47
-75.03
-71.60
-68.16
-64.72
-61.28
-57.84
-54.40
-50.96
-47.53
-44.10
-40.67
-37.24
-33.83
-30.42
-27.02
-23.63
-20.24
-16.87
-13.50
-10.14
-6.80
-3.48
-0.17
+3.13
-79.89
-76.94
-73.68
-70.40
-67.12
-63.84
-60.55
-57.25
-53.96
-50.66
-47.35
-44.05
-40.74
-37.44
-34.13
-30.83
-27.53
-24.23
-20.94
-17.65
-14.37
-11.09
-7.82
-4.56
-1.30
+1.94
+5.17
+8.39
+11.60
+14.80
+17.98
-61.81
-58.99
-55.86
-52.72
-49.58
-46.43
42.27
-40.10
-36.94
-33.77
-30.60
-27.43
-24.26
-21.08
-17.90
-14.73
-11.56
-8.40
-5.23
-2.06
+1.09
+4.25
+7.40
+10.54
+13.67
+16.79
+19.90
+23.00
+26.11
+29.19
+32.27
-44.34
-41.65
-38.64
-35.63
-32.62
-29.60
-26.58
-23.54
-20.51
-17.47
-14.43
-11.38
-8.34
-5.29
-2.25
+0.80
+3.85
+6.89
+9.94
+12.98
+16.01
+19.04
+22.06
+25.08
+28.10
+31.11
+34.12
+37.11
+40.09
+43.07
+46.03
-27.47
-24.89
-22.01
-19.14
-16.24
-13.36
-10.46
-7.56
-4.65
-1.73
+1.18
+4.10
+7.02
+9.95
+12.87
+15.79
+18.72
+21.64
+24.56
+27.48
+30.40
+33.31
+36.22
+39.13
+42.03
+44.92
+47.81
+50.69
+53.56
+56.43
+59.29
-11.14
-8.67
-5.92
-3.16
-0.41
+2.36
+5.15
+7.92
+10.70
+13.50
+16.29
+19.08
+21.88
+24.68
+27.49
+30.29
+33.10
+35.90
+38.70
+41.51
+44.30
+47.10
+49.90
+52.69
+55.48
+58.26
+61.04
+63.80
+66.57
+69.33
+72.06
+4.66
+7.02
+9.65
+12.29
+14.93
+17.57
+22.89
+22.89
+25.55
+28.23
+30.90
+33.58
+36.26
+38.94
+41.63
+44.31
+47.00
+49.69
+52.37
+55.06
+57.75
+60.43
+63.12
+65.80
+68.48
+71.15
+73.81
+76.48
+79.14
+81.78
+84.83
+19.98
+22.23
+24.74
+27.26
+29.78
+32.31
+34.85
+37.39
+39.94
+42.50
+45.05
+47.61
+50.18
+52.75
+55.32
+57.89
+60.46
+63.04
+65.62
+68.19
+70.77
+73.34
+75.90
+78.48
+81.05
+83.61
+86.81
+88.73
+91.29
+93.83
+96.38
DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL
EXPANSION FACTOR ( 0 C -1 ) (10 -6)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 15 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
TABLE - A
0
C
Bar
0.981
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
10
11
12
13
14
15
+34.82
+36.97
+39.36
+41.76
+44.18
+46.60
+49.02
+51.44
+53.88
+56.32
+58.77
+61.21
+63.67
+66.12
+68.58
+71.05
+73.51
+75.97
+78.44
+80.91
+83.37
+85.84
+88.30
+90.67
+93.22
+95.69
+98.14
+100.60
+103.05
+105.50
+107.94
+4922
+51.26
+53.55
+55.84
+58.14
+60.45
+62.76
+65.08
+67.40
+69.73
+72.07
+74.41
+76.74
+79.09
+81.45
+83.80
+86.15
+88.51
+90.87
+93.23
+95.59
+97.95
+100.31
+102.67
+105.03
+107.39
+109.74
+112.10
+114.44
+116.79
+119.13
+63.20
+65.15
+67.33
+69.51
+71.70
+73.90
+76.10
+78.32
+80.53
+82.75
+84.98
+87.22
+89.45
+91.69
+93.93
+96.18
+18.43
+100.68
+102.94
+105.19
+107.45
+109.71
+111.97
+114.23
+116.48
+118.74
+121.00
+123.25
+125.50
+127.75
+130.00
+76.78
+78.64
+80.71
+82.79
+84.87
+86.96
+89.07
+91.17
+93.29
+95.41
+97.53
+99.66
+101.79
+103.93
+106.07
+108.21
+110.36
+112.51
+114.66
+116.82
+118.97
+121.13
+123.29
+125.45
+127.60
+129.76
+131.92
+134.08
+136.24
+138.39
+140.54
+89.99
+91.75
+93.72
+95.70
+97.68
+99.68
+102.67
+103.68
+105.69
+107.70
+109.73
+111.75
+113.79
+115.83
+117.67
+119.90
+121.96
+124.01
+126.06
+128.12
+130.17
+132.24
+134.29
+136.36
+138.42
+140.48
+142.54
+144.61
+146.67
+148.73
+150.79
+102.83
+104.51
+106.39
+108.26
+110.14
+112.04
+113.93
+115.84
+117.76
+119.67
+121.59
+123.52
+125.46
+127.39
+129.34
+131.20
+133.74
+135.19
+137.15
+139.11
+141.07
+143.03
+144.99
+146.96
+148.93
+150.90
+152.87
+154.84
+156.84
+158.78
+160.75
+115.34
+116.93
+118.71
+120.49
+122.28
+124.07
+125.88
+127.69
+129.50
+131.32
+133.15
+134.98
+136.82
+138.67
+140.51
+142.37
+144.22
+146.08
+147.94
+149.81
+151.68
+153.55
+155.42
+157.30
+159.18
161.05
+162.93
+164.81
+166.69
+168.57
+170.45
DIFFERENCE BETWEEN THE THERMAL EXPANSION FACTOR THE STEEL THERMAL EXPANSION
FACTOR ( 0 C -1 ) (10 -6)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 16 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
TABLE - A
0
C
Bar
0.981
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
16
17
18
19
20
21
22
23
+127.52
+129.02
+130.71
+132.40
+134.10
+135.80
+137.51
+139.22
+140.95
+142.67
+144.42
146.15
+147.90
+149.65
+151.40
+153.16
+154.93
+156.69
+158.47
+160.24
+162.01
+163.80
+165.58
+167.36
+169.16
+170.94
+172.73
+174.53
+176.32
+178.11
+179.90
+139.41
+140.83
+142.42
+144.02
+145.62
+147.24
+148.86
+150.49
+152.11
+153.75
+155.40
+157.04
+158.70
+160.36
+162.03
+163.70
+165.37
+167.05
+168.73
+170.42
+172.10
+173.80
+175.43
+177.19
+178.89
+180.59
+182.30
+184.00
+185.70
+187.42
+189.13
+151.00
+152.36
+153.85
+155.35
+156.87
+158.39
+159.92
+161.46
+163.00
+164.56
+166.11
+167.66
+169.24
+170.81
+172.39
+173.98
+175.56
+177.15
+178.75
+180.35
+181.95
+183.55
+185.16
+186.78
+188.39
+190.01
+191.63
+193.25
+194.88
+196.50
+198.13
+162.31
+163.58
+165.00
+166.42
+167.85
+169.85
+170.73
+172.18
+173.64
+175.10
+176.58
+178.05
+179.54
+181.02
+182.51
+184.00
+185.51
+187.02
+188.53
+190.05
+191.57
+193.09
+194.62
+196.14
+197.68
+199.21
+200.75
+202.29
+203.83
+205.37
+206.92
+173.37
+174.56
+175.90
+177.23
+178.58
+179.93
+181.29
+182.66
+184.03
+185.41
+186.80
+188.20
+189.59
+191.00
+192.41
+193.82
+195.24
+196.66
+198.09
+199.52
+200.97
+202.40
+203.85
+205.30
+206.75
+208.20
+209.66
+211.12
+212.59
+214.05
+215.51
+184.18
+185.30
+186.55
+187.80
+189.07
+190.34
+191.62
+192.91
+194.20
+195.50
+196.80
+198.12
+199.44
+200.75
+202.09
+203.42
+204.76
+206.10
+207.45
+208.80
+210.16
+211.53
+212.89
+214.26
+215.63
+217.00
+218.40
+219.77
+221.16
+222.54
+223.93
+194.75
+195.79
+196.96
+198.14
+199.33
+200.52
+201.72
+202.93
+204.14
+205.36
+206.59
+207.82
+209.06
+210.31
+211.56
+212.81
+214.08
+215.34
+216.61
+217.89
+219.17
+220.46
+221.74
+223.04
+224.33
+225.63
+226.93
+228.24
+229.55
+230.86
+232.18
+205.08
+206.07
+207.16
+208.26
+209.37
+210.49
+211.61
+212.74
+213.88
+215.03
+216.17
+217.33
+218.49
+219.66
+220.84
+222.02
+223.20
+224.39
+225.55
+226.79
+227.99
+229.20
+230.41
+231.63
+232.85
+234.08
+235.31
+236.54
+237.77
+239.01
+240.26
STEEL
THERMAL
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
HYDROSTATIC TESTING OF
ONSHORE PIPELINE
DOCUMENT NO.
Page 17 of 17
MEC/S/05/21/03
REVISION : 0
EDITION : 1
TABLE -A
0
C
Bar
0.981
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
24
25
26
27
28
29
30
+215.22
+216.13
+217.15
+218.18
+219.21
+220.25
+221.30
+222.35
+223.42
+224.48
+225.56
+226.64
+227.73
+228.82
+229.92
+231.03
+232.14
+233.26
+234.38
+235.51
+236.64
+237.77
+238.91
+240.06
+241.21
+242.36
+243.52
+244.68
+245.84
+247.01
+248.18
+215.14
+225.99
+226.94
+227.88
+228.85
+229.82
+230.79
+231.78
+232.77
+233.76
+234.76
+235.78
+236.79
+237.81
+238.84
+239.87
+240.91
+241.96
+243.01
+244.06
+245.12
+246.18
+247.26
+248.33
+249.41
+250.49
+251.58
+252.66
+253.76
+254.86
+255.96
+234.88
+235.66
+236.53
+237.41
+238.30
+239.20
+240.11
+241.02
+241.94
+242.87
+243.79
+244.73
+245.68
+246.63
+247.59
+248.55
+249.52
+250.49
+251.47
+252.46
+253.45
+254.45
+255.45
+256.46
+257.46
+258.48
+259.49
+260.52
+261.54
+262.57
+263.60
+244.41
+245.13
+245.94
+246.75
+247.58
+248.40
+249.24
+250.08
+250.93
+251.79
+252.66
+253.53
+254.40
+255.28
+25618
+257.07
+257.97
+258.88
+259.79
+260.71
+261.63
+262.50
+263.49
+264.43
+265.37
+266.31
+267.27
+268.23
+269.18
+270.15
+271.11
+253.79
+254.44
+255.18
+255.93
+256.69
+257.45
+258.22
+258.99
+259.78
+260.57
+261.36
+262.17
+262.98
+263.69
+264.62
+265.44
+266.28
+267.12
+267.97
+268.82
+269.67
+270.54
+271.40
+272.28
+273.16
+274.04
+274.92
+275.82
+276.71
+277.61
+278.51
+263.00
+264.59
+264.27
+264.95
+265.64
+266.33
+267.04
+267.75
+248.47
+269.19
+269.92
+270.77
+271.41
+272.16
+272.92
+273.69
+274.46
+275.23
+276.01
+276.80
+277.59
+278.39
+279.19
+280.00
+280.82
+281.63
+282.46
+283.29
+284.12
+284.95
+285.79
+272.03
+272.57
+273.18
+273.80
+274.42
+275.07
+275.70
+276.35
+277.01
+277.66
+278.33
+279.01
+279.69
+280.38
+281.08
+281.78
+282.49
+283.20
+283.92
+284.64
+285.37
+286.11
+286.85
+287.59
+288.35
+289.11
+289.86
+290.64
+291.40
+292.18
+292.95
DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL
EXPANSION FACTOR ( 0 C -1 ) (10 -6)
Rev. : 0
Edition : 1
SPECIFICATION
FOR
MAJOR WATER CROSSINGS
(CONVENTIONAL)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
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REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
0.0
DESCRIPTION
DEFINITION
1.0
SCOPE
2.0
GENERAL
3.0
TRENCHING
4.0
5.0
HYDROSTATIC PRE-TESTING
6.0
INSTALLATION
7.0
8.0
9.0
POST-CONSTRUCTION SURVEY
10.0
FINAL CLEAN-UP
11.0
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Nov. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
00
DOCUMENT NO.
Page 1 of 11
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REVISION : 0
EDITION : 1
DEFINITION
A major water crossing shall be reckoned the one which will necessitate passing
the gas pipeline across a water body such as perennial river, major irrigation canal,
pond, lake, lagoon, creek etc. using special attention and means. The parameters
required to classify a particular water body as a major water crossing shall
comprise of size, hydrological data, authority/ownership, importance and other
ecological/ environmental factors associated with it, and the authority to classify it
such, shall rest with the COMPANY.
1.0
SCOPE
1.1
This specification covers the minimum requirements for the various activities to be
performed by CONTRACTOR for the construction of pipeline major water crossings by
conventional trenching method. Provisions of this specification are applicable only for
"major water crossings" specifically named as such in the CONTRACT.
1.2
This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY CONTRACTOR.
1.3
CONTRACTOR shall, with due care and diligence, execute the work in compliance
with all laws, by-laws, ordinances, regulations etc. and provide all services and
labour, inclusive of supervision thereof, all materials excluding the materials indicated
as "Company supplied Materials" in the CONTRACT, equipment, appliances or other
things of whatsoever nature required in or about the execution of the work, whether
of a temporary or permanent nature.
1.4
CONTRACTOR shall take full responsibility for the stability and safety of all
operations and methods involved in the work.
1.5
CONTRACTOR shall be deemed to have inspected and examined the work area and
its surroundings and to have satisfied himself so far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic conditions,
the extent and nature of the work and materials necessary for the completion of the
work, and the means of access to the work area.
1.6
1.7
CONTRACTOR shall, in connection with the work, provide and maintain at his own
costs all lights, guards, fencing, watching etc., when and where necessary or
required by COMPANY or by any duly constituted authority for the protection of the
work and properties or for the safety and the convenience of public and/ or others.
1.8
For the purpose of this specification, the following definitions shall hold :
MECON LIMITED
REGD. OFF: RANCHI
834002
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2.0
GENERAL
2.1
All works of the pipeline major water crossing shall be performed in accordance with
the approved construction drawings, procedures, other applicable documents as per
the CONTRACT, good pipeline practice and as directed by COMPANY.
2.2
Before start of the field construction, CONTRACTOR shall submit to COMPANY, for
approval for each major water crossing a complete report containing at the
minimum:
i)
installation method
ii)
proposed time schedule indicating start and finish dates and detailed breakup of time period for all critical activities associated with the work.
iii)
iv)
v)
vi)
The description of the installation method as a minimum shall include the following:
a)
b)
c)
Buoyancy studies
d)
e)
f)
Pre-test procedure including trial mix, design & tests for concrete coating.
g)
h)
i)
MECON LIMITED
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834002
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j)
k)
l)
m)
n)
o)
p)
q)
Communication.
r)
s)
COMPANY shall inform CONTRACTOR within 21 days if any objection against the
document and procedure described requires resubmission by CONTRACTOR.
Approval by COMPANY of the methods used by CONTRACTOR shall in no way relieve
CONTRACTOR from the sole responsibility for safe and satisfactory installation of the
crossing.
2.3
CONTRACTOR shall comply with all the conditions and requirements issued by
authorities having jurisdiction in the area where the work is to be performed.
CONTRACTOR shall, at his own responsibility, obtain necessary permits from the
authorities having jurisdiction, for performing his work.
If no public roads exist, CONTRACTOR shall arrange on his own for access to his
work area at no extra cost to COMPANY.
2.4
Pre-construction Surveys
Prior to start of any work, CONTRACTOR shall carry out a survey of the major water
crossings and acquaint himself with site conditions and to collect any data regarding
the water velocity and the tidal variations in the flow pattern and shall verify the
suitability of his equipment and the methods of construction.
3.0
TRENCHING
3.1
Dredging/ Excavating
3.1.1
CONTRACTOR shall dredge or excavate the trench for the water crossing in
conformity with the approved drawings. Dredging of the trench shall be executed as
accurately as possible.
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3.1.2
The trench shall be excavated to such depth as required to provide the minimum
cover and the pipeline configuration as specified. The pipeline profile of the crossings
shall be followed as accurately as possible. Before laying, the trench shall be cleaned
and levelled. The trench shall be subject to inspection by COMPANY prior to
installation of the pipe.
3.1.3
Navigational traffic shall not be obstructed, unless permission has been given
thereto. CONTRACTOR shall issue all necessary publications according to the local
regulations. Instructions given by authorities shall be followed accurately and
immediately, so that there in no hindrance to traffic. For stoppage of navigational
traffic public notification, PA system, signal/ sign etc. shall be provided.
CONTRACTOR cannot request a compensation if his work is hampered or delayed
due to weather conditions, any obstacles/ or by any traffic on the spot, where work
is executed.
3.1.4
3.1.5
3.1.6
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CONTRACTOR shall keep the trench in good condition until the pipe is laid, and no
claim is to be made to the COMPANY by reason of its caving either before or after
the pipe is laid. CONTRACTOR shall do whatever is required to excavate the trench,
install the pipe in it and backfill the trench in accordance with these specifications at
no extra cost to COMPANY.
3.1.8
3.1.9
CONTRACTOR shall grade the trench in such a manner as to give the maximum
amount of uniform support to the pipeline when it is lowered or pulled into place. The
maximum unsupported span shall not exceed 10.0m.
3.1.10
3.2
Pumping Line
In case CONTRACTOR uses pumping lines to discharge the spoil, he shall take care of
the necessary permits.
Pumping lines, discharges and siphons shall be installed by CONTRACTOR and
removed before the completion of the work. At crossings with existing roads, the
pumping lines shall be led through a casing pipe bored/ jacked under the road or led
through a porch over the road. A stress calculation must then be handed over to
COMPANY. The necessary provisions to embank the dumping area and also the spoil
basins shall be made by CONTRACTOR. CONTRACTOR is responsible for transportation
of the soil and dumping on land and is liable for damage to works of third parties
caused by leakage of pumping lines, etc. CONTRACTOR shall at all time prevent
overflow of pumping water, spoil or sand over embankments, parcels or roads. Further
more, CONTRACTOR shall safeguard COMPANY from claims of compensation by third
parties due to encountered damage.
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REGD. OFF: RANCHI
834002
TITLE
3.3
DOCUMENT NO.
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EDITION : 1
Spoil
Spoil which is not dumped on and including spoil acquired after cleaning the water
crossing trench, shall be transported and dumped in places, designated thereto by
agreement between CONTRACTOR and authorities and approved of by COMPANY.
Spoil shall be transported in (split) barges; only those barges shall be used that avoid
spilling during transportation due to incorrect closing of the flaps, etc. Spoil which is
dumped outside the designated places shall be removed by CONTRACTOR at first
notice by COMPANY.
3.4
4.0
5.0
HYDROSTATIC PRE-TESTING
CONTRACTOR shall hydrostatically pre-test the pipe string of each water crossing
before installation as per approved procedure.
Joint coating of the welds shall be done after this pre-test.
The section of the pipeline corresponding to the major water crossing shall, before
installation, be subjected to hydrostatic pre-testing to a combined equivalent stress
of 90% of the SMYS of the pipe material.
After the temperature has been stabilised, the pressure shall be maintained in the
pipeline for at least twenty four (24) hours and recorded by manothermograph. During
the test CONTRACTOR shall check all welds for leakage. Failure, if any, during the test
shall be rectified by the CONTRACTOR. If the same is due to failure on account of any
cause other than defect in material supplied by COMPANY, the repairs shall be done
free of cost, to the satisfaction of COMPANY.
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REGD. OFF: RANCHI
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EDITION : 1
6.0
INSTALLATION
6.1
CONTRACTOR shall submit a detailed scheme for the method he proposes to adopt for
installing the pipeline to COMPANY for approval. CONTRACTOR shall calculate all
stresses in the pipeline while laying and check whether the stresses remain within
permissible limits. A set of all calculations shall be submitted to the COMPANY for
approval.
6.2
CONTRACTOR shall perform all work required to install the water crossings, including
the possible appurtenances indicated in the drawings. The water crossings shall be
installed in such a manner as to comply with the requirements and conditions stated
by the Authorities issuing the permits. CONTRACTOR shall pay special attention to
minimize any damage to embankments and dykes in the vicinity of water crossings.
6.3
The equipment for launching shall be arranged in such a way that the pipeline is laid
without impact or jerking and is not subjected to stresses of any type other than those
which are allowable. Minimum allowed radius of curvature shall be followed,
particularly at the end of the launching way towards the water in the freely suspended
section.
6.4
After the water-crossing section has been installed in place, CONTRACTOR shall fill this
section including the pertaining land sections with water for the final testing.
6.5
CONTRACTOR shall check if the position and depth of the water crossing are in
accordance with the approved drawings, by means of a profile of the pipeline, before
and after the water-crossing section is filled with water. CONTRACTOR shall lower each
pipeline section which is not sufficiently deep by dredging or jetting the underlying
ground.
6.6
The maximum allowed horizontal deviation from the required center line shall be
limited to the following :For pipeline dia. upto and including 24" - 300 mm
For pipeline dia greater than 24" - 500 mm
6.7
Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom
contour of the trench grade, so that it will be firmly, uniformly and continuously
supported. COMPANY may employ a diver or use other suitable methods to inspect the
bottom of the trench and/ or after the pipe is installed prior to backfilling of the trench.
CONTRACTOR shall facilitate the work of the diver and shall furnish the necessary
equipment and helpers (other than actual diving equipment) necessary for the diver/
inspector to perform his work.
6.8
If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy
the minimum requirements of cover as specified in approved drawings, the
CONTRACTOR shall make necessary corrections to either trench or the pipe alignment
or to both so that the pipe, when finally in position in the trench, shall fully meet the
specifications, failing which CONTRACTOR may be asked to remove the pipeline. This
shall be done at no extra to the COMPANY.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
6.9
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EDITION : 1
6.9.1
Depending on the diameters of the parallel pipelines, the characteristics of the crossing
and the limitations of CONTRACTOR's equipment, CONTRACTOR may propose
installation of the parallel pipelines either together in a combined operation or
separately in a common trench.
6.9.2
If the pipelines are installed together, the minimum clear distance between the parallel
pipelines (measured from the outside diameters of the concrete coated pipes) shall be
300mm. CONTRACTOR shall provide spacers at sufficient intervals along the length of
the pipe section(s), securely fixed to the pipes, or shall propose other suitable
alternative methods, so as to ensure that the stipulated minimum clear distance is
maintained. The spacers may be removed before the trench is backfilled.
CONTRACTOR shall furnish detailed drawings for the pipe assembly showing the
details of spacers/ other arrangements for COMPANY's approval before start of
construction.
6.9.3
If the parallel pipelines are installed separately in a common trench, the minimum clear
distance between the parallel pipelines in the trench shall be 5000mm. CONTRACTOR
shall ensure that this minimum spacing be maintained till the time the trench is
backfilled.
7.0
7.1
7.1.1
The bottom of the waterway shall be reinstated to its original level by backfilling the
trench in a manner and with suitable material and as prescribed and approved by the
authorities and COMPANY. In case material other than the original spoil is required,
this shall be supplied and applied by CONTRACTOR.
Wherever boulders, rock, gravel and other hard object are encountered, they shall not
be placed directly on the pipe. Sufficient earth, and or selected and approved backfill
material shall be backfilled initially around and over the pipe to provide a protective
padding or cushion extending to a minimum thickness of 50 centimeters around the
pipe before backfilling remainder of the trench with excavated or other material.
Wherever required by COMPANY, CONTRACTOR shall cover the (nearly) backfilled
trench with a layer of rock boulders to be approved by COMPANY over a width equal to
the width of the excavated trench with an extra of 5 m on either side at no extra cost
to COMPANY.
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7.1.2
Backfilling progress of the trench shall be checked continuously, and a daily progress
report shall be made and handed over to COMPANY.
7.1.3
All embankments and/ or dykes, bed and banks shall be reinstated to their original
state and levels, unless otherwise prescribed in the drawings or by the Competent
authorities or COMPANY.
7.1.4
7.2
Bank Protection
7.2.1
Trenches in banks of major water crossings shall be backfilled with soil approved by
COMPANY. The fill at the banks shall be tamped firmly and reinforced with sacked
earth, rip-rap, or by other means as directed by COMPANY to the satisfaction of
authorities having jurisdiction thereof. In areas where the backfilled soil is expected to
be of loose type which is prone to flow, the trench shall be backfilled with boulder/
crushed rock of minimum 75mm thickness. The boulder/ crushed rock shall be derived
from solid, stable, non-soluble and approved quality store approved by COMPANY and
pipe shall be provided with adequate padding of soil of a quality approved by
COMPANY. Wherever necessary the boulder/ crushed rock shall be held to the bed by
use of 6.1 wire nets of minimum dia. of 3.2mm, made from steel having tensile
strength of 400 N/mm2 and with a minimum elongation at failure of 12%. The
minimum zinc coating of 275 gm-2 shall be applied on single/ double twisted wire. After
the trench has been backfilled and during the clean up works, the water crossing shall
be cleaned across the whole width of ROW. The existing bed profile shall be
maintained after restorations.
7.2.2
2m above Highest Water Level, (recordable) or upto the top of bank, whichever
is higher.
5m below Low Water Level (recordable) or upto pipe trench level in the bed.
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REGD. OFF: RANCHI
834002
TITLE
7.2.3
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EDITION : 1
Before final hydrostatic testing, CONTRACTOR shall `prove' the diameter of the
pipeline by passing a gauging (caliper) pig through the pipeline. The gauging pig
shall have a diameter equal to 95% of the internal diameter of the pipe.
CONTRACTOR shall supply and install all temporary scraper, launchers. Receivers
and other equipment, piping and materials and consumables for the purpose.
8.0
9.0
POST-CONSTRUCTION SURVEY
After laying of the pipeline, CONTRACTOR shall carry out a post-construction survey
jointly with COMPANY. Any defects brought to the notice of CONTRACTOR shall be
promptly corrected by CONTRACTOR at his own expense to the complete satisfaction
of COMPANY.
10.0
FINAL CLEAN-UP
After completion of construction, CONTRACTOR shall clear the site of all balance
material and debris. All balance pipe lengths, in case supplied by COMPANY, shall be
returned to COMPANY's designated stock yard(s). Site shall be cleared to the complete
satisfaction of COMPANY and authorities having jurisdiction. All such works shall be
done at no extra cost to COMPANY.
11.0
DOCUMENTATION
11.1
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TITLE
11.2
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EDITION : 1
After completion of construction CONTRACTOR shall prepare & furnish six sets of
copies and two sets of reproducible of As-built drawing for the crossings.
As-built drawings shall be as a minimum, include the following information.
11.3
True profile of the bed and banks of the water crossing along the pipeline after
backfilling.
True profile of the pipeline as installed and the top of cover to top of pipe at
regular intervals.
Extent of backfill.
Rev. : 0
Edition : 1
SPECIFICATION
FOR
PIPELINES CROSSING ROADS, RAILROADS,
MINOR WATER AND OTHER CROSSINGS
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
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EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
3.0
GENERAL
4.0
5.0
6.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Nov. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
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REVISION : 0
EDITION : 1
1.0
SCOPE
1.1
This specification covers the minimum requirement for the various activities to be
carried out by the CONTRACTOR for or about the installation of pipelines crossing
roads, railroads, minor water courses and other services.
The provisions of this specification are not applicable for pipelines crossing water
courses, which are specifically designated as "Major Water Courses" in the CONTRACT.
1.2
This specification shall be road in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.
For the purpose of this specification the following definitions shall hold :
are
non-mandatory,
advisory
2.0
2.1
Reference has been made in this specification to the latest edition (edition enforce at
the time of floating the enquiry) of the following codes, standards and specifications.
a)
ASME B 31.4
for
Liquid
b)
ASME B 31.8
c)
API RP 102
d)
OISD 226
e)
f)
Part 195
2.2
3.0
GENERAL
3.1
Crossing of roads, railroads, buried services, canals and minor water courses with
equipment and/ or personnel is allowed only after acquiring approval from the
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authorities having jurisdiction and after making arrangements for safeguarding the
roads, etc. and the buried services with appropriate provisions.
Highways, main-roads and railroads and their verges and banks of water crossings are
not allowed to be used for loading, unloading or stacking of materials and/ or
equipment. For secondary roads, such loading/ unloading is permitted only after prior
approval from the concerned authorities CONTRACTOR is not allowed to close or divert
roads or water courses without prior approval from the COMPANY and the concerned
authorities. CONTRACTOR shall never unnecesarilly hamper the users of the roads,
railroads, buried services and/ or water courses. The water flow shall not be obstructed
in any way.
3.2
COMPANY reserves the right to demand for individual crossings from the
CONTRACTOR a separate detailed report for approval, containing :
Time schedule
Working method with equipment
Test procedure
Manpower deployment
Calculations of temporary works
Soil investigations, etc.
Approval letter from Competent Authority.
Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically
pretested ex-situ, prior to joint coating, whenever,
River crossing pipes which are to be continuously concrete weight coated (to
be tested prior to concrete coating);
The section of the pipeline for the crossings shall be tested as a single string. Unless
specified otherwise in the CONTRACT, the test pressure shall be the one resulting in a
hoop stress corresponding to 90% of SMYS of pipe material. Test pressure shall be
retained in the pipeline for minimum period of 4 hours. Test section shall be visually
examined for leaks/ defects, etc.
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4.0
4.1
The work under crossings shall include necessary clearing, grading and trenching to
required depths and widths, welding of casing (when required) and carrier pipes,
coating, lowering-in, backfilling, clean-up, restoration to the original condition and
further strengthening and protective works, testing, installation of assemblies,
insulators and seals, and temporary works such as sheet pilling, bridges, etc.
The work shall be carried out in accordance with the approved drawings and job
standards, as directed by COMPANY and to the satisfaction of COMPANY and the
authorities having jurisdication over th facility crossed. The work carried out for road
and railroad crossings shall meet the minimum requirements of API RP 1102, latest
edition.
Before the installation work of crossings is started, the CONTRACTOR shall provide
suitable barricades, temporary bridge/ bypass work (especially where roads are opencut) with railing, if required by COMPANY for safety of traffic. Adequate traffic warning
signals and/ or traffic lights and suitable diversions shall be provided as directed by
COMPANY/ Authority having jurisdication over these areas. Such diversions shall not
cross the pipeline where it has already been installed, unless proper safeguarding in
COMPANY's opinion is ensured.
Prior approval from the statutory authorities shall be obtained to lay the pipeline across
highways/ roads either by boring or by open-cut method. Installation of the crossing
shall be by the method (i.e., boring/ open-cut) approved by Authorities having
jurisdiction. Railroad crossings shall always be bored/ jacked.
4.2
Boring/ jacking of carrier pipes for crossings is allowed only if the pipes for boring/
jacking are provided with a suitable corrosion coating and CONTRACTOR remains liable
for the suitablity of the pipe and weld-coating of carrier pipes to be bored and for
which coating and method of application are anyhow to be authorised by COMPANY
without prejudice to CONTRACTOR's liability. In all other cases the carrier pipes shall
be cased.
Before start of the boring/ jacking CONTRACTOR shall execute a soil investigation
and determine the ground water table. Based on these investigations CONTRACTOR
shall prepare a construction drawing and submit to COMPANY for approval including
time schedule and soil investigation report. The CONTRACTOR shall submit for
approval of COMPANY the method of boring / trenchless to be carried out,
depending on the nature of soil conditions, nature of crossing, local requirements
etc.
During the execution of boring the ground water table over the length of the boring
shall be lowered up to atleast 0.50 M below bottom of the pipeline. This water table
is to be regularly inspected and maintained by CONTRACTOR and reported to
COMPANY. To safeguard the stability of the borepit, CONTRACTOR shall, if necessary
in COMPANY's opinion, use a closed sheetpiling which shall extend atleast over 50%
of the length in undisturbed soil. The length of the boring shall be in accordance with
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the length of the ROW of the crossing (road, railroad, etc.) with minimum 0.6 m
extra on either side.
If the soil conditions and groundwater for a particular boring give reasons for this,
CONTRACTOR is entitled to suggest to COMPANY for a relaxation of one or more of
the following requirements as defined hereforth :
Soil investigation
Lowering of groundwater table
Sheetpiling
Length of boring etc.
The bottom of the trench and/ or the pit for at least twelve (12) metres at the
approach to each end of a casing shall be graded and if necessary backfilled with clean
sand and compacted upto atleast 95% Proctor density to an elevation that will provide
sufficient and continuous support to the pipeline so that the pipeline remains correctly
aligned at the casing ends during and after backfilling.
4.4
The diameter of the hole for a bored section shall have a hole diameter as close as
practicable to the outside diameter of the carrier or casing pipe. If excessive void or
too large hole results, or if it is necessary, in the opinion of COMPANY, to abandon the
bored hole, prompt remedial measures such as filling the hole with suitable material
shall be taken to the entire satisfaction of the COMPANY and Authorities having
jurisdication thereof at no extra cost to COMPANY. Equipment used for installation of
casing pipe shall be of the type approved by COMPANY.
An installation consisting of hydraulic jacks shall be provided with easily readable
pressure gauges (in bar) and sealable pressure limits. Their proper operation shall be
demonstrated before the work is started. COMPANY can request that the maximum
pressing force be limited.
At the front of the pipe there may be a cutting ring which may be 12mm larger than
the outside diameter for the pipe or casing. A lubricating pipe can also be used in
jacking, the nipples of which shall not protrude from the cutting edge. Said
lubricating pipe shall not be fixed to the pipe casing. When jacking, only biologically
degradable lubricants shall be used (e.g. WRC Medlube or an emulsion of bentonite).
Removal of soil from the pipeline during jacking shall be done mechanically by means
of a standard, locked auger, which has to be safeguarded against jacking ahead of the
pipe.
During jacking the progress of the pipe to be jacked and the cutting capacity of the
auger shall be mutually adjusted, by regulating the speed of the auger, to prevent the
road from bulging (rpm too low) or cave-ins (rpm too high). In any case no more soil
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shall be removed than the volume of the pipe. The auger drive shall be provided with a
clutch.
The progress in the work, the readings of the gauge pipes, the jacking pressures
observed, etc., shall be recorded in a log book, to be shown to COMPANY upon
request. All information shall be supplied to COMPANY on completion of the work.
If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and
plugged at either end. The diameter of the casing pipe shall conform to API RP 1102
recommendations or as directed by the Engineer in - charge.
COMPANY reserves the right to inspect certain lengths of pipes to assess damages, if
any, to the corrosion coating of the carrier pipe used for boring. CONTRACTOR shall
weld additional lengths of pipe and pull the required extra lengths of COMPANY's
inspection. If during inspection any defects are noticed, CONTRACTOR, in consultation
with COMPANY, shall carry out the remedial measures required.
4.5
While welding of the casing and vent/ drain pipes, internal high or low is not allowed.
Welding of casing and vent/ drain pipes need not be radiographed, however, only
normal visual checks shall be carried out. Before welding, the single length of pipe shall
be inspected in order to check that there is no out of roundness and dents. When such
defects are noticed, these must be completely removed before joining the pipes. If
these defects cannot be repaired, the defective section shall be cut out.
4.6
In the case of crossing where excavation has been authorised, the welding for the
casing pipe and for a continuous sectio of the pipeline corresponding to the expected
length shall be carried out in the proximity of the crossing. Casing must be laid
immediately after the trenching. Casing pipe must be laid with a single gradient in
order to allow for an easy insertion and, if necessary at a future date, to allow for the
removal or replacement of the pipeline, leaving the casing undisturbed.
4.7
The assembly of vent pipe units as approved by COMPANY shall be carried out by
direct insertion and welding to the ends of the casing pipe before introducing the
carrier pipe. The operation of assembling and extending the vent pipe shall be carried
out in such a way that there is no contact with the carrier pipe. The painting/ coating
of the vent pipes shall be applied before backfilling as per relevant specifications.
4.8
The casing pipe shall be considered ready for installation of the carrier pipe, after
careful inspection and internal cleaning with the removal of soil, mud, stones and other
foreign materials.
4.9
Insulators, as approved by COMPANY, shall be securely fastened to the pipe with all
bolts and fixtures firmly tightened. The number of insulators and spacing shall be as
shown in the drawings or at 2.5m intervals (whichever is more stringent). At the end of
both sides of the casing, a double set of insulators shall be installed.
4.10
Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is
aligned correctly in the casing and that the pushing or pulling force is evenly and
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constantly applied to avoid damages to the insulators. A nose piece having a diameter
equal to that of the pipe shall be welded on the front and back end of the carrier pipe
to facilitate installation of the carrier pipe properly in the casing and to keep it dry and
clean.
4.11
After installation of the carrier pipe section, the casing and the appurtenances, but
prior to making tie-in welds and backfilling, an electrical test shall be conducted by the
CONTRACTOR in the presence of the COMPANY, to determine the resistance between
the casing and the carrier pipe or the carrier pipe and the soil. These tests shall show
at least a resistance of 100 kohm/m2. After backfilling and compaction, additional tests
shall be conducted to determine if the casing is electrically shorted to the pipe. If the
installation is found to be shorted, CONTRACTOR shall make the necessary corrections
and repairs at his cost, until a test to the satisfaction of the COMPANY is obtained.
5.0
5.1
The pipeline under construction may pass above or below the existing buried facilities
such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of
cover as required in the drawings and specifications are guaranteed. The minimum
clearance required between pipeline and the existing facility shall be 500mm.
5.2
5.3
For buried services to be crossed by boring/ jacking, the relevant provisions of Section
3.0 shall apply.
6.0
6.1
Minor water crossings are crossings of ditches, canals, water courses, rivers, streams
etc, whether the bed(s) contain(s) water or not, and not being specified as `Major
Water Crossings' in the CONTRACT.
6.2
For minor water crossings a standard drawing or a separate detailed approved drawing
for individual crossing shall be applicable, and all further specifications are applicable.
6.3
Whenever minor water crossings in the ROW are to be crossed, CONTRACTOR shall
install/ temporary bridges to facilitate movement.
6.4
In crossings of water courses with either moderate flow rate or of torrential nature
with marked and unpredictable flooding, an adequate survey shall be carried out
before starting the work with the object of determining what precautions are necessary
and the most favourable period for executing the work.
6.5
In case of crossings of water courses for which no special methods of laying are
required, a pipe section of a size as per the the approved drawings shall be assembled
and subsequently laid. Bends shall be of cold field type.
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For crossings beneath the bed of water courses, the pipe section shal be made in such
a way that it conforms to the existing or future bed as indicated in the approved
drawings. In crossings for which an individual drawing has not been prepared, the
minimum cover of the pipeline shall not be less than that indicated in the standard
drawings for a similar type of crossing.
6.8
Whenever the crossing requries a straight section of pipe between the lower bends
coinciding with the river bed, this section shall be laid at a single horizontal level.
6.9
For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall
be prepared, laid and tested in accordance with the applicable clauses of Section 3.0 of
this specification.
6.10
6.11
Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by COMPANY and shall be thoroughly compacted to prevent soil and bank
erosion as per the drawings and standards to the satisfaction of authorities having
jurisdication thereof and the COMPANY. Whenever boulders, rock, gravel and other
hard objects are encountered, they shall not be placed directly on the pipe. Sufficient
earth, sand or selected and approved backfill material shall be backfilled initially around
and over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 30 centimeters around the pipe before backfilling remainder of the trench
with excavated or other material as per approved drawings and standards.
After the trench has been backfilled and during the clean up works, the minor water
crossing shall be cleaned at least across the whole of the ROW.
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When directed by the COMPANY, CONTRACTOR shall stabilise and restore the bank
of the water crossings with materials to be supplied by him as follows.
The excavation shall be trimmed in steps-and-berms backfilled with well compacted
solid soil, followed by a minimum 0.25m thick layer of properly shaped boulders (75150mm) encased in a net of galvanised iron wire of dia 3mm spaced at a maximum
distance of 50mm to be laid over the backfilled, compacted and graded banks.
The GI wire shall be made from steel having tensile strength of 400 N/mm2 and with a
minimum elongation at failure of 10%. The minimum zinc coating of 200 gm-2 shall be
applied on single/ double twisted wire.
The length of the above protection shall be equal to the actual bank excavation edge
including damage and extending 2m on either sides. The width of this protection on
the slope shall be determined by the following :
2m plus the highest water level (recoverable) or upto the top of bank
whichever is higher.
Upto the bottom of the crossing or 20m below the highest water level
whichever is smaller.
Bank stabilisation for certain minor water crossings shall be determined by COMPANY
based on nature of crossing e.g. type of river, canal, major nallah, flood control
banks and other water bodies; type of soil, regulations of local authorities; and any
other socio-economic consideration evaluated by the COMPANY.
6.12
The crossing of any embankments shall be carried out strictly in accordance with
approved drawings.
No drilling work on embankments shall be permitted without prior written approval
from the competent authorities.
Rev. : 0
Edition : 1
SPECIFICATION
FOR
PIPING FABRICATION AND ERECTION
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CONTENTS
SL.NO.
DESCRIPTION
1.0
GENERAL
2.0
SCOPE
3.0
4.0
FABRICATION
5.0
ERECTION
6.0
WELDING
7.0
ERECTION
8.0
INSPECTION
9.0
PROTECTIVE COATING
10.0
FLUSHING
11.0
HYDROSTATIC TESTING
ANNEXURE-1 - WELDING SPECIFICATION
EXHIBIT-A EXHIBIT-B EXHIBIT-C EXHIBIT-D EXHIBIT-E EXHIBIT-F EXHIBIT-G -
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Dec. 2008
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1.0
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GENERAL
This specification covers general requirements of fabrication and erection of aboveground and
trench piping systems at site. The specification covers the scope of work of contractor, basis of
work to be carried out by contractor and standards, specifications and normal practice to be
followed during fabrication and erection by the contractor.
2.0
SCOPE
Generally the scope of work of contractor shall include the following :
2.1
Transportation of required piping materials, pipe support and all other necessary piping
materials from Owner's storage point or contractor's storage point (in case of contractor's
scope of supply) to work site / shop including raising store requisitions for issue of materials in
the prescribed format & maintaining an account of the materials received from Owner's stores.
2.1.1
Piping materials include the following but not limited to the same.
a.
b.
c.
d.
e.
f.
g.
h.
Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air
traps etc.
i.
Online instruments like control valve, orifice flange, rotameter, safety valves etc.
2.2
Shop & field fabrication and erection of piping in accordance with documents listed under Cl.
3.0 i.e. 'BASIS OF WORK' including erection of all piping materials enumerated above.
2.3
Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips,
cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, teeposts
including erection of spring supports and sway braces.
2.4
Fabrication
2.4.1
Fabrication of piping specials like special radius bends, reducers, mitres etc.
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2.4.2
Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3
2.4.4
Fabrication of odd angle elbow like 60, 30 or any other angle from 90/45 elbows as and
when required.
2.4.5
Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
2.4.6
2.4.7
Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven / different
thickness wherever required.
2.5
Modifications like providing additional cleats, extension of stem of valve, locking arrangement
of valves etc. as and when required.
2.6
Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines upto 2-1/2"
within the unit battery limit and get subsequent approval from Engineer-in-Charge as and
when called for.
2.7
Obtaining approval for drawings prepared by contractor from statutory authority, if required.
2.8
Spun concrete lining of the inside of pipes 3" NB & above including fittings and flanges as
required in accordance with specification.
2.9
Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10
Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specification.
2.11
Performing PMI using alloy analysers as per 'Standard Specification for Positive Material
Identification at Construction Sites, 6-82-0002'.
2.12
Casting of concrete pedestals and fabrication & erection of small structures for pipe supports
including supply of necessary materials.
2.13
Providing insert plates from concrete structures and repair of platform gratings around pipe
openings.
2.14
Making material reconciliation statement and return of Owner's supply left over materials to
Owner's storage.
2.15
Flushing and testing of all piping systems as per standard specification for inspection, flushing
and testing of piping systems (Specification No. MEC/S/05/21/11).
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3.0
3.1
The complete piping work shall be carried out in accordance with the following
3.1.1
"Approved for Construction" drawings and sketches issued by MECON to the Contractor - Plans
and/or Isometrics.
3.1.2
"Approved for Construction" drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
Drawings, sketches and documents prepared by contractor duly approved by Engineer-inCharge' (such as isometrics and offsite piping etc.)
3.1.5
3.1.6
3.1.7
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Any other MECON or OTHER specifications attached with Piping Material Specification
or special condition of contract.
k.
ASME B 31.3
ASME Sec. VIII
IBR Regulations
:
:
Process Piping
Code for unfired pressure vessel.
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d.
IS:823
e.
NACE Std.
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Deviations
Where a deviation from the "Basis of Work" and approved job procedure described above is
required or where the basis of work does not cover a particular situation, the matter shall be
brought to the notice of Engineer - in - Charge and the work carried out only after obtaining
written approval from him in each case.
4.0
FABRICATION
4.1
Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall
be strictly as per the "Piping Material Specification" for the "Pipe Class" specified for that
system. To ensure the above requirement, all piping material supplied by the Owner /
Contractor shall have proper identification marks as per relevant standards / MECONs
specifications / Licensors specification. Contractor shall provide identification marks on left over
pipe lengths wherever marked up pipe lengths have been fabricated / erected. Material
traceability is to be maintained for AS., S.S., NACE, LTCS, material for Hydrogen service and
other exotic materials by way of transferring heat number, etc. (hard punching) as per
approved procedure. This shall be in addition to colour coding for all piping materials to avoid
mix-up.
4.2
Fabrication
4.2.1
All fabrication shall be carried out in accordance with piping general arrangement drawings,
(prepared by CONTRACTOR and approved by COMPANY) including this specification and codes
as specified in section 2.0.
4.2.2
CONTRACTOR shall be responsible for working to the exact dimensions as per the approved
drawings. Dimensional tolerances to be adopted during implementation of fabrication work
shall be as per attached sketch "TOLERANCES FOR FABRICATION".
4.2.3
Flange bolt holes shall generally straddle the established centre lines unless other orientation is
required and as called out in approved drawings.
4.2.4
Threading shall be NPT to ANSI B 1.20.1. Threading shall preferably be done after bending,
forging or heat treatment operation. However if it is not possible, precaution shall be taken to
protect threading against deformation. Thread shall be clean cut with no burrs or stripping.
Dies shall be new, sharp and properly designed for piping material. Ends shall be reamed to
remove burrs.
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4.2.5
All threaded joints shall be aligned properly. The pipe entering unions shall be true to
centrelines so as to avoid forcing of union coupling during make up. Damaged threads shall be
cut from the end of run and the pipe shall be rethreaded.
4.2.6
Immediately before testing the piping, all threads of pipe and fittings shall be thoroughly
cleared of cuttings, fuel oil or other foreign matter. The male threads shall be sealed with
thread sealant and the piping made up sufficiently for the thread to seize. Sealant shall be
teflon tape.
4.2.7
Seal welding of threaded connections when specified shall include the first block valve, cover
all threads. The joint shall be cleaned of all cutting oil and other foreign material and made up
dry to full thread engagement. Instrument threaded connections which are frequently
subjected to testing and maintenance shall not be seal welded.
4.2.8
All threaded connections shall be protected from rusting by applying greases or oil when in
operating condition.
4.2.9
When socket weld fittings or valves are used, pipe shall be spaced approximately 1/16" to
avoid bottoming which could result in excessive weld stress.
4.2.10 Where the ends of the piping components being welded have an internal surface misalignment
exceeding 1.6mm, the wall of the component extending internally shall be trimmed by
machining so that the adjoining internal surface will approximately flush.
For the purpose of common understanding the construction job procedure, to be submitted by
the contractor, shall include proposal for
4.3
Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per MECON Standard Specification.
The Contractor shall be responsible for working to the dimensions shown on the drawings.
However, the Contractor shall bear in mind that there may be variations between the
dimensions shown in the drawing and those actually existing at site due to minor variations in
the location of equipments, inserts, structures etc. To take care of these variations "Field
Welds" shall be provided during piping fabrication. An extra pipe length of 100 mm over and
above the dimensions indicated in the drawing may be left on one side of the pipe at each of
the field welds. During erection, the pipe end with extra length at each field weld, shall be cut
to obtain the actual dimension occurring at site. Isometrics, if supplied may have the field
welds marked on them. However, it is the responsibility of the Contractor to provide adequate
number of field welds. In any case no extra claims will be entertained from the Contractor on
this account. Wherever errors / omissions occur in drawings and Bills of Materials it shall be
the Contractor's responsibility to notify the Engineer-in-Charge prior to fabrication or erection.
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4.4
IBR Piping
4.4.1
Contractor shall be supplied generally with all drawings for steam piping falling under the
purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor
shall carry out the fabrications, erection and testing of this piping as per requirements of
Indian Boiler Regulations and to the entire satisfaction of the local Boiler Inspector. The
Contractor shall also get the approval of IBR inspector for all fabrication and testing done by
him at his own cost. All certificates of approval shall be in proper IBR forms. .
.
4.4.2
Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by
the contractor at his own cost.
4.5
Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general, joining
of lines 2" and above in process and utility piping shall be accomplished by butt welds. Joining
of lines 1-1/2" and below shall be by socket welding / butt welding / threaded joints as
specified in "Piping Material Specifications". However, in piping 1-1/2" and below where socket
welding/ threaded joints are specified butt - welds may be used with the approval of Engineerin-Charge for pipe to pipe joining in long runs of piping. This is only applicable for nongalvanized piping without lining.
Flange joints shall be used at connections to Vessels, Equipment's, Valves and where required
for ease of erection and maintenance as indicated in drawings.
4.6
4.7
Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B 2.1 NPT as required
to match threads on fittings, valves etc. All other piping shall have threads as per ANSI B 2.1,
tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed.
Threading of pipes shall be done preferably after bending, forging or heat treating operations.
If this is not possible, threads shall be gauge checked and chased after welding heat treatment
etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly
cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with
thread sealant and the joint tightened sufficiently for the threads to seize and give a leakproof
joint.
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Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and
made up to full thread engagement before seal welding.
4.8
Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation is
shown in the drawing.
Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the
flange, shall be done before welding it to the pipe.
4.9
Branch Connections
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using forged
tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
4.10
Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be
used.
Cold bends for lines 1-1/2" and below, with a bend radius of 5 times the nominal diameter
shall be used as required in place of elbows wherever allowed by piping specifications.
Bending of pipes 2" and above may be required in some cases like that for headers around
heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles, bulges,
flat spots and other serious defects. They shall be true to dimensions. The flattening of a
bend, as measured by the difference between the maximum and minimum diameters at any
cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal and
external pressure respectively.
4.11
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4.13
4.14
Galvanised Piping
Galvanised carbon steel piping shall be completely cold worked, so as not to damage
galvanised surfaces. This piping involves only threaded joints and additional external threading
on pipes may be required to be done as per requirement.
4.15
Jacketed Piping
The Jacketing shall be done in accordance with MECON Specification or Licensors specification
as suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at
shop by Contractor. Position of jumpover and nozzles on the jacket pipes, fittings etc. shall be
marked according to pipe disposition and those shall be prefabricated to avoid damaging of
inner pipe and obstruction of jacket space. However, valves, flow glasses, in line instruments
or even fittings shall be supplied as jacketed.
4.16
4.17
Miscellaneous
4.17.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler,
supporting elements like turn buckles, extension of spindles and interlocking arrangement of
valves, operating platforms as required by Engineer-in-Charge.
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ERECTION
5.1
5.2
Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without the
consent of Engineer- in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings
shall be strictly followed as these clearances may be required for the free expansion of piping /
equipment. No deviations from these clearances shall be permissible without the approval of
Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall be
brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his
instructions.
5.3
Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as indicated
in the drawing. Confirmation in writing shall be obtained by the Contractor from the Engineerin-Charge, certifying that the gap between the pipes is as indicated in the drawing, before
drawing the cold pull. Stress relieving shall be performed before removing the gadgets for cold
pulling.
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Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the Contractor.
Corrective action shall be taken by the Contractor in consultation with Engineer-in-Charge
wherever the Contractor is not able to maintain the specified slope.
5.5
All Expansion joints / Bellows shall be installed in accordance with the specification and
installation drawings, supplied to the Contractor.
Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the
case(s) and check for any damage occurred during transit.
The Contractor shall bring to the notice of the Engineer-in-Charge any damage done to
the bellows / corrugations, hinges, tie-rods, flanges / weld ends etc.
Each Expansion Joint / Bellow shall be blown free of dust / foreign matter with
compressed air or cleaned with a piece of cloth.
For handling and installation of Expansion Joints, great care shall be taken while
aligning. An Expansion Joints shall never be slinged from bellows corrugations /
external shrouds, tie / rods, angles.
An Expansion Joints / Bellow shall preferably be slinged from the end pipes / flanges or
on the middle pipe.
Expansion Joints stop blocks shall be carefully removed after hydrostatic testing.
Angles welded to the flanges or weld ends shall be trimmed by saw as per
manufacturer's instructions and the flanges or weld ends shall be ground smooth.
The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned
or shall have specified lateral deflection as noted on the relevant drawings.
The pipe ends / flanges shall be spaced at a distance specified in the drawings.
The Expansion Joint shall be placed between the mating pipe ends / flanges and shall
be tack welded/bolted. The mating pipes shall again be checked for correct alignment.
Butt-welding shall be carried out at each end of the expansion joint. For flanged
Expansion Joint, the mating flanges shall be bolted.
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After the Expansion Joint is installed the Contractor shall ensure that the mating pipes
and Expansion Joints are in correct alignment and that the pipes are well supported
and guided.
The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain
parallelism of restraining rings or bellows convolutions.
Precautions
For carrying out welding, earthing lead shall not be attached with the Expansion
Joint.
The Expansion bellow shall be protected from arc weld spot and welding spatter.
Hydrostatic Testing of the system having Expansion Joint shall be performed with
shipping lugs in position. These lugs shall be removed after testing and certification
is over.
Flange Connections
While fitting up mating flanges, care shall be exercised to properly align the pipes and to check
the flanges for trueness, so that faces of the flanges can be pulled together, without inducing
any stresses in the pipes and the equipment nozzles. Extra care shall be taken for flange
connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange
connections to these equipments shall be checked for misalignment, excessive gap etc. after
the final alignment of the equipment is over. The joint shall be made up after obtaining
approval of Engineer-in-Charge.
Temporary protective covers shall be retained on all flange connections of pumps, turbines,
compressors and other similar equipments, until the piping is finally connected, so as to avoid
any foreign material from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between these
flange faces is uniformly compressed. To achieve this the bolts shall be tightened in a proper
sequence. All bolts shall extend completely through their nuts but not more than 1/4".
Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts uniformly
after bringing flange flush with gaskets with accurate pattern and lateral alignment.
5.7
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Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. In case of any difficulty in doing this or if the spindle orientation / position is not
shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his
instructions. Care shall be exercised to ensure that globe valves, check valves, and other unidirectional valves are installed with the "Flow direction arrow "on the valve body pointing in
the correct direction. If the direction of the arrow is not marked on such valves, this shall be
done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking arrangements of valves
(if called for), shall be carried out as per drawings / instructions of Engineer-in-Charge.
5.9
Instruments
Installation of in-line instruments such as restriction orifices, control valves, safety valves, relief
valves, rotameters, orifice flange assembly, venturimeters, flowmeters etc. shall form a part of
piping erection work.
Fabrication and erection of piping upto first block valve / nozzle / flange for installation of
offline Instruments for measurement of level, pressure, temperature, flow etc. shall also form
part of piping construction work. The limits of piping and instrumentation work will be shown
in drawings / standards / specifications. Orientations / locations of take-offs for temperature,
pressure, flow, level connections etc. shown in drawings shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above and the
precautions to be taken are covered in flushing, testing and inspection of piping. Care shall be
exercised and adequate precautions taken to avoid damage and entry foreign matter into
instruments during transportation, installation, testing etc.
5.10
5.11
5.12
Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal effects of
the piping system and to prevent its vibrations. Location and design pipe supports will be
shown in drawing for lines 2 NB. However, any extra supports desired by Engineer-in-Charge
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6.0
All temporary tack welds provided during erection have been fully removed.
7.0
ERECTION
7.1
7.1.1
Field joint shall be decided by CONTRACTOR keeping in view the transportation of prefabricated pieces to site.
7.1.2
There can be some variations in the dimensions and level appearing in the
arrangement drawings and those actually occurring at site due to minor variations in
the location of equipments, structures, cut out etc. Adequate field joints shall be
provided, permitting assembly and erection of pipe work without major modification.
7.2
Supporting
Location and design of pipe supports shown in approved drawings and support
drawings shall be strictly followed.
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7.2.1
Supports shall be installed in such a way that they do not contribute to over stressing
of a line.
7.2.2
Fabrication and erection of additional supporting elements and structural fixtures which
in COMPANY's view are required for proper supporting of the system, shall be carried
out by CONTRACTOR at no extra cost.
7.2.3
All temporary supports, elements required for alignment, erection and assembly shall
be removed after completion of work.
7.3
Equipment hook-up
7.3.1
Prior to hook-up, the alignment and trueness of flange faces shall be checked to
ensure that no undue stresses shall be induced in the system while hooking up.
8.0
INSPECTION
8.1
8.2
CONTRACTOR shall provide all facilities/ assistance to COMPANY for proper execution
of their inspection without any extra charge.
8.3
All piping work shall be subjected to inspection by COMPANY at any time during
fabrication. CONTRACTOR shall furnish to COMPANY detailed work programme
sufficiently in advance, in order to enable COMPANY to arrange for inspection.
9.0
PROTECTIVE COATING
9.1
All above ground piping system shall be applied with protective coating in accordance
with specification for shop & field painting.
9.2
All under ground portion of piping system shall be coated with three layer P.E. coating.
CONTRACTOR shall prepared procedure for epoxy painting of burried pipeline for
approval of COMPANY. Procedure shall include surface preparation, brand and type of
coating to be adopted. Coating of pipes shall not commence without approval of
coating procedure. Total dry film thickness to be achieved shall not be less than 300
microns. Compatible primer and finish coat as recommended by coating manufacturer
shall only be applied. Coating integrity shall be checked by "Holiday detector" over full
length of coated pipe work. Coating to be supplied by CONTRACTOR shall be suitable
for design temperature.
9.3
Once the coating has been accepted by COMPANY, backfiling operation can be started.
In order to protect coated pipe from damage, the excavated trench shall be examined
for stone, rock and any other hard substance detrimental to coating. All such
substances shall be removed before lowering the pipe in the trench. COMPANY may
ask for a 100mm padding of clear sand under and above pipeline in rocky or otherwise
hard soil area. No additional payment on account of padding shall however be
admissible.
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FLUSHING
Completed piping systems shall be flushed by CONTRACTOR with fresh water, to clean
the pipe of all dirt, debris, and foreign material. CONTRACTOR shall prepare a
procedure for flushing of the system for approval of COMPANY. Flushing shall not be
commenced without approval of flushing procedure.
10.1
CONTRACTOR shall perform all activities like dismantling and reinstalling of all
strainers, in line instruments etc. before and after completion of flushing.
10.2
10.3
10.4
Date of flushing
b)
11.0
HYDROSTATIC TESTING
11.1
11.2
CONTRACTOR shall prepare hydrostatic test procedure based on specified codes. The
hydrostatic test shall commence only after approval of procedure by COMPANY.
11.3
11.4
Fresh water shall be used as test media. CONTRACTOR shall locate the source of water
supply and arrange for transportation of water to test site. CONTRACTOR shall arrange
at his own cost the water analysis and confirm that water is suitable for testing. In
case any corrosion inhibitor is to added, the same shall be done after approval of
COMPANY.
11.5
Lines repaired subsequent to hydrostatic test shall be retested using the same
procedure as originally adopted. However COMPANY may waive such retest in case of
minor repairs by taking precautionary measures to ensure sound construction.
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11.6
All equipment and instruments used for hydrostatic test shall be approved by
COMPANY before start of tests.
11.7
Pressure gauges shall be installed on line to measure test pressures. In case of longer
lines two or more pressure gauges shall be installed as directed by COMPANY. One
gauge shall be installed at the discharge of the pressurising pump. Pressure gauge
used for hydrostatic testing shall be calibrated with dead weight tester in the presence
of Engineer-in-charge. Range of pressure gauge shall generally be 1.5 times the test
pressure.
11.8
Orifice plates and restriction orifices shall not be installed until hydrostatic testing is
completed. Temporary gaskets shall be used during testing.
11.9
First block valve of pressure instruments shall be half open & plugged at the time of
hydrostatic testing. Temperature connections shall be blanked off during testing.
11.10
All equipments, in line instruments, relief valves shall be disconnected from piping
system by means of blinds during testing. Control valves shall be replaced by spool
pieces during testing.
11.11
High point vents and low point drain required for testing in addition to those marked in
the drawings shall be provided by CONTRACTOR at his own cost.
11.12
All welded and screwed joints shall be kept clean for detecting leaks during testing.
11.13
Test pressure shall be maintained long enough to facilitate complete inspection of the
system. Minimum duration of test shall be 6 hours unless other wise specified.
Pressurising equipment shall be isolated immediately after test pressure is attained.
11.14
11.15
Test Records
The records in duplicate shall be prepared and submitted by CONTRACTOR as below :
a)
b)
c)
d)
e)
f)
Date of test
Identification of pipe tested - line number
Test pressure
Test results
Signature of CONTRACTOR
Approval signature by COMPANY.
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ANNEXURE-1
WELDING SPECIFICATION
1.0
GENERAL
This specification shall be followed for the fabrication of all types of welded joints of
carbon steel above ground natural gas service piping systems.
The welded pipe joints shall include the following :
a)
All line pipe joints of the longitudinal and circumferential butt welded.
b)
c)
d)
e)
f)
The attachments of smaller connections for vents drain drips and other
instrument tappings.
Any approval granted by the Engineer-in-charge or owner's inspectors shall not relieve
the contractor of his responsibilities & guarantees.
1.1
Code for gas transmission and distribution piping systems. ANSI B31.8.
Code for petroleum refinery piping, ANSI B31.3.
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In the event of any difference due to the additional requirements mentioned in this
specification, over and above those obligation as per codes, this specification shall be
binding.
1.2
Base Material
a)
b)
1.3A
Filler Materials
a)
The Contractor shall provide all the necessary welding electrodes, filler
materials, etc. required for the execution of the work.
b)
The welding electrodes/ filler wires supplied by the Contractor shall conform to
the class specified in the welding specification chart. The materials shall be of
the make approved by the Engineer-in-charge.
c)
The electrode shall be suitable for the welding process recommended and base
metal used. Unless otherwise specified physical properties of the welds
produced by a electrode recommended for the welding of a particular base
metal shall not be lower than the minimum valves specified for the base metal
and shall correspond to the physical properties of the class of electrode
adopted. The choice of electrode shall be made after conducting the required
tests on the electrodes as per relevant standards, and shall be the sole
prerogative of the Engineer-in-charge.
d)
e)
f)
The Contractor shall submit batch test certificate from the electrode
Manufacturers giving details of physical and chemical tests carried out by them,
for each batch of electrodes to be used.
g)
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h)
All low hydrogen type of electrodes shall be rebaked at 350C for 1 hour
minimum and stored in ovens kept at 80-100C before use. Recommendations
of the electrode Manufacturer shall be followed if available.
i)
The electrodes, filler wires and flux used shall be free from rust, oil, greases,
earth and other foreign matter which can affect the quality of welding.
Argon gas used in GTA welding for shielding purposes shall be 99.995% pure.
The purity of the gas shall be certified by the manufacturer. The rate of flow for
shielding purposes shall be established through procedure qualification tests.
Normally this rate may be 12-20 CFH.
b)
Argon gas with a purity level of 99.995% shall be used for purging.
c)
d)
Initial purging shall be maintained for sufficient period of time so that at least
4-5 times the volume between the dams is displaced, in order to completely
remove the entrapped air. In no case should the initial purging period be less
than 10 minutes. High gas pressure should be avoided.
e)
After initial purging, the flow of the backing gas should be reduced to a point
where only a slight positive pressure prevails. For systems, which have a small
volume (up to 1/2 cubic foot) to be purged, a gas flow rate of 6-CFH is usually
adequate. Systems of larger volume may require higher flow rates and these
should be established during procedure qualification tests.
f)
Gas backing (purging) is not required for socket type of welded joints.
g)
Dams, used for conserving inert gas during purging, shall be removed after
completion of the welding, and shall be accounted for. Wherever, removal of
dams is not possible after welding, use of water-soluble dams should be made.
Welding Consumables
The Contractor shall provide at this own expense all the welding consumables
necessary for the execution of the job such as electrodes filler wires, oxygen,
acetylene, etc. and these should bear the approval of the COMPANY.
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1.5
1.5.1
The Contractor should have the arrangement of sufficient number of welding and
cutting equipments, auxiliaries and accessories of sufficient capacities so as to meet
the target schedule.
1.5.2
All the equipment for performing the heat treatment, including transformers,
thermocouples, flow meters, automatic temperature recorders with suitable calibration
arrangement etc. shall be provided by the Contractor, at his own expense and these
should bear the approval of the COMPANY.
1.5.3
Contractor shall make necessary arrangements at his own expense for providing the
radiographic equipment, radiographic films, and all the equipment/ materials required
for carrying out the dye penetrant/ magnetic particle test for satisfactory and timely
completion of the job.
1.5.4
1.6
Welding Processes
1.6.1
Welding of various materials under this specification shall be carried out using Shielded
Metal Arc Welding (SMAW) Process with the approval of the Engineer-in-charge.
1.6.2
The welding processes to be employed are given in the welding specification chart. Any
deviation desired by the Contractor shall be obtained through the express consent of
the Engineer-in-charge.
1.6.3
Automatic and semi-automatic welding processes shall be employed only with the
express approval of the Engineer-in-charge. The welding procedure adopted and
consumables used shall be specifically approved.
1.6.4
1.7
End Preparation
1.7.1
End Preparation
The edges to be welded shall be prepared to meet the joint design requirements by
gas cutting, machining or grinding method. After gas cutting, oxides shall be removed
by chipping or grinding.
1.7.2
Cleaning
a)
The ends to be welded shall be properly cleaned to remove paint, oil, greases,
rust, oxides, sand, earth and other foreign matter. The ends shall be
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1.8
Prior to alignment, the contractor shall inspect the pipe ends inside and outside
for damage, dents, laminations etc. Pipe for welding shall be set up correctly
spaced. Temporary attachment of any kind shall not be welded. Every effort
shall be made to reduce misalignment by the use of clamp and rotation of
pipes to the best fit. For pipes of same nominal wall thickness, the off set
should not exceed 1.6mm. Any branch connections sleeve shall be at least
150mm from any other weld. The welds for fitting shall be so located that top
of the weld shall not come within 50mm of any other weld. The use of internal
line up clamps is mandatory for diameters 10" and above. However, in case
where it is impossible to use internal line up clamp, external line up clamp may
be used.
b)
Tack welds, for maintaining the alignment, of pipe joints shall be made only by
qualified welders using approved WPS. 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.
1.9
Weather Conditions
1.9.1
The parts being welded and the welding personnel should be protected from rain and
strong winds. In the absence of such a protection no welding shall be carried out.
1.9.2
During field welding using GTAW process, particular care shall be exercised to prevent
any air current affecting the welding process.
1.10
Welding
1.10.1
Root Pass
a)
Root pass shall be made with electrodes/ filler wires recommended in the
welding specification chart. The preferable size of the electrode is 2.5mm
diameter (12 SWG) but in no case greater than 3.25mm (10 SWG).
b)
Uphill welding shall be adopted for welding pipes weld fixed with its axis
horizontal. Downward technique of welding shall not be used for welding of
pipes in horizontal position, unless specifically permitted by Engineer-in-charge
for a particular case.
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1.10.3
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c)
The root pass of but joints should be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
pipe shall not exceed .4mm wherever not specified by the applicable code.
d)
e)
f)
g)
While the welding is in progress care should be taken to avoid any kind of
movement of components, to prevent occurrence of weld cracks.
h)
Fillet welds shall be made by shielded metal arc/ GTAW welding process
irrespective of the thickness and class of piping.
i)
Peening shall not be used unless specified in the welding specification chart.
Joint Completion
a)
b)
Two weld beads shall not be started at the same point in different layers.
b)
Butt joints shall be completed with a cover layer that would effect good cover
at the joint edge and a gradual notch free surface.
d)
e)
Weld identification mark shall be stamped clearly at each joint, just adjacent to
the weld. Metal stamping shall not be used on the thin wall pipe. Suitable paint
shall be used on thin wall pipes for identification.
f)
No painting shall be done until the weld joint has been hydrostatically tested.
Dissimilar Welds
Where welds are to be produced between carbon steels and alloy steels, preheat and
post weld heat treatment requirements shall be those specified for corresponding alloy
steels and filler wire / electrodes shall correspond to ER 70 S-G or AWS E-7016/7018
type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld
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heat treatments shall be those specified for higher alloy steel and electrodes used shall
correspond to those specified for steel of lower alloy content. For carbon steel or alloy
steel to stainless welds, use of filler wire / electrodes E/ER-309/E-310/E NiCr Fe-3 shall
be made. The welding procedure, electrodes / filler wires to be used shall be approved
by the Engineer-in-Charge.
1.11
Heat Treatment
1.11.1
Preheating
1.11.2
a)
Preheating requirements for the various materials shall be as per the welding
specification chart attached. No welding shall be carried out without preheating
the joint to 10C (50F) when the ambient temperature is below 10 degree.
b)
c)
Preheating shall extend uniformly to atleast three times the thickness of the
joint, but not less than 50mm, on both sides of the weld.
d)
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 by the contractor to check the temperature.
e)
Preheating temperature shall be maintained over the whole length of the joint
during welding. Temperature recorders shall be provided by the Contractor to
record the temperature.
Post Heating
In case of alloy steel materials such as Cr-Mo steels, if the post weld heat treatment is
not performed immediately after welding, the weld joint and adjacent portion of pipe,
at least 50 mm on either side of weld, shall be uniformly heated to 300c. This
temperature shall be maintained for half an hour minimum, and then wrapped with
mineral wool before allowing it to cool to room temperature. If the Post Heating
temperature specified in the Welding Specification Charts exceeds 300C, the same
shall be followed. Similarly, if the welding specification chart specifies post-heat time,
the same shall be applicable. Post weld heat treatment as specified in the Welding
Specification Chart shall be carried out later on.
1.11.3
Post weld heat treatment, wherever required for joints between pipes, pipes an
fittings, pipe body and supports shall be carried out as per the relevant
specifications, applicable standards and the instructions of the Engineer-incharge. In this regard procedure qualification to be done before carrying out
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The heat treatment of welded joints shall be carried out as per the
requirements laid down in ANSI B31.8 and welding specification chart.
c)
The contractor shall submit for the approval of the Engineer-in-charge, the
details of the post weld heat treatment procedure, as per Exhibit `B'
attached, that the propose to adopt for each of the materials/ assembly/ part
involved, well before carrying out actual heat treatment.
d)
e)
While carrying out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the portion
being heat treated. Care shall be taken to ensure that width of treated band
over which specified post weld heat treatment is carried out, the temperature
attained is atleast as that specified in the relevant applicable standards/ codes.
f)
Throughout the cycle of heat treatment, the portion outside the heated band
shall be suitably wrapped under insulation so as to avoid any harmful
temperature gradient at the exposed surface of pipe. For this purpose
temperature at the exposed surface of the pipes should not be allowed to
exceed 400C.
g)
h)
i)
j)
Each joint shall bear an identification number which shall be maintained in the
piping sketch to be prepared by the contractor. The joint identification number
should appear on the corresponding post weld heat treatment charts. The
same identification numbers shall also be followed for identification for
corresponding radiographic films. The chart containing the identification
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1.12
k)
The hardness of the heat affected zone as well as of the weld metal, after heat
treatment, shall be measured using suitable hardness tester and shall not
exceed the maximum hardness specified in the welding specification chart. The
weld joint shall be subjected to re-heat treatment when hardness measured
exceeds the specified limit, at the contractor's own expenses.
l)
The contractor shall arrange for the hardness testing and shall maintain the
records of all joints tested. These records shall be checked by the plant
Owner's inspector.
1.13
1.13.1
General
a)
The owner's inspector shall have free access to all concerned areas, where the
actual work is being performed. The contractor shall also offer the Owner's
inspector all means and facilities necessary for carrying out inspection.
b)
The owner is entitled to depute his own inspector to the shop or field where
pre-fabrication and erection of pipelines are being done with (but not limited
to) the following objectives :i.
ii.
iii.
c)
1.13.2
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b)
1.13.3
1.13.4
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COMPANY's inspector will review, check and approve the welding procedure
submitted and shall release the procedure for procedure qualification tests. The
procedure qualification test shall be carried out by the Contractor under field
conditions at this own expense. A complete set of test results in format as per
Exhibit-D (attached) shall be submitted to the COMPANY's inspector for
approval immediately after completing the procedure qualification test and
atleast 2 weeks before the commencement of actual work. Standard tests as
specified in the code shall be carried out in all cases. In addition to these tests,
other tests like radiography, macro/ micro examination, hardness testers, dye
penetrant examination, Charpy V-notch etc. shall be carried out on specimens.
It shall be the responsibility of the contractor to carry out all the tests required
to the satisfaction of the COMPANY's Inspector. The destructive testing of
welded joints shall be as per Annexure-2 and ASME Sec-IX.
Welder's Qualification
a)
Welders shall be qualified in accordance with the API 1104/ ASME IX and other
applicable codes by the contractor at his expense. The butt weld test pieces of
the qualification test shall meet the radiographic tests requirements as
mentioned in this specification. The COMPANY's inspector shall witness the test
and certify the qualification of each welder separately. Only those welders who
have been approved by the COMPANY's inspector shall be employed for
welding. Contractor shall submit the welder qualification test reports in the
standard format and obtain express approval, before commencement of the
work. No welder shall be permitted to work without the possession of the
identify card. It shall be the responsibility of contractor to carry out
Qualification tests of welders.
b)
The welders shall always have in their possession the identification card as
shown in Exhibit-E and shall produce it on demand by the COMPANY's
Inspector. It shall be the responsibility, of the Contractor to issue the identify
cards after it has been duly certified by the COMPANY. If a welder is found to
perform a type of welding 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 at the expense of the Contractor.
Visual Inspection
Inspection of all welds shall be carried out by COMPANY as per the latest editions of
the applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity of welds,
shrinkage, cracks, under cuts, dimensions of the weld, surface porosity and other
surface defects. Under-cutting adjacent to the completed weld shall not exceed the
limits specified in the applicable standard/ code.
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Non-destructive Examination
The non destructive examination shall mainly consist of examination using x-ray
radiography as detailed in Annexure-4.
Radiographic examination of one hundred percent (100%) girth welds will be required
by the COMPANY. Welds shall meet the standards of acceptability as set forth in API
1104 and as per the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the radiographic examination of
work covered by this specification at his expense.
The COMPANY will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the COMPANY shall be final and binding
in this regard.
All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, for pipes with wall thickness
9.5mm and above, ultrasonic inspection is required in the following cases as per
Annexure-3 of this specification.
a)
b)
When 20mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 20mm to ensure no
lamination exist.
c)
d)
e)
In addition, ultrasonic inspection may be required for certain critical weldings of the
pipeline (i.e. tie-ins, welding of valves, flanges) randomly selected at COMPANY's
discretion. All fillet and groove welds other than that radiographed shall be subjected
to dye pentrant/ MP inspection. The non destructive test system used for inspecting
welds must be approved by the COMPANY.
Weld quality is judged on the basis of the acceptability criteria mentioned below :
Any weld which as a result of radiographic and / or ultrasonic examination in the
opinion of COMPANY exhibits imperfections greater than the limits stated in API-1104
latest edition or as superseded in this article shall be considered defective and shall so
be marked with an identification paint marker.
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EDITION : 1
In addition to the API-1104 requirements, the welds containing cracks including crater
cracks regardless of size of location are unacceptable.
i.
ii.
Any amount of incomplete fusion between the root and bevel as defined by
API-1104 is unacceptable.
iii.
Contractor shall appoint agency for carrying out the radiography works at site from the
list of agency (ies) enclosed in the bid document.
Type of Radiation source and film to be used shall be as per Exhibit-H for
carrying out radiographic examination. However if specifications (as given else
where in the contract) for some critical material require usage of X-Radiation,
then Radiography shall be done using X-Rays only.
The Contractor shall fulfill all the statutory and owner's safety requirements
while handling X-ray and Gamma-ray equipments.
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EDITION : 1
The Contractor shall provide the Owner's Inspector, all the necessary facilities
at site such as a dark room with controlled temperature, illuminator (viewer)
suitable for varying densities, a duly calibrated electronic densitometer with
batteries, magnifying glass, tracing papers, ruler, marking pencils etc. to enable
him to review the radiographs.
Where random radiography is specified, the first weld of each welder shall be
completely radiographed. In the case of pipe of size 6" and below, the first two
welds shall be completely radiographed.
The Contractor shall carry out these additional radiographic testing at his own
expense. To avoid the possibility of too many defective welds by a single
welder remaining undetected for a long period to time, the Contractor shall
promptly arrange for Radiographic Examination so that there is no
accumulation of defective joints.
Contractor shall quote rates for X-ray as well as Gamma Ray for joints indicated
to be radiographed by X-ray in Table of Exhibit-H.
Check shots
(a)
Owner / Engineer- in- charge or his representative shall select 5% of the total
joints radiographed on a day for check shots. Contractor shall carry out check
shots as directed.
(b)
Weld profiles of check shots shall be compared with weld profile observed in
the earlier Radiographs. In the event of anyone variation in the check shots
and earlier Radiographs, contractor shall re-shoot the entire lot of joints
radiographed by particular Radiography agency on the particular date. All the
re-shot films shall be compared with the originally submitted films.
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1.13.8
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EDITION : 1
Whenever such tests are specified, the tests shall be carried out on joints
chosen by the Owner's inspector, as per ASME Section V article 6 and 7
respectively. The tests are to be performed by a person possessing a valid
ASNT / ISNT Level-II qualification in the method being used.
(b)
For austenitic stainless steels and other nonmagnetic materials, liquid (dye)
penetrant test shall be carried out. For carrying out this test, the materials shall
be brought within a temperature limit of 15 to 50C.
Hardness Test
Hardness requirements for welds shall be as per the Welding Specification Chart / Non
Destructive Examination Specification attached elsewhere in the contract. Hardness
testing shall be carried out by Vickers Hardness Tester during welding procedure
qualification and shall be cross sectional. For production welds, hardness testing shall
be carried out by portable digital hardness testers. Poldi hardness tester shall not be
permitted. Contractor shall produce documentary evidence/calibration certificate to the
Owner's Inspector and obtain approval of the hardness testing equipment.
1.13.9
Proof Tests
Hydrostatic and pneumatic tests shall be performed as per the requirements laid down
in the respective flushing & testing specification/ applicable codes to demonstrate the
soundness of the welds. The tests shall be conducted only after fulfilling the
requirements of visual examination, radiography etc. and after the entire work has
been certified by the Owner's inspector, as fit for subjecting to such test.
1.14
Repairs of Welds
a)
b)
c)
No repair shall be carried out without prior permission of the Owner's inspector.
d)
Where random radiography is specified, the test welds of each welder shall be
completely radiographed. In the case of pipes of sizes 6" and below, the first
two welds shall be completely radiographed.
e)
For each weld found unacceptable due to a welder's fault, two additional
checks should be carried out on welds performed by the same welder. This
operation is interactive and the procedure of radiographing two additional
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EDITION : 1
welds for each weld deemed unsatisfactory shall be continued till such time
that the two consecutive welds of satisfactory quality are found for every
defective weld.
The contractor shall carry out these additional radiographic testing.
To avoid the possibility of too many defective welds by a single welder
remaining undetected for a long period of time, the Contractor shall promptly
arrange for radiographic examination so that there is no accumulation of
defective joints.
1.15
Limitations on Repairs
Only one attempt at repair of any region is permitted. Repairs are limited to a
maximum 30% of the weld length. For internal or external repairs which open the weld
root, only 20% of the weld length may be repaired. Repairs opening the root must
only be carried out in the presence of COMPANY. The minimum length of a repaired
area shall be 100mm as measured over the recapped length. Welds containing cracks
shall be cut out and rebevelled to make a joint, COMPANY shall authorise all repairs.
1.16
1.17
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EXHIBIT-A
Sheet 1 of 4
ELECTRODE QUALIFICATIONS TEST RECORD
A:
Tested at
(Site Name)
Date :
Manufacturer's Name
Test Period :
Brand Name
B:
:
:
Visual Examination
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Sheet 2 of 4
Tensile Test Results
:
------------------------------------------------------------------------------------------------------------------------Sl.
Identification U.T.S. Yield Point
Elongation
Remarks
No.
Number
-------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------C:
Notch in :
Size of Specimens :
------------------------------------------------------------------------------------------------------------------------Specimen No.
Impact Value
Average
------------------------------------------------------------------------------------------------------------------------1.
2.
3.
4.
5.
------------------------------------------------------------------------------------------------------------------------D:
Batch No.
----------------------------------------------------------------------------------------------------------------%C
%S
%P
%Si %Mn
%Cr
%Ni
%Mo
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Sheet 3 of 4
Base Materials
1)
2)
3)
Remarks
F:
DOCUMENT NO.
In Combination with
Position of Welding
Preheat Temperature
Radiography
----------------------------------------------------------------------------------------------------------------Identification No.
U.T.S.
Fracture in
Remarks
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Sheet 4 of 4
2.
3.
Conclusions
Approved By :
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EXHIBIT-B
Sheet 1 of 2
General Details
Name of the Equipment : ............................................................................
Name of the Assembly/ Part : .....................................................................
Assembly/ Part Drawing No. : .....................................................................
Material : .................................................................................................
2.
Furnace Details
Type of Heating : Gas/ Oil/ Elec. Res./ Induction (Tick Mark)
Capacity (size) : ........................................................................................
Maximum Temp. (C)
Method of temp. measurement : ...................................................................
Atmosphere Control : .................................................................................
3.
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EDITION : 1
Sheet 2 of 2
4.
5.
ii)
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EDITION : 1
EXHIBIT-C
Sheet 1 of 2
Position .....................................................................................................
Direction of Weldings
Downhill, Mixed)
Cleaning ....................................................................................................
..................................................................................
(Uphill,
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Sheet 2 of 2
Minimum No. of welders required for the first pass and second pass :
Tested : ....................................... Welder ......................................
Approved
Accepted
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EDITION : 1
EXHIBIT-D
Sheet 1 of 2
Location .............................................................................................................
Date ................................... State ................................ Roll Weld ...................... Fixed position
weld ............................................... welder ................................... Mark
.................................................. Welding Time .......................................... Time of day
............................... M. Temperature ................................ F. Weather Condition
........................................ Wing break used ......................................... Voltage
.................................. Amperage ............................................... Type of welding machine
...................................................... Size ................................... Filler Metal
......................................................................................................... Size of reinforcement
........................................................................................... Pipe kind and Grade
............................................................................................. Wall thickness
........................................................... Dia O.D. ............................
------------------------------------------------------------------------------------------------------------------------1
2
3
4
5
6
7
Bead No. ............................................................................................................ Size of electrode
................................................................................................ No. of electrode
..................................................................................................
------------------------------------------------------------------------------------------------------------------------1
2
3
4
5
6
7
Coupon Stenciled ................................................................................................ Original
Dimension of Plate .................................................................................. Original area of plate
(inch2) ................................................................................ Maximum Load
................................................................................................... Tensile S/ in. plate area
....................................................................................... Fracture Location
................................................................................................
Procedure
Welder
Qualifying Test
Line Test
Qualified
Disqualified
.................................................................................................................
2.
.................................................................................................................
3.
.................................................................................................................
4.
.................................................................................................................
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Sheet 2 of 2
Remarks on Bend Tests
1.
.................................................................................................................
2.
.................................................................................................................
3.
.................................................................................................................
4.
.................................................................................................................
.................................................................................................................
2.
.................................................................................................................
3.
.................................................................................................................
4.
.................................................................................................................
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EDITION : 1
EXHIBIT-E
WELDER's IDENTIFICATION CARD
Name
Identification
Date of Testing
Valid Unit
Approval of Welding
Welding Position
Material
Diameter
Wall Thickness
Approved By :
Employer's Signature
with Seal
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EDITION : 1
EXHIBIT-F
Sheet 1 of 1
1.
Location
2.
Date of Testing
3.
4.
Material
5.
6.
7.
8.
9.
10.
Filter type and placement mask, diaphragm lead screen etc. adjacent to radiation sources or
specimen.
11.
Geometric relationship (source local spot size, max and min source strength, object to film
distance, radiation angle with respect to weld and film).
12.
13.
14.
Exposure Time
15.
Processing (time temperature for development stop bath or rinse, fixation, washing, drying
etc.)
16.
Density
17.
Sensitivity
18.
Type of penetrameter
Signature of CONTRACTOR
with seal
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EXHIBIT-G
Sheet 1 of 2
Material Specification :
Pipes
Fittings
Flanges
Other
44 Gr. F6C
:
E6010G/ E7010G
E7010/ E7018G/ E8018G
Filler Pass
F7010G/ E8010G/ E8818G
Filler Pass
F7016/ E7018G/ E80118G
Consumable :
Gases : Purging
Sheilding
Sheilding
Post heating
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EDITION : 1
Sheet 2 of 2
Charpy `V' notch impact test valve :
Normal
:
Average
At temperature
Hardness
22 J
:
:
:
27 J
0 C
300 HV10 (for weld & HAZ)
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EDITION : 1
TECHNICAL NOTES
1.
Welding, heat treatment and non destructive testing shall be carried out in accordance with
the requirement of ANSI B31.8/ API-1104 and additional requirement specified in the
specification. In case of conflict between code and specification more stringent conditions shall
be applicable.
2.
No welding shall be carried out without preheating the joint to 10C (50 F) when the ambient
temperature is below 10C (50 F).
3.
Preheat shall be applied while welding the following material as detailed below :
API 5L Gr. B
A 105
MSS-SP-44 Gr. F60
A 234 Gr. WPB
MSS-SP-75-WPHY60
:
:
:
Thickness upto
and inclusive of 12mm
100 F min.
Thickness beyond
12 mm
200 F
4.
For fillet welds complete welding may be carried out using the electrodes recommended for
filler passes.
5.
All weldments & HAZ shall meet the hardness requirements of 300 HV10 during procedure
qualification. If the hardness exceeds 300 HV10 the joints shall be heat treated at temp. 11001250 F for one hour. The heating and cooling rates shall be decided during procedure
qualification subject to a maximum of 200 C/Hr. Hardness testing shall be carried out by
Vickers hardness tester during welding procedure qualification test only. No hardness test is
required for production welds.
6.
7.
E7018-G
52.7 kg/mm2
20 ft. lb. at 0C
E7018-I
52.7 kg/mm2
E6010
E6018
20 ft. lb. at 0C
All the weldments & HAZ shall meet the impact test requirement of 20 ft. lb at 0C.
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EDITION : 1
ANNEXURE-2
1.0
1.1
Preparation
Having passed the visual and the non destructive inspection, the test weld shall be subjected
to mechanical test.
After satisfactory completion of all visual and non destructive testing the procedure test weld
shall be set aside for a period not less than 24 hours. No further work on the test weld and no
cutting of test specimens from the weld be performed till a period of at least 24 hours has
expired.
Weld specimens, for pipe diameter greater than or equal to 12.3/4" shall be taken from the
positions indicated in Fig. 1 of this specification from areas as free from defects as possible.
For this reason it is necessary to take the previous non destructive tests into account. The
minimum no. of tests to be carried out is given in Table-I of this specification.
The test shall be carried out at laboratories approved by COMPANY. The specimens shall be
prepared in accordance with the figure given in the paragraphs which refer to the individual
test.
Table-I
TYPE AND NUMBER OF TEST SPECIMENS FOR
PROCEDURE QUALIFICATION TEST
Pipe Size,
Out-side
diameter
Inches
Under 2 3/8
2 3/8 to 4
incl.
Over 4 less
than 12 3/4
12 3/4 and
over
4 and
smaller
Over 4 less
than 12 3/4
12 3/4 and
over
Tensil
e API
Tensil
e ISO
Nick
Break
Number of Specimens
Root
Face
Side
Macro
Bend
Bend
Bend
Hardness
Impa
ct
Total
0
0
0
0
0
0
4
4
12
24
24
44
12
24
24
44
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EDITION : 1
Tensile Strength
Specimens for pipe diameter over 12 3/4" shall be taken from the position indicated in
Fig. 1 of this specification. Two API type specimen shall be taken for pipe diameter
greater than or equal to 12 3/4".
1.3
Nick-Break Test
1.3.1
Preparation
Specimens for nick-break test with notches thus worked can break in the base metal,
instead of in the fusion zone; therefore an alternative test piece may be used after
authorisation by the COMPANY with a notch cut in the reinforcement of outside weld
bead to a maximum depth of 1.5mm measured from the surface of the weld bead.
1.4
Macroscopic Inspection
1.4.1
Preparation
Specimens shall be taken from the positions indicated in Fig. 1 of this specification and
shall be prepared in accordance with ASTM E2 and E3.
The width of the macrosection has to be at least three times the width of the weld.
The section is to be prepared by grinding or polishing and etching to clearly reveal the
weld metal and heat effected zone.
1.4.2
Method
Specimens shall be carefully examined under the microscope with a magnification of at
least 25 times. The COMPANY may ask for a macrograph with 5 times magnification
for documentation purposes.
1.4.3
Requirements
Under macroscopic examination, the welded joints shall show good penetration and
fusion, without any defect exceeding the limits stated in the evaluation criteria of the
nick break test.
1.5
Hardness Test
1.5.1
Preparation
The prepared macrosection is to be used for hardness testing using the Vickers
method with 100 N (10 kg) load. Indentations are to be made along traverses each
approximately 1mm below the surface at both side of the weld.
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EDITION : 1
In the weld metal a minimum of 6 indentations equally spaced along the traverses are
to be made. The HAZ indentations are to be made along the traverses for
approximately 0.5mm each into unaffected material, and starting as close to the fusion
line as possible.
One indentation at each side of the weld along each traverse has to be made on
parent metal. Reference is made to fig. 3 of this specification. The indentation are to
be made in the adjacent region as well as on the opposite side of the macrosection
along the specified traverses.
1.5.2
Method
The test shall be carried out in accordance with Recommendation ISO R81, Vickers
hardness, using laboratory type machine controlled as per-recommendation of ISO R
146 and using a diamond pyramid penetrator set at 2.37 rad. (136) with a load of 100
N (10 kg).
1.5.3
Requirements
Hardness value shall not exceed 300 H VI0 . In case of a single reading slightly (+10
HV) higher than the specified limit, further indentations should be made to check if the
high value was an isolated case.
All the hardness values obtained from the heat effected zone shall not exceed 100 HV
with respect to the average hardness of the values obtained for the base metal.
If these additional tests mentioned above give a hardness within the specification limit,
the slightly higher value may be accepted.
1.6
1.6.1
Specimens shall be taken from the position indicated in Fig. 1 of this specification. The
test specimens will be prepared in accordance with ISO R 148. Charpy V-notch
specimens shall have dimensions as given in Fig. 3 of the specification.
Three test specimens shall be taken from each sample and they shall be cut and
worked so that their length is transversal and perpendicular to the weld bead with the
notch position as shown in Fig. 4 of this specification. The notch shall be perpendicular
to the roller surface. The test specimens width shall depend upon the pipe wall
nominal thickness as following :
------------------------------------------------------------------------------------------------------Nominal wall thickness in
Test Specimens width in
mm
mm
------------------------------------------------------------------------------------------------------> 12
12
------------------------------------------------------------------------------------------------------> 9.5 and 12
7.5
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EDITION : 1
Test Method
The test shall be carried out as indicated in ISO R 148 "Beam Impact Test V-notch.
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall than be placed in the testing machine
and broken within 5 seconds of their removal from the batch.
1.6.3
Requirements
The impact energy shall be greater or equal to :------------------------------------------------------------------------------------------------------Test Specimens in
Average of
Minimum
mm
Three specimens
Single Value
Joule (min) (Note-2)
Joules (Note 1)
------------------------------------------------------------------------------------------------------10
27
22
7.5
21.5
17.5
5
18.5
15.0
2.5
10.0
8.0
------------------------------------------------------------------------------------------------------Note:
1)
Only one value is permitted to be lower than average upto the value specified.
1.7
A'
B'
C'
=2t
= 3 t + 1.6mm
= 50.8
The acceptance criteria shall however be as per para 2.643 and 2.653 of API-1104
sixteenth edition - May, 1983.
Note t = Thickness of Specimen (nominal)
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1.0
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ULTRASONIC INSPECTION
EDITION : 1
ANNEXURE-3
The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.
The CONTRACTOR appointed to carry out UT inspection shall supply the instruments
necessary for their execution on site.
1.2
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1.3
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EDITION : 1
1.4
Test Procedure
Circumferential weld shall be inspected from both sides using angled. Probes.
The surface with which the probe comes into contact shall be free of metal spatter,
dirt, iron oxide and scales of any type: therefore it shall be necessary to clean a strip at
least 50mm wide on both sides of the weld with steel - wire brushes and anyhow the
cleaned strip must be atleast wide enough to allow full skip examination.
If during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam
transducer in order to check whether any manufacturing defects are present which
could have interfered with the ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following :
b)
continuous operation
All the instruments and equipment shall be approved by the COMPANY before
being used. The COMPANY has the authority to reject any item which is
considered unsuitable. The decision of the COMPANY is final.
The
CONTRACTOR appointed to carry out ultrasonic inspection shall also ensure
the operational efficiency and maintenance of the instruments and equipment,
and shall immediately substitute any item rejected by the COMPANY.
All the instrument and equipment necessary for carrying out ultrasonic
inspection on site shall satisfy the requirements laid down by the public board
of institutions which regulate "safety at work".
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EDITION : 1
Ultrasonic Instruments
The ultrasonic instruments :
1.6
Shall be each pulse type, able to generate, receive and display, on the screen a
cathode ray tube (CRT) pulse, at frequencies between 1 and 6 mhz. The useful
part of the CRT screen shall be at least 70m wide and at least 50mm high.
The regulation control shall be accurate to within 1 dB and this accuracy shall
be certified by the instrument manufacturer.
Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to
the type of steel, the diameter the thickness of the pipeline and to the joint design.
1.7
In addition, the calibration piece shall have a hole, 2mm in diameter, passing through
its thickness and positioned so that during calibration the echoes returning from the
two grooves do not interfere with those returning from the hole.
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EDITION : 1
Calibration
For a precise check of the sound paths necessary for a full inspection of the weld joint,
the probe shall be moved (half skip and full skip distance) until internal and external
notches on the test piece are detected (see Fig. 5 of this specification).
The relevant defect limits the path lengths on the time base. The calibration of
reference sensitivity is obtained by utilising the through drilled test hole in the
thickness of the reference block to draw the distance amplitude correction curve
relevant to the test probe.
Calibration shall be carried out according to the following procedure : place its internal
vertex until the maximum height of echo is displayed on the screen; this echo is
adjusted to 80% of full screen height by means of the sensitivity adjuster set in dB.
Without varying the amplification, the probe placed at full skip distance from the hole
is moved to detect the external vertex the hole until the maximum height of echo is
obtained. The straight line connecting the peaks of the two echoes obtained by the
above procedure, represents the 100% reference level, while the one connecting the
two points at half height of the same echoes represents "50% reference level".
The two straight lines shall be marked on the screen with a pen. Calibration shallbe
repeated each time tests are re-started at intervals not longer than 30 minutes during
normal operations; each time the conditions fixed in advance are altered. This
calibration is applicable provided that the crystal of the probe is 8 x 9mm size. Should
this size of the crystal be different, the value of the sensitivity obtained from the
calibration by a crystal of a different size shall be brought to the value of sensitivity
obtained from the calibration by a 8 x 9mm crystal. The sensitivities of the two
different size probes shall be compared through the echoes obtained on the notch of
the test piece with the probe position at half skip of the distance.
1.9
1.10
1.11
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If, under these conditions, the height of the defer echo is equal to or greater than that
of the reference echo, the defect shall be evaluated. If the defect has also been
detected by the radiographic and or visual examination, the dimensions shall be
judged according to the type of examination which detects the greater defects.
Returns which are less than 50% of the reference echo, will not be considered. It
returns are above 50% but lower than 100% of the reference echo, and if the operator
has good reasons to suspect that the returns are caused by unfavorably oriented
cracks, he shall inform the COMPANY. Moreover, when there is a defect to be repaired
such defect shall be removed for a length corresponding to the one where no more
return echo is given.
1.12
Other Equipment
The use of rules calibrated in centimeters, attached if possible to the probe, for the
precise location of the position of welding defects, it recommended. Defect location is
effected by measuring the projection distance between the probe output and the
reflecting surface.
The operators carrying out the tests shall have besides the probing instrument, tools
for cleaning the pipe surface (files, brushes, etc.) as well as the coupling liquid or paste
appropriate for the temperature of the section to be examined.
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ANNEXURE-4
RADIOGRAPHY
1.0
SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the
main pipeline. The welded joints shall include the following :
2.0
i)
Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii)
Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.
iii)
iv)
Terminal Piping.
APPLICABLE STANDARDS
This specification shall apply in conjunction with the following (all latest edition) :
i)
ii)
ANSI B31.8, code for Gas Transmission and Distribution Piping Systems.
iii)
iv)
v)
vi)
3.0
PROCEDURE
3.1
3.2
Lead foil intensifying screens, at the rear of the film shall be used in all
exposures.
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ii)
iii)
iv)
3.3
The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior
to use.
3.4
3.5
All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved
format. The details of the radiographs alongwith the joint identification number shall
be duly entered in a register and signed by the CONTRACTOR and submitted to the
COMPANY for approval.
3.6
When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each
exposure shall not exceed the values given in Table 4 of API 1104. The minimum film
overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on
nominal pipe sizes of 2 inch and smaller provided that the source to film distance used
is a minimum of 12 inches.
3.7
3.8
Three copies of the exposure charts relating to material thickness, kilo voltage, source
to film distance and exposure time shall also be made available to aCOMPANY by the
CONTRACTOR.
3.9
The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiography
number (2) approximate chainage of weld location, (3) whether or not the welds meet
the specified acceptance standards and (4) the nature and approximate location of
unacceptable defects observed. It must be possible to relate to a particular butt weld
and welder on piping drawing and pipeline alignment drawing.
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3.10
3.11
The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room
with controlled temperature, film viewer etc. to enable the COMPANY to examine the
radiographs.
3.12
3.13
COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.
3.14
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0
RADIATION SOURCE
4.1
4.2
Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360).
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40mm at the ends of
each film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
5.0
LEVEL OF QUALITY
The quality level of radiographic sensitivity required for radiographic inspection shall be
at least equivalent to the values in Figure-6.
6.0
PENETRAMETERS
6.1
The image quality indicator (abbreviation : IQI) shall be used for the qualification of
the welding procedure and during normal line production. Radiographic sensitivity shall
be measured with the wire image quality indicator (Penetrameter). The penetrameter
shall be selected according to DIN 54109 or ISO 1027. For radiographs made with the
source on the outside, a penetrameter shall be placed on each side of the film with the
smaller wire of the penetrameter turned towards the end of the film itself. When a
complete weld is radiographed in a single exposure using a source inside the piping,
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8.0
8.1
All unexposed films shall protected and stored properly as per the requirements of API
1104 standard and ASTM E 94.
8.2
The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging
radiation prior to and following the use of the film for radiographic exposure.
9.0
RE-RADIOGRAPHY
9.1
9.2
All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
in the same manner as that followed for the original welds. In addition, the repaired
weld area shall be identified with the original identification number plus the letter `R'
to indicate the repair.
9.3
When evaluating repair film, radiographers shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original defect
removed.
9.4
The COMPANY will review prior to any repair of welds, all the radiographs of welds
which contain, according to the CONTRACTOR's interpretation, unacceptable defects.
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The final disposition of all unacceptable welds shall be decided by the COMPANY.
10.0
QUALIFICATION OF RADIOGRAPHERS
10.1
Pipeline radiographers shall be qualified in according with the requirement of API 1104
and to the full satisfaction of COMPANY.
10.2
Certification of all the radiographers, qualified as per 10.1 above, shall be furnished by
the CONTRACTOR to the COMPANY before a radiographer will be permitted to perform
production radiography. The certificate record shall include :
i)
ii)
iii)
iv)
v)
10.3
The radiographers shall be required to qualify with each radiographic procedure they
use, prior to performing the work assigned to him in accordance with the specification.
11.0
PRESERVATION OF RADIOGRAPHS
11.1
The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographers shall be presented in suitable folders for
preservation alongwith necessary documentation.
11.2
12.0
12.1
CONTRACTOR shall make necessary arrangement at his own expense, for providing
the radiographic equipment, radiographic films and the accessories for carrying out the
radiographic examination for satisfactory and timely completion of the job.
12.2
For carrying out the mainline radiographic examination the CONTRACTOR shall be
equipped with suitable mobile/ stationary type with rooms. These shall have all the
required facilities for film processing. Film viewer used shall be equipped with the film
illuminator that has a light source of sufficient intensity and can be suitably controlled
to allow viewing film densities upto 4.0 without damaging the film.
13.0
RADIATION PROTECTION
13.1
CONTRACTOR shall be responsible for the protection and personal monitoring of every
man with or near radiation sources.
13.2
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13.3
14.0
14.1
The safety provisions shall be brought to the notice of all concerned by display on a
notice board at prominent place at the work spot. The person responsible for the
"safety" shall be named by the CONTRACTOR.
15.0
15.1
16.0
16.1
CONTRACTOR shall maintain first aid facilities for its employees and those of its subcontractors.
16.2
CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. shall be posted
prominently in CONTRACTOR's field office.
16.3
All critical industrial injuries shall be reported promptly to the COMPANY and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.0
NO EXEMPTION
17.1
Not withstanding the above there is nothing in these clauses to exempt the
CONTRACTOR from the operation of any other act or rules in force.
Rev. : 0
Edition : 1
SPECIFICATION
FOR
SHOP & FIELD PAINTING
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SL. NO.
DESCRIPTION
CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
7.1
GENERAL
SCOPE
CODES & STANDARDS
EQUIPMENT
SURFACE PREPARATION
PAINT MATERIALS
PAINTING SYSTEMS
PRE-ERECTION/ PRE-FABRICATION AND SHOP PRIMING FOR CARBON STEEL, LOW
TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL STRUCTURES, PIPING
AND EQUIPMENT ETC.
7.2
REPAIR OF PRE-ERECTION/ FABRICATION AND SHOP PRIMING AFTER ERECTION/
WELDING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY
STEEL, ITEMS IN ALL ENVIRONMENTS.
8.0
FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON
STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)
9.0
FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW
TEMPERATURE CARBON STEEL AND LOW ALLOY STEEL)
10.0
FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREA (FOR CARBON STEEL, LOW
ALLOY STEEL) EXTERNAL SURFACE OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOERS, PIPING, PUMPS, TOWERS, COMPRESSORS, FLARE LINES,
STRUCTURAL STEEL ETC.
11.0
FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL
ENVIRONMENTS
12.0
FIELD PAINT SYSTEM FOR CARBON STEEL AND LOW ALLOY STEEL STORAGE TANK
(INTERNAL)
13.0
COATING SYSTEM FOR EXTRNAL SIDE OF UNDERGROUND CARBON STEEL, PLANT
PIPING AND TANKS.
14.0
PAINTING UNDER INSULATION FOR (HOT, COLD & SAFETY) CARBON STEEL LOW
TEMPERATURE CARBON STEEL & STAINLESS STEEL PIPING AND EQUIPMENT IN ALL
ENVIRONMENT
15.0
INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS/ CONDENSERS.
16.0
FIELD PAINTING SYSTEM FOR GI TOWERS/ NON-FERROUS TUBE SHEET
17.0
STORAGE
18.0
COLOURS CODE FOR PIPING
19.0
IDENTIFICATION OF VESSELS, PIPING ETC.
20.0
PAINTING FOR CIVIL DEFENCE REQUIREMENTS
21.0
INSPECTION AND TESTING
22.0
GUARANTEE
23.0
QUALIFICATION CRITERIA O PAINTING CONTRACTOR.
24.0
PROCEDURE FOR APPROVAL OF NEW PAINT MANUFACTURERS.
ANNEXURE-I- LIST OF RECOMMENDED MANUFACTURES
ANNEXURE-II- LIST OF RECOMMENDED MANUFACTURES PRODUCTS.
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Dec. 2008
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1.0
GENERAL
1.1
These technical specifications shall be applicable for the work covered by the
contract, and without prejudice to the various codes of practice, standard
specifications etc. it is understood that contractor shall complete the work in all
respects with the best quality of materials and workmanship and in accordance
with the best engineering practice and instructions of Engineer-in-charge.
1.2
2.0
SCOPE
Scope of work covered in the specification shall include, but not limited to the
following.
2.1
This specification defines the requirements for surface preparation, selection and
application of paint on external surfaces of equipment, vessels, machinery,
piping, ducts, steels structures, external & internal protection of storage tanks for
all services RCC Chimney & MS Chimney with or without refractory lining and
flare lines etc.
2.2
Extent of Works
2.2.1
The following surface and materials shall require shop, pre-erection and field
painting.
a.
b.
All uninsulated carbon and low alloy piping fitting and valves (including
painting of identification marks), furnace, ducts and stacks.
c.
d.
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2.2.2
e.
f.
g.
h.
i.
Supply of all primers, paints and all other materials required for painting
other than owners supply.
j.
k.
Painting under insulation for carbon steel and stainless steel as specified.
l.
The following surface and materials shall not be painted unless otherwise
specified:
a.
b.
c.
2.3
Documents
2.3.1
The contractor shall perform the work in accordance with the following
documents issued to him for executions of work.
a.
b.
c.
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2.4
Unless otherwise instructed final painting on pre-erection/ shop primed pipes and
equipments shall be painted in the field, only after mechanical completion and
testing on system are completed as well as, after completion of steam purging
wherever required.
2.5
Changes and deviations required for any specific job due to clients requirement
or otherwise shall be referred to MECON for deviation permit.
3.0
3.1
Without prejudice to the provision of clause 1.1 above and the detailed
specifications of the contract, the following codes and standards shall be
followed for the work covered by this contract.
3.2
IS:5
Colour coding
IS-101
IS-2379:1990
ANSI A 13.1-1981
3.2.1
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3.2.2
3.2.3
3.2.4
3.2.5
3.3
The contractor shall arrange, at his own cost, to keep a set of latest edition of
any one of the above standards and codes at site.
3.4
b.
c.
d.
4.0
EQUIPMENT
4.1
All tools, brushes, rollers, spray guns, abrasive materials hand/ power tools for
leaning and all equipments, scaffolding materials, shot/ wet abrassive blasting,
water blasting equipments & air compressors etc. required to be used shall be
suitable for the work and all in good order and shall be arranged by the
contractor at site and in sufficient quantity.
Mechanical mixing shall be used for paint mixing operations in case of two pack
systems except that the Engineer-in-Charge may allow the hand mixing of small
quantities at his discretion.
5.0
5.1
General
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5.1.1
5.1.2
Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure
that a clean and dry surface is obtained. The minimum acceptable standard in
case of manual or hand tool cleaning shall be St. 2 or equivalent, in case of
mechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blast
cleaning it shall be Sa 2 or equivalent as per Swedish Standard SIS-0559001967/ ISO-8501-1-1988. Where highly corrosive condition exits, then blast
cleaning shall be Sa3 as per Swedish Standard.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent
prior to surface cleaning.
5.1.3
Blast cleaning shall not be performed where dust can contaminate surfaces
undergoing such cleaning or during humid weather conditions having humidity
exceeding 85%.
5.1.4
Irrespective of the method of surface preparation, the first coat of primer must be
applied on dry surface. This should be done immediately and in any case within
4 hours of cleaning of surface. However, at times of unfavourable weather
conditions, the Engineer-in-Charge shall have the liberty to control the time
period, at his sole discretion and / or to insist on recleaning, as may be required,
before primer application is taken up. In general, during unfavourable weather
conditions, blasting and painting shall be avoided as far as practicable.
5.1.5
The external surface of R.C.C. chimney to be painted be dry and clean. Any
loose particle of stand, cement, aggregate etc. shall be removed by rubbing with
soft wire brush if necessary, acid etching with 10-15% HCL solution about 15
minutes shall be carried out and surface must be thorought washed with water to
remove acid & loose particles then dry completely before application of paint.
5.2
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5.2.1
Blast Cleaning
5.2.1.1
5.2.1.2
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Water
Sand
Nozzle
:
:
:
Special equipments for water blast cleaning with abrasives now available shall
be used.
5.2.2
5.2.3
Rust, mill scale spatters, old coating and other foreign matter, shall be removed
by hammering, scrapping tools, emery paper cleaning, wire brushing or
combination of the above methods. On completion of cleaning, loose materials
shall be removed from the surface by clean rags and the surface shall be
brushed, swept, deducted and blown off with compressed air/ steam to remove
all loose matter. Finally the surface may be washed with water and dried for
effective cleaning.
5.3
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coat shall not be removed. The touch up primer and finishing coat(s) shall be
identified for application by Engineer-in-Charge.
5.4
Shop coated (coated with primer & finishing coat) equipment should not be
repainted unless paint is damaged.
5.5
Shop primed equipment and surface will only be spot cleaned in damaged
areas by means of power tool brush cleaning and then spot primed before
applying one coat of filed primer unless otherwise specified. If shop primer is not
compatible with field primer then shop coated primer should be completely
removed before applications of selected paints system for particular
environment.
5.6
For packaged units/ equipment, shop primer should be as per the paint system
given in this specification. However, manufacturers standard can be followed
after review.
5.7
5.7.1
5.7.2
Blast cleaned surface shall be coated with one complete application of primer as
soon as practicable but in no case later than 4 hrs. the same day.
5.7.3
5.7.4
Each coat shall be proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an
additional coat can applied without the development of any detrimental film
irregularities such as lifting or loose of adhesion of the under coat. Manufacturer
instruction shall be followed for intercoat interval.
5.7.5
When the successive coat of the same colour have been specified, alternate
coat shall be tinted, when practical, sufficiently to produce enough contrast to
indicate complete coverage of the surface. The tinting material shall be
compatible with the material and not detrimental to its service life.
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5.7.6
The equipment used shall be suitable for the intended purpose, shall be
capable of properly atomizing the paint to be applied, and shall be
equipped with suitable pressure regulators and gauges. The air caps,
nozzles, and needles shall be those recommended by the manufacturer
of the equipment for the material beign sprayed. The equipment shall be
kept in satisfactory condition to permit proper paint application.
b.
c.
d.
The pressure on the material in the pot and of the air at the gun shall be
adjusted for optimum spraying effectiveness. The pressure on the
material in the pot shall be adjusted when necessary for change in
elevation of the gun above the pot. The atomizing air pressure at the gun
shall be high enough to properly atomize the paint but not so high as to
cause excessive fogging of paint, excessive evaporation of solvent, or
less by overspray.
e.
Spray equipment shall be kept sufficiently clean so that dirt, dried paint,
and other foreign materials are not deposited in the paint film.
Any solvents left in the equipment shall be completely removed before
applying paint to the surface begin painted.
f.
g.
All runs and sags shall be brushed out immediately or the paint shall be
removed and the surface repainted.
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5.7.7
h.
i.
j.
k.
5.7.8
Brushes shall be of a style and quality that will enable proper application
of paint
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5.7.9
b.
Round or oval brushes are most suitable for rivets, bolts, irregular
surfaces and rough or pitted steel. Wide flat brushes are suitable for
large flat areas, but they shall not have width over five inches.
c.
d.
e.
f.
A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m longs
is hold under the pipe by two men. Liquid coating poured on the sling at each
side of the pipe. The men holding this sling move it up and down and walk slowly
forward while fresh coating is poured on the pipe and they manipulate the sling
so that an even coating is ontained all round the bottom. This work shall be done
vey carefully and by experienced personnel. There shall bot be any formation of
Whiskers and holes in the coating. The coating film shall be inspected by
mirror.
5.7.10
For each coat the painter should know the WFT corresponding to the specified
DFT and standardise the paint application technique to achieve the desired
WFT. This is to be ensured in the qualification trial.
5.8
5.8.1
No coat shall be applied unit the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without the
development of any film irregularities such as lifting or loss of adhesion of
undercoats. Drying time of the applied coat should not exced maximum specified
for it as a first coat; if it exceeds the paint material has possible deteriorated or
mixing is faulty.
5.8.2
No paint shall be force dried under condition which will cause checking, wrinkling
blistering formation of pores, or detrimentally after the condition of the paint.
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No drier shall be added to a paint on the job unless specifically called for in the
manufacturers specification for the paint.
Paint shall be protected from rain, condensation, contamination snow and
freezing until dry to the fullest extent practicable.
5.9
5.9.1.
Where paint has been damaged in handling and in transportation, the repair of
damaged coating of pre-creation/ fabrication shall be as given below.
5.9.2.
5.9.3
5.10
PAINT APPLICATION
5.10.1
Shop priming/ pre-erection priming with F9 of F12 shall be done only on blasted
surface.
5.10.2
Shop priming/ pre-erection priming with F-9 or F-12 shall be done only with
airless spray.
5.10.3
For large flat surface field painting shall be done by airless spray otherwise brush
can be used.
5.11
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5.12
Identify the environment from area classification details and chose the
appropriate table.
Identify the need of repair of shop primer and execute as per Table 7.2.
Documentation.
A written quality plan with procedure for qualification trials and for the actual
work.
Daily progress report with dedtails of weather condition, particular of application
no of coats and type of materials applied, anomolies, progress of work versus
programme.
Result of measurement of temperature relative humidity, surface profile, film
thickness, holiday detection, adhesion tests with signature of appropriate
authority.
Particular of surface preparation and paint application during trials and during the
work.
Details of non-compliance, rejects and repairs.
Type of testing equipments and calibration.
Code and batch numbers of paint material used.
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1.
2.
DESCRIPTION
ST.2
SSPC-SP2
ST.3
SSPC-SP3
REMARK
-DO-
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3.
DESCRIPTION
REMARKS
3.1
SA-3
SSPC-SP5
NACE#1
FIRST
QUALITY
3.2
SA 2
SSPC-SP10
NACE #2
SECOND
QUALITY
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3.3
DESCRIPTION
COMMERCIAL BLAST
BLAST CLEANING UNIT AT LEAST
TWOTHIRD OF EACH ELEMENT OF
SURFACE AREA IS FREE OF ALL
VISIBLE RESIDUES WITH DESIRED
SURFACE PROFILE.
3.4
BRUSH-OFF BLAST
BLAST CLEANING TO WHITE METAL
CLEANLINESS, REMOVAL OF ALL
VISIBLE RUST, MILL SCALE , PAINT &
FOREIGN MATTER, SURFACE PROFILE
IS NOT SO IMPORTANT.
SA-2
SSPC-SP-6
No. 3
SA-1
SSPC-SP-7
No. 4
THIRD
QUALITY
REMARKS
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6.0
PAINT MATERIALS
Paint manufacturers shall furnish all the characteristics of paint material
on printed literature, alongwith the test certificate for all the specified
characteristics given in this specifications. All the paint materials shall be
of first quality and conform to the following general characteristics as per
the table 6.1, 6.2 and 6.3.
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PAINT MATERIALS
TABLE NO.: 6.1 PRIMERS
S.
DESCRIPTION
No.
1.
Technical Name
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
P-2
P-4
P-6
7-8%
8-10
8-10
40%
40-50
8-10
1.3
30 minutes
Min.: 8 hrs.
Max.: no limitation
Min : 8 hrs
Max : No limitation
Not applicable
1.2
2 hrs.
Min.: 2 hrs.
Max.: 24 hrs.
Min : 4.6 hrs
Max : 24 hrs
Not applicable
1.4
After 30 mins.
Min.: 8 hrs.
Max.: 3-6 months
Min : 8 hrs
Max : 3-6 months
8 hrs.
60C
Not applicable
80C
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PAINT MATERIALS
TABLE NO.: 6.2FINISH PAINT
S.
No
1.
Technical Name
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
DESCRIPTION
F-2
F-3
F-6
F-7
Acrylic polyurethane
finish paint
Two-pack aliphatic
isocynate
cured
acrylic finish paint
Chlorinated
rubber
based finish paint
Single pack plasticised
chlorinated rubber
based medium with
chemical and weather
resistant pigments.
40%
30-40
40%
40-50
Epoxy-High build
finish paint
Tow- pack
polyamide/
ployamine cured
epoxy resin
medium suitable
pigmented.
62%
100-125
65%
100-125
10-13
8-10
5-6
5-2-6.5
1.3
1.2
1.4
1.5
1 hrs.
Overnight
Min.: Overnight (12)
hrs.
Max.: Unlimited
6-8 hrs.
30 minutes
8 hrs.
Min.: Overnight
Max.: Unlimited
3 hrs.
Overnight
Min.: Overnight
Max.: 5 day
4 hrs.
48 hrs.
Min.: 24 hrs.
Max.: 5 day
Not applicable
4-6 hrs.
4-6 hrs.
80C
60C
80C
125C
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PAINT MATERIALS
TABLE NO.: 6.3 FINISH PAINTS
S.
No
1.
F-8
F-9
F-11
F-12
Technical Name
Heat
resistant
synthetic
medium
based
two
pack
aluminum
paint
suitable upto 250C
dry temperature
2.
Heat resistant
synthetic medium
based two pack
aluminum paint
suitable upto 250C
3.
4.
72%
100-125
60%
65-75
25%
20-25
20%
20-25
6.0-7.2
8-9
10-12
8-10
1.4
2.3
1.2
1.1
3 hrs.
24 hrs.
Min.: 10 hrs.
Max.: 6 months
30 min.
12 hrs.
Min.: 8 hrs. at 20C
and 50% RH.
Max.: Unlimited
3 hrs.
12 hrs.
Min.: 16 hrs.
Max.: Unlimited
30 min.
24 hrs.
Min.: 16 hrs.
Max.: Unlimited
5.
6.
7.
8.
9.
DESCRIPTION
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S.
No
10.
11.
DESCRIPTION
Pot life (approx) at 30 C for
two component paints
(approx).
Temperature resistance
F-8
F-9
F-11
F-12
90 min.
4-6 hrs.
Not applicable
Not applicable
80C
400C
250 C
500 C
F-14: Specially for mulated polyamine cured coal tal epoxy suitable for-45C to 125C for application under insulation
F-15: Two pack cold curved epoxy phenolic coating suitable for 45C to 125C for application under insulation
F-16: Eoxy siloxane anser coat 738
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PAINT MATERIALS
TABLE NO. 6.4 FINISH PAINTS
Sl.
No.
1.
F-14
F-15
F-16
F-17
Technical name
Polyamine cured
coal tar epoxy
Two-component
Epoxy phenolic
coating
cured
with polyamine
adduct hardner
system (primer +
intermediate
coat + finish
paint)
Two component
solvent free type
high build epoxy
phenolic
/
novalac epoxy
phenolic coating
cured
with
Polyamine
adduct hardner
system.
2.
Specially
formulated
polyamine cured
coal tar epoxy
suitable
for
application
under insulation
3.
Volume
Solids
(minimum)
DFT
(Dry
Film
thickness) per coat
(minimum)
Theoretical covering
2
capacity in M / coat
/ litre (minimum)
Weight per liter in
kgs/litre (max paint)
(minimum)
Touch dry at 30C
(maximum)
70%
Two
pack
ambient
temperature
curing
epoxy
phenolic coating
system suitable
for
application
under insulation
of CS / SS
piping.
65%
Ambient
temperature
curing
Poly
Siloxane coating
/ High build cold
applied
inorganic
copolymer
based aluminum
coating suitable
for
under
insulation
coating of CS
and SS piping
for
high
temperature
service.
Amercoat
738
from
Ameron
Products, USA /
Berger 938 from
Berger
Paints
Ltd.,
or
Intertherm 751
CSA from Akzo
Nobel coating.
Note : 6
60%
Two component
solvent free type
high build epoxy
phenolic
/
novalac epoxy
phenolic coating
cured
with
Polyamine
adduct hardner
system.
98-100%
125 m
75 - 100 m
75 - 100 m
125- 150 m
5.5
6.5-8.5
6.0-8.0
6.5-8.0
1.5
1.7
1.3
1.7
4 hrs.
2 hrs.
1 hr.
2 hrs.
4.
5.
6.
7.
Description
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Sl.
No.
8.
9.
10.
11.
Description
F-14
F-15
F-16
F-17
24 hrs.
24 hrs.
16 hrs.
24 hrs.
Min. 6 hrs.
Max. 5 days
Min. 36 hrs.
Max. 21 days
Min. 16 hrs.
Max. 21 days.
4 hrs.
1.5 hrs.
Min. 16 hrs.
Max.
Not
applicable
1 hr.
-45C to 125C
under insulation
-45C to 125C
under insulation
(Note : 5)
Up to 400C for
CS & SS under
insulation
-45C to 150C
for
immersion
service
1 hr.
Notes:
1.
Covering capacity and DFT depends on method of application. Covering
capacity specified above are theoretical. Allowing the loose during the
application, minimum specified DFT should be maintained.
2.
All primers and finish coats should be cold cured and air drying unless otherwise
specified.
3.
4.
Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
6.4
7.0
PAINT SYSTEM
The paint system should vary with type of environment envisaged in and around
the plants. Three types of environment as given below are considered for
selection of paint system. The paint system is also given for specific
requirements.
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P-4
P-6
F-3
F-6
F-7
F-8
F-9
F-11
F-12
F-14
F-15
F-16
F-17
:
:
:
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TABLE 7.1: PRE-ERECTION/ PRE-FABRICATION AND SHOP PRIMING FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL, STEEL STRUCTURE, PIPING AND EQUIPMENT ETC.
S. No.
DESIGN TEMPERATURE IN
C
SURFACE
PREPARATION
PAINT SYSTEM
TOTAL
DFT
IN
MICRONS (MIN.)
REMARKS
No overcoating is to
be done
Finish Coat at Site
For Damaged Area
of more than 5 x 5
Cm2.
7.1.1
-90 TO 400
SSPC-SP-10
1 COAT OF F-9
65-75
7.1.2
7.1.3
401 To 500
-40 to 150 for Structures, hand rails and
Grating only
SSPC-SP-10
SSPC-SP-3
1 COAT OF F-12
1 COAT OF F-9 OR
2 COATS OF P-7 @
40 DFT / COAT
40-50
65-75 OF F-9
OR
80 (P-7)
TABLE 7.2:
S. No.
REPAIR OF PRE-ERECTION/ PRE- FABRICATION AND SHOP PRIMING AFTER ERECTION/ WELDING FOR CARBON STEEL
LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, ITEMS IN ALL ENVIRONMENT.
7.2.1
DESIGN TEMPERATURE IN
C
-90 TO 400
7.2.2
401 TO 550
SURFACE PREPARATION
SSPC-SP-3 (FOR
ONLY)
SSPC-SP-10
SSPC-SP-3
REPAIR
1 COAT OF F-9
TOTAL DFT IN
MICRONS (MIN.)
65-75
1 COAT OF F-12
20
PAINT SYSTEM
REMARKS
FOR
DAMAGED
AREA
OF
MORE
THAN 5X5 CM.
FOR
DAMAGED
AREA
OF
MORE
THAN 5X5 CM.
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TABLE 8.0:
FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL)
ALL NORMAL CORROSIVE AREAS SUCH AS OFF SITES EXTERNAL SURFACE OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, STRUCTURAL STEEL WORKS, RCC CHIMNEY WITH
OR WITHOUT REFRACTORY LINE INSIDE CHIMNEY (ALL ENVIRONMENTS), EXCLUDING TANK TOPS, FLARE LINES, D.M.
PLANTS, INTERIOR OF TANKS ETC. FLARE LINES FOR NORMAL CORROSIVE ENVIRONMENT ALSO TO NE PAINTED AS PER
TABLE 9.0
S.
NO.
PAINT SYSTEM
FIELD PRIMER
TOTAL
DFT IN
MICRONS
(MIN.)
65-75
DESIGN
TEMPERATUR
E IN C
SURFACE
PREPARATIO
N
8.1
-90 TO 15
SSPC-SP-10
REPAIR
OF
PRE-FABRICATION
PRIMER 1 COAT OF F-9 @65-75
DFT/ COAT
NONE
8.2
-14 TO 60
SSPC-SP-10
2 COATS OF F-3 @
40 DFT/ COAT
2 X 40 = 80
225
8.3
61 TO 80
SSPC-SP-10
REPAIR
OF
PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT + 2 COATS OF P-2 @ 40
DFT/ COAT
2 X 40 = 80
REPAIR
OF
PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT + 2 COATS OF P-6 @ 40
DFT/ COAT
2 X 40 = 80
1 COATS OF F-6 @
100 DFT/ COAT
245
FINISH PAINT
REMARKS
No over coating to be
done
follow
repair
procedure
only
on
damaged areas of preerection/ pre-fabrication
primer/ coating F-9
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S.
NO.
SURFACE
PREPARATIO
N
8.4
81 TO 250
SSPC-SP-10
REPAIR
OF
PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT
3 COATS OF F-11 @
20 DFT/ COAT
3 X 20 = 60
8.5
251 TO 400
SSPC-SP-10
REPAIR
OF
PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT
2 COATS OF F-12 @
20 DFT/ COAT
2 X 20 = 40
105
8.6
401 TO 500
SSPC-SP-10
2 COATS OF F-12 @
20 DFT/ COAT
2 X 20 = 40
80
NOTE 1 :
NOTE 2 :
NOTE 3 :
PAINT SYSTEM
FIELD PRIMER
TOTAL
DFT IN
MICRONS
(MIN.)
125
DESIGN
TEMPERATUR
E IN C
FINISH PAINT
REMARKS
FOR MS CHIMNEY OR WITHOUT REFRACTORY LINING 8.3, 8.4 AND 8.5 SHALL BE FOLOWED.
FOR EXTENAL SURFACE OF RCC CHMNEY: 2 COATS OF F-6 @ 100 DFT/ COAT TO OBBTAIN 2 X 100=200
SHALL BE APPLIED AFTER MAKING SURFACE PREPARATION AS PER GUIDELINES IN 1.5
WHEREVER REQUIRED S.NO. 8.3 SHALL BE USED FOR 14C TO 80C AND S.NO. 8.2 WILL BE DELETED.
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TABLE 9.0: FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL)
FOR ALL CORROSIVE AREAS ABOVE GROUND WHERE H2S, SO2 FUMES OR SPILLAGES OF ACID/ ALKALI/ SALT
ARE LIKELY TO COME IN CONTACT WITH SURFACE SUCH AS EXTERNAL SURFACE OF UNINSULATED COLUMNS,
VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, FLARE LINES,
STRUCTURAL STEEL ETC.
S.
NO.
9.1
DESIGN
TEMPERATUR
E IN C
-90 TO 15
SSPC-SP-10
REPAIR OF PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT
NONE
9.2
-14 TO 80
SSPC-SP-10
REPAIR OF PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT + 1 COATS OF P-6
@40 DFT/ COAT
9.3
81 TO 400
SSPC-SP-10
REPAIR OF PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT
9.4
401 TO 500
SSPC-SP-10
1 COATS OF F-6
@ 100
DFT/
COAT
+ 1 COAT OF F-2
@ 40
DFT/
COAT
2 COATS OF F-12
@ 20 DFT/
COAT
2 X 20 = 40
2 COATS OF F-12
@ 20 DFT/
COAT
SURFACE
PREPARATION
PAINT SYSTEM
FIELD PRIMER
FINISH PAINT
TOTAL DFT
IN MICRONS
(MIN.)
65-75
225
105
80
REMARKS
Repair of pre-erection/
pre fabrication primer
shall be done wherever
damage is observed.
Surface preparation is
required only for repairing
of damaged pre-erection/
fabrication primer
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TABLE 10.0: FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE (FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL) EXTERNAL SURFACES OF UNINSULATED COLUMNS,
VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING PUMPS, TOWERS, COMPRESSORS, FLARE
LINES, STRUCTURE STEEL ETC.
EXPOSED TO SPILLAGE OR FUMES OF HCL H2S04, SALTY WATER IMPINGEMENT, CHLORIDE ETC.
S.
NO.
DESIGN
TEMPERATUR
E IN C
SURFACE
PREPARATION
PAINT SYSTEM
FIELD PRIMER
10.1
-90 TO 15
SSPC-SP-10
REPAIR OF PRE-FABRICATION
PRIMER 1 COAT OF F-9 65-75
DFT/ COAT
NONE
10.2
-14 TO 80
SSPC-SP-10
REPAIR OF PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT + 1 COATS OF P-6
@40 DFT/ COAT
10.3
81 TO 400
SSPC-SP-10
REPAIR OF PRE-FABRICATION
PRIMER 1 COAT OF F-9 @ 65-75
DFT/ COAT
10.4
401 TO 500
SSPC-SP-10
2 COATS OF F-6
@ 100
DFT/
COAT = 2 X 100=
200 + 1 COAT OF
F-2 @ 40 DFT/
COAT
2 COATS OF F-12
@ 20 DFT/
COAT
2 X 20 = 40
3 COATS OF F-12
@ 20 DFT/
COAT
2 X 20 = 40
FINISH PAINT
TOTAL
DFT IN
MICRONS
(MIN.)
65-75
345
105
80
REMARKS
Repair of pre-erection/
fabrication primer shall be
followed. No over coating is
allowed
Surface preparation is
required only for repairing
of damaged pre-erection/
fabrication primer.
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TABLE 11.0 :
S. NO.
FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL
ENVIRONMENTS.
DESIGN
PAINT SYSTEM
SURFACE
TOTAL DFT IN
TEMPERATURE IN
PREPARATION
MICRONS (MIN.)
FILED PRIMER
FINISH PAINT
C
1.1
EXTERNAL SHELL. WIND GIRDERS APPARATUSES, ROOF TOPS OF ALL GROUND TANK INCLUDING TOP SIDE OF
FLOATING ROOF
OF OPEN TANK AS WELL AS COVERED FLOATING ROOF AND ASSOCIATED STRUCTURAL WORK
ROLLING AND STATIONARY LADDERS,
SPIRAL STAIRWAYS, HAND TAILS FOR ALL ENVIRONMENTS FOR GRUDE OIL,
LDO, HSD, ATF KEROSENE, GASOLINE, MOTOR SPIRIT, DM
WATER, FIREWATER, RAW WATER, POTABLE WATER, ACIDS,
ALKALIS SOLVENTS AND CHEMICALS ETC.
11.1.1 -14 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 1 COATS OF F-6 285
F-6
should be
65-75
DFT/ @ 100
DFT/
suitable
for
COAT + 1 COATS COAT + 2 COATS
occasional water
OF P-6 @40 OF
F-2 @ 40
immersion
DFT/ COAT
DFT/ COAT
65 X 40 = 105
2 X 40 = 80
11.1.2 81 TO 500
SSPC-SP-10
1 COAT OF F-9 @ 2 COATS OF F-12 105
65-75
DFT/ @ 20 DFT/
COAT
COAT
2 X 20 = 40
11.2
EXTERNAL SURFACE OF BOTTOM PLATE (SOIL SIDE) FOR ALL STORAGE TANKS.
11.2
-14 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 3 COATS OF F - 7 365
F7
should
be
65-75
DFT/ @ 100 DFT/
suitable
for
COAT
COAT
immersion service
3 X 100 = 300
of the products
given.
REMARKS
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TABLE 12.0 :
FIELD PAINT SYSTEM FOR CARBON STEEL AND ALLOY STORAGE TANK: (INTERNAL)
PAINT SYSTEM
DESIGN TEMPERATURE IN
SURFACE PREPARATION
TOTAL DFT IN
REMARKS
C
MICRONS (MIN.)
FILED PRIMER
FINISH PAINT
INTERNAL SURFACE OF UNDERSIDE OF FLOATING ROOF, INTERNAL STRUCTURAL OF CONE ROOF, BOTTOM PLATE, ROOF STRUCTURE,
STEEL, LADDERS SUPPORTS FOR STORING GRUIDE OIL, LDO AND HSD (EXCLUDING WHITE OIL PRODUCTS)
F7 should be suitable for
12.1
-14 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 65- 3 COATS OF F-7 @ 100 365
immersion service of the
75 DFT/ COAT
DFT/ COAT
products given.
3 X 100 = 300
12.2
BARE SHEEL OF INSIDE FLOATING ROOF TANK AND CONE ROOF TANK FOR PRODUCTS MENTIONED IN 12.1
12.2.1
-14 TO 80
SSPC-SP-10
PHOSPHATING
2 COATS OF @10
20
TREATMENT
WITH 2 X 10 = 20
PHOSPHATING
CHEMICALS
(2
COATS)
12.3
FLOATING CONE ROOF TANKS FOR PETROLEUM PRODUCTS SUCH AS ATF, GASOLINE, NAPHTHA, KEROSENE, MOTOR SPIRIT,
INSIDE
OF BOTTOM PLATE, UNDERSIDE OF FLOATING ROOF AND SHELL ABOVE MAXIMUM LIQUID LEVEL AND STRUCTURAL STEEL ,
LADDERS ETC.
F-6 should be suitable for
12.3.1
-14 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 65- 3 COATS OF F-6 @ 100 365
immersion
service
of
75 DFT/ COAT
DFT/ COAT
petroleum produce like
3 X 100 = 300
S. NO.
12.4
12.4.1
BARE SHELL OF INSIDE OF FLOATING CONE ROOF TANKS FOR PRODUCTS MENTIONED IN 12.3
-14 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 65- NONE
75 DFT/ COAT
65-75
12.5
INTERNAL PROTECTION IF FIXED ROOF TYPE STORAGE TANKS FOR POTABLE WATER: INSIDE OF SHELL, UNDER SIDE OF ROOF AND ROOF STRUCTURE
INSIDE SURFACE BOTTOM PLATE AND STRURAL STEEL WORKS, LADDERS, WALKWAYS, PLATFORMS ETC.
12.5.1
-14 TO 80
SSPC-SP-10
2 COAT OF F-6 @ 40 2 COATS OF F-6 @ 100 280
F-6 shall be suitable for
DFT/ COAT
DFT/ COAT
immersion service.
2 X 40 = 80
2 X 100 = 200
12.6
D. M. (DEMINERALISED WATER) AND HYDROCHLORIC ACID (HCL): INTERNAL SHELL, BOTTOM PLATE AND ALL ACCESSORIES
12.6.1
-14 TO 80
SSPC-SP-10
EBONITE RUBBER LINING AS PER SMMS SPECIFICATION 6-06-204
12.7
EG TANKS (INTERNAL SHELL, BOTTOM PLATE ROOF AND ALL ACCESSORIES)
12.7.1
ALL
SSPC-SP-10
3 COATS VINYL CHLORIDE CO-POLYMER 225
AMERCOAT 23 @ 75 / COAT
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S. NO.
12.8
12.8.1
12.9
12.9.1
DESIGN TEMPERATURE IN
SURFACE PREPARATION
PAINT SYSTEM
C
FILED PRIMER
FINISH PAINT
INSIDE PONTOON AND INSIDE OF DOUBLE DECK OF ALL FLOATING ROOFS.
-14 TO 80
SSPC-SP-3
1 COAT OF F-8 @ 1 COATS OF F-6 @ 100
100 DFT/ COAT
DFT/ COAT
1 X 100 = 100
INTERNAL SURFACE OF AMINE & SOUR WATER STORAGE TANKS
-14 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 65- 2 COATS OF F-15 @ 75
75 DFT/ COAT
DFT/ COAT
2 X 40 = 80
2 X 75 = 150
TOTAL DFT IN
MICRONS (MIN.)
200
215-225
REMARKS
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TABLE 13.0 :
S. NO.
13.1
13.1.1
13.1.1.1
13.1.2
13.1.2.1
13.2
13.2.1
13.3
13.3.1
13.3.2
COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL PLANT PIPING
AND TANKS
DESIGN TEMPERATURE
SURFACE PREPARATION
PAINT SYSTEM
IN C
PRIMER
FINISH PAINT
CARBON STEEL PLANT PIPING (UNDERGROUND)
YARD COATING
25 TO 60
SSPC-SP-10
1
COAT
OF 4mm THICK COALTAR
SYNTHETIC FAST COATING WRAPPING
DRYING
PRIMER AS PER AWWA-C-203
TYPE-B AS PER IN 2 LAYER OF EACH
2mm THICKNESS
AWWA-C-203
(1991)
OVER THE DITCH COATING
LAYERS
OF
25 Tto 60
SSPC-SP-10
1
COAT
OF 2
BASED
SYNTHETIC FAST COALTAR
DRYING
PRIMER TAPE COATING AS
TYPE-B AS PER PER AWWA-C-203.
AWWA-C-203
(1991)
CARBON STEEL PLANT PIPING (UNDERGROUND)
61 TO 400
SSPC-SP-10
1 COAT OF F-9 @ NONE
65-75 DFT/ COAT
EXTERNAL SIDE OF UNINSULATED UNDERGROUND STORAGE TANKS:
40 TO 80
SSPC-SP-10
1 COAT OF F-9 @ 3 COATS OF F-7 @
65-75 DFT/ COAT
100 DFT/ COAT
3 X 100 = 300
-90 TO 41
SSPC-SP-10
1 COAT OF F-9 @ NONE
81 TO 400 c
65-75 DFT/ COAT
1 COAT OF
NONE
AMERCOAT 738 @
250 DFT/ COAT
TOTAL DFT IN
MICRONS (MIN.)
4mm
4 mm
65-75
365
65-75
250
REMARKS
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EDITION : 1
TABLE 14.0 :
S. NO.
14.1
14.1.1
14.1.2
14.2
PAINTING UNDER INSULATION FOR INSULATED (HOT COLD SAFETY CARBON STEEL, LOW
ALLOY STEEL, LOW TEMPERATURE CARBON STEEL & STAINLESS STEEL PIPING,
STORAGE TANKS EQUIPMENTS IN ALL ENVIRONMENT
DESIGN TEMPERATURE
IN C
SURFACE PREPARATION
PAINT SYSTEM
PRIMER
FINISH PINTS
TOTAL DFT IN
MICRONS (MIN.)
REMARKS
INSULATED CARBON STEEL, LOW ALLOY STEEL AND LTCS PIPING AND EQUIPMENT & TANKS
-4 TO 125
OPERATING
TEMPERATURE 45 TO
125 C BUT DESIGN
TEMPERATURE 126-400
C
SSPC-SP-10
SSPC-SP-10
REPAIR OF PREFABRICATION
PRIMER F-9 @ 6575 DFT
2 COATS OF F-14 @
125 DFT/ COAT
REPAIR OF PREFABRICATION
PRIMER F-9 @ 6575 DFT
3 COATS OF F-12 @
20 DFT/ COAT
315
2 X 125 = 250 OR 3
COATS OF F-15= 3 X
80=240
105-115
3 X 20 = 60
14.2.1
BELOW 0 C TO ALL
MINUS TEMPRATURE
ALUMINUM SHEETING WITH ALUMINUM FOIL AND CHLORIDE FREE MINERAL SEALANT
CONTAINING BARIUM CHROMATE SHALL BE APPLIED
14.2.2
0 TO 120
SSPC-SP-10
(
15-25
SURFACE PROFILE)
NONE
2 COATS OF F-14 @
125 DFT/ COAT
2 X 125 = 250 OR 3
COATS OF F-15= 3 X
80 = 240
250
If
the
piping
&
equipments are already
erected then surface
shall be prepared by
cleaning with emery
paper and wash/ flush
with chloride free DM
water
followed
by
wiping with organic
solvent
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S. NO.
14.2.3
DESIGN TEMPERATURE
IN C
121 TO 500
SURFACE PREPARATION
SSPC-SP-10
PAINT SYSTEM
PRIMER
FINISH PINTS
NONE
3 COATS OF F-12 @
20 DFT/ COAT
TOTAL DFT IN
MICRONS (MIN.)
REMARKS
60
No
pre
erection
primer to be applied
3 X 20 = 60
14.2.4
501 TO 1000
SSPC-SP-10
NONE
1
COAT
OF
AMERCOAT 738 @
150 DFT/ COAT
150
14.2.5
CYCLIC SERVICE-196 TO
480 EXCEPTING 45 TO
120
SSPC-SP-10
NONE
1
COAT
OF
AMERCOAT 738 @
150 DFT/ COAT
150
14.3
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EDITION : 1
TABLE 15.0 :
S. NO.
15.1
15.2
DESIGN
TEMPERATURE IN C
Upto 65
Upto 65
NON FERROUS AND
BRASS
TUBE
SHEETS
SURFACE PREPARATION
SSPC-SP-10
SSPC-SP-10
PAINT SYSTEM
PRIMER
FINISH PAINT
1 COATS OF F-6 @ 2 COATS OF F-7 @
40 DFT/ COAT
125 DFT/ COAT
2 x 125 = 250
1 COATS OF P-4 @ 2 COATS OF F-7 @
125 DFT/ COAT
8 DFT/ COAT
1 COATS OF P-6 @ 2 x 125 = 250
40 DFT/ COAT
TOTAL DFT IN
MICRONS (MIN.)
290
300
REMARKS
For C. S.
FOR
FERROUS
SURFACE
NON
TABLE 16.0 FIELD PAINTING SYSTEM FOR GI TOWERS/ NON-FERROUS TUBE SHEET
S. NO.
16.1
16.2
DESIGN
TEMPERATURE IN C
Upto 65
Upto 65
NON FERROUS AND
BRASS
TUBE
SHEETS
SURFACE PREPARATION
SSPC-SP-10
SSPC-SP-10
PAINT SYSTEM
FILED PAINT
FINISH PAINT
1 COATS OF P-4 @ 2 COATS OF F-2 @ 40
8-10 DFT/ COAT + DFT/ COAT
1 COAT OF P-6 @ 2 x 40 = 250
4 DFT/ COAT
1 COATS OF P-4 @ 2 COATS OF F-7 @
125 DFT/ COAT
8 DFT/ COAT
1 COATS OF P-6 @ 2 x 125 = 250
40 DFT/ COAT
TOTAL DFT IN
MICRONS (MIN.)
130
300
REMARKS
SHADE AS PER
DEFENCE
REQUIREMENTS
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EDITION : 1
17.0
STORAGE
17.1
18.0
18.1
SR. NO.
18.1.1
18.1.2
GROUND
COLOUR
FIRST
COLOUR BAND
SECOND
COLOUR
BAND
Sea Gree
-do-do-do-do-do-do-do-doFire red
Sea Green
French Blue
Gulf Red
French Blue
Gulf Red
Light Brown
Dark Grey
Ganary Yellow
Oxide Red
Crimson Red
White
Signal Red
Signal Red
-
Aluminiumto
IS2339
-do-do-do-do-
Signal Red
French Blue
Gulf Red
Canary Yellow
Grey
Canary Yellow
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EDITION : 1
SR. NO.
18.1.3
18.1.4
18.1.5
18.1.6
DESCRIPTION
GROUND
COLOUR
FIRST
COLOUR BAND
SECOND
COLOUR
BAND
COMPRESSED AIR
PLANT AIR
INSTRUMENT AIR
NITROGEN
OXYGEN
CO2
GASES
FUEL GAS AND SOUR GAS
CHARGE GAS
RESIDUE GAS, LPG
ACETYLENE
SWEET GAS
Sky Blue
-do-doCanary Yello
-do-do-
Signal Red
Silver Grey
French Blue
Black
White
Light Grey
Canary Yellow
-do-do-do-do-
Grey
Signal Red
Oxide Red
Service Brown
Grey
Dark Violet
French Blue
White
-
DARK Violet
-do-do-dosmoke Grey
Canary Yellow
Briliant Green
French Blue
Signal Red
Silver Grey
Light Orange
Dark Violet
Light Orange
-do-do-do-do-
Dark Admiralty
Grey
-do-do-do-do-do-doDark Admiralty
Grey
-do-do-do-do-do-do-do-doLight Brown
-do-do-
Brilliant Green
-do-do-doGulf Red
Canary Yellow
Black
Light Grey
Signal Red
Light Grey
Signal Grey
Brilliant Green
White
Brilliant Green
Signal Green
Brilliant Gren
-do-do-
Black
Smoke Grey
Gulf Red
-
HYDRO CARBONS
NAPTHAS
PROPYLENE
PROPYLENE C.G. (LIQ)
ETHYLENE GLYCOL
ETHYLENE DICHLORIDE
BENZENE
BUTADIENE
ETHANE(LIQ)
PROPYLENE(LIQ)
ETHYLENE(LIQ)
TAR
AROMATIC GASOLINE
METHANOL (LIQ)
PYROLYSIS GASOLINE
MIXED C4(LIQ)
LPG(LIQ)
KEROSENE
DIESEL OIL (WHITE)
DIESEL OIL (BLACK)
French Blue
Black
Black
Brilliant Green
Canary Yellow
Gulf Red
Black
Light Brown
Dark Violet
-
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EDITION : 1
18.2
18.3
b.
c.
d.
e.
18.4
Identification Sign
18.4.1
18.4.2
18.4.3
Product names shall be marked at pump inlet, outlet and battery limit in a
suitable size as approved by Engineer-in-charge.
18.4.4
18.5
Colour Bands
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EDITION : 1
18.5.1
Width : L(mm)
25mm
50mm
75mm
100mm
Note: For insulated pipes, nominal pipe size means the outside diameter
of insulation.
Nominal pipe size figures are to be inches.
18.5.2
18.5.3
18.6
19.0
19.1
150mm(high)
50mm (high)
40-150mm
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EDITION : 1
19.2
20.0
20.1
All columns
All tanks in offsites
Large vessels
Spheres
20.2
20.3
Method of Camouflaging
20.3.1
Light Green
3:
20.3.2
20.3.3
20.3.4
20.3.5
20.3.6
20.3.7
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EDITION : 1
21.0
21.1
21.2
21.3
Surface preparation
Primer application
Each coat of paint
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EDITION : 1
21.4
Primer Application
After surface preparation the primer should be applied to cover the
crevices, corners, sharp edges etc. in the presence of inspector
nominated by Engineer-in-Charge.
21.5
21.6
21.7
21.8
21.9
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EDITION : 1
21.10
The contractor shall arrange for spot checking of paint materials for Sp.
Gr., flow time (ford cup) and spreading rate.
22.0
GUARANTEE
22.1
The contractor shall guarantee that the chemical and physical properties
of paint materials used are in accordance with the specifications
contained herein/ to be provided during execution of work.
22.2
The contractor shall produce test report from manufacturer regarding the
quality of the particular batch of paint supplied. The Engineer-in-Charge
shall have the right the test wet samples of paint at random, for quality of
same as stipulated in clause 11 above. Batch test report of
manufacturers for each batch paint supplied shall be made available by
the contractor.
23.0
24.0
24.1
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24.2
24.3
24.4
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EDITION : 1
24.5
24.6
Density
Dipping properties
D 1475
D 823
Film Characteristics
Drying time
Flexibility
Hardness
D 1640
D 1737/ D 522
D 3363
Adhesion
Abrasion resistance
DFT/ Coat
Storage Stability
D 2197
D 968/ D 1044
AS PER SSPC GUIDELINES
D 1849
Resistance to
Humidity for 2000 hrs.
Salt Spray for 2000 hrs.
Accelerated Weathering
% Zn in DFT
D 2247
B 117
D 822
G 53
Coating system for panel test shall be decided after discussion with
MECON.
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EDITION : 1
ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
Indian Vendors
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
Note: This list subjected to revision based fresh approval which will be intimated to
PDD/ Vendor Cell.
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EDITION : 1
ANNEXURE-II
LIST OF RECOMMENDED MANUFACTURERS PRODUCTS
S.
No.
MANUFACTURER
NAME
1.
2.
3.
AMERON/ GODDLASS
NEROLAC PAINTS
LTD.
JENSON & NICHOSON
PAINTS LTD. AND
CHOKUGU JENSON
NICHOLSON
SHALIMAR PAINTS
LTD.
4.
5.
P2
CHLORINATED RUBBER
Zp PRIMER
P4
ETCH PRIMER/ WASH
PRIMER
P6
EPOXY ZINC PH.
PRIMER
F9
INORGANIC ZINC
SILICATE PRIMER/
COATING
APCOCIL 605
APCODUR HB.
RO.ZP-PC433
EPILUX 610
AMERCOAT 187
AMERCOAT 71
DIMET COTE-9
JENSOLAC CHLORINATED
RUBBER HB ZN.PH.
PRIMER
EPILAC ZINC
PHOSPHATE
PRIMER
CHIOROKOTE ZINC
PHOSPHATE PRIMER
GREY
SIGMA NUCOL UNICOAT
7321
-
TUFFKOTE ETC
PRIMER
EPIGUARD 4 ZINC
PHOSPHATE
PRIMER GREY
COLTURE CM
PRIMER 7412
CARBOLINE 893
TUFFKOTE ZILICATE TL
U17/ 92 ETHYL
SILICATE INORGANIC
ZINC
-
6.
SIGMA COATING
7.
8.
PRIMER PRODUCTS
LTD.
P-15/3A
U-16/92
9.
CORAMANDEL PAINTS
CHEMICALS LTD.
COROPEX EPOXY
ZH. PH. HIGH BILD
PRIMER
SIGMASIL MC (7568)
CARBOZINC 11
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EDITION : 1
S.
No.
MANUFACTURER
NAME
P2
CHLORINATED RUBBER
Zp PRIMER
P4
ETCH PRIMER/ WASH
PRIMER
P6
EPOXY ZINC PH.
PRIMER
F9
INORGANIC ZINC
SILICATE PRIMER/
COATING
10.
ANUPAM
ENTERPRISES
ANUCHLOR ZP PRIMER
ANUPRIME 291
ANUPAM ANILICOR
A-EZP-500
11.
12.
GRAND POLYCOATS
BOMBAY PAINTS
LTD. THEMPEL
MAKINE PAINTS
VANAPRABHA
ESTERS &
GLYCERIDES,
SUNIL PAINTS AND
VARNISHED PVT.
LTD.
COURTAULDS
COATING LTD.
MARK-CHEM
INCOPORATED,
(FOR PHOSPHATING
CHEMICAL ONLY)
VCM
POLYURETHANE
PAINTS (FOR POLY
EURETHANE PAINTS
ONLY)
JOTUN PAINTS
GP CHILOROPRIME 601
HEMPA TEX HIGHBUILD
4633
GP PPRIME 401
PENTOLITE WASH
PRIMER 8520
HEMPELS SHOP
PRIMER E-1530
GALVASOL 1570
VEGCHLOR HB PRIMER
1143
VEGPOX 1241 Z/
P
SUNCHLOR HB ZINC
PHOSPHATE PRIMER
SUN WASH
SUNPOXY ZINC
PHOSPHATE
PRIMER
INTERGARD 251
INTERZINC
EPOXY CQ
JOTACOTE 2
13.
14.
15.
16.
17.
18.
RUST PREVENTIVE
LIQUID DRSAIO
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EDITION : 1
S.
No.
MANUFACTURER
NAME
P2
CHLORINATED RUBBER
Zp PRIMER
P4
ETCH PRIMER/ WASH
PRIMER
P6
EPOXY ZINC PH.
PRIMER
F9
INORGANIC ZINC
SILICATE PRIMER/
COATING
SPECIAL ZINC
PHOSPHATE
PRIMER
19.
KCC PRODUCTS
(KOREA)
EZ 180(N)
1.
2.
3.
4.
MANUFACTURER
NAME
AMERON/
GODDLASS
NEROLAC PAINTS
LTD.
JENSON &
NICHOSON PAINTS
F2
ACRYLIC-POLY
YURETHANE FINISH
PAINT
APCOTHANE CF76 (PC
1109)
BARGER THANE
ENAMEL (81)
AMERCOAT 450GL
F3
CHLORINATED
RUBBER FINISH
PAINT
ASIOCHLOR CF 621
(PC 161)
LINOSOL
CHLORINATED
RUBBER HB
COATING
AMERCOAT 515
J & N 993 HB
POLYURETHANE
JENSON HB
CHLORINATED
F6
HIGH BUILD
FINISH PAINT
APCODUR HB
COATING 9466
EPILUX 04 AND 78
HB EPOXY
COATING
F7
HIGH BUILD COAL
TAR EPOXY
COATING
APCODUR CF 300
EPILUX 555
AMERCOAT 78 HB
EPILAC 981
ENAMEL
EPILAC
SOLVENTLESS COAT
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EDITION : 1
S.
No.
5.
MANUFACTURER
NAME
6.
SIGMA COATING
7.
CDC CARBOLINE
LTD.
PRIMER PRODUCTS
LTD.
CORAMANDEL
PAINTS CHEMICALS
ANUPAM
ENTERPRISES
GRAND POLYCOATS
8.
9.
10.
11.
F2
ACRYLIC-POLY
YURETHANE FINISH
PAINT
FINISH PAINT.
F3
CHLORINATED
RUBBER FINISH
PAINT
RUBBER FINISH
PAINT
SHALITHANE FINISH
CHLORKOTE FINISH
EPIGARD KL
FINISH
SIGMADOUR HS
SEMIGLOSS 7530
CARBOLINE 132
SIGMA NUCOL
FINISH 7308
-
SIGMA COVER
CM 7456
CARBOLINE 191
CARBOMASTIC-14
U3/ 92 POLYURETHANE
COROCLORE CR
FINISHING
ANUCHLOR HB
ENAMEL
GP CHILOROGAURD
631
42B/ 4A HIGH
BUILD EPOXY
COROPEX EPOXY
HB COATING
DURACOAT-6000
GP GUARD HP
234
POLYGUARD GE
ANUTHANE ENAMEL
GP COAT 131, 132
GP BOND 141
F6
HIGH BUILD
FINISH PAINT
F7
HIGH BUILD COAL
TAR EPOXY
COATING
TAR EPOXY
COATING
BIPIGARDS BLACK
HB COAL TAR EPOXY
COATING
COLTURIET TCN 300
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EDITION : 1
14.
15.
16.
17.
18.
19.
MANUFACTURERS
NAME
BOMBAY PAINTS
LTD./ PAINTS
VANAPRABHA
ESTERS &
GLYCERIDES,
SUNIL PAINTS AND
VARNISHED PVT.
LTD.
COURTAULDS
COATING LTD.
MARK-CHEM
INCOPORATED,
(FOR PHOSPHATE
PAINTS ONLY)
VCM
POLYURETHANE
PAINTS (FOR POLY
EURETHANE PAINTS
ONLY)
JOTUN PAINTS
KCC PRODUCTS
(KOREA)
F2
F3
F6
F7
PENTATHANE FP 4510
HEMPATEX HIBUILD
4633
VEGCHLOR FP 3140
HEMPADUR HIGH
BUILD 5520
VEGPOX- 3265
VEGPOX 3562
HEMPADUR 1510
SUNTHANE (ALIPHATIC)
SUNCHLOR HB CR
COATING
LPOXY HB PS
901
LPOXY BLACK P. S.
551
INTERTHANE
INTEGARD EM
SERIES
PENGUARD
KOPOX TOPCOAT
HB ET 5740
JOTAGUARD 85
EH 173
VEGTHANE FP 3641
VEGPOX 4265
PIPCOTHANE
ALIPHATIC
POLYURETHANE
FINISH PAINT
HARDTOP AS
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EDITION : 1
MANUFACTURERS NAME
F-8
EPOXY MASTIC COATING
SURFACE TOLERANT
1.
APCODOR CF 640
2.
PROTECTOMASTIC
3.
AMERLOCK 400
4.
AMERON/ GODDLASS
NEROLAC PAINTS LTD.
JENSON & NICHOSON PAINTS
LTD. AND CHOKUGU JENSON
NICHOLSON
5.
EPIPLUS 56
6.
SIGMA COATING
7.
8.
9.
CORAMANDEL PAINTS
CHEMICALS
ANUPAM ENTERPRISES
CARBOMASTIC-15
HB EPOXY MATIC 150B/
150A
-
10.
ANUMASTIC-102
F-11
HEAT RESISTANCE
SYNTHETIC MEDIUM
ALUMINUM PAINT
ASIAN HR ALUMINUM
PAINT (PC 300)
FERROLOT HR
ALUMINUM PANT
F-12
HEAT RESISTANCE SILICON
AL. PAINT
HR SILICON ALUMINUM PAINT
(PC 189)
BARGER HEAT RISISTANT
SILICON ALUMINUM PAINT
AMERCOAT 878
FERROTECT
SYNTHETIC RUBBER
H/R ALUMINUM PAINT
4000
HEAT RESISTING
LUSTROL ALUMINUM
HIGH TEMPERATURE
RESISTANT EPOXY
SUSTEM UPTO 200 C
4062
CARBOLINE 1248
SILVOTOL HR
ALUMINUM PAINT
-
CARBOLINE 4674
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EDITION : 1
MANUFACTURERS NAME
GRAND POLYCOATS
F8
GP PRIME GUARD
235
HEMPADUR 1708
18.
JOTUMATIC 87
19.
EH 4158H
13.
14.
15.
16.
17.
VEGEPOX MASTIC
2255
LPOXY HIGHBUILD
P.S.901
INTERPLUX
F11
F12
-
KANGAROO HHR
ALUMINUM 4950
VEG HR AL PAINT TO
IS211339
-
INTERTHERM 50
Rev. : 0
Edition : 1
SPECIFICATION
FOR
REPAIR OF PIPELINE CORROSION COATING
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
REPAIR OF PIPELINE
CORROSION COATING
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/08
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.
SCOPE
2.
3.
APPLICATION PROCEDURE
4.
INSPECTION/ TEST
5.
HOLIDAY INSPECTION
6.
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Nov. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
REPAIR OF PIPELINE
CORROSION COATING
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/08
REVISION : 1
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
1.0
REPAIR OF PIPELINE
CORROSION COATING
DOCUMENT NO.
Page 1 of 3
MEC/S/05/21/08
REVISION : 0
EDITION : 1
SCOPE :
This specification covers the minimum requirement of material and equipment,
installation procedure and inspection of repair of damaged polyethylene coatings on
steel pipes.
1.1
The repair shall be carried out using repair patch made of radiation crosslinked
Polyolefin backing, coated on the inside with semi-crystalline thermoplastic Adhesive
and filler mastic
1.2
The repair patch shall have thermal indicators to ensure correct heat is being applied
during application.
2.0
2.1
CONTRACTOR shall supply all ,equipment and manpower required for a skillful and
adequate application in the field in accordance with the specification.
2.2
Certified by DIN to meet the requirement of EN12068 stress class CHT 80.
2.3
The material shall not be older than their period of validity at the time of Application by
CONTRACTOR. Deteriorated/decomposed materials shall not be used.
2.4
Material shall be stored in sheltered storages in the manufacturer's original packing and
away from direct sunlight and in accordance with manufacturer's recommendations.
3.0
APPLICATION PROCEDURE
The application procedure to be followed for Holiday type of damage shall be in
accordance with manufacturers instructions and minimum requirements specified
below whichever is more stringent.
Preparation : Remove coating from damaged area with knife, scraper or power brush.
Scrap off the damaged area and adjacent coating to remove oil, grease, ruse dirt and
moisture.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
REPAIR OF PIPELINE
CORROSION COATING
DOCUMENT NO.
Page 2 of 3
MEC/S/05/21/08
REVISION : 0
EDITION : 1
Preheating : Preheat the exposed bare metal surface to about 80C and adjacent pipe
coating to about 60C with a torch moved back and forth over the surface.
Application of the Filler : Plastic filler shall be applied to all exposed metal surface. The
mastic is heated and smoothed down with a paint scraper to cover all bare metal in a
manner such that all entrapped air is removed.
Application of repair tape : Cut a patch from the tape in a manner such that it extends
50 mm beyond the damaged area, position it over the damaged area, heat until the
temperature sensitive paint on the outside of the patch changes colour. It shall be
smoothed down to confirm with the contour of lap, and shall be freed of any air
bubbles or wrinkles.
For cosmetic type of defects such as minor gauging tearing, scratches which do not
indicate holiday during holiday inspection, following procedure shall be adopted :
The defect area shall be roughened to remove loose polyethylene coating, oil grease,
dirt etc.
This shall be followed by application of repair patch as described above.
4.0
INSPECTION, TEST
A visual inspection shall be carried out for the following :
-
5.0
HOLIDAY INSPECTION
-
The holiday detector used shall be checked and calibrated easily with an
accurate D.C. Voltmeter. The detector electrode shall be in direct contact with
the surface of coating to be inspected.
The entire surface of the repaired section shall be inspected by means of a full
circle holiday detector approved by company set to a DC Voltage of at least 25
KV. Inspection of repaired patch shall be conducted only after it has cooled
below 50C.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
REPAIR OF PIPELINE
CORROSION COATING
DOCUMENT NO.
Page 3 of 3
MEC/S/05/21/08
REVISION : 0
EDITION : 1
No repaired point shall be covered or lowered in the trench until it has been
approved by the COMPANY.
Procedure qualification shall be carried out for repair patch. The value for peel
strength to pipe surface and to factory coating carried out as per EN 12068
shall be 0.5 N/mm minimum at 60C.
6.0
DOCUMENTATION
6.1
Prior to procurement of coating repair materials, Contractor shall furnish four copies of,
but not limited to, the following for qualification of the Manufacturer and material :
i)
ii)
iii)
Reference list of previous supplies of the similar material indicating the project
details such as diameter, quantity, service conditions, year of supply, project
name, contact person and feed back on performance.
Once the Companys approval has been given, any change in material or Manufacturer
shall be notified to Company, whose approval in writing of all changes shall be
obtained before the materials are manufactured.
6.2
Prior to shipment of materials from the Manufacturers works. Contractor shall furnish
six copies of the following :
i)
ii)
iii)
6.3
Rev. : 0
Edition : 1
SPECIFICATION
FOR
PIPELINE MARKERS
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PIPELINE MARKERS
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/10
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
3.0
GENERAL
4.0
AERIAL MARKERS
5.0
KILOMETRE MARKERS
6.0
7.0
8.0
DIRECTION MARKERS
9.0
MEC/TYP/05/21/10/002
MEC/TYP/05/21/10/003
MEC/TYP/05/21/10/004
:
:
:
MEC/TYP/05/21/10/005
MEC/TYP/05/21/10/006
:
:
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Jan. 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PIPELINE MARKERS
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/10
REVISION : 1
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PIPELINE MARKERS
DOCUMENT NO.
Page 1 of 3
MEC/S/05/21/10
REVISION : 0
EDITION : 1
1.0
SCOPE
1.1
This specification covers the minimum requirements for supply, fabrication and
erection of pipeline markers to be installed by CONTRACTOR at various locations along
the route of a cross-country pipeline.
1.2
This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.
2.0
REFERENCE CODES
Reference has been made in this specification to the latest revision of the following
code :
API RP 1109
3.0
GENERAL
3.1
CONTRACTOR shall supply, fabricate and install the pipeline markers along the pipeline
route. The locations of markers as indicated in the approved drawings shall be treated
for guidance purposes only and the exact location of the markers shall be based on AS
BUILT drainage and as directed by COMPANY.
3.2
The pipeline markers shall be fabricated, painted (Painting shall be in accordance with
the MECON Standard Specification for Shop & Field Painting) and installed in
accordance with the MECON standard drawings included herein. Before start of
fabrication of the markers, CONTRACTOR shall prepare and submit for COMPANY's
approval the detailed scheme for the marker plates as applicable for the project.
3.3
The pipeline markers shall be installed, as far as possible, at locations such that to
cause no hindrance to the regular use of the land or to the traffic.
4.0
AERIAL MARKERS
Aerial markers shall in general be installed along the pipeline at every five (5)
kilometres intervals and at places specified by COMPANY. Refer MECON Standard
Drawing No. MEC/TYP/05/21/10/005 for details.
5.0
KILOMETRE MARKERS
Kilometre markers shall in general be installed along the pipeline between the aerial
markers at every one (1) kilometre interval. Markers shall indicate cumulative distance
in kilometres from the reference station, as directed by COMPANY. A kilometre marker
is not required if the relative length between its location and any pipeline warning sign
is less than 200 metres. Refer MECON Standard Drawing No. MEC/TYP/05/21/10/002
for details.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PIPELINE MARKERS
DOCUMENT NO.
Page 2 of 3
MEC/S/05/21/10
REVISION : 0
EDITION : 1
6.0
(2 Nos.)
(1 No.)
Railway Crossings
(2 Nos.)
(1 No.)
(2 Nos.)
(2 Nos.)
Valve Station
(1 No.)
And at any other location as shown in the approved drawings and as directed
by the COMPANY.
Pipeline Warning Sign shall identify the existence of the pipeline and display the name
of the COMPANY, with an emergency telephone number, as shown in MECON Standard
Drawing No. MEC/TYP/05/21/10/003 for details.
7.0
8.0
DIRECTION MARKERS
Direction markers as shown in MECON Standard Drawing No. MEC/TYP/05/21/10/006
shall be installed to identify the significant turning points of the pipeline during aerial
traverse. One direction marker shall be installed at each turning point, in addition, two
more direction markers shall be installed along the pipeline alignment, one on either
side of the turning point at 200m from the turning point.
9.0
SPECIAL MARKERS
As directed by Company, Special Marker shall be installed at Location where the
following changes takes place :
-
The above data may be provided on other types of marker (except RoU boundary
marker), if the relative distance between the two does not exceed 100 m.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PIPELINE MARKERS
DOCUMENT NO.
Page 3 of 3
MEC/S/05/21/10
REVISION : 0
EDITION : 1
10.0
Rev. : 0
Edition : 1
SPECIFICATION
FOR
FLUSHING AND TESTING OF
PIPING SYSTEMS
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/11
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION
1.0
SCOPE
2.0
REFERENCES
3.0
INSPECTION
4.0
FLUSHING
5.0
TESTING
5.1
EXTENT OF TESTING
5.2
5.3
5.4
TESTING PROCEDURE
5.5
COMPLETION OF TESTING
5.6
TEST RECORDS
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Dec. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/11
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit / Drawing
Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
1.0
DOCUMENT NO.
Page 1 of 8
MEC/S/05/21/11
REVISION : 0
EDITION : 1
SCOPE
This specification covers the general requirements for Inspection, flushing and testing
of piping systems. However testing of steam lines falling under IBR shall also be
governed by Indian Boiler Regulations.
Flushing and testing of all piping system shall be witnessed by the Consultant
Representative / Engineer-in- Charge.
2.0
3.0
REFERENCE
ASME B31.3-2004
Process Piping
IBR
INSPECTION
During various stage and after completion fabrication and erection, the piping system
shall be inspected by the Consultant Representative / Engineer- in - Charge to ensure
that :
-
4.0
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 materials.
Required pressure of 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 the line for this purpose. This procedure shall be
repeated as many times as required till the inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and
other instruments like thermowells which may interfere with flushing shall not be
included i m the flushing circuit.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 2 of 8
MEC/S/05/21/11
REVISION : 0
EDITION : 1
From all permanent strainers the screens/meshes shall be removed before flushing.
Screens/meshes shall be re- installed 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 an 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 equipment thus included in the circuit, shall be completely cleaned and dried
with comprss4ed air, after flushing is completed.
During flushing discharged water/air shall be drained at the place directed 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 equipment,
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, online instruments and any other piping
part before flushing. The flanges to 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 re-installed by the contractor with permanent gaskets. However, flanges of
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 the proforma provided / approved by EIC.
5.0
TESTING
Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless
otherwise specified, herein. Lines carrying highly hazardous / poisonous fluids must
have a sensitive leak test. For IBR lines, IBR Regulations shall also be followed.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
5.1
DOCUMENT NO.
Page 3 of 8
MEC/S/05/21/11
REVISION : 0
EDITION : 1
Extent of testing
With the exclusion of instrumentation. piping system fabricated or assembled in the
field shall be tested irrespective of whether or not they have been pressure tested prior
to site welding of fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be
included in the system with the prior approval of Engineer-in-charge, if the test
pressure specified is equal to or less than that for the vessels and other equipments.
Pumps, compressors and other votary equipments shall not be subjected to field test
pressures.
Lines which are directly open to atmosphere such as vents, drains, safety valves,
discharge need not be tested, but all joints shall be visually inspected wherever
necessary such lines shall be tested by continuous flow of fluid to eliminate the
possibility of blockage. However, such lines if provided with block valve shall be
pressure tested upto the first block valve.
Seats of all vales shall not be subjected to a pressure in excess of the maximum cold
welding pressure of the valve. Test pressure applied to vales shall not be grater than
the manufacturer is recommendation nor less than that required by the applicable
code. Where desirable set pressure is less than test pressure, test shall be made
through an open valve.
Instruments in the system to be tested, shall be excluded from the test by isolation or
removal, unless approved otherwise by the Engineer-in-charge. Restrictions which
interfere with filling, venting and drawing such as orifice plates etc. shall not be installed
unless testing is complete.
Control valves shall not be included in the test system. Where by-passes are provided
test shall be performed through the by-pass end/or necessary spool shall be used in
place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test
pressure shall not be installed until the system has been tested. Where piping systems
to be tested are directly connected at the battery limits to piping for which the
responsibility tests with other agencies, the piping to be tested shall be isolated from
such piping by physical disconnection such as valves or blinds.
5.2
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 4 of 8
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REVISION : 0
EDITION : 1
No pressure test shall be carried out against close valve unless approved by the
Engineer-in-charge.
The Engineer-in-charge shall be notified in advance by the contractor, of the testing
sequence and programme, to enable him to be present for witnessing the test. The
contractor shall be fully responsible for making arrangements with the local boiler
inspector to witness the tests for steam lines falling under IBR. IBR certificates for
these tests shall be obtained in the relevant IBR forms and furnished to the
Engineer-in-charge. Before testing, all piping shall be cleaned by flushing to make it
free from dist loose scale, debris and other loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points and
the systems purged of air before the test pressure is applied.
Wherever in the line any void is existing due to any reasons, for absence of control
valve, safety valve, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the
test. Before pressuring the lines, each weld joint shall be cleaned by wire brush to free
it from rest and any other foreign matter.
Where a system is to be isolated of a pair of companion flanges, a blank shall be
inserted between the companion flanges. Minimum thickness of the blank shall be
designed in accordance with applicable design code.
Open ends of piping system where blanks cannot be used, such as pumps,
compressors, turbines or wherever equipment or pipe spool have been receivered or
disconnected prior to hydrostatic testing, shall be blinded off by using standard blind
flanges of same rating as the piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest
point in the piping system to be tested, to avoid overstressing of any of the lower
portion of the system. For longer lines and vertical lines, two or more pressure gauges
shall be installed at locations selected by the Engineer-in-charge. For lines containing
check valves any of the following alternatives shall be adopted for pressure testing.
Wherever possible pressurise up-stream side of valve.
Replace the valve by a temporary spool and re-install the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. All these flanges, temporary gaskets
shall be provided during testing and shall be replaced by permanent gaskets
subsequently. For check valves in lines 1-1/2" and below, flapper or seat shall be
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 5 of 8
MEC/S/05/21/11
REVISION : 0
EDITION : 1
removed during testing (if possible). After completion of testing the flopper/ seat shall
be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary
supports during testing as directed by Engineer-in-charge.
Piping which is spring or counter weight supported shall be temporarily supported,
where the weight of the fluid would overload the support. Retaining pins for spring
supports shall be removed only after testing is completed and test fluid is completely
drained.
2
When testing any piping system, air or steam of approximately 2 kg/cm (g) may be
used as preliminary test to detect missing gaskets etc. as this avoids the necessity of
purging the gas to make repairs. However, this method may not be used for this
purpose, if the steam temperature is more than the design temp. of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where the
pipe is continuously packed, before it is jacketed. The outer jacket shall be tested
separately as a system for piping with discontinuous jacketing, the core pipe and the
jacket shall be tested as separate system.
5.3
5.3.1
Testing Modes
In general all pressure test shall be hydrostatic using iron free water, which is clean
and free of silt. Maximum clorine content in water for hydrostatic testing for MS piping
shall be 15-20 ppm. Air shall be used for testing only if water would cause corrosion of
the system or overloading of supports etc. in special cases as directed by
Engineer-in-charge.
If operating fluid in the line is much lighter than testing fluid, the additional weight of
testing fluid may render piping supports (as designed) inadequate. This will call for
additional temporary supports. The typical examples are flare and vapor lines. It is
preferable that hydrostatic testing is avoided in such systems and instead pneumatic
testing may be specified.
Where air/water tests are undesirable substitute fluid such as gas, oil, methanol etc.
shall be used as the testing medium, with due consideration to the hazards involved.
These test fluids shall be specified in the line list given to the contractor.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
5.3.2
DOCUMENT NO.
Page 6 of 8
MEC/S/05/21/11
REVISION : 0
EDITION : 1
Test Pressure
The hydrostatic/pneumatic test pressure shall be as indicated in the line list or as per
the instruction of Engineer-in-charge.
The selection of the piping system for one individual test shall be based on the
following :Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping depending upon
the above requirements and based on construction progress, maximum length of
piping shall be included in each test.
5.3.3
5.4
Testing Pressure
5.4.1
Hydrostatic Test
All vents and other connections used as vents shall be kept open while filling the line
with test fluid for complete removal of air. For pressurising and depressurising the
system, temporary isolating valves shall be provided if valves, vents, drains do not exist
in the system.
Pressure shall be applied only after the system/line is ready and approved by the
Engineer-in-charge.
Pressure shall be applied by means of a suitable test pump or other pressure source
which shall be isolated from the system as the desired test pressure is reached and
stabilised in the system.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 7 of 8
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EDITION : 1
A pressure gauge shall be provided at the pump discharge for guiding the system to
the required pressure.
The pump shall be attended constantly during the test by an authorised person. The
pump shall be isolated from the system wherever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time to permit through
inspection of all joints for leakage or signs of failure. Any joint found leaking during a
pressure test, shall be re-tested to the specified pressure after repair. Test period shall
be maintained for a minimum of four hours.
The pump and the piping system to be tested are to be provided with separate
pressure indicating test gauges. There gauges are to be checked by the standard test
gauge before each pressure test.
Care shall be taken to avoid increase in the pressure due to atmospheric variation
during the test.
5.4.2
Air Test
When testing with air, pressure shall be supplied by means of a compressor. The
compressor shall be portable type with a receiver after cooler & oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so
that the joints can be examined for leaks.
All other activities shall be same as per hydrotesting procedure (specified above).
5.5
Completion of Testing
After the hydrostatic test has been completed, pressure shall be released in a manner
and at a rate so as not to endanger personnel or damage equipments.
All vents and drains shall be opened before the system is to be drained and shall
remain open till all draining is complete, so as to prevent formation of vacuum in the
system. After draining lines/systems shall be dried by air.
After testing is completed the test blinds shall be removed and equipment/piping
isolated during testing shall be connected using the specified gaskets, bolts and nuts.
These connections shall be checked for tightness in subsequent pneumatic tests to be
carried out by the contractor for complete loop/circuit including equipments (except
rotary equipments).
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 8 of 8
MEC/S/05/21/11
REVISION : 0
EDITION : 1
Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping
system, for the pressure test done in the proforma provided / approved by the
Engineer-in-charge.
SPECIFICATION
FOR
CASING INSULATORS
AND END SEALS
MECON LIMITED
DELHI - 110 092
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
MECON LIMITED
REGD. OFF: RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 1 OF 6
SEALS
MEC/S/05/62/12
REVISION 0
CONTENTS
PART-A
PART-B
PART-C
CASING INSULATIONS
1.0
SCOPE
2.0
FUNCTION
3.0
DESIGN
4.0
MATERIAL
5.0
CASING END-SEALS
1.0
SCOPE
2.0
FUNCTION
3.0
DESIGN
4.0
MATERIAL
5.0
SUPPLEMTARY REQUIREMENTS
PREPARED BY
CHECKED BY
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
APPROVED BY
MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
SPECIFICATION NO.
PAGE 2 OF 6
SEALS
MEC/S/05/62/12
REVISION
PART-A
1.0
STANDARD SPECIFICATION
CASING INSULATORS
SCOPE
This specification covers the minimum requirements of design, material,
manufacture and supply of casing insulators intended to be used for cased
pipeline crossings.
2.0
FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing
pipe and electrically isolate the carrier pipe from the casing pipe at the cased
crossings.
The casing insulators shall:
3.0
Resist corrosion
Have high electrical insulating value and low water absorption, thus
preventing leakage and maintain electrical isolation between carrier and
casing pipes
DESIGN
The arrangement of insulator shall be generally in accordance with Fig. 3.0. It
shall be made in segments duly held together with cadmium plated bolts and
nuts, to be supplied with casing insulators.
The number of segments shall be two for pipe diameters upto 12 (generally).
For larger diameters, the number of segments may be more than two, but their
number shall be kept minimum.
The skid height shall be such that it is slightly less than the value obtained by
following formula.
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 3 OF 6
SEALS
MEC/S/05/62/12
REVISION
MATERIAL
Casing insulators shall be made of injection moulded high density polyethylene
or other material equivalent or superior as approved by COMPANY and shall
meet the following specifications:
5.0
Property
Value
Dielectric strength
450-500 Volts/Mil
D-149
Compresssive strength
3200 psi
D-695i
Tensile strength
3100-5000
D-638, D-651
Impact strength
Water Absorption
0.01%
D-570
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
SPECIFICATION NO.
PAGE 4 OF 6
SEALS
MEC/S/05/62/12
REVISION
PART-B
1.0
STANDARD SPECIFICATION
CASING END-SEALS
SCOPE
This specification covers the minimum requirements of design, material,
fabrication and supply of casing end-seals intended to be used for pipeline
cased crossings.
2.0
FUNCTION
Casing end seals are intended to be used for sealing the annular space
between casing pipe and carrier pipe at casing ends so as to prevent ingress
of moisture and water.
3.0
DESIGN
The scale shall be suitable for the casing and carrier pipe diameters as
applicable for each case.
The casing end-seal shall be flexible to cater for the expansion and contraction
of carrier and casing pipes and shall be able to tolerate both angular and
concentric misalignment of casing pipe without loss of sealing efficiency.
The design of the casing end-scale shall permit easy installation of the seal to
the cased pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated life
of the buried pipeline.
Manufacturer shall obtain prior approval from COMPANY on casing end seals
design/drawings.
4.0
MATERIAL
The casing end-scale shall be made of head shrink high density radiation
crosslinked polyethylene with an adhesive having a melt point suitable for the
pipeline service temperature and ambient temperatures foreseen during
construction. End-seals material shall be resistant to heat, cold, vibration,
impact, abrasion, corrosive fluids, disbonding, organic and bio-deterioration.
Manufacturer shall confirm compatibility of end seals with carrier pipe coating.
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 5 OF 6
SEALS
MEC/S/05/62/12
REVISION
Minimum Value
Test Method
2200 psi
ASTM D-638
Ultimate Elongation
400%
ASTM D-638
Heat Shock
No visual cracks,
flow or drips
(at 225C, 4 hours)
ASTM D-2671
90C
ASTM E-28
Lap Shear
60C - 25 psi
23C - 250 psi
(2 inch/min)
ASTM D-1002
5 pli
(10 inch/min.)
ASTM
D-1000
b) Adhesive
5.0
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 6 OF 6
SEALS
MEC/S/05/62/12
REVISION
PART-C
SUPPLEMENTARY REQUIREMENTS
1.0
The Manufacturer shall replaces, at no extra cost, any material not conforming
to the material and performance requirements of this specification.
2.0
3.0
Manufacturer shall submit all the documents, test reports, records and other
information in six copies to the COMPANY for record after approval as per
clause 2.0 above.
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
Rev. : 0
Edition : 1
SPECIFICATION
FOR
FIELD JOINT COATING
(ONSHORE PIPELINES)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/13
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
4.0
APPLICATION PROCEDURE
5.0
INSPECTION
6.0
TESTING
7.0
REPAIRS
8.0
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
May 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/13
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit / Drawing
Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
1.0
DOCUMENT NO.
Page 1 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
SCOPE
This specification covers the minimum requirements of materials, equipment and
installation of field joint anti-corrosion coating of underground onshore factory coated
pipelines with either three layer polyethylene or fusion bonded epoxy (FBE) coating by
heat shrink wraparound sleeves conforming to DIN EN 12068 Cathodic Protection
External Organic Coatings for the Corrosion Protection of Buried or Immersed Steel
Pipelines used in Conjunction with Cathodic Protection Tapes and Shrinkable
Materials and the requirements of this specification. Unless modified / replaced by
this specification, all requirements of DIN EN 12068 shall remain fully applicable and
complied with.
This specification shall be read in conjunction with the conditions of all specifications
and documents included in the Contract between Company and Contractor. Unless
specified otherwise, all sections of this specification shall apply to all specifications
referred in this specification.
2.0
REFERENCE DOCUMENTS
Reference has been made to the latest edition (edition enforce at the time of floating
the enquiry) of the following standards, codes and specifications:
a)
ASTM D-149 :
b)
ASTM D-257 :
c)
ASTM D-570 :
d)
ISO 8502-3
e)
ISO:8503-1
f)
ISO:8503-4
Resistance
or
MECON LIMITED
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TITLE
DOCUMENT NO.
Page 2 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
g)
SIS-055900
h)
SSPC-SP 1
In case of conflict between the requirements of this specification and that of above
referred documents, the requirements of this specification shall govern.
The Contractor shall be familiar with the requirements of these documents and shall
make them readily available at the site to all personnel concerned with carrying out the
works specified in this specification.
3.0
3.1
Contractor shall supply joint coating materials, all equipment and manpower required
for a skillful and adequate application of coating in the field in accordance with the
specifications.
Contractor shall submit and demonstrate to Company proposed materials and works
procedures for applying field coating and repair procedures for same. These
proposed procedures and all materials, equipment and tools used in the work shall
be subject to Companys approval.
3.2
3.2.1
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DOCUMENT NO.
Page 3 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
The total thickness of heat shrinkable wraparound sleeve in the as applied condition
shall be as follows :
Pipe Size
(Specified Outside Diameter)
4 (114.3 mm) to 10 (273.0 mm)
12 (323.9 mm) to 18 (457.2 mm)
20 (508.0 mm) to 30 (762.0 mm)
32 (812.8 mm)
Thickness (mm)
On Pipe Body
On Weld Bead
(Min.)
(Min.)
2.0 mm
1.6 mm
2.2 mm
1.8 mm
2.5 mm
2.0 mm
3.0 mm
2.5 mm
The heat shrink wraparound sleeve shall have the required adhesive properties when
applied on various commercial pipe-coating materials. The pre-heat and application
temperatures required for the application of the shrink sleeve shall not cause loss of
functional properties of the pipe coating.
Heat shrinkable wraparound field joint coating system manufactured by M/s Covalence
and M/s Canusa are acceptable for the supply of field joint coating materials. The
Contractor shall propose the specific grade of field joint coating system meeting the
requirements of this specification from these manufacturers. In case the Contractor
proposes to supply heat shrinkable wraparound sleeve from any other manufacturer,
then the Contractor shall propose only those coating systems that have been
previously used for pipelines of size same or higher than the size indicated in tender,
for a length of 50 km and above in a single project for similar operating conditions.
3.2.2
3.3
3.3.1
Properties of the PE backing and the as applied joint corrosion coating shall be as
follows :
MECON LIMITED
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834002
TITLE
Sl.
No.
i)
ii)
iii)
iv)
v)
vi)
3.3.2
DOCUMENT NO.
Page 4 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
Property
Tensile Strength @+25C
Ultimate Elongation % @+
25C
Dielectric withstand KV with
1000 Volts/sec
Water absorption
@+ 25C for 24 hours
Volume Resistivity @+25C
Unit
Requirement
N/mm2
12
250
kv
30
0.05
Ohm-cm
1015
Change in
elongation 250
Test
Method
DIN EN
12068
DIN EN
12068
ASTM D
149
ASTM D
570
ASTM D
257
DIN 30672
b)
Inner to Inner +
Outer to Inner
Outer to Outer
To Pipe Surface
To Factory
Coating
Unit
@23C
@Tmax
@23C
@Tmax
@23C
@Tmax
@23C
@Tmax
Notes
(Tmax shall be (+) 60C)
N/mm
N/mm
N/mm
N/mm
N/mm
N/mm
N/mm
N/mm
Requirement for
Mech Resistance
Class C
(Minimum)
1.5
0.3
1.5
0.3
3.5
0.3
3.5
0.3
Test
Method as
per DIN EN
12068
Annexure-B
Annexure-C
MECON LIMITED
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TITLE
DOCUMENT NO.
Page 5 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
Contractor shall obtain prior approval from Company regarding the manufacturer of the
joint coating material. Complete technical details alongwith test certificates complying
with the requirements of clause 3.2.1 and 3.2.2 shall be submitted to Company for this
purpose. The Contractor shall furnish test certificates from an independent DIN
recognized / approved laboratory for all the properties required for the specified EN
designation of field joint coating and the requirements of this specification.
3.3
The materials shall not be older than their period of validity at the time of application by
CONTRACTOR. Deteriorated/ decomposed material shall be disposed of and replaced
by CONTRACTOR at his own expense.
CONTRACTOR shall ensure that the coating materials supplied by him are properly
packed and clearly marked with the following :
-
Manufacturers name
Material qualification
Batch number
Date of manufacturing and date of expiry.
3.4
CONTRACTOR shall ensure that the manufacturer has carried out all quality control
tests on each batch and manufacturer shall provide test certificates to certify that the
supplied materials meet the manufacturers specifications as indicated in the purchase
order and as approved by COMPANY. Certificates and data sheets certifying the
qualities of the coating materials shall be submitted by CONTRACTOR to COMPANY
prior to application. COMPANY reserves the right to have the materials tested by an
independent laboratory.
3.5
3.6
CONTRACTOR shall provide and maintain mobile facilities which contains all
necessary equipment and its spares for cleaning, coating repairs, inspection and tests.
3.7
CONTRACTOR shall furnish sufficient number of the following equipment and the
required spares as a minimum for inspection and test purpose for each crew.
a)
b)
c)
d)
Fully automatic full circle adjustable holiday detector with a visible and audible
signal system for inspection of coatings.
Thickness gauge for measuring thickness.
Contact type temperature recording thermometer (Digital Pyrometer with flat
probe type contact).
Roughness profile measuring (Stylus) instrument
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 6 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
4.0
APPLICATION PROCEDURE
4.1
General
4.1.1
4.1.2
Operators for coating application shall be given necessary instructions and training
before start of work, by the Contractor. To verify and qualify the application
procedures, all coating applied during the qualification test, shall be removed for
destructive testing until the requirements stated in sections Inspection and
Testing of this specification are met.
4.1.3
Oil, grease and salt shall be removed from steel surface by wiping with rags soaked
with suitable solvents such as naphtha or benzene. Kerosene shall not be used for
this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed.
4.1.4
Each field joint shall be blast cleaned using a closed cycle blasting unit or an open
expendable blasting equipment. With the first equipment type, steel or chilled shot
and iron grit shall be used and Garnet material with the second one (in case the
authority having jurisdiction have no objection, the contractor may adopt sand
blasting instead of garnet material). During blast cleaning the pipe surface
temperature shall be simultaneously more than 5 and more than 3C above ambient
Dew Point, while the ambient Relative Humidity shall not be greater than 85%. Prior
to surface cleaning the surface shall be completely dry. The surface shall be
cleaned to a grade Sa 2 in accordance with Swedish Standard SIS-055900 with a
roughness profile of 50-70 microns. Surface roughness profile shall be measured
using an approved profile comparator in accordance with ISO 8503-1 and shall be
calibrated prior to the start of the work in accordance with ISO:8503-3 or ISO:85034. The blast cleanliness shall be checked on every joint and the roughness profile
shall be checked 1 every 10 joints.
Dust grit or foreign matter shall be removed from the cleaned surface by an industrial
vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per
ISO:8502-3. The frequency of checking for dust contamination shall be 1 every 10
joints.
Blast cleaned field joint shall be coated within 2-4 hours according to the conditions
below :
MECON LIMITED
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DOCUMENT NO.
Page 7 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
2 Hours
3 Hours
4 Hours
Pipes delayed beyond this point or pipes showing any visible rust stain shall be blast
cleaned again.
4.1.5
The field joint surface shall be inspected immediately after blast cleaning and any
feature of the steel surface such as weld spatter, scabs, laminations or other
imperfections considered injurious to the coating integrity made visible during blast
cleaning shall be reported to the Company Representative and on permission from
Company Representative, such defects shall be removed by filing or grinding. Pipes
affected in this manner shall be then re-blast cleaned if the defective area is larger
than 50 mm in diameter.
4.1.6
The ends of existing pipe protective coating shall be inspected and chamfered.
Unbounded portions of the coating shall be removed and then suitably trimmed.
Portions where parent coating is removed shall be thoroughly cleaned as specified.
The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded,
to expose a clean uniform fresh surface of uncontaminated factory applied coating.
4.1.7
All steel joint surfaces shall be thoroughly examined before the application of the
coating in order to ensure the surface are free of soil, grease, rust, mud, earth or any
other foreign matter. All these substances shall be removed before coating, to the
procedures herein described.
4.1.8
Protection coating shall be applied on the joints immediately after the completion of
cleaning operation.
4.2
4.2.1
The wrap around sleeves shall be of a size such that a minimum overlap of 50mm is
ensured (after shrinking) on both sides of yard applied corrosion coating of the pipes.
In cases where carrier pipe is installed by direct boring/jacking, the overlap on the mill
coating for the leading edges of the joints shall be minimum 200mm. When this extra
overlap is achieved by providing an additional patch of heat shrink tape/wraparound, it
shall be applied in such a manner that the square edge of the patch on the joint
coating is in the direction opposite to the direction of boring/jacking.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 8 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
4.2.2
Before centering the wraparound sleeve, the bare steel surface shall be preheated
with torch moved back and forth over the surface or by induction heating. The
minimum preheat temperature shall be as recommended by manufacturer and shall
be checked by means of contact type temperature recording thermometer (Digital
Pyrometer with flat probe type contract) to check this, approved temperature
indicates shall be used. Temperature indicating crayons shall not be used. Pre-heat
temperature shall be checked on every joint. Care shall be taken to ensure that the
entire circumference of the pipe is heated evenly. Temperature measuring
instruments shall be calibrated immediately before the start of the works and
thereafter at intervals recommended by the manufacturer of the instrument.
4.2.3
Upon pre-heating the pipe surface shall be applied with two pack epoxy primer of wet
film thickness 150 microns or as per manufacturers recommendation whichever is
higher, to cover the exposed bare metal of the welded field joint and 10mm min. onto
the adjacent pipe coating if recommended by the manufacturer. The wet film
thickness of the primer shall be checked or every joint with a wet film thickness
gauge prior to installation of sleeve. Thickness gauge shall be calibrated once per
shift.
4.2.4
4.2.5
A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to
start shrinkage of the sleeve beginning from the center of the sleeve and heat
circumferentially around the pipe. Continue heating from the center towards one end
of the sleeve until recovery is completed. In a similar manner, heat and shrink the
remaining side. Shrinking has been completed when the adhesive begins to ooze at
the sleeve edges all around the circumference.
The complete shrinking of the entire sleeve shall be obtained without undue heating
of existing pipe coating and providing due bonding between pipe, sleeve and pipe
coating. The installed sleeve shall not be disturbed until the adhesive has solidified.
The coatings mentioned are for undergrounds installations.
For HDD Joint Coating fiber glass reinforced heat shrinkable sleeve certified to
Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX shall be used.
Directional drilling kit, multilayer sleeve system or equivalent to be approved by
Owner / Engineer.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 9 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
Only coating material C-60 Class as per EN 12068 and DVGW certified (wrapping
tape and heat shrinkable material) will be accepted for all material to be coated.
For the buried valve station (moulded piece, valves, elbows etc) Thermoset plastic
coatings may be used. They will be of type S50 certified as per DIN 30671 & DIN
30677.
Underground bare valves if any will be coated with above material.
At the point of transition from the aboveground pipe to underground pipe special
coating material FIBAROLL or equivalent to be used over the coated part of U.G.
pipe and painted part of A.G. Pipe end over lapping shall be at least 500 mm inside
the ground and 500 mm on painted AG line. Minimum thickness shall be 1.5 mm.
The application of the material will be as per supplier's specification.
Wherever Thrust Boring (Jacking) method is carried out, for mechanical protection of
coating of carrier pipe extra layer of hard cold applied tapes C-70 class as per DIN
30675-1 or solvent free PUR (1000 microns) as per DIN 3067712 Ep-50 types shall
be applied. Surface preparation (sand blasting) of PE layer shall be appropriate as
per applicator's recommendations. The type & thickness of coating must got
approved by Owner / Engineer prior to coating.
4.3
4.3.1
Cold applied joint protection tapes shall be of the type which can be applied by spirally
wrapping on the pipe.
4.3.2
Immediately after the completion of surface preparation the approved primer of wet
film thickness 150 microns or as per manufacturers recommendation whichever is
higher to cover the exposed bare metal of the welded field joint and 10mm min. onto
the adjacent pipe coating if recommended by the manufacturer. Any dirt on the
primed surface shall be removed. If the primer is damaged, the damaged area shall
be cleaned and re-primed.
4.3.3
Approximately 100mm of tape interleaving paper shall be peeled back and tape shall
be applied with the adhesive side to the pipe. Whilst continuously removing the
interleaving paper, the tape shall be spirally applied to provide a minimum of 55%
overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air
pockets and also continuously smooth out as the wrapping proceeds. The wrapping
shall start and finish to give a minimum of 50mm overlap on to the adjoining yard
applied coating. Outer wrap shall also be applied in similar method.
MECON LIMITED
REGD. OFF: RANCHI
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DOCUMENT NO.
Page 10 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
In the cases where carrier pipe is installed by direct boring/jacking, the overlap on the
mill coating for the leading edges of the joints shall be minimum 200mm. The direction
of spiral wrapping in these cases shall be such that the square edge of the wrapping
with the joint coating is in the direction opposite to the direction of boring/jacking.
4.4
vii)
Company Representative shall witness the tests and inspection. Regular application of
field joint coating shall commence only upon successful completion of the prequalification testing.
After successful completion of the pre-qualification testing as above, the entire field
joint coating shall be removed, the pipe surface re-blasted and field joint coating reapplied as per the requirements of this specification.
5.0
INSPECTION
5.1
MECON LIMITED
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5.2
DOCUMENT NO.
Page 11 of 13
MEC/S/05/21/13
REVISION : 0
EDITION : 1
Holiday Inspection
The holiday detector used shall be checked and calibrated daily with an accurate DC
voltmeter. The detector electrode shall be in direct contact with the surface of coating
to be inspected.
The entire surface of the joint section shall be inspected by means of a full circle
holiday detector approved by Company set to a DC voltage of at least 25 kV.
Inspection of the sleeves shall be conducted only after the joint has cooled below 50C.
(applicable for heat shrink wraparounds).
5.3
No field joint shall be covered or lowered in the trench until it has been approved by the
Company.
5.4
6.0
TESTING
6.1
Company reserves the right to remove and test one out of every 50 joint coatings or
one joint coating out of every days production whichever is stringent. Contractor shall
provide all assistance in removing and testing of field joint coatings.
6.2
From each test sleeve, one or more strips of size 25mm x 200 shall be cut
perpendicular to the pipe axis and slowly peeled off.
The required peel strength shall meet the requirements of clause 3.2.4.2 (ii) as
applicable for 23C or 60C whichever is feasible. This test shall be conducted
between wrapping & metal and mill coating & between layers at overlap with joint
coating (wherever applicable). After removal of strip the bulk of adhesive shall remain
adhered to the pipe showing on bare metal, otherwise, test shall be considered failed.
The adhesive layer that remains on the pipe surface shall generally be free of voids
resulting from air or gas inclusion. In case the peel strength test at a different
temperature than that specified in warranted due to the ambient site conditions, then
the peel strength shall comply the recommendation of the manufacturer. Manufacturer
MECON LIMITED
REGD. OFF: RANCHI
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DOCUMENT NO.
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REVISION : 0
EDITION : 1
If the sleeve taken away for test does not meet the requirements of clause 6.2 the
adjacent two sleeves shall also be removed and inspected.
If the adjacent two sleeves are acceptable the test rate shall be increased to one
sleeve in every twenty five until Company's Representative is satisfied. The test rate
can then be reduced as per clause 6.1.
If either or both of the adjacent two sleeves do not meet the requirements of clause
6.2, the field coating shall be stopped. (Refer clause 7.0).
6.4
6.5
Coating thickness shall be checked by non-destructive methods for each fields joints.
7.0
REPAIRS
7.1
If a field joint is detected to be unacceptable after testing as per section 6.0 of this
specification the Contractor shall, at his own cost :
determine the cause of the faulty results of the field coating.
mobilise the expert of manufacturer, if required.
test to the complete satisfaction of the Company, already completed field
coatings.
stop field coating until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the Company.
7.2
Contractor shall replace all joint coating found or expected to be unacceptable a per
section 6.0 of this specification.
7.3
Contractor shall, at his own cost repair all areas where the coating has been removed
for testing by the Company.
7.4
After the coating work on welded joints, fittings and repairs to the coating have been
completed the coating as a whole shall be tested with a spark-tester before lowering or
jacking the pipeline.
7.5
Company shall be entitled to check the coating on buried pipelines or parts of pipelines
with equipment such as the "Pearson Meter" and the resistance meter. If Coating
defects are establish, the Contractor shall be responsible for excavations at such
points, repairing the coating, spark testing and backfilling the excavation without extra
charge.
MECON LIMITED
REGD. OFF: RANCHI
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EDITION : 1
8.0
DOCUMENTATION
8.1
ii.
Test certificates and results of previously conducted tests, for all properties
listed in clause 3.2.4 of this specification.
iii.
Once the Companys approval has been given, any change in material or
Manufacturer shall be notified to Company, whose approval in writing of all changes
shall be obtained before the materials are manufactured.
8.2
Prior to shipment of materials from the Manufacturers Works Contractor shall furnish
the following documents :
i.
ii.
iii.
8.3
Rev. : 0
Edition : 1
SPECIFICATION
FOR
VENTS, DRAINS AND WELLS
MECON LIMITED
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TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/15
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION OF DRAWING
DRAWING NO.
1.
MEC/SD/05/21/15/01
2.
MEC/SD/05/21/15/02 (Sheet 1 of 2)
3.
MEC/SD/05/21/15/02 (Sheet 2 of 2)
4.
MEC/SD/05/21/15/03
5.
Pressure Tapping
MEC/SD/05/21/15/05
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Binita Brahma)
(Sunil Kumar)
(A.K. Johri)
Feb. 2009
MECON LIMITED
REGD. OFF: RANCHI
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DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/15
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit / Drawing
Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
Edition : 1
SPECIFICATION
FOR
TEMPORARY CATHODIC PROTECTION
SYSTEM
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
TEMPORARY CATHODIC
PROTECTION SYSTEM
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/016A
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION
1.0
SCOPE
2.0
3.0
CORROSION DATA
4.0
5.0
6.0
SYSTEM DETAILS
7.0
INSTALLATION
8.0
CIVIL WORKS
9.0
10.0
11.0
12.0
SYSTEM MONITORING
13.0
14.0
15.0
PREPARED BY:
ISSUE DATE :
(Amit Lavania)
(D.K. Pande)
Feb. 2009
MECON LIMITED
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TITLE
TEMPORARY CATHODIC
PROTECTION SYSTEM
DOCUMENT NO.
Page 1 of 22
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1.0
SCOPE
1.1
1.2
1.3
In case where temporary and permanent cathodic protection works are being
executed by the same agency, activities of permanent CP system which are common
to temporary CP system shall be completed as part of temporary CP system. In
cases where temporary and permanent cathodic protection works are being
executed by different agencies, the contractual scope of work shall be referred for
further details.
1.4
Corrosion survey data interpretation report and design basis for CP system.
CP system design package
Purchase requisitions for major equipment and vendor approval
Detailed engineering package
Field testing and commissioning procedure
Procedures for interference testing and mitigation
CPL survey and system monitoring procedures
2.0
2.1
The system design, performance and materials to be supplied shall unless otherwise
specified, conform to the requirements of latest relevant applicable standards of :-
Standard
Recommended
Practice
Control of External Corrosion on
Underground or Submerged Metallic
Piping systems.
MECON LIMITED
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TITLE
TEMPORARY CATHODIC
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DOCUMENT NO.
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Standard
Recommended
Practice
Mitigation of Alternating Current and
Lighting Effects on Metallic Structures
and Corrosion Control Systems.
Cathodic Protection
Buried Pipelines.
BS 7361 Part I
VDE 0150
IS : 7098 Part I
Monitoring
for
The equipment shall also confirm to the provisions of Indian Electricity rules and
other statutory regulations currently in force in the country.
2.3
Statutory Regulations
Data Sheets
Job Specification
This Specification
Codes and Standards.
3.0
CORROSION DATA
3.1
The corrosion survey including soil resistivity data along ROW and other data
required for CP design is attached with this document. However, verification of its
veracity and adequacy shall be the entire responsibility of the contractor. In addition,
contractor shall have to generate/ collect additional data as required for
completeness of the job. Contractor shall also carry out soil resistivity survey at
temporary anode ground bed locations for proper design of ground beds. Wenner's
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TITLE
TEMPORARY CATHODIC
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4-pin method or approved equal shall be used for such measurements. Survey
instruments shall have maximum AC and DC ground current rejection feature.
Care shall be taken to ensure that the resistivity observations are not influenced by
the presence of foreign pipelines / structures, and earth currents in the vicinity of
EHV / HV lines and installations using earth return in their power system etc.
3.2
ii.
iii.
Detail of the existing cathodic protection system protecting the services i.e.
location, rating, type of protection, anode beds, test station locations and their
connection schemes.
iv.
v.
vi.
vii.
viii.
ix.
Voltage rating, number of cores and sheathing details of under ground power
cables, running in parallel or crossing ROW.
x.
line
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xi.
Any masonry work for other concrete or non conductive constructions in the
ROW which may block the CP current or cause interference to the pipeline.
xii.
3.3
Report
On completion of all field work a report incorporating all the results generated from
surveys and details of additional data collected shall be furnished. The report shall
also contain detailed interpretation of survey results and resistivity data enclosed,
probable interference prone areas etc. to form design basis for the scheme of
cathodic protection. This report shall be plotted on semi-log graph sheets.
4.0
4.1
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(ii)
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Pipe to soil "ON" potential shall not be more negative than (-) 1.5V.
*
Actual current density to be adopted shall be decided based upon soil and
other environmental conditions, proximity of foreign pipelines and structures
affecting interference. Where considered necessary for satisfactory
protection of pipeline the current density shall be suitably increased by
contractor.
4.2
4.3
4.4
4.5
5.0
5.1
a)
b)
c)
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5.2
A positive potential swing of 50-100 mV shall be considered the criteria for presence of
an interference situation requiring investigation and incorporation of mitigation
measures by the CONTRACTOR.
6.0
SYSTEM DETAILS
The system shall include the following major equipment/sub-systems unless
otherwise specified:
-
6.1.1
6.1.2
Along ROW where soil resistivity predominantly remains low, ranges from 0-10 ohm. m
and pH value is within 9, zinc anodes may be provided. Anodes of type I as per ASTMB 418 standard shall be used for seawater, brackish water or saline electrolyte
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application and anode of type II as per ASTM-B 418 standard shall be used for fresh
water, back fill and soil applications.
6.1.3
Along ROW where soil resistivity predominantly in the range of 10 ohm. m to 30 ohm.
m low potential (1.55V) magnesium anodes may be provided.
6.1.4
6.1.5
At high resistivity area where resistivity is of the order of 50 ohm. m and above
magnesium ribbon anodes may be provided.
6.1.6
Where magnesium anodes are used for protection of polyethylene coated pipelines,
the anodes shall be preferably of low potential (1.55 V) type.
6.1.7
Anodes shall be installed along the pipeline at suitable intervals as per pipeline
protection voltage attenuation calculations and ground bed resistance/ current output
of anode installations. Minimum one anode installation shall be provided for every one
km. of the pipeline. In congested area, minimum one anode installation shall be
provided for every 250 meter of pipeline length. At high resistivity area the magnesium
ribbon anodes shall be installed all along the pipeline by the side of the pipeline in the
pipeline trench.
6.1.8
6.1.9
The anodes shall be installed at sufficient depth to reach moist soil and shall be
separated from the pipe line by at least 5m and 2m for magnesium and zinc anodes
respectively. The magnesium ribbon abode shall be separated from the pipeline by at
least meter. The anode connections to pipeline shall be routed through test stations.
6.1.10
At the temporary cathodic protection anode ground bed, the leads of all the anodes
shall be joined together in a junction box filled with epoxy and buried. A single cable
shall be routed from the junction box to the test station. At permanent CP anode
ground bed, the leads of all the anodes shall be brought up to the test station and shall
be terminated individually.
6.1.11
For sacrificial anode ground bed which shall be integrated with permanent CP System
the leads of all the anodes shall be brought up to the test station and shall be
terminated individually.
6.1.12
The number of anodes at each ground bed shall be sufficient for providing the
specified pipe protection current density taking into consideration the ground bed
resistance, pipe coating resistance, cable resistance, etc. Contractor shall prepare a
table for number of anodes required at different soil resistivities to produce the
specified protection current. Any deficiency in the protection system if noticed during
commissioning or during monitoring shall be corrected by the CP contractor by suitably
augmenting the system with additional anodes without any cost / schedule implications.
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6.1.13
For the portion of the pipeline for which for CP system has been specified based on the
permanent CP system parameters, the contractor shall ascertain the requirement of
the cathodic protection current density indicated in Cl. No. 4.1 above. Where specified
in the project specification / datasheet the requisite current density test /survey shall be
conducted by the contractor to establish the adequacy of the CP current requirement &
number of anode ground beds.
6.2.1
Magnesium anode
The anode shall confirm to the requirements of ASTM-B 418 standard. The anode
shall be of high manganese, magnesium alloy packed with special back fill. The
metallurgical composition, potential and consumption rate of anode shall be as
below:
(i)
Composition:
Element
Manganese
Copper
Silicon
Zinc
Aluminium
Iron
Nickel
Weight
(Low Potential type)
0.15 0.7%
0.02% max.
0.1% max.
2.5% - 3.5%
5.3% - 6.7%
0.003% max.
0.002% max.
Weight
(High Potential type)
0.5 1.3%
0.02% max.
0.05% max.
0.01% max.
0.03% max.
0.001% max.
0.05% max.
0.3% Max.
Balance
1.55 volts
1.75 volts
Zinc Anode
The anode shall confirm to the requirements of ASTM-B 418 standard. The anode
(other than ribbon anode) shall be packaged with special back fill. The metallurgical
composition of anode, potential and consumption rate shall be as below. Anodes of
Type-I shall be used for seawater, brackish water or saline electrolyte application
and anodes of Type-II shall be used for fresh water, back fill and soil applications.
(i)
Composition:
Element
Aluminum
Weight
Type-I
0.1% to 0.5%
Weight
Type-II
0.005% max.
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Cadmium
Copper
Iron
Lead
Others
Zinc
(ii)
(iii)
DOCUMENT NO.
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0.025 0.07%
0.005% max.
0.005% max.
0.006% max.
0.01% max.
Remainder
0.003% max.
0.002% max.
0.0014% max.
0.003% max.
Remainder
1.1 volts
11.24 kg/(A yr) max.
6.2.3
Contractor shall furnish spectrographic analysis from each heat both for zinc and
magnesium anodes along with electrochemical test results.
6.2.4
6.2.5
Special Backfill
The composition of special back fill for anodes shall be as below. In any case, the
thickness of back fill shall not be less than 50 mm on all sides of the anode.
Gypsum
Bentonite
Sodium Sulphate
75%
20%
5%
6.2.6
The anodes shall be provided with cable tail of sufficient length to reach junction box
test station as applicable without tension.
6.2.7
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For transverse cracks the acceptable limits shall be furnished by the bidders along
with the offer.
The anode shall be free from excessive shrinkages. The following limits shall be
used:
-
Maximum 10% of the depth of anode or 50% of the depth of the anode core
whichever is less. The depression may be measured from the edged of one
side.
The surface of the anodes shall be free from coatings and slag/dross inclusions etc.
The maximum deviation from straightness shall not exceed 2%.
The weight tolerance on individual anodes may be taken as 5%. The total weight of
the anodes shall not have negative tolerance.
Recommended dimensional tolerance shall be as follows:
Length
Width/thickness
2.5%
5%
6.3
Test Stations
6.3.1
Test stations shall be provided along the pipeline ROW for monitoring the
performance of the Cathodic Protection system at intervals not exceeding 1000
meters in uncongested & 250 meters in congested area unless otherwise specified.
In addition to above, test stations shall also be provided at the following locations:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
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6.3.2
Bond stations shall be provided with shunt & resistor at required locations as a
means to monitor and control current flow between the pipeline and foreign pipelines
/ structures / electrified railway tracks etc. that crossing and running parallel to the
pipeline in common ROW or within 25 metre from the pipeline.
6.3.3
Test stations used for sacrificial anodes shall have shunt for measurement of anode
current, and provision for resistance insertion to limit the anode current output &
anode disconnecting link.
6.3.4
Test station with current measuring facility shall be provided at each intermediate CP
station drainage point (to measure pipeline from drainage point), at interference
prone areas, on both sides of major river crossings and minimum one for every 10
km (max.) alongwith pipeline.
6.3.5
All test stations shall have weather proof enclosure, having degree of protection IP
55 with hinged lockable shutter. Enclosure shall be made of sheet steel of at least 3
mm thickness and shall be suitable for M.S. post mounting. The test stations shall be
designed with terminals required for both temporary and permanent CP system and
shall be suitable for total life of permanent CP system.
6.3.6
The test stations shall be installed with the front of the test station facing the pipeline.
The name plate of test stations shall in minimum carry following information.
-
6.3.7
Terminal blocks and different scheme of wiring as required shall be provided in the
test station as per the test station connection scheme sketch. Minimum 20% spare
terminals shall be provided in each TLP.
6.3.8
The location of all the test stations shall be marked with their connection schemes
and other relevant information's on alignment sheets. A detailed test station schedule
shall be prepared.
6.4
6.4.1
Where high voltage (66 KV and above) transmission line runs in parallel or crosses
the pipeline, the pipeline shall be grounded through polarisation cells & zinc anodes
of minimum 20 kg net wt. each. Alternatively, grounding could be done directly with
zinc galvanic anodes of minimum 20 kg wt. net each at the discretion of owner.
Grounding shall be done at regular intervals of maximum 1 km where transmission
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lines run parallel within 25 meter of the pipeline to ground any surges on the pipeline
that would appear in case of transmission line faults.
6.4.2
6.4.3
Explosion proof Surge Diverter (Spark Gap Arrester) shall be connected across each
insulating joint to protect it from high voltage surges.
6.4.4
Alternatively, zinc grounding cell may be provided across insulating joints along
ROW where the pipeline on both the sides of the insulating joint are cathodically
protected and difference of protection voltage is not more then 0.4 volts.
Alternatively, owner on its own discretion may permit use of Magnesium / Zinc
galvanic anodes for protection of insulating joints. Choice between Magnesium or
zinc anodes shall depend upon the potential valves on either side of the insulating
joint. These anodes shall be sized for the specified design life of permanent cathodic
protection system.
6.4.5
The total system including cables, cable termination, anodes/ surge diverters,
polarization cells shall be suitable for the anticipated fault current at the location of
installation.
6.4.6
Unless otherwise specified on data sheet, the minimum rating of grounding cells,
polarisation cells and surge diverters shall be as below:
(i)
(ii)
(iii)
Grounding Cell
Type
Current rating
:
:
Polarisation cell
Type
Rating
Spark gap
100 kA
1 kV
2.2 kV
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EDITION : 1
micro sec)
6.4.7
The grounding cell, Surge Diverter (Spark Gap Arrester), and polarisation cell
system shall be sized for the design life of permanent CP system. The zinc or
magnesium anodes meant for pipeline grounding shall also be sized for the life of
the permanent CP system taking into account the current discharge from the
anodes. The grounding system shall have minimum resistance to earth to restrict the
pipeline voltage as per NACE / VDE criteria but shall not exceed 5 ohms. The
anodes shall be pre packed with special backfill adequately so that the performance
of the anode is not affected by the carbonates, bicarbonates, nitrates, etc. present in
the soil. In any case, the thickness of back fill shall not be less than 50 mm on all the
sides of the anode.
6.4.8
6.4.9
Motor operated valves where located on the cathodically protected portion of the
pipeline shall be grounded by a zinc or magnesium anode of 20 kg net where the
type of anode provided for the CP system of the pipeline is zinc or magnesium
respectively. The MOV power supply cable armour shall be insulated (by cutting and
taping with insulation tape) at MOV end to avoid armour carrying CP current.
6.4.10
6.5
6.5.1
6.5.2
The material of the E/R probe element shall be of the same alloy as of the pipeline
material. The E/R probes shall be provided preferably at the bottom portion of
pipeline. The locations of E/R probes shall be got approved. Portable E/R probe
reading instrument shall be supplied by contractor.
6.6
CP at Cased Crossing
At cased crossings where casing is coated, the casing shall be protected by
sacrificial anode installations. The sacrificial anode installations shall be provided at
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both ends of casing. The anode installation shall be sized based on permanent C.P.
design parameters specified for the main pipeline. At cased crossings where casing
is painted or uncoated, additional protection for casing pipes may not be provided.
The carrier pipe inside the casing shall be protected by zinc ribbon anodes weld
connected to the outer surface of bottom of carrier pipe extending upto hour hand
positions of 4 and 8 o'clock. The anodes shall be placed at close intervals as per
design calculations with minimum one number of anodes installed between every two
supports provided between carrier & casing and sized based on the permanent CP
design parameters for marshy area and design life of permanent CP system.
6.7
6.8
Painting
The sheet steel used for fabrication shall be thoroughly cleaned and degreased to
remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and
then rinsed to remove any trace of acid. The under surfaces shall be prepared by
applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The
under surfaces shall be free from all imperfections before undertaking the finished
coat. After preparation of the under surface, spray painting with two coats of final
paint shall be done. The finished panel shall be dried in oven in dust free
atmosphere. Panel finish shall be free from imperfections like pin holes, orange
peels, run off paint, etc.
All unpainted steel parts shall be cadmium plated to prevent rust information.
6.9
Cables
Cables shall be annealed high conductivity, tinned, stranded copper conductor,
XLPE insulated 650/1100 V grade, armoured, PVC sheathed. The size of the copper
conductor shall be 6 sq mm for anode cable from anode to buried junction box, 10 sq
mm from junction box to test station, 10mm from test station to pipeline. The size of
the conductor shall be 6 sq mm for potential measurement, 10 sq.mm for current
measurement and 25mm for bonding, polarisation cell/grounding cell and surge
diverter connection purpose. The anode cable from anode to junction box (buried)
shall be unarmoured. The length of anode tail cable shall be sufficient enough to
reach junction box (buried) in case of temporary CP anodes and up to test station in
case of permanent CP sacrificial anodes. PE Sleeves shall be provided for
unarmoured cables.
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7.0
INSTALLATION
7.1
Cable Laying
7.1.1
7.1.2
All cables inside station/plant area shall be laid at a depth of 0.75 M. Cables outside
station/plant area shall be laid at a depth of 1.5m. Cables shall be laid in sand under
brick cover back filled with normal soil. Outside the station/plant area the routes shall
be marked with Polyethylene cable warning mats placed at a depth of 0.9m from the
finished grade.
7.1.3
All underground unarmoured cables forming part of permanent CP system shall run
through PE sleeves. Cables along the pipeline shall be carried along the top of the
pipe by securely strapping it with adhesive tape or equivalent as required.
7.1.4
RCC of proper size shall be provided for all underground cables for road crossings.
7.1.5
7.1.6
In case of above ground cable, all unarmoured CP cables shall be laid in GI conduits
of sufficiently large size, up to accessible height for protecting against the
mechanical damage.
7.1.7
The armour of all the cables from pipeline to test station (potential measurement,
reference cell cables, cathode cables, etc.) and test station to ground bed (anode
cable) shall be earthed only at test station end of the cable to avoid armour carrying
CP current. The cable armour shall be insulated by cutting and taping with insulation
tape.
7.2
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EDITION : 1
CIVIL WORKS
All civil works associated with the complete cathodic protection work shall be
included in the scope of contractor. This shall include providing cable trenches,
foundation for equipment and all test stations, etc.
9.0
9.1
9.2
The minimum testing, inspection requirements for all components/ equipments shall
confirm to the requirements as defined in the relevant codes and standards. Detailed
inspection and testing procedures along with the acceptance criteria shall be
prepared by CONTRACTOR for OWNER's approval.
9.3
Test certificates including test records, performance curves etc., shall be furnished.
All test certificates shall be endorsed with sufficient information to identify equipment
to which the certificate refers to and must carry project title, owner's name and
purchase order details etc.
9.4
Owner reserves the right to ask for inspection of all or any item under the contract
and witness all tests and carry out inspection or authorise his representative to
witness test and carry out inspection. CONTRACTOR shall notify the OWNER or
OWNER's representative at least 20 days in advance giving exact details of tests,
dates and addresses of locations where the tests would be carried out.
10.0
11.0
11.1
11.1.1
Contractor shall furnish the detailed field testing and commissioning procedure for
approval. Field tests as per the approved procedures shall be carried out on the
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EDITION : 1
equipment/systems before being put into service. the acceptance of the complete
installation shall be contingent upon inspection and field test results.
11.1.2
Before the CP facilities are placed in operation all necessary tests shall be carried
out to establish that all equipment, devices, wiring and connection, etc., have been
correctly installed, connected and are in good working condition as required for
intended operation.
11.1.3
Owner/owner's representative may witness all the tests. At least one week's notice
shall be given before commencing the tests.
11.1.4
All tools, equipments and instruments required for testing shall be provided by
CONTRACTOR.
11.1.5
Generally following tests shall be carried out and recorded in proforma given in
subsequent clauses:
Checking
Inspection
Testing
Cable no.
Voltage grade
Conductor cross-section
Continuity check
Voltage test
Insulation resistance values between core to earth and
between cores
All cables shall be tested by 500 V megger
Cables
Insulating joint
Checking of insulating joint for leakage, before and after energisation of C.P. by
means of insulating joint tester. Pipe to soil potential of both protected and nonprotected sides of insulating joint shall be checked before and after energistaion of
CP system.
Polarisation cell
Location/identification number
Rating
Check for electrolyte
Check for wiring
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EDITION : 1
Check for standby current drain with CP energisation (current drain with
respect to voltage across the cell shall be recorded)
Details of grounding provided for polarization cell.
Grounding cell
-
Location
Type (no. of anodes)
Ratings
Surge diverter
-
Location/identification no.
Ratings
Check for healthiness
Explosion proof enclosure
Check for proper connection.
E/R Probe
-
11.2
Commissioning
11.2.1
Natural pipe to soil potential shall be measured at each test station location and
casing pipeline at the locations of cased crossings prior to connecting anodes to
pipeline. The pipe to soil potential observation shall be repeated after connecting the
anodes after allowing sufficient time for polarisation. The current output of the anode
installation shall also be measured to ensure that it does not exceed the output
current capacity of the anodes. In case the anode output current exceeds the rated
capacity it shall be controlled by insertion of resistance element in the anode circuit
inside test station and the pipe to soil potential shall be rechecked for adequacy of
protection. Additional anodes shall be provided where required to achieve desired
level of protection. In case pipe to soil potential exceeds the specified value, suitable
resistance shall be inserted in the anode circuit to limit the potential.
Each anode installation shall become individually operational as above.
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11.2.2
After connecting all the anode ground beds to pipeline, measurement of pipe to soil
potentials shall be taken at each test station to ensure conformity to protection
criteria.
11.2.3
In case of insufficient protection as per the CP design criteria on any portion of the
pipeline, CONTRACTOR shall carry out necessary additions modification to the
provided protection in consultation with the OWNER / OWNERs Representative.
11.2.4
Resistance readings of the probe shall be taken at all the locations of electrical
resistance probes.
11.3
Interference Mitigation
11.3.1
Investigation shall be made for stray current electrolysis of the pipeline, mutual
interface between the pipeline and foreign pipelines / structures, interference on
foreign pipeline / structures due to the CP of the pipeline and ground bed. AC
induction on pipeline due to overhead high voltage line, interference due to high
voltage DC lines & grounding, electric traction, etc.
11.3.2
Where transmission lines cross the pipeline or run in parallel within or more than
25m from the pipeline, AC voltage measurements shall also be made on the pipeline
to find out continuous induction of voltage. In case of induced voltage being beyond
safe limits, the pipeline shall be grounded in line with clause no. 6.4 above.
11.3.3
Measurements including pipe to soil potential and pipeline current etc., on the
pipeline/structure being CP protected shall be made to investigate the current
discharge and collection locations.
In case of fluctuating stray currents investigation shall be made continuously over a
period of time and if required simultaneously at different locations to find out the
stray current source. For long time measurements, recorders shall preferably be
used.
11.3.4
11.3.5
11.3.6
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
TEMPORARY CATHODIC
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DOCUMENT NO.
Page 20 of 22
MEC/S/05/21/016A
REVISION : 0
EDITION : 1
Galvanic anodes installed as a mitigation measure shall be sized for the life specified
for permanent CP.
12.0
SYSTEM MONITORING
The temporary CP system provided shall be monitored at all the test stations once in
a month for healthiness/adequacy of protection till commissioning of permanent CP
or for design life of temporary CP specified, whichever is less. During this period if
any deficiency/interference in protection system is noticed the same shall be
rectified/augmented by additional anodes as required. The monitoring report shall be
submitted regularly to owner for his review/information.
13.0
13.1
General
13.1.1
Within three weeks from the date of issue of PURCHASE ORDER, CONTRACTOR
shall submit four copies of the list of all drawings/ data/ manuals/ procedures for
approval, identifying each by a number and descriptive title and giving the schedule
date. This list shall be revised and extended, as necessary, during the progress of
work
13.1.2
All drawings and documents shall be in English and shall follow metric system.
Number of copies of each submission shall be as follows unless otherwise specified.
Submission
a.
For review/approval
b.
c.
d.
No. of Copies
6
6
6
13.2
13.2.1
As a part of the contract, drawings and documents shall be furnished which shall
include but not be limited to the following:
a.
b.
c.
13.2.2
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
TEMPORARY CATHODIC
PROTECTION SYSTEM
a.
b.
c.
d.
e.
f.
g.
h.
DOCUMENT NO.
Page 21 of 22
MEC/S/05/21/016A
REVISION : 0
EDITION : 1
i.
j.
k.
l.
Miscellaneous
Equipment inspection and testing procedure
Construction, installation procedures
Field testing and commissioning procedures
Procedure for monitoring of cathodic protection after commissioning
Quality control procedures
14.0
14.1
CONTRACTOR shall supply all instruments, tools and tackles necessary for
proper operation and maintenance of complete cathodic protection system and
associated equipment.
14.2
CONTRACTOR shall provide a list of spares and consumables required for proper
operation and maintenance of part of cathodic protection system to be integrated
with permanent CP system designed on the basis of permanent CP design
parameters and associated equipment, for two years operation of the system.
15.0
Basis and calculations for preliminary system design for cathodic protection
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
TEMPORARY CATHODIC
PROTECTION SYSTEM
b.
c.
d.
e.
f.
g.
h.
i.
DOCUMENT NO.
Page 22 of 22
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EDITION : 1
system.
List of formulas to be used for detailed system design calculations.
Basis of system design, design calculations, equipment selection criteria,
sizing calculations along with characteristics curves for various equipments.
Preliminary bill of material for major equipment.
Details of the equipment/material offered along with technical leaflets/related
literatures/catalogues, make, rating, type test certificates.
Dimensions, weight and general arrangement drawings for each offered
equipment.
List of instruments, tools and tackles offered for maintenance and operation.
List of recommended maintenance/operation spares.
Clause-wise deviations, if any, to the specifications along with justifications.
Rev. : 1
SPECIFICATION
FOR
PERMANENT CATHODIC
PROTECTION SYSTEM
MECON LIMITED
REGD. OFF:
RANCHI 834002
TITLE
PERMANENT CATHODIC
PROTECTION SYSTEM
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
CONTENTS
1.0
SCOPE
2.0
3.0
SYSTEM IMPLEMENTATION
4.0
CORROSION SURVEY
5.0
6.0
7.0
SYSTEM DETAILS
8.0
INSTALLATION
9.0
10.0
11.0
12.0
INTERFERENCE MITIGATION
13.0
14.0
15.0
16.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Amit Lavania)
(D.K. Pandey)
(D.K. Pandey)
March, 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PERMANENT CATHODIC
PROTECTION SYSTEM
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Rev.
By
Date
Name
Verified
Sig.
Name
Sig.
MECON LIMITED
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DOCUMENT NO.
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MEC/TS/05/21/016B
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EDITION : 1
1.0
SCOPE
1.1
1.2
2.0
2.1
ii)
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
ii)
iv)
v)
vi)
vii)
IS 8062
viii)
BS 7361 Part I
ix)
VDE 0150
x)
xi)
IS : 7098 Part I
IS : 1554 Part I
:
:
2.2
2.3
The equipment shall also confirm to the provisions of Indian Electricity rules
and other statutory regulations currently in force in the country.
2.4
3.0
Statutory regulations.
Data sheets.
Job specification.
This specification.
Codes and standards.
SYSTEM IMPLIMENTATION
All work to be performed and supplies to be effected as a part of contract shall
require specific approval of owner or his authorised representative. Major activities
requiring approval shall include but not limited to the following :
MECON LIMITED
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
a)
b)
c)
d)
e)
f)
g)
h)
i)
Corrosion survey data interpretation report and plot plans for land acquisition.
Conceptual system design.
Basic engineering package.
Purchase requisition for major equipment and vendor approval.
Detailed engineering package.
Field testing and commissioning procedures.
Procedures for interference testing and mitigation.
CPL survey procedure.
As built documentation.
4.0
CORROSION SURVEY
4.1
General
4.1.1
The details of corrosion survey including soil resistivity data along the right of way
and other data required for CP design if available with owner shall be included as
part of project specification. However, verification of its veracity and adequacy shall
be the entire responsibility of the contractor. In addition contractor shall have to
generate / collect additional data required for completeness of the job.
4.1.2
To carry out soil resistivity measurement (at pipeline depth) Wenners 4-pin method
or an equivalent method approved by owner shall be used. Survey instruments shall
have maximum AC and DC ground current rejection feature.
Care shall be taken to ensure that the resistivity observations are not
influenced by the presence of foreign pipelines/ structures, and earth currents
in the vicinity of EHV/HV lines and installations using earth return in their
power system etc.
4.2
4.2.1
Each selected anode bed plot shall be sub- divided into sub-plots. Sizes of sub-plots
shall depend upon the expected depth for soil resistivity investigations. Each of these
sub-plots shall be investigated for restivity data individually. Sufficient observations
shall be taken at each of these sub-plots as required and desired by Owner/ Owners
representative to obtain sufficient information about sub- soil stratification and,
wherever possible, to establish the depth of water table/ basement. The number of
subplots at each ground bed plot may very from six to ten. The exact number of subplots etc shall be decided at site in consultation with OWNER/ OWNERs
representative.
4.2.2
Number, location, demarcation and size of sub-plots and number of sets of resistivity
observations required for each sub-plot shall be individually decided for each ground
bed plot location.
4.2.3
One or more ground bed plots may be required to be selected and surveyed at each
CP station to form a suitable ground bed.
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DOCUMENT NO.
Page 4 of 26
MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
4.3
Topographic Surveys
Cathodic protection stations consisting of anode ground bed, CP power supply
equipment etc. alongwith all associated cabling upto pipeline and any other related
equipment and accessories for CP stations shall be demarcated on the ground.
Ground plots so demarcated shall be surveyed for all other topographical and
cadestral features and topo- sheets shall be developed by the CONTRACTOR which
should be suitable for use in land acquisition etc.
4.4
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
Route and types of foreign services / pipeline in and around or crossing the
right of way (including those existing and those which are likely to come up
during contract execution).
Diameter, wall thickness, pressure, soil cover, and coating scheme used in
case of pipelines.
Details of the existing cathodic protection system protecting the services i.e.
location, type of protection, anode beds, test station locations and their
connection scheme. Present output of current and voltage readings of CP
power supply units.
Remedial measures existing on foreign pipeline/ services to prevent
interaction.
Graphical representation of existing structure/ pipe-to-soil potential records,
T/R unit current / voltage readings.
Possibility of integration / isolation of CP systems which may involve
negotiations with owners of other services.
Information on existing and proposed DC/AC power sources and system
using earth return path in the vicinity of the entire pipeline route such as
HVDC/ earthing stations/ substations, fabrication yards with electric welding
etc.
Crossing and parallel running of electrified and non-electrified traction
(alongwith information regarding operating voltage, AC/DC type etc.) as well
as abandoned tracks near ROW having electrical continuity with the tracks in
use and the track to soil potential measurement using Cu to CuSo4 half cell
after tracks in use.
Crossing or parallel running of any existing or proposed HT AC/DC overhead
power lines alongwith details of voltage, AC/DC type etc.
Voltage rating, phases, sheathing details of underground power cables along
ROW or in its vicinity.
Any other relevant information that may be needed in designing and
implementation proper protection scheme for the proposed pipeline.
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
PERMANENT CATHODIC
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DOCUMENT NO.
Page 5 of 26
MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
Report
On completion of all field work, a report incorporating all the results generated from
surveys and details of additional data collected shall be furnished. The report shall
also contain detailed interpretation of survey results and resistivity data enclosed,
probable interference prone areas etc. to form a design basis for the scheme of
cathodic protection. This report shall also include various drawings prepared in
connection with the above work. The soil resistivity values shall be plotted on semilog
graph sheets.
5.0
5.1
ii)
The pipe to soil ON potential must not exceed a value more negative than (-) 1.5V.
*
Actual current density to be adopted shall be decided based on soil and other
environmental conditions, proximity of foreign pipelines and structures and
other interference areas affecting the installation.
Where considered
necessary for satisfactory protection of pipeline, the current density shall be
suitably increased by Contractor.
5.2
Safety Factor
(SF)
: 1.3
5.3
(I2)
: 10 mA/m2
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DOCUMENT NO.
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REVISION : 0
EDITION : 1
5.4
Service Life
5.5
Type of Anode
5.6
5.7
5.8
: 10mm2
5.9
5.10
5.11
: String Anode
5.12
5.13
5.14
5.15
5.16
Steel resistivity
5.17
5.18
5.19
(SL)
: 30 years
: MMO Coated Titanium Anode/ HiSiCr
Fe Anode
0.2 kg/amp Year for HiSiCrFe anode
2.0 mg/ Amp Year for MMO Titanium
anode
2
: 10,000 ohm/m for normal soil
4,500 ohm/m2 for marshy area
15,000 ohm/m2 for high resistvity area
: (-) 0.45 V
MECON LIMITED
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DOCUMENT NO.
Page 7 of 26
MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
6.0
ii)
iii)
7.0
The pipe to soil potential measurements shall be between (-) 0.95 V (Off)
& (-) 1.25 V (Off) with respect to a copper/ copper sulphate reference
electrode.
In rare circumstances, a minimum polarisation shift of (-) 100 millivolts may
be accepted as an adequate level of cathodic protection for the pipeline with
the written approval of owner.
Discretion to use any of the criteria listed above shall solely rest with the
owner/ owners representative.
A positive potential swing of 50 to 100 millivolts shall be considered as
sufficient to indicate the presence of an interaction situation requiring
investigation and incorporation of mitigation measures by the
CONTRACTOR.
SYSTEM DETAILS
The system shall include the following major equipment / sub-system unless
otherwise specified in project specifications :
CP stations
TR units/ cathodic protection power supply modules (CPPSM).
Anode ground beds and anodes.
Anode lead junction box.
Test stations.
Permanent reference cells.
Electrical resistance probes.
Polarisation cell/ surge divertor/ grounding cell.
CP system at cased crossing.
Cables.
Cathode Junction Box.
The detailed specification of each system and equipment shall be furnished by the
CONTRACTOR. However, certain minimum requirements for the major equipment
are highlighted in this document.
All equipment shall be new and procured from approved reputed manufacturers.
Equipment offered shall be filed proven. Equipment requiring specialised
maintenance or operation shall be avoided as far as possible. Prototype equipment
shall not be accepted. Make and construction of all materials shall be subject to
owners approval.
As far as possible, equipment including test stations, anode lead junction boxes etc.
shall be located in safe non-hazardous areas. However, all equipment to be installed
in hazardous areas shall be of flameproof type confirming to IS:2148 and suitable for
gas groups IIA & IIB and temperature class T3.
MECON LIMITED
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TITLE
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
7.1
ii)
iii)
Number of CP stations and their selected location shall ensure that these
remain valid and are adequate for the full design life of the system after
considering all foreseeable factors.
As far as possible, the availability of near by low resistivity areas for location
of associated ground beds must be ensured while selecting the locations of
CP stations.
As far as possible, locations of intermediate CP stations shall co-incide with
the locations of SV stations.
The proposed location of CP stations are detailed in project specifications. The same
shall be verified for adequacy by the contractor and any additional requirements shall
be clearly brought out at the bidding stage itself.
7.2
7.2.1
7.2.2
Cathodic Protection Power supply Module (CPPSM) for supply of power to Cathodic
Protection System shall work on DC input power supply & control the output DC
supply using power switch mode principle. The CPPSM shall be field proven. The
design, internal components, quality, rating & layout of components shall ensure high
MTBF & low MTTR. The CPPSM shall conform to MECON Standard Specification
No. MEC/TS/05/62/072A and CPPSM Data Sheet.
7.3
Each CP station shall have an independent anode ground bed which may be
of shallow or deep well construction depending upon the corrosion data
collected by the contractor. Deep well ground beds may also be used in the
congested locations where availability of suitable land for spread out ground
beds is restricted.
MECON LIMITED
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
ii)
iii)
Ground bed shall be located electrically remote from the pipeline. Nearest
part of the anode bed shall atleast be 100 metres away from the pipeline and
foreign pipelines/ structures. The anodes installed in the ground shall be
located in perennially moist strata, wherever possible. Horizontal ground beds
shall be at right angles to the pipeline, as far as possible.
The location of ground bed shall be checked and ensured for
remoteness from the pipeline and other burred foreign pipelines/
structures, building foundations, switchyards, electrical earthing
systems etc.
Anodes shall be of MMO coated titanium anode or HiSiCrFe anode. alongwith
tail cable.
MMO Titanium Anode
Max. Recommended
Current density
Service Life
Anode Cable
Cable Length
As per manufacturers
recommendation
Recommended by manufacturer
w.r.t. dimension
100 A/m2
35 years
Single MMO Anode XLPE/PVC
Streng MMO Anode EPR/CSPE
As required
iv)
:
:
:
:
:
:
14.2 14.75%
1.5% max.
0.7 1.1%
3.25 5.0%
:
0.5% max.
0.2% max.
Reminder
The anode shall be hollow type centrally connected or solid type end
connected, cable to anode joint shall be reliable and adequate for derigh life
of anode.
Sheet steel anode canisters of adequate size shall be provided for each
anode of Shallow bed type. Anode canisters shall be filled with petroleum
coke breeze with a Chemical Composition as given below:-
MECON LIMITED
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834002
TITLE
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
String anode shall be used for days well ground bed. In case of deep well
ground beds calcined fluid petroleum coke breeze with chemical composition
as given below shall be provided in the well surrounding the anodes.
v)
vi)
vii)
viii)
ix)
x)
xi)
7.4
Each shallow anode bed shall contain anodes with canisters positioned
horizontal or vertical in the soil with suitable backfill at minimum depth of 2
meter with respect to configuration horizontal or vertical
Layout of anode installation in anode bed shall be detailed out in drawings
showing anode installation details, anode grouping, anode wiring, anode
cable routing etc.
The deepwell anode ground bed details shall include the details of anodes,
deepwell casing, anode positioning, anode cable supporting, deepwell gas
venting, active, passive portions of ground bed etc.
Anodes shall be supplied complete with tail cables which shall be long
enough for termination on their associated junction boxes without
intermediate joints. Exact lengths and termination details shall be indicated in
construction drawings by Contractor.
Anode bed separation from pipeline shall be tested for interference.
Potential gradient around the anode bed shall be within safety requirements
and its effective boundary shall be defined and secured.
In case two parallel pipelines running in the same ROW. The anode ground
beds of respective pipelines shall be located on the respective sides of the
pipelines.
The depth of deepwell anode ground bed shall be sufficient enough to reduce
anode influence on incidental structures within proposed location.
ii)
Depending on the size and configuration of anode ground beds, one or more
anode junction boxes shall be provided at each ground bed.
All cable tails from individual anodes shall be terminated onto these anode
junction boxes which shall be further connected to anode cable coming from
CP station power source.
Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness
and hinged lockable shutters. They shall be weatherproof with degree of
protection IP-55. Junction boxes shall have anode bus and terminal plate with
adequate number of antiloosening type of identified terminals. Provision shall
be made for measurement and control of individual anode current by
providing suitable shunt and resistors. Anode disconnecting link shall be
provided for each anode circuit. 30% spare terminals shall be provided.
MECON LIMITED
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DOCUMENT NO.
Page 11 of 26
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REVISION : 0
EDITION : 1
iii)
7.5
7.6
Test Stations
i)
Test stations shall be provided along the pipeline ROW for monitoring the
performance of the cathodic protection system at intervals not exceeding
1000 meters. In addition to above, test stations shall also be provided at the
following locations :a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
MECON LIMITED
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REVISION : 0
EDITION : 1
o)
ii)
iii)
iv)
v)
vi)
vii)
7.7
Test stations with current measuring facility shall be provided at interval not
exceeding 3.0 KM, at each intermediate CP station drainage point (to measure
pipeline current on any one side of pipeline from drainage point), at
interference prone areas, on both sides of major river crossings and at least at
two additional locations along the pipeline ROW between two CP stations.
All test stations shall have weatherproof enclosure, with hinged lockable
shutter and degree of protection IP-55. Enclosure shall be made of sheet
steel of atleast 3 mm thickness and shall be suitable for MS post mounting.
Test station shall be installed with the face of the test station facing the
pipeline. The nameplate of test stations shall carry the following minimum
information:
Test station number
Chainage in Km.
Test station connection scheme
Distance from pipeline in mtrs.
Direction of product flow.
Number of terminals and different schemes of wiring shall be as per the test
station connection scheme sketch. Minimum twenty percent spare terminals
shall be provided in each test station.
The location of all the test station shall be marked with their connection
scheme and other relevant information on alignment sheets. A detailed teststation schedules shall be prepared.
ii)
iii)
iv)
v)
High purity copper / copper sulphate reference cells with proven high
reliability shall be provided for stable pipe to soil potential measurement
reference at CP stations and at computerized test station locations along
ROW.
Three numbers reference electrodes shall be installed at each cathodic
protection station.
The reference cell for high resistivity areas shall be suitable for the prevailing
dry soil conditions to give maximum service life.
Permanent reference cells shall be installed with backfill material.
Silver/ Silver Chloride reference cells in place of copper / copper sulphate
cells shall be provided at marshy area locations where water table is high and
sub-soil water or soil shows chlorine concentration more than 300 PPM.
MECON LIMITED
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DOCUMENT NO.
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REVISION : 0
EDITION : 1
vi)
vii)
7.8
The cable from reference cells shall be provided upto CP power source at CP
stations. The cable shall be routed through cathod junction box near pipeline.
The life of reference cell shall be minimum 20 years under installed condition.
7.9
ii)
iii)
iv)
Where high voltage (66 KV and above) transmission line runs in parallel or
crosses the pipeline, the pipeline shall be grounded through polarisation cells
& zinc anodes of minimum 20 kg net each. Alternatively, grounding could be
done directly with zinc galvanic anodes of minimum 20 kg net each at the
discretion of owner. Grounding shall be done at regular intervals of maximum
01 km where transmission lines run parallel within 25 meter of the pipeline to
ground any surges on the pipeline that would appear in case of transmission
line faults.
In case of continuous induction of voltage on the pipeline beyond safe limits
is expected or observed during commissioning due to HV Line of any rating
or others equipment., the pipeline shall be grounded to the earth system of
nearest HV transmission tower of the transmission line causing the voltage
induction through polarisation cell or the pipeline shall be grounded to a
separate earthing system of zinc galvanic anodes through polarisation cell.
Alternatively, the pipeline shall be directly grounded with zinc galvanic anodes
of minimum 20 kg net each at the discretion of the owner. The polarisation
cell shall be installed in test station.
Spark gap arrestor alongwith zinc ground cell shall be connected across each
insulating joint to protect it from high voltage surges.
Alternatively, zinc grounding cell may be provided across insulating joints
along ROW where the pipeline on both the sides of the insulating joint are
cathodically protected and difference of protection voltage is not more then
0.4 volts.
MECON LIMITED
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DOCUMENT NO.
Page 14 of 26
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REVISION : 0
EDITION : 1
v)
vi)
The total system including cables, cable termination, anodes/ surge divertors
shall be suitable for the anticipated fault current at the location of installation.
Unless otherwise specified on data sheet, the minimum rating of grounding
cells, polarisation cells and surge diverters shall be as below:
a)
Grounding Cell
Type
:
Current rating :
b)
Polarisation cell
Type:- Solid station Electrolytic tie multi pairs S.S plate grounding cell.
c)
Type
:
Current, 8/20
:
micro second wave
Spark- over, AC Voltage
50 Hz
:
Impulse (1.2/50
:
micro sec)
vii)
viii)
ix)
x)
Spark gap.
100 Kilo Amp.
1 KV
2.2 KV
The grounding cell, spark gap arrester and polarisation cell system shall be
adequately sized and suitable for the design life of permanent CP system.
The directly buried zinc or magnesium anodes shall also be adequately sized
for the life of the permanent CP system, taking into consideration discharge
from the anodes. The grounding system shall have minimum resistance to
earth to restrict the pipeline voltage as per NACE Criteria but shall not exceed
5 ohms.
The anodes shall be pre packed with special backfill adequately so that
the performance of the anode is not affected by the carbonates,
bicarbonates, nitrates, etc. present in the soil. In any case, the
thickness of back fill shall not be less than 50mm on all the sides of the
anode.
Motor operated valves where located on the cathodically protected
portion of the pipeline shall be grounded by a zinc anode of 20 kg net.
Magnesium anodes grounding, if any, provided during temporary CP
system shall be disconnection. The MOV power supply cable armour
shall be insulated (by cutting and taping with insulation tape) at MOV
end to avoid armour carrying CP current.
The above ground cathodically unprotected pipeline at terminals,
intermediate SV stations, pigging station, etc. shall be earthed with GI
earth electrodes. The resistance to earth of grounding shall be limited
to 5 ohms max.
MECON LIMITED
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DOCUMENT NO.
Page 15 of 26
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REVISION : 0
EDITION : 1
xi)
7.10
CP at cased crossing
i)
ii)
7.11
7.12
Painting
The sheet steel used for fabrication shall be thoroughly cleaned and degreased to
remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and
then rinsed to remove any trace of acid. The under surface shall be prepared by
applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The
under surface shall be free from all imperfections before undertaking the finishing
MECON LIMITED
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TITLE
PERMANENT CATHODIC
PROTECTION SYSTEM
DOCUMENT NO.
Page 16 of 26
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REVISION : 0
EDITION : 1
coat.
After preparation of the under surface, spray painting with two coats of final paint
shall be done. The finished panels shall be dried in ovens in dust free atmosphere.
Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint
etc. Bidder shall furnish detailed painting procedure alongwith bids.
All unpainted steel parts shall be cadmium plated to prevent rust formation.
7.13
Cables
i)
ii)
iii)
7.14
MECON LIMITED
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TITLE
PERMANENT CATHODIC
PROTECTION SYSTEM
DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
8.0
INSTALLATION
8.1
Cable Laying
i)
ii)
iii)
iv)
v)
vi)
8.2
8.3
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
8.4
Civil Works
All civil works as per enclosed specifications associated with the complete cathodic
protection system are included in scope of contractor. This shall include providing
cable trenches and foundations for all equipment, outdoor T/R units, anode lead
junction boxes, all test stations, polarisation cells, etc.
9.0
ii)
iii)
iv)
10.0
11.0
11.1
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
i)
ii)
iii)
iv)
v)
a)
-
Cables
Cable no.
Voltage grade.
Conductor cross section
Continuity check
Voltage test
Insulation resistance values between each core & earth, between cores.
E/R Probe
Location / Identification number
Checking of wiring as per schematics
Resistance reading of probe
c)
-
Reference Cell
Location
Potential reading
Type of cell
d)
Insulating Joint
Insulation resistance across the joint shall be checked before and after
charging the pipeline by means of insulating joint tester. Pipe to soil potential
of both protected and non-protected sides of the insulating joint shall be
MECON LIMITED
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
11.2
e)
-
Surge Diverter
Location / identification number
Rating
Check for healthyness
f)
-
Polarisation Cell
Location / Identification number
Rating
Check for electrolyte
Check for wiring
Check standby current drain after CP system energisation. (Current drain
with respect to voltage across the cell shall be recorded).
Details of grounding provided for the polarisation cell.
g)
-
h)
-
i)
-
Grounding Cell
Location
Type / no. of anodes
Ratings
CP Commissioning Procedure
A model commissioning procedure for a 2 station CP system of a pipeline is given
below for general guidance. Contractor shall develop detailed commissioning
procedure as per this guideline and get it approved before commencing CP system
commissioning activities.
i)
ii)
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MEC/TS/05/21/016B
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EDITION : 1
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
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MEC/TS/05/21/016B
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EDITION : 1
xiv)
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DOCUMENT NO.
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MEC/TS/05/21/016B
REVISION : 0
EDITION : 1
INTERFERENCE MITIGATION
12.1
Investigation shall be made for stray current electrolysis of the pipeline, mutual
interference between the pipeline and foreign pipelines / structures, interference on
foreign pipelines / structures due to the CP of the pipeline and ground bed,
interference on metallic structures which lie in between pipeline and ground bed or
near to ground bed, AC induction on pipeline due to overhead high voltage power
lines, interference due to high voltage DC lines, electric traction, HV earthing system
etc.
12.2
Measurements including pipe to soil potentials and pipe currents etc. on the pipeline
/ structure being CP protected and on foreign pipelines / structures, and ground
potential gradient etc. shall be made to investigate the current discharge and pickup
locations. In case of fluctuating stray currents, investigations shall be made
continuously over a period of time and if required simultaneously at different
locations to find out the stray current source (s). Recorders shall be preferably be
used for long time measurements.
12.3
12.4
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MEC/TS/05/21/016B
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EDITION : 1
12.5
Where high voltage (66 KV and above) transmission lines run in parallel or cross the
pipeline, the pipeline shall be grounded through polarisation cells at regular intervals
to ground any surge on the pipeline that would appear in case of transmission line
faults. Alternatively, grounding could also be done with galvanic anodes (Magnesium
or Zinc depending on pipeline voltage) at the discretion of the owner. These
grounding installation shall be provided wherever transmission lines run within 25
mtr. of the pipeline.
A.C. voltage measurements shall also be made on the pipeline to find out continuous
induction of voltage beyond safe limits. In such a case, the pipeline shall be
grounded to the earth of nearest transmission tower causing voltage induction
through polarization cell or to a separate earthing system of zinc anodes through
polarization cell.
13.0
14.0
14.1
General
i)
Within three weeks from the date of issue of Purchase Order, Contractor
shall submit four copies of the list of all drawings / data/ manuals /
procedures to be submitted for approval, identifying each document by a
number and descriptive title and schedule date. This list shall be revised and
extended, as necessary, during the progress of work.
ii)
All drawings and documents shall be in English and shall follow metric
system. Number of copies for each submission shall be as follows unless
specified otherwise :
Submission
a)
No. of copies
6 copies
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DOCUMENT NO.
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EDITION : 1
14.2
b)
6 copies
c)
d)
Operation / Maintenance
Manual, Vendor data
6 copies
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
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EDITION : 1
m)
n)
o)
p)
15.0
ii)
16.0
Various measurement data at all relevant test stations with and without
mitigation measures provided.
Detailed commissioning report including various measurement data at all test
stations.
Vendor drawings and catalogues, test certificates.
Operation and maintenance manual.
Miscellaneous
Equipment inspection and testing procedures.
Construction, installation procedures.
Field testing and commissioning procedures.
Procedures and report on close interval potential survey.
Procedure for monitoring of cathodic protection after commissioning.
Quality control procedure.
Contractor shall provide a list of all instruments, tools and tackles necessary
for proper operaiton and maintenance of complete cathodic protection system
and associated equipemnt alongwith prices.
Contractor shall provide a list of spares and consumables required alongwith
prices for proper operaiton and maintenance of complete cathodic protection
system and associated equipment for two years operaiton of the system.
Edition : 1
SPECIFICATION
FOR
CORROSION SURVEY
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TITLE
CORROSION SURVEY
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/016C
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION
1.0
SCOPE
2.0
3.0
GENERAL
4.0
5.0
6.0
7.0
REPORT
8.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Amit Lavania)
(Sunil Kumar)
(A.K. Johri)
Feb. 2009
MECON LIMITED
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TITLE
CORROSION SURVEY
DOCUMENT NO.
Page 1 of 4
MEC/S/05/21/016C
REVISION : 0
EDITION : 1
1.0
SCOPE
The specification covers the corrosion survey including measurement of soil
resistivity, chemical analysis of soil/ water and other cathodic protection related data
collection along right of way of the pipelines.
2.0
3.0
GENERAL
This specification defines the basic guidelines for carrying out the corrosion survey.
Contractor shall be responsible for providing necessary data interpretation based on
corrosion survey measurement which is intended to form a basis for design of
cathodic protection system for the pipeline to be burried along ROW.
4.0
4.1
Unless otherwise specified the soil resistivity measurements shall be carried out at
intervals of approximately 500 mtr. along the ROW. Where soil resistivity is less than
100 ohm mtr and two successive readings differ by more than 2:1 then additional soil
resistivity readings in between the two locations shall be taken.
4.2
4.3
At places where Right-of-way has not yet been cleared measurement shall be made
right over the centre line of pipeline route surveyed accounting for the cuttings/
fillings also.
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EDITION : 1
4.4
Observations shall be made enclosing the soils adjoining the trench wherever
pipeline trenching has already been done.
4.5
The observations shall be made enclosing the soil immediately surrounding the
pipeline route where right of way has been cleared but trenching has not been done.
4.6
All measurement shall be taken at right angles to the right of way unless otherwise
asked by Owner or his representative at site.
4.7
At places in right of way where other pipelines are already existing care shall be
taken to precisely locate such pipes line and take such precautions that observations
are not adversely affected by presence of such pipelines.
4.8
Care shall also be taken that the observations are not influenced by presence of
other earth currents in the area especially in the vicinity of HT lines and plants using
earth return in their source of power etc.
4.9
Wherever possible/ advised by Owner or his representative depth of water table shall
be determined by resistivity observations.
4.10
All measurements shall be made and recorded in metric units. While recording the
data reference to the nearest point shall be made. To provide visual representation
of variations in the resistivities along right of way, values shall be plotted on semilog
graph sheets. The resistivity graph shall also indicate the resistivities at additional
depths measured at various locations and depth of water table.
5.0
6.0
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CORROSION SURVEY
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MEC/S/05/21/016C
REVISION : 0
EDITION : 1
6.1
Route and types of foreign service/ pipelines in and around, running parallel or
crossing the right of way.
6.2
Diameter, wall thickness, pressure, soil cover etc. of the foreign pipeline.
6.3
6.4
6.5
6.6
6.7
6.8
Crossings or parallel running of any H.T. AC/ DC overhead line with in approximately
25 mtr from ROW along with details of voltage rating, fault level etc.
6.9
Voltage rating, phases and sheathing details of parallel running or crossing of under
ground cables with ROW.
6.10
Crossing and parallel running of electrified and non-electrified railway tracks along
with details of operating voltage and type (AC/ DC) as well as abandoned tracks near
ROW having electrical continuity with track in use.
6.11
6.12
6.13
6.14
Any other relevant information that may be needed in designing and implementing of
proper cathodic protection scheme for the proposed pipeline.
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CORROSION SURVEY
DOCUMENT NO.
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MEC/S/05/21/016C
REVISION : 0
EDITION : 1
7.0
REPORT
On completion of all the field and laboratory work, an interim report incorporating
results generated from surveys, additional data collected, results of test carried out,
etc. shall be submitted for comments/ approval. The final report incorporating
comments/ missing data shall be furnished for records. The report alongwith various
drawings, graphs etc. prepared in connection with the work shall be submitted
alongwith six prints by the contractor.
8.0
8.1
Instruments that will be used for carrying out soil resistivity survey.
8.2
Measures that will be taken to avoid foreign pipelines/ HT lines etc. affecting the soil
resistivity observations.
8.3
8.4
8.5
8.6
8.7
Rev. : 0
Edition : 1
SPECIFICATION
FOR
GASKETS, BOLTS & NUTS
MECON LIMITED
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TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/19
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
GASKETS
2.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Jan. 2009
MECON LIMITED
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TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/19
REVISION : 1
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
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DOCUMENT NO.
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MEC/S/05/21/19
REVISION : 0
EDITION : 1
All gaskets shall conform to the codes/standards and specifications given in the requisition.
Vendor shall strictly comply with MR / PR stipulations and no deviations shall be permitted.
2.0
3.0
Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified
in the requisition.
4.0
Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test
reports on samples.
5.0
Manufacturer's test certificate for filler material and spiral material as per the relevant
material specifications.
b.
Manufacturer's test certificate for raw materials and tests for compressibility / sealability & recovery as per the relevant material specifications.
6.0
7.0
Filler material for spiral wound gaskets shall not have any colour or dye.
8.0
All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall be
CS unless other wise specified in the MR.
9.0
For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip
material. In addition to the requirements as per code and as specified in the MR, inner rings
shall be provided for the following:
10.0
a.
b.
Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwise
specified in MR :
Ring Gasket Material
Soft Iron
Carbon steel
5 Cr. Mo
Type 304, 316, 321, 347
Type 304L, 316L
90
120
130
140
120
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MEC/S/05/21/19
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EDITION : 1
11.0
12.0
Gaskets of different types and sizes shall be placed in separate shipping containers and each
container clearly marked with the size, rating, material specification and item code.
13.0
All items shall be inspected and approved by MECON Inspector or any other agency authorized
by MECON.
14.0
Any additional requirements specified in the requisition, shall be fully complied with.
15.0
Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto 24"
(except 22" size) and to ASME B16.47B above 24" unless specified otherwise. For 22" size, the
matching flange standard shall be MSS-SP44 unless specified otherwise.
16.0
Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto 24" (except
22" size) and to ASME B16.47B above 24" unless specifically mentioned otherwise. For 22"
size, the matching flange standard shall be MSS-SP44 unless specified otherwise.
17.0
The following abbreviations have been used in the Material Requisition for Spiral Wound
Gaskets :
(I)
(O)
CAF
GRAFIL
:
:
:
:
Inner Ring
Outer Ring
Compressed Asbestos Fibre
Grafoil Filler
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DOCUMENT NO.
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MEC/S/05/21/19
REVISION : 0
EDITION : 1
The process of manufacture, heat treatment, chemical & mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the codes
/ standards and specification given in the requisition. The applicable identification symbol in
accordance with the material specification shall be stamped on each bolt and nut. Vendor shall
strictly comply with MR / PR stipulations and no deviations shall be permitted.
2.0
Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
3.0
Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and
Mechanical Requirement)
4.0
Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453 bolting
material irrespective of the temperature.
5.0
All bolting shall be as per ANSI B 18.2.1 for studs. M/c bolts and jackscrews and ANSI BI8.2.2
for nuts.
6.0
Threads shall be unified (UNC for 1" dia and BUN for> 1" dia) as per ANSI B.1.1 with class 2A
fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.
7.0
Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall
be in accordance with the requirement as per ANSI B 16.5.
8.0
The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made
by the hot forged process and stamped as per respective material specification.
9.0
Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be
rounded.
10.0
Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in separate
containers marked with size and material specifications. 'CRYO' shall be marked additionally in
case 'CRYO' is specified in the requisition.
11.0
All items shall be inspected and approved (stagewise) by MECON inspector or any other
agency authorized by MECON.
12.0
The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
13.0
All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition
unless specified otherwise in the material specification.
14.0
Any additional requirements specified in the requisition shall be fully complied with.
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MEC/S/05/21/19
REVISION : 0
EDITION : 1
15.0
Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material
specification and also where the material specification is indicated as "CRYO". For" S.S. nuts
and bolts minimum impact energy absorption shall be 27 Joules and test temperature shall be
-196C unless mentioned otherwise. For other materials impact energy and test shall be as per
respective code.
16.0
Bolts / nuts of material of construction B7M / 2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A 193.
17.0
When specified as galvanized, the studs, m/c bolts and nuts shall be 'hot dip zinc coated' in
accordance with requirements of 'class C' of 'ASTM A 153'. As an alternative, electrogalvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable.
18.0
All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts irrespective
of whatever has been specified elsewhere in the MR.
Edition : 1
SPECIFICATION
FOR
SUMP TANK
MECON LIMITED
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SUMP TANK
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/021A
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
GENERAL
2.0
SCOPE OF SUPPLY
3.0
SCOPE OF SERVICES
4.0
DESIGN
5.0
MATERIALS
6.0
TECHNICAL REQUIREMENTS
7.0
8.0
9.0
10.0
SPARE PARTS
11.0
GUARANTEE
12.0
13.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(AK Gupta)
(A.K. Johri)
Nov. 2009
MECON LIMITED
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TITLE
SUMP TANK
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/021A
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Rev.
By
Date
Name
Verified
Sig.
Name
Sig.
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MEC/TS/05/21/021A
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EDITION : 1
1.0
GENERAL
1.1
This specification defines the responsibility of the supplier and covers supplementary
requirements relating to design, materials, fabrication, inspection, testing, painting,
packing and despatch etc. The specification shall be read in conjunction with code,
specification data sheet and other enquiry documents. The vendor shall contact
MECON for clarifications if any. As a general rule the most stringent requirement shall
govern.
1.2
The offer shall include the sketch indicating thickness of major parts, empty weight,
operating weight and test weight. After detailed design and during approval of drawing/
documents, if thicknesses are to be changed to meet the code, MECON standards and
specification requirement, same shall be taken into account without any commercial/
delivery implications.
1.3
1.4
MECON shall have the right to split the part orders which shall be acceptable to the
supplier.
1.5
The offer must be technically and commercially complete. In-complete offers are liable
to be rejected.
1.6
Any deviation from the clauses stipulated herein, specified codes and other enquiry
documents shall be clearly mentioned in the offer with proper reference to clause
numbers. In absence of any such indication it shall be assumed that the offer complies
with all the requirements and such assumption shall be strictly binding on the supplier.
1.7
Order of Precedence
The following order of precedence shall govern in interpretation of various requirement
and data.
Data sheets.
This specification.
Codes & standards.
Vendors standards.
2.0
SCOPE OF SUPPLY
2.1
Unless otherwise specified in the data sheet and Material Requisition the complete
main equipment and its various components shall be included in supplier's scope of
supply.
Scope of supply shall include but not be limited to the following.
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MEC/TS/05/21/021A
REVISION : 0
EDITION : 1
Cover flanges for manholes, handholes and inspection openings etc. with
bolting and gaskets.
Test blind flanges in addition to companion flanges.
All internals complete with supports and fasteners.
Manhole davits.
All external welded attachments like platforms and ladder cleats, insulation
supports and pipe support cleats etc.
Lifting lugs/ erection lugs.
Cleats for earthing connections/ earthing boss.
Name plate with bracket.
Foundation/ Anchor/ Holding down bolts with nuts and washers. Shall be
supplied within one months from L.O.I.
Support stool/ steel saddle supports.
Special tools/ tackles, if any.
Documents as called in "Vendor Data Requirement Sheet"/ Para 13.0 of this
specification.
Spare parts for two years normal operation.
Any other equipment/ instrumentation item as specified in Data Sheet/ Drawing/
Material Requisition.
3.0
SCOPE OF SERVICES
3.1
The responsibility of the supplier shall include but not be limited to the following. Any
other item/ activity which is not listed here but is required for completion of the supply
as per the enquiry document shall also be the responsibility of the supplier.
a)
b)
c)
d)
e)
Submission of the periodic progress report showing the status of the job.
f)
g)
h)
i)
j)
k)
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MEC/TS/05/21/021A
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EDITION : 1
4.0
DESIGN
4.1
4.2
Following codes & standards (latest edition) shall be followed for design, manufacture,
testing etc. of the equipment.
API 650
:
BIS 10987.1992
:
(Reaffirmed 2003)
ASME Sec-VIII Div-1 :
ASME Sec-IX
:
ASME Sec-II & ASTM :
ANSI B16.5
:
ANSI B16.1
:
ASME B16.47
:
ANSI B36.10
:
4.3
Detailed design calculations for adequacy of strength of all individual parts shall be
made and submitted to Purchaser/ Consultant for comments and approval. After
receipt of approval from Purchaser/ Consultant the design of equipment shall be
considered as final. Any change/ comment, made on design calculations to satisfy the
requirements of Code/enquiry documents, without any commercial implications, shall
have to be incorporated. For high alloy steel parts/components designed as per ASME
Sec VIII Div.I lower allowable stresses shall be adopted, unless otherwise specified.
After the approval of various documents subsequent deviations shall be discouraged.
4.4
4.5
Wind and seismic analysis shall be in accordance with IS: 875 and IS: 1893 unless
otherwise stated in specifications.
Detailed vibration analysis for wind forces and seismic forces shall be submitted
alongwith the design calculations. For the design consideration, wind forces shall be
increased by 20% to cater for the effect of piping system, platforms and ladders etc.
4.6
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SUMP TANK
DOCUMENT NO.
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4.7
Forces & moments coming on the nozzles shall be furnished after order placement
by Purchaser/ Consultant which shall be considered in the design by the supplier,
without any commercial implication. Alternatively supplier shall indicate maximum
permissible forces & moments for review and confirmation by Purchaser/ Consultant.
4.8
Unless otherwise specified, removable internal parts shall be designed in units as large
as can be installed through the nearest/upper manhole or opening.
Bolts and nuts for fixing internals shall be 18/8 SS and minimum size of bolt shall be
M10.
4.9
Support for packing/internals shall be designed for the worst condition. In case of
packing liquid hold-up of minimum 20% of packing volume shall be considered unless
otherwise specified.
4.10
Unless otherwise specified minimum corrosion allowance for CS and low alloy steel
shall be 1.5 mm.
4.11
5.0
MATERIALS
5.1
For purpose of material selection national code of the country of origin shall also be
acceptable provided the vendor specifically establishes, to the satisfaction of the
purchaser, the equivalence or superiority of the proposed material with respect to
those specified.
5.2
All materials, whatsoever, required to complete the supplies shall be procured by the
supplier and all such materials shall be covered with due identifiable material test
certificates.
5.3
Materials indicated in specification data sheets/ drawings are recommended for the
required services conditions. Supplier, however, may use better or equivalent material
with prior approval of Purchaser/ Consultant. Details of such materials must be
indicated in the offer with proper reference.
5.4
Unless otherwise specified all C.S. material used for pressure parts shall be fully killed.
5.5
Unless otherwise specified copper or copper alloys shall not be used. Steel conditions
with copper content upto 0.35% maximum are acceptable.
5.6
Materials for low temperature service shall be impact tested (Charpy) at the lowest
design temperature in accordance with requirements of code/ specification.
5.7
For course grained and high tensile materials in carbon steel (UTS > 45 kg/mm2) and
low alloy steel, guarantee impact strength shall be ensured at a temperature 15C
below envisaged hydraulic test temperture as precaution against brittle fracture during
hydraulic test.
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5.8
C.S. and low alloy steel exceeding thickness of 50mm shall be vacuum degassed
except for plate ring flanges.
5.9
For AISI 316 and 316L material, ferrite content for plates, pipes and tubes shall be
maximum 0.6% and for forging maximum 1%.
5.10
Intergranular corrosion test shall be carried out on all S.S. materials as per ASTM A
262 practice C if specified. The corrosion rate shall not exceed 0.6 mm/year.
5.11
All plate material over 50mm thickness shall be ultrasonically tested both on surfaces
and edges as per ASTM A 435.
5.12
All forgings shall be ultrasonically tested as per ASTM A 388 for thickness greater than
100 mm with the criteria shown in ASME VIII Div. 2 para AM-203-2. In case any defect
is found no repair by welding shall be allowed. ANSI flanges, for equipment designed
as per ASME SCE VIII Div. I need not be ultrasonically tested.
5.13
For IS 2062 materials without mill test certificates check test, if called for by the
inspector, shall be performed without any commercial implication.
6.0
FABRICATION
6.1
The equipment shall be procured from a source possessing proven track record for
trouble free and reliable operation.
6.2
6.3
The equipment shall be of the type as mentioned in the data sheets and shall meet the
duty requirements and performance parameters as mentioned therein.
6.4
6.5
All flanges shall be WNRF unless specified otherwise in data sheets/ drawings.
6.6
Dimensions of flanges including shell flanges, blind head cover flanges, nozzle flanges
and blind flanges shall be as per ANSI B16.5. Larger flanges shall be as per ANSI
B16.47.
6.7
Pressure parts joined by butt welds shall be with full penetration welds. Where both
sides welding is not accessible, root run by tungsten inert gas process or backing strip,
shall be used to ensure full penetration. Backing strip if used, shall be removed after
welding.
6.8
Vessels shall be post weld heat treated, whenever it is required due to service
requirement or due to code requirements. Vessels shall be post weld heat treated as a
complete unit and no welding shall be permitted after the post weld heat treatment is
completed.
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6.9
For vessels in stainless steel construction, lower allowable stress values shall be
considered as per ASME Code for their design.
6.10
Vessel shall be provided with lifting and earthing lugs. Fire proofing and insulation
supports shall be provided if indicated in data sheet/ drawing.
6.11
The manufacturer of the equipment shall comply in all respects with the provisions of
the applicable code/ standards and specifications including such jobs as welding,
fabrication, forming of heads etc. radiography, heat treatment, inspection, testing and
quality control.
6.12
All welding jobs shall be carried out by qualified welders using welding procedure that
has already been qualified to requirement of code & specifications etc. and approved
by the inspecting authority. All welding procedures must be got approved from
authorised inspecting authority before starting any fabrication job. Welding of all parts
must be completed before heat treatment.
6.13
Plates of different thickness shall be made flush with the inner surfaces of equipment
unless otherwise stated.
6.14
C.S./ Alloy steel dished end/ toriconical head including come if cold formed or formed
below normalised temperature shall be subsequently normalised. In case of austenitic
S.S. materials solution annealing shall be carried out if not worked. Formed ends of
vessels with diameters less than 1800mm shall preferably be made in one piece.
Larger heads which can not be formed in one piece shall be fabricated as follows.
a)
In two pieces, with the welding seam included in the middle third and preferably
on the centre line.
b)
In petal construction, with meridional seams and a central cap of diameter not
larger than 0.75 times the vessel OD.
Formed heads when fabricated in pieces shall be heat treated and weld seam
radiographed after forming.
6.15
Impact, test when required as per code & specifications shall be carried out on parent
metal, weld and HAZ.
6.16
Product control coupons, when required as per code & specifications, shall be
subjected to all tests like impact test corrosion test etc. in addition to mechanical test
as required. In case of heat treated equipment test coupons shall be given similar heat
treatment as for the equipment.
6.17
The shall sections, to the extent possible, shall be made out of a single plate with one
longitudinal seam.
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Vessels made up of two or more courses shall have the centres of the welded
longitudinal joints of adjacent courses staggered or separated by a distance of five
times the thickness of the thicker plate or 100mm whichever is greater.
6.19
All parts involving welding construction including internals shall have continuous welds
unless otherwise stated.
6.20
In case of S.S. welds, procedure must be qualified to ensure that the weld meets the
minimum requirements of C. Cr. Ni and Mo as that of the parent metal. In addition to
various tests required as per code, weld procedure shall be qualified for intergranular
corrosion test as per ASTM A 262 practice C if specified. Carbide contamination shall
be avoided during welding.
6.21
All welds shall be full penetration welds with back chipping and rewelding from the
second side. For those joints which are inaccessible for back chipping the root run
shall be carried out with TIG process. Single side welding with backing strips shall not
be permitted.
6.22
Due provisions must be kept for venting out entrapped cases during welding of pads,
flanges and liner plates etc.
6.23
Pads for supports and external cleats etc. shall be of same material as that of shell.
6.24
6.25
All welding neck flanges shall be bored to suit nozzle I.D. Flange facings shall have
suitable serrations of gasket seating in case of plain male/ female raised faces. In
case of spiral wound gaskets no serrations are required.
6.26
Unless otherwise stated all girth flange joints shall be confined type. Minimum depth of
gasket facing for girth flanges shall be 5mm for asbestos gaskets and 6mm for spiral
wound jacketed gaskets.
6.27
All internals fabricated in pieces shall be shop assembled and properly match marked
for easy assembly at site.
6.28
In case of equipment to be assembled at site trial assembly in shop shall be carried out
and match marked for proper assembly at site.
6.29
Equipment shall be provided with suitable brackings/ stiffeners to avoid any damage
during transportation and erection at site.
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6.30
In case of equipment involving site assembly/ fabrication the entire site job including
fabrication, radiography, heat treatment, inspection, testing and transportation to site
shall be in suppliers scope of works at his cost. In case of ODC movement, ODC
sanction for movement either by rail/ road shall be arranged by the supplier from the
appropriate authority in advance to meet the schedule delivery.
6.31
All flange bolts & skirt-bolts shall straddle centre line unless otherwise stated.
6.32
All nozzles less than or equal to DN 65 shall be stiffened with three equispaced plate
ribs of 6mm thickness of the same material as that of shell. All nozzle above 80 NB
size shall be provided with reinforcement pad solution specified otherwise.
6.33
For studs to be tightened with hydraulic tensioner, caps shall be provided for protection
of stud ends.
6.34
External bolting for gasketed flanges shall always be stud bolts and nuts.
Threads of bolts and nuts shall be coated before installation with lubricant to prevent
galling of the threads.
7.0
7.1
7.2
Testing at vendor's works shall include but not limited to the following:
7.3
All raw materials shall be inspected at source and test certificates to enable proper
identification shall be submitted.
7.4
All equipment shall be inspected during various stages of manufacture starting from
identification of raw materials to completion. The equipment shall be considered
acceptable for despatch only after final certification for acceptance is issued by the
inspector.
7.5
Bought out items or items sub-contracted to other sub-suppliers shall also be inspected
at the sub-supplier's works.
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7.6
7.7
Inspection order on third party shall also include specific instructions for marking copies
of all correspondence from inspecting authorities to purchaser/ consultant and
reporting monthly progress of the order to purchaser/consultant Complete
responsibility of getting approval of drawings/ calculations and documents from
inspecting authority shall be that of the supplier.
7.8
For equipments coming under IBR purview, the items shall be inspected during
various stages of fabrication and testing by an inspecting authority acceptable to
IBR.
7.9
For equipment coming under the purview of IBR the inspection by local IBR authorities
shall have to be arranged by the supplier and all cost borne by the supplier.
7.10
7.11
Unless otherwise stated gaskets used during testing shall be same as specified for
operating conditions. After testing, gaskets used during testing shall be replaced by
new gaskets.
7.12
Ultrasonic Examinations
i)
ii)
b)
ii)
iii)
iv)
v)
vi)
vii)
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c)
Radiography
i)
ii)
iii)
iv)
7.13
7.14
7.15
Any or all the tests, at purchaser's option, shall be witnessed by purchaser/ its
authorised inspection agency. However, such inspection shall be regarded as checkup and in no way absolve the vendor of this responsibility.
8.0
8.1
All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside
and outside to remove scale, rust, dirt and other foreign materials by wire brushing and
sand blasting as applicable and specified in the data sheet. Minimum acceptable
standard in case of power tool cleaning shall be St. 3 and incase of blast cleaning shall
be Sa 2 as per Swedish Standard SIS 0055900.
8.2
8.3
Stainless steel surfaces both inside and outside shall be pickled and passivated.
8.4
Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
8.5
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Description
Acceptable Standards
Surface Preparation
Primer
:
:
Finish
Sa 2
Two coats high build coal tar epoxy
(thinned) 50 microns/ coat (min.)
Two coats high build coal tar epoxy 100125 microns/ coat
8.6
The colour of finish coat shall be intimated to vendor after placement of order.
9.0
9.1
All packaging shall be done in such a manner as to reduce the volume. The equipment
shall be dismantled into major components suitable for shipment and shall be properly
packed to provide adequate protection during shipment. All assemblies shall be
properly match marked for site erection.
9.2
Attachments, spares parts of the equipment and small items shall be packed
separately in wooden-cases. Each item shall be appropriately tagged with identification
of main equipment, its denomination and reference number of the respective assembly
drawing.
9.3
Detailed packing list in water-proof envelope shall be inserted in the package together
with equipment.
9.4
Each equipment shall have an identification plate giving salient equipment data, make,
year of manufacture, equipment number, name of manufacturer etc.
10.0
SPARE PARTS
10.1
Vendor shall submit his recommended list of spare parts with recommended quantities
and itemised prices for first two years of operation of the equipment. Proper coding
and referencing of spare parts shall be done so that later identification with appropriate
equipment will be facilitated.
10.2
Recommended spares and their quantities should take into account related factors of
equipment reliability, effect of equipment downtime upon production or safety, cost of
parts and availability of vendor's service facilities around proposed location of
equipment.
10.3
Vendor shall also submit a list of recommended commissioning spares with quantities
and the itemised prices.
11.0
GUARANTEE
11.1
The supplier shall guarantee the equipment and their components against faulty
design with regard to mechanical adequacy, improper material of construction and
poor workmanship for the specified period.
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11.2
Approval by MECON of design calculations and detailed shop drawings will not in any
way absolve the supplier from his responsibilities.
11.3
Should any repair or replacement be necessary owing to any type of failure on account
of design, material or workmanship of the equipment, the supplier shall by this
guarantee be bound to replace the same either in part or in entirely, without additional
cost, at site. Repaired or replaced parts shall be covered by same guarantee as in
case of main supply.
11.4
In case process design is also in supplier's scope guarantee shall include process
guarantee also in addition to above. All special instruments required to verify the
guarantee. Fixtures as outlined in the equipment specification shall have to be brought
by the supplier on draw-back basis.
12.0
12.1
12.2
12.3
12.4
Reference list of similar equipments already supplied indicating various parameters &
material of construction.
12.5
12.6
In case of failure to submit the documents listed above, the offer may be rejected.
13.0
13.1
Inspection & test reports for all mandatory tests as per the applicable code. Test
reports for any supplementary tests, in nicely bound volumes.
13.2
13.3
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13.4
Filled in QAP for Owner's/ Consultants approval. These QAP's shall be submitted in
four copies.
13.5
13.6
Within two(2) weeks of placement of order, the detailed fabrication drawings alongwith
mechanical design calculations for Owner's/ Consultants approval. These drawings
shall be submitted in four copies.
13.7
Detailed completion schedule activity wise, within one week of placement of order.
13.8
Weekly & fortnightly progress reports for all activities including procurement.
13.9
13.10
Manufacturer's drawings for bought out items, in 4 copies, for Owner's/ Consultant
approval within 4 weeks.
13.11
Manufacturer related information for design of civil foundation & other matching items
within 6 weeks of LOI.
13.12
All approved drawings/ documents as well as inspection and test reports for Owner's/
Consultants reference/ record in nicely category wise bound volumes separately.
Note: All drawings, instructions, catalogues, etc. shall be in English language and all
dimensions shall be metric units.
Edition : 1
TECHNICAL SPECIFICATION
FOR
CENTRIFUGAL PUMP
(PETROLEUM SERVICES)
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CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
SCOPE
REFERENCE
TERMS & DEFINITIONS
3.20 Maximum Discharge Pressure
PUMP DESIGNATIONS
4.3
Units and Governing Requirements
BASIC DESIGN
5.1
General
5.2
Pump Types
5.3
Pressure Casings
5.5
External Nozzle Forces and Moments
5.7
Wear Rings and Running Clearances
5.8
Mechanical Shaft Seals
5.9
Dynamics
5.10 Bearings and Bearing Housings
5.11 Lubrication
5.12 Materials
ACCESSORIES
6.1
Drivers
6.2
Couplings & Guards
6.3
Base-Plates
6.4
Instrumentation
6.5
Piping & Appurtenances
INSPECTION, TESTING AND PREPARATION FOR SHIPMENT
7.1
General
7.2
Inspection
7.3
Testing
7.4
Preparation for Shipment
SPECIFIC PUMP TYPES
8.2
Between Bearings Pumps
VENDOR DATA
9.1
General
9.2
Proposals
9.3
Contract Data
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(ANIL KUMAR)
(GURDEEP SINGH)
(A.K. JOHRI)
Nov. 2008
SR. MANAGER
AGM
DGM
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AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Rev.
By
Date
Name
Verified
Sig.
Name
Sig.
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1.
SCOPE (Substitution)
i)
This specification together with the attendant Data Sheets and other specifications /
attachments to inquiry / order defines the minimum requirements for vertical and
horizontal centrifugal pumps including pumps running in reverse direction as
hydraulic power recovery turbines and their accessories / auxiliaries for use in the
petroleum, heavy duty chemical, pipeline and gas industry services.
ii)
Vendor shall make all possible efforts to comply strictly with the requirements of this
specification and other specifications / attachments to inquiry / order.
In case deviations are considered essential by the vendor (after exhausting all
possible efforts) these shall lie separately listed in the vendor's proposal under
separate section titled as "List of deviations / exceptions to the inquiry document".
Deviation shall be listed separately for each document with cross reference to Page
No. / Section / Clause No. / Para etc. of the respective document supported with
proper reasons for the deviation for purchaser's consideration. Any deviation not
listed under the above section, even if reflected in any other portion of the proposal
shall not be considered applicable.
No deviation or exception shall be permitted without the written approval of the
purchaser.
iii)
Compliance with this specification shall not relieve the vendor of the responsibility of
furnishing equipment and accessories / auxiliaries of proper design, materials and
workmanship to meet the specified start up and operating conditions.
In case the vendor considers requirement of additional instrumentation, controls,
safety devices and any other accessories / auxiliaries essential for safe and
satisfactory operation of the equipment, he shall recommend the same along with
reasons in a separate section along with his proposal and include the same in his
scope of supply.
iv)
v)
Except for new paragraphs, the number and title of the paragraphs in this
specification correspond to the respective sections and paragraphs of the above
standard. Paragraphs not addressed in this specification shall be strictly in
accordance to API Standard 610, 10th Edition, October 2004 requirements.
The word in parenthesis following the number or title of a paragraph indicates the
following :
(Addition)
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(Modification)
1.2
(New)
(Delete)
1.3
1.3.1
1.3.2
1.3.3
The pump model offered shall be from the existing regular manufacturing range of
the pump manufacturer. The mechanical as well as the hydraulic performance
(including NPSHR) for the complete range of operation of the offered model shall
have been established in the shop test. The offered pump model shall meet the
following minimum service and manufacturing experience requirements.
Pumps shall be identical or validly similar in terms of Power rating, Hydraulic
Performance (including NPSHR), Inlet flow, Differential Head, Operating Pressure &
Temperature, Pumping Liquid, Speed, Number & Type of Impellers, Mechanical
Design, Materials, Bearing span (applicable for between bearing pumps), Column
Length (applicable for vertically suspended pumps) etc. as compared to at least TWO
UNITS of the proposed model designed, manufactured, tested and supplied from the
proposed manufacturing plant in the last ten years and at least ONE of these units
shall have successfully operated in the field for at least 8000 hours individually
without any major overhaul as on the date of issue of inquiry.
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1.3.4
In case the vendor is a licensee and does not meet on his own the above criteria as
per 1.3.3, the vendor can substitute the references of his Collaborator (licensor)
provided the following conditions are met by the vendor.
1.3.4.1
The vendor shall be regular & established manufacturer of centrifugal pump and
shall have supplied several smaller & larger sizes of pumps from the proposed
manufacturing plant and proves to the satisfaction of the purchaser that the vendor
does possess the manufacturing & testing facilities for the offered pump.
1.3.4.2
1.3.4.3
Vendor's license agreement is valid and continues to remain valid till, atleast TWO
years after the delivery of the pumps.
1.3.4.4
The vendor imports as a minimum the following critical components from his
Collaborator (licensor) / Collaborators sub-vendors.
-
1.3.7
2.
ii)
OISD : 113
iii)
iv)
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This document has been prepared to the National / International Standards detailed
within. Vendor shall ensure that the scope of work is executed in accordance with all
mandatory Indian Statutory requirements.
All standard given under normative reference Cl. No. 2 and also covered in
Bibliography shall apply.
3.
3.20
4.
4.3
4.3.1
(Modification)
Unless otherwise specified, MKS system of units shall be used.
5.
BASIC DESIGN
5.1
General
5.1.10
(Addition)
Pumps where difference between NPSHA and NPSHR from quoted minimum flow to
rated flow is less than 0.6 meter are not acceptable. The said NPSHR value shall
correspond to the maximum value of NPSHR from rated flow down to the
recommended minimum continuous stable flow specified by the vendor.
Pumps fitted with inducers for reducing NPSHR are not acceptable.
5.1.13
(Substitution)
Pumps shall have stable head / flow rate curves (continuous head rise to shutoff) for
all applications. If parallel operation is specified, the head rise from rated point to
shutoff shall be at least 10%. Use of discharge orifice as a means of meeting the
above requirements shall be subject to approval of the purchaser.
5.1.14
(Substitution)
Pumps shall have preferred operating region of 70% to 120% of best efficiency flow
rate of the pump as furnished. Rated flow shall be within 110% of best efficiency
flow rate of the pump as furnished. Vendor shall indicate Preferred Operating
Range and Allowable Operating Range on the characteristic curve.
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5.1.16
(Modification)
Unless otherwise specified, the maximum permissible sound level shall not exceed 88
dBA measured at 1 meter from pump surface for the recommended range of
operation.
5.1.22
(Modification)
Unless otherwise specified, water cooling systems (jackets, heat exchangers and so
forth) shall be designed for the following conditions on the water side :
Velocity over heat exchanger surface
Maximum Allowable Working Pressure (MAWP)
Test Pressure (1.5 x MAWP)
Maximum Pressure Drop
Maximum Inlet Temperature
Maximum Outlet Temperature
Maximum Temperature Rise
Minimum Temperature Rise
Fouling Factor on Water Side
Shell side corrosion allowance (not for tubes)
5.1.30
:
:
:
:
:
:
:
:
:
:
(Addition)
Unless otherwise specified, equipment shall be designed to be suitable for outdoor
installation without a roof.
5.1.32
(New)
For balancing axial thrust in multi-stage pumps, only the following arrangements,
shall be used :
-
5.2
5.3
Pressure Casings
5.3.1
(Substitution)
The maximum discharge pressure shall be the maximum suction pressure plus the
maximum differential pressure (including the allowable positive performance
tolerance) the pump is able to develop when operating with the finished impeller at
the rated speed and specified maximum relative density (specific gravity).
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5.3.3
(Modification)
The NOTE stands modified as under :
Vendor to note that the criteria specified in (a) shall also be used for design of
purchasers associated piping system.
5.3.6
(Modification)
Regions of vertically suspended, double-casing and horizontal multistage pumps
(pumps with three or more stages) that are subject only to suction pressure shall be
designed for the same MAWP as the discharge section.
5.5
5.5.1
(Modification)
Steel and alloy steel horizontal pumps and their base plates and vertically suspended
pumps shall be designed for satisfactory performance if subject to twice the values
of forces and moments indicated in Table 4.
5.7
5.7.3
(Modification)
Tack welding shall not be employed for fitting of the wear rings.
5.7.4c)
(Modification)
Non-metallic wear rings, if offered, shall be subject to purchaser's specific approval.
5.7.4d)
(New)
The maximum permissible running clearances shall not be less than twice the new
running clearances.
5.8
5.8.1
(Addition)
For the applicable flushing plans, the vendor shall also include in his scope of supply,
all items shown as optional items in Annexure D of API standard 682 (Standard Flush
Plan and auxiliary Hardware) along with other additional specified / required items, if
any.
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5.9
Dynamics
5.9.2.6
(Modification)
Replace the words If specified by If torsional analysis is performed.
5.9.3
VIBRATION
5.9.3.3
(Modification)
The words 'if specified' in the last sentence stand deleted.
5.10
5.10.2
5.10.2.7
(Addition)
Bearing housings shall be equipped with suitable replaceable bearing isolators where
shaft passes through the housing.
5.10.2.12
(Substitution)
A flat surface at least 25 mm in diameter shall be supplied for the location of
magnetic based vibration measuring equipment, whether or not vibration measuring
equipment is included in the vendor's scope of supply.
5.10.2.13
(New)
Bearing housing shall he equipped with magnetic, drain plug except for multistage
pumps where vendor's standard design may not permit this.
5.11
Lubrication
5.11.3
(Substitution)
Provision shall be made for pure oil mist lubrication.
5.12
Materials
5.12.1.6c)
(Substitution)
Unless otherwise specified, casing in cast iron construction shall not be offered.
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TITLE
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5.12.1.8
(Modification)
The words 'if specified' stand deleted.
5.12.1.12
(Modification)
Where even trace quantities of wet H2S are indicated to be present, reduced
hardness materials in accordance with NACE MR0I75 / MR0103 shall be provided by
the vendor.
5.12.2.5
(Modification)
The words "if specified" stand deleted.
5.12.3.4
(Modification)
e)
5.12.4.3
(Modification)
ASME Sec VIII, Div I shall apply with regard to impact testing requirements.
6.
ACCESSORIES
6.1
DRIVER
6.1.3
(Modification)
Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service
factor equal to 1) not lower than the following :
Motor Name plate Rating
Upto 22 kW
22 kW to 55 kW
Higher than 55 kW
:
:
The electric motor shall be suitable for the electrical area classification specified on
the data sheet.
Note :
1.
The motor nameplate rating for pumps under parallel operation or for pumps
with auto-start operation shall not be less than the max. BKW indicated on
pump data sheet (maximum power at any point on the pump performance
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EDITION : 1
curve from shutoff to end of the curve for the rated impeller) or shall have
the specified margin as per this clause whichever is greater. The pump
motors shall also be suitable for start-up under open discharge valve
condition.
2.
The motor nameplate rating for applications where the specific gravity of
pumped fluid is less than 1.0 shall either be 100% of the BKW of pump at
minimum continuous stable flow with clean cold water of sp. gravity 1.0 or
shall have the specified margin as per this clause, whichever is greater.
6.2
6.2.2
(Addition)
The coupling service factor shall not be less than 1.5 over the driver rating.
6.2.3
(Modification)
The words 'if specified' stand deleted
6.2.4
(Substitution)
Unless otherwise specified, all couplings required for multistage pump package(s)
shall conform to API standard 671 where either the driver rating is greater than 400
kW or the maximum continuous speed is greater than 3800 rpm. In case of gear box
driven multistage pump units, both low speed and high speed couplings shall
conform to API standard 671, even if the lower speed happens to be less than or
equal to 3800 rpm.
6.2.7
(Addition)
The coupling service factor shall not be less than 1.5 over the driver rating.
6.2.14a)
(Addition)
Coupling guard shall be open at the bottom to permit manual shaft rotation.
6.2.14c)
(Modification)
Coupling guard shall be fabricated from non-sparking material.
6.3
BASE PLATES
6.3.1
(Addition)
Pumps in corrosive service shall have provision to collect and drain the leakage from
mechanical seal or packing, through a drip pan of metallurgy equivalent or superior
to pump casing. Leakages from drip pan shall be piped to base-plate with a flanged
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TITLE
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connection for onward disposal by purchaser. Where the design of bearing prohibits
provision of drip pan, the material of bearing bracket shall be suitable for the
corrosive service.
6.3.3
(Modification)
Replace "if specified" by "For all multistage pumps".
6.3.19
(Modification)
6.3.21
6.4
Instrumentation
6.4.2.2
(Modification)
The words 'if specified' stand deleted. The vendor shall supply the detectors.
6.4.2.3
(Modification)
The words 'if specified' stand deleted.
6.4.2.4
(Modification)
The words 'if specified' stand deleted.
6.4.2.5
(New)
Horizontal multistage pumps intended for pumping temperature above 120C shall
be provided with pump casing skin temperature monitoring system consisting of the
following :
-
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6.5
6.5.1
GENERAL
6.5.1.6
(Modification)
The words 'if specified' stand deleted.
6.5.1.7
(Modification)
Flange fasteners on stainless steel piping systems shall be of stainless steel.
6.5.2
6.5.2.3
(Modification)
Auxiliary process fluid piping material shall be SS-316 as a minimum.
6.5.2.6
(Substitution)
Casing shall be provided with drain connection with nipple, threaded and seal welded
and provided with a socket welded gate valve terminated at edge of the base plate.
Gate valve shall he of 800# rating with material of construction (MOC) equal or
superior to the pump casing. For multistage pumps with more than one drain point,
block valves at each drain point shall he provided and the piping shall be terminated
at edge of the base plate with a flange. Unless made self venting design, vent
connections shall also be provided with a nipple, threaded and seal welded and
terminated with a gate valve. Pressure gauge connection shall not be provided
unless specifically required in the inquiry. Nipples shall meet the requirements of
5.4.3.5 & 5.4.3.6.
6.5.2.8
(Modification)
Flanges are required in places of socket welded unions for all auxiliary process fluid
piping.
6.5.2.9
(New)
Material for seal flushing liquid cooler shall be as under:
Tube or Coil
(Modification)
Sight flow indicator shall have ball or flag for easy verification of water flowing
through pipes.
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TITLE
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6.5.3.5
(New)
Thermal relief valve (in each isolatable cooling water circuit) shall be provided
upstream of globe valve on the cooling water outlet line.
7.
7.1
General
7.1.8
(Addition)
Prior to start of test, manufacturer shall furnish the Certificate of calibration of driver
and measuring instruments which should be recalibrated after a period of every one
year. Pressure gauges shall be calibrated prior to start of test and after completion
of test.
7.1.8
(New)
Prior to start of test manufacturer shall furnish the valid Certificate of calibration of
driver and measuring instruments.
7.2
Inspection
7.2.1
General
7.2.1.3
(Substitution)
The minimum material inspection requirement for pressure containing casings shall
be as per the following inspection category:
Inspection
Category
Category A:
Category B :
Inspection Requirement
Remarks
Nozzle weld
Butt welds on pressure B2.
containing components
Fillet welds on pressure
containing components.
Shaft
Liquid
penetrant
inspection
shall
be
performed only when
specified
magnetic
particle inspection is not
feasible.
Magnetic particle or
liquid
penetrant
inspection
shall
be
carried
out
in
accordance with table
13.
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TITLE
EDITION : 1
Inspection
Category
Category C :
Inspection Requirement
Visual inspection and Magnetic C 1.
Particle or Liquid Penetrant
inspection
of
following
components as a minimum :
-
Nozzle weld
Butt welds on pressure
C2.
containing components
Fillet welds on pressure
containing components.
Shaft
Radiographic
or
ultrasonic
inspection of the following as a
minimum :
C3.
Nozzle weld
Butt welds on pressure
containing components
Remarks
Liquid
penetrant
inspection
shall
be
performed only when
specified
magnetic
particle inspection is not
feasible.
Magnetic particle or
liquid
Penetrant
inspection
shall
be
carried
out
in
accordance with table
13.
Ultrasonic
inspection
shall be carried out
when radiography is not
feasible. Radiography or
ultrasonic
inspection
shall be carried out in
accordance with table
13.
Note:
Category A:
This category is applicable for carbon steel and cast iron for services with process design
pressure up to 40 kg / cm2g and design temperature from 0 to 150 C.
Category B :
This category is applicable for services within the design pressure and temperature range
other than covered under category A above and category C below.
Category C:
This category is applicable for services with process design pressure above 70 kg/cm2g
design temperature below -29C or above 300C.
7.2.1.5
(New)
Inspection shall also include dimensional check of pump, driver and auxiliaries (if
any) duly mounted on the base plate, in accordance with certified general assembly
drawing. This will include all main pump dimensions, base plate dimensions, location
of foundation bolt holes, size / position / rating of flanges, coupling guard
arrangement, verification of the required material certificates and their trace-ability
to the respective components. In addition, following checks shall also be carried out:
-
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7.2.2
7.2.2.2
Material Inspections
(Modification)
The words "if specified" stand deleted.
7.2.2.3
(Modification)
The words "if specified" stand deleted.
7.3
TESTING
7.3.1
GENERAL
7.3.1.1
(Modification)
Table 14 stands modified as under :
7.3.1.2
:
:
Rated BKW
(Modification)
The words 'if specified' stand substituted with 'Unless otherwise specified'.
7.3.1.4
(New)
Unless otherwise specified the following tests shall be witnessed by the Purchaser or
by their authorised representative or by both together.
1.
Hydrostatic test as per 7.3.2.
2.
Performance test as per 7.3.3 and mechanical run test as per 7.3.4.7.
3.
NPSHR test as per 7.3.4.2 when specified in the material requisition or when
the difference between NPSHA and NPSHR is less than or equal to one (1)
meter.
4.
Dismantling inspection and reassembly, after the running test.
5.
Sound level test (witnessed).
7.3.3
Performance Test
7.3.3.2
(New)
i)
Shop driver shall be used for testing and the rating of the driver shall not
exceed 150% of power that may be consumed while running at duty point
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with water; or power at full valve open condition, whichever is higher. The
limitation of 150% is applicable only for medium voltage motors.
7.3.3.4(b)
(Addition)
During the performance test, rise in temperature of bearing oil shall be measured
and results recorded on the test log.
7.3.3.4(e)
(New)
During the performance test, the equipment shall be checked for its sound level at
minimum flow, at rated flow, at flow at best efficiency point and at 120% BEP flow.
The maximum allowable value shall not exceed 88 dBA measured at 1 meter from
pump surface or as specified in data sheet whichever is lower. During the
performance test, the pump shall be run for a minimum duration of four hours.
7.3.3.5(b)
(Modification)
The words 'if specified' stand deleted.
7.3.4
OPTIONAL TESTS
7.3.4.2
NPSHR Test
7.3.4.2.1
(Substitution)
If NPSHR test is specified or if it is required to be done as per para 7.3.1.4(3),
NPSHR shall be determined al each test point (7.3.3.3a) except shut-off.
7.3.4.4
7.3.4.5
7.3.4.7
7.3.4.7.1
(Delete)
7.3.4.7.2
(Modification)
The words 'if specified' stand deleted.
7.3.4.7.3
(Modification)
The words 'if specified' stand deleted.
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7.4
7.4.1
(New)
Unless otherwise specified, the equipment shall be protected for a storage of 12
months at site. If any extra precaution is to be taken by the Purchaser for storage
beyond 12 months the same shall be explicitly indicated in the operation and
maintenance manuals.
7.4.6
(Substitution)
Two copies of the manufacturers job specific installation manual shall be packed and
shipped with the equipment.
8.
8.2
8.2.1.2
(Substitution)
Pumps for all services shall be centreline mounted irrespective of pumping
temperature.
8.2.2.3
(Modification)
The words 'if specified' stand deleted.
8.2.2.5
(New)
Maximum number of stages shall not exceed 10 for horizontal pumps.
8.2.4
Dynamics
8.2.4.1.2
8.2.4.1.2(b)
Deleted.
8.2.6
Lubrication
8.2.6.2
(Modification)
The words 'ISO 10438-3' shall be replaced with 'ISO 10438-3/API standard 614,
Chapter 3'
8.2.6.5
(Modification)
The words 'ISO 10438-2' shall be replaced with' ISO 10438-2/API standard 614,
Chapter 2'
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8.2.6.6
(New)
The pump manufacturer shall supply all the specified / required instrumentation.
However, purchaser shall approve the make, type and the specification.
8.2.6.7
(New)
In case a pressure lubrication system is required and is supplied with shaft-driven
main oil pumps (MOP), the MOP shall be suitable for safe coast down of the
complete equipment train without necessitating the requirement of overhead
rundown tank.
In case MOP is not suitable for safe shutdown of the complete equipment train, the
vendor in his offer may propose for purchaser's consideration any special
arrangement / provision provided for equipment safety and protection when the
equipment decelerates. Provision shall be adequate for coast down time and cool-off
time as applicable.
8.2.6.8
(New)
External pressure-lubrication systems shall comply with the following additional
requirements :
-
Pumps, filters, strainers, coolers, traps, valves and all other components that
retain oil under pressure and are external to the reservoir shall be made of
steel.
A removable tube bundle design is required for shell and tube coolers with
more than 0.5 m2.
The oil side operating pressure of the oil cooler shall be higher than the
water-side operating pressure to prevent contamination of oil in case of
cooler failure.
Oil system shall have drain rim or pan to catch oil spills.
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8.2.7
TESTING
8.2.7.1
(Modification)
The words ISO 10438-3 shall be replaced with ISO 10438-3/API standard 614,
Chapter 3.
8.2.7.5
(Modification)
The words "if specified" stand deleted.
8.2.8
8.2.8.2
(Modification)
The words "if specified" stand deleted.
8.2.8.3
(Modification)
The words "if specified" stand deleted.
8.2.8.4
(Modification)
The words "if specified" stand deleted.
9.
VENDOR'S DATA
9.1
General
9.1.2a)
(Substitution)
The purchasers / owners / consultants corporate name.
9.1.3
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9.2
PROPOSALS (Substitution)
The vendor's proposals shall as a minimum include the following:
a)
b)
c)
d)
e)
All data sheets, drawings and documents listed under "PRINTS WITH
QUOTE" in
the enclosed Vendor Data Requirement Form.
Vendor's confirmation / comments on post-order Vendor Data Requirements
(Type of Documents, no. of prints and date needed) indicated in Vendor Data
Requirement forms data sheets and specs.
List of recommended commissioning spares included in the offer.
List of mandatory spares (where specified by the purchaser) included in the
offer.
List of Spare Parts For Two Years Normal Operation
This list shall be made separately for each items including auxiliaries and
drivers in the form of a table & shall show
i)
ii)
iii)
iv)
v)
f)
g)
h)
i)
Note: Clearance less than those required by Table 5 shall be stated as an exception
to API 610.
9.3
9.3.1
General
9.3.1.1
Drawings and data as required after purchase order has been specified in Vendor
Data Requirement. Vendor to note that the drawing / document descriptions / titles
as given in the Vendor Data Requirement are generic in nature. It is possible that
against one drawing / document specified there are several drawings to be furnished
by the vendor or vice versa.
9.3.1.2
Vendor shall complete & forward a document "Vendor Data Index & Schedule" to the
purchaser (Destination & contact person as per order).
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This document shall list out in consolidated form all drawings and documents
required by purchaser (As specified in Data Sheets, Specifications and Vendor Data
Requirement forms enclosed with the order).
Against each drawing / document vendor shall indicate the vendor's drawing
numbers, titles, Rev. No., category (whether for information or approval) and
schedule of submission.
This shall be the first document to be submitted by vendor within two weeks of
order.
9.3.1.3
All transmittal letters (covers), drawings and data shall have a title block (in addition
to vendor's standard title block) which shall as a minimum contain the following
contract information:
i)
ii)
iii)
iv)
v)
Title Block on drawings shall be placed on the lower right hand comer.
9.3.1.4
All vendor data / drawings / documents shall be in English Language and in Metric
Systems.
9.3.1.5
Data specified in the VDR is the minimum requirements of Purchaser. Any additional
document / data required or requested by Purchaser for engineering or construction
shall also be made available by the vendor.
9.3.1.6
Whether or not specified the vendor shall furnish the following, before shipment:
-
A supplementary list of spare parts other than those included in his original
proposal. The supplementary list shall include recommended spare parts,
cross-sectional or assembly type drawings, parts numbers, materials, prices
and delivery period. The vendor shall forward this supplementary list to the
purchaser promptly after receipt of the reviewed drawings and in time to
permit order and delivery of parts before field start-up.
A parts list for all equipment supplied. The list shall include pattern, stock, or
production drawing numbers and materials of construction. The list shall
completely identify each part so that the purchaser may determine the
interchangeability of the parts with other equipment furnished by the same
manufacturer. Standard purchased items shall be identified by the original
manufacturer's name and part number.
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At least 8 weeks before shipment, the vendor shall submit his preservation,
packaging and shipping procedures to the purchaser's for his review.
9.3.2
9.3.2.1
The number of prints and/or reproducible required and the times within which these
are to be submitted by vendor are specified in Purchaser's inquiry / order.
9.3.2.2
The purchaser's review of the vendor's drawings shall not constitute permission to
deviate from any requirements in the purchase order / specifications unless
specifically agreed upon in writing. After the drawings have been reviewed, the
vendor shall furnish certified copies in the quantity specified. All drawings must be
clearly legible and shall be folded to 216 mm x 279 mm size. All transparencies shall
be rolled.
9.3.3
Technical Data
9.3.3.1
ii)
iii)
Location (in all three planes), size, type, rating and identification of all
purchaser's interface connections including those of vents, drains, lubricating
oil, sealing fluid, cooling water, steam & Electrical / Instrumentation.
iv)
v)
vi)
vii)
viii)
ix)
Speeds of Driven Equipment and Driver with Driver rating. Location of driver
terminal box (in case of Electric Motor Driver).
x)
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9.3.3.2
xi)
Make, Type and Size of couplings and the location of guards and their
coverage.
xii)
xiii)
Foundation Drawings
A foundation drawing shall indicate complete information required for foundation
design by purchaser including the following :
9.3.3.3
i)
Foundation bolt sizes, pipe sleeve details, pocket sizes and locations.
ii)
iii)
Static weight of each skid / independently grouted item and location of center
of gravity of each of such skid / items in all three planes.
iv)
Weight distribution for each bolt / subsole plate location and total static
weight.
v)
vi)
vii)
viii)
ix)
x)
ii)
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maintenance.
9.3.3.4
iii)
Layout for water piping, trenches for water piping, cable tray / trenches
layout.
iv)
v)
vi)
9.3.3.5
9.3.3.6
9.3.3.7
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EDITION : 1
correspond to the part number on the bill of materials. The bill of material shall
include the part no., name of component, materials quantity installed per unit &
sizes where applicable (say for bolts, nuts, rings, gaskets etc.). All bought out items
shall also be indicated with make and brief specifications.
A separate cross-sectional drawing showing installation and setting dimensions for
the seals shall be furnished.
9.3.3.8
9.3.3.8.1
The vendor shall provide complete performance curves to encompass the map of
operations, with any limitations indicated thereon.
9.3.3.8.2
9.3.3.8.3
Certified test curves and data shall be submitted within 15 days after testing and
shall include head, power recalculated to the proper specific gravity and efficiency
plotted against capacity. If applicable, viscosity corrections shall be indicated. If
NPSHR test is specified, the water NPSHR curve (drawn upto minimum continuous
flow) shall also be included. The curve sheet shall include the maximum and
minimum diameters of the impeller design supplied the eye area of the first stage
impeller, the identification number of the impeller or impellers and the pump serial
number.
9.3.3.9
Data Sheet
The Vendor shall provide completely filled in data sheets, first for" As Purchased"
and then for "As Built". This shall be done by the vendor correcting and filling out
the data sheets and submitting copies to the purchaser.
9.3.3.10
Installation Manual
The vendor shall provide sufficient written instructions, including a cross-reference
list of all drawings, to enable the purchaser to correctly install, operate and maintain
all the equipment. It shall include any special information required for proper
installation that is not on the drawings, special alignment or grouting procedures,
utility specifications (including quantity) and all installation data. It shall also contain
the following information:
9.3.3.10.1
Instructions for erecting, piping, aligning (including the expected thermally induced
shaft centerline shift between normal site ambient temperature position and that at
normal equipment operating temperature).
9.3.3.10.2
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9.3.3.10.3
9.3.3.11
9.3.3.11.1
9.3.3.11.2
(b)
Maximum and minimum bearing, labyrinth and seal clearances including any
other clearance between moving and stationary parts of the equipment
affecting proper running and maintenance of the equipment.
(b)
Instructions for measuring and adjusting cold clearance, shaft run out,
concentricity etc.
(c)
(d)
(e)
Balancing tolerances.
(f)
(g)
(h)
(i)
MECON LIMITED
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834002
TITLE
CENTRIFUGAL PUMP
DOCUMENT NO.
Page 26 of 27
(PETROLEUM SERVICES)
MEC/TS/05/21/024A
REVISION : 0
EDITION : 1
9.3.3.11.3
Bolting sequence and torque values for all bolts affecting equipment
Performance / integrity / safety.
(b)
(c)
(d)
(e)
(f)
Parts list indicating cross-sectional drawings of various assemblies and subassemblies, part numbers, materials of construction (ASTM) etc. to facilitate
identification of parts and for procurement of spares.
9.3.4
Final Documentation
9.3.4.1
9.3.4.1 .1
9.3.4.1 .2
Not later than two weeks after successful completion of all specified tests, the
vendor shall furnish the required number of technical data manual / mechanical
catalogues for the equipment, any auxiliaries and instruments that the vendor is
providing. The technical data manual / mechanical catalogue shall include the
following documents as a minimum:
9.3.4.1 .3
a)
All drawings and data as listed in the vendor data index & schedule. (For
drawings, where purchaser's approval is required, the final certified drawings
shall be attached.) Sections of technical data manual / mechanical catalogue
shall be organized in a manner that data and drawings related to one subject
are grouped together such as Mechanical, Electrical, Instrumentation, etc.
b)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
CENTRIFUGAL PUMP
DOCUMENT NO.
Page 27 of 27
(PETROLEUM SERVICES)
MEC/TS/05/21/024A
REVISION : 0
EDITION : 1
(b)
Instructions for preserving the equipment after it has been installed. This is
particularly required in cases where a long time gap is expected between
equipment installation and commissioning.
(c)
9.3.4.1 .4
Technical data manual / mechanical catalogue shall be in Hard board folder(s) of size
265 mm x 315 mm (10" x 12'") and shall not be more than 90 mm thickness; it
may be of several volumes and each volume shall have a volume number, index of
volumes & index of contents of that particular volume.
9.3.4.1 .5
Title sheet (Top sheet) of each volume of technical data manual / mechanical
catalogue shall contain the contract information as defined under 5.2.1.2 besides the
volume number.
9.3.4.1 .6
In case order contains more than one item, separate dedicated mechanical
catalogues shall be submitted for each item.
9.3.4.1.7
Final drawings & documents shall also be submitted as Electronic Files (preferably in
portable document format i.e. PDF) on CD-ROMs / Pen Drive / Flash Drive.
**************
Basic Design :
5.1.13
(Substitution)
Pumps shall have stable head / flow rate curves (continuous head rise to
shutoff) for all applications.
Pumps not specified for parallel operations, the head rise from rated point to
shut off shall be at least 5%. If parallel operation is specified the head rise
from rated point to shut off shall be at least 10%. Use of discharge orifice as
a means of meeting the above requirements shall be subject to approval of
the purchasers.
5.1.3
(Amendment)
Unless otherwise specified about availability of cooling water all cooling
system is to be designed using air coolers.
5.1.10
(Addition)
The Net Positive Suction Head Availability (NPSHA) shall exceed the Net
Positive Suction Head required (NPSHR) by at least 2 m through out the
range from minimum continuous stable flow upto and including the rated
capacity. Pumps where difference between NPSHA and NPSHR from
continuous stable minimum flow to rated flow is less than 0.6 m are not
acceptable.
Pumps fitted with inducers fro reducing NPSHR are not acceptable.
SPECIFICATION
FOR
RECIPROCATING PUMP (METERING)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
CONTENTS
1.0
GENERAL
2.0
BASIC DESIGN
3.0
MATERIALS
4.0
5.0
SPARE PARTS
6.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
Nov. 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Rev.
By
Date
Name
Verified
Sig.
Name
Sig.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 1 of 5
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
1.0
GENERAL
1.1
This specification along with data sheets, other specifications & attachments
to inquiry / order describes and constitutes the minimum requirement for
positive displacement pumps and their accessories / auxiliaries for use in the
process & pipeline applications.
The intent of these requirements is to supplement the requirements as given
in data sheets, other specifications and other applicable standards referred to
in data sheets / specifications.
1.2
Contractor and vendor shall make all possible efforts to comply strictly
with the requirements of this specification and other aforesaid specifications
/ attachments to inquiry / order and no deviation and exception from
this specification shall be permitted without written approval of Company.
In case any deviations are considered essential by vendor, these shall be
separately listed in vendors offer as List of deviations / exceptions to the
inquiry document, supported with proper reasons for the deviation for
Companys considerations. Any deviation indicated elsewhere, but not listed
in the deviation list shall not be considered applicable.
1.3
This specification
1.4
1.5
Compliance with this specification shall not relieve Contractor / vendor of the
responsibilities of furnishing equipment and accessories of proper design,
materials and workmanship to meet the specified start up and operating
conditions.
1.6
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 2 of 5
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
1.7
The pump model offered shall be from the existing regular manufacturing
range of the pump vendor. Vendor's / manufacturers catalogue and general
reference list shall be furnished along with the offer.
1.8
1.9
1.10
Pump and all auxiliaries shall be suitable for the specified area classification.
1.11
1.12
Special tools and tackles required either for installation, erection or operation
and maintenance of the pump units shall be included in vendors scope of
supply.
2.0
BASIC DESIGN
2.1
Pump rated capacity shall be equal to the maximum capacity specified in the
data sheet.
2.2
The pump unit and auxiliary shall be designed and constructed for continuous
full load duty.
2.3
Pump shall have positive return stroke mechanism and not the spring return
motion mechanism.
2.4
Unless otherwise specified, the pump flow rate shall be adjustable over the
range 10% to 100% of rated capacity while the pump is running.
2.5
Pump speed shall not exceed 100 strokes per minute. In case of higher
viscosity of pumping liquid, speed should be suitably lowered.
2.6
Relief valve shall be included in pump vendors scope of supply and shall be
mounted on pump discharge flange / piping furnished by pump vendor.
Relief valve shall be selected to pass 100% rated capacity of pump when
open to limit accumulation pressure to 110% of rated discharge pressure.
2.7
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 3 of 5
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
2.8
2.9
All exposed rotating / moving parts shall be provided with non-sparking type
guards.
2.10
2.11
2.12
2.13
2.14
Electric motor drivers shall have minimum horse power rating ( excluding
service factor ) at least 125% of rated BkW including transmission losses or
end of curve operation whichever is higher.
2.15
Unless otherwise specified the driver motor shall be in the scope of pump
vendor.
2.16
The electric motor shall be suitable for the electrical area classification
specified in the pump data sheets.
3.0
MATERIALS
Material of construction shall be as per data sheet. Contractor and vendor
shall however assume responsibility for suitability of selected material for
specified service. If necessary, vendor should furnish superior materials than
specified.
4.0
4.1
Unless otherwise specified all the pumps shall be inspected and witness
tested by authorized representative of Company.
4.2
As a minimum, tests shall be carried out as specified in the data sheets and
elsewhere ( if any ).
4.3
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 4 of 5
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
4.4
4.5
4.6
Acceptance of shop test shall not relieve Contractor and vendor from any of
their responsibilities.
4.7
All pressure containing parts shall be hydro tested with water at pressure 1.5
times the maximum operating pressure.
4.8
Unless otherwise specified, NPSH test shall be carried out whenever the
margin between (NPSH) available and (NPSH) required is less than 1.0
meter.
4.9
All instrumentation controls and safety devices shall be tested for satisfactory
operation and settings.
4.10
5.0
SPARE PARTS
5.1
5.2
Recommended spares and their quantities should take into account related
factors of safety, equipment reliability, effect of equipment downtime upon
production, cost of parts and availability of vendors service facilities around
proposed location of equipment.
5.3
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
6.0
RECIPROCATING PUMP
(METERING)
DOCUMENT NO.
Page 5 of 5
MEC/TS/05/21/24B
REVISION : 0
EDITION : 1
SL
NO
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13
WITH
OFFER
Yes
Yes
I
I
R*
R*
I
LEGEND:
I - INFORMATION, LOI - LETTER OF INTENT, PO - PURCHASE ORDER,
R- REVIEW, * at the time of inspection.
NOTE: Number of copies shall be as per Vol. -1
FINAL
Drgs.
# of copies
Edition : 1
SPECIFICATION
FOR
PRE-COMMISSIONING AND COMMISSIONING
OF
PIPELINE PROJECT
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/61
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION
1.0
INTRODUCTION
2.0
GENERAL
3.0
THE WORK
4.0
PRE-COMMISSIONING
5.0
PRE-COMMISSIONING CHECKS
6.0
COMMISSIONING
7.0
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Feb. 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
1.0
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 1 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
INTRODUCTION
This specification covers the minimum technical requirements for pre-commissioning and
commissioning of hydrocarbon pipeline, including commissioning activities such as precommissioning checks, flushing of terminal piping, dewatering, swabbing and nitrogen
purging.
2.0
GENERAL
The scope of work for testing and commissioning including pre-commissioning activities
shall include, but not be limited to the manpower, machinery & equipment, detailed
procedures, materials and consumables, communications etc. to perform the work
satisfactorily.
Contractor shall prepare detailed procedures for flushing of terminal piping, dewatering,
swabbing, inertisation and commissioning of the pipeline, covering all aspects of work for
companys approval. This shall include, but not be limited to, the sequence and description
of all operations, data on materials, equipment, instruments, consumables, communications
systems, necessary calculations, detailed time schedule and organisation chart.
The Contractor shall be responsible for demonstrating the successful completion of all the
activities i.e. flushing of terminal piping, dewatering, swabbing, inertisation and
commissioning of the pipeline. All necessary work to perform the job successfully including
necessary modifications required shall be the responsibility of the Contractor.
Contractor shall design and supply all temporary line connections, valves, instruments, etc.
as required during the various operations.
In the event of any detail which is not fully addressed, it is warranted by Contractor that work
shall be performed in accordance with companys specification and the best recognised
practices in the on-shore pipeline industry.
3.0
THE WORK
The work to be performed by the Contractor shall consist of the following activities :
Pre-commissioning
Dewatering
Swabbing
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
4.0
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 2 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
Inertisation
Commissioning
PRE-COMMISSIONING
In order to execute and perform pre-commissioning activities, the pipeline contractor shall
be responsible for (but not limited to) the following :
Dewatering of Pipeline and above ground piping, flushing / air-blowing and leak
testing of piping i.e. piping and equipments under their scope of work.
Erection of all temporary facilities like pig launcher / receiver, line connections, spool
pieces, pigs and requisite accessories, valves, instruments, manpower etc. as
required during various operations.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 3 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
All necessary work to perform the job successfully including all modifications that
would be required at various stages.
The pipeline contractor shall demonstrate to the OWNER / CONSULTANT (for
approval) the successful completion of all the above-mentioned activities.
5.0
PRE-COMMISSIONING CHECKS
5.1
The pre-commissioning checks shall be carried out for the pipeline to ascertain that the
pipeline system has been mechanically completed in all respects. These checks shall cover
the main pipeline including distribution network system and sectionalising valve stations.
The pre-commissioning checks shall include the following:
i)
System Checks
The entire facilities shall be checked against the latest P&IDs, Engineering & Vendor
Drawings / Documents and other design specification codes. Any shortcoming
observed shall be listed down in the form of punch lists and these should be duly
attended or liquidated. The pipeline contractor should check the stations systems
from the angle of pre-commissioning and commissioning and spell out any additional
requirement of vents / drains, temporary arrangement / modification etc. that may be
required during the pre-commissioning and commissioning activities and arrange for
the same in consultation with the OWNER / CONSULTANT representative.
ii)
iii)
iv)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
v)
DOCUMENT NO.
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MEC/S/05/21/61
REVISION : 0
EDITION : 1
vi)
vii)
Checking of Utilities
This is to check that utilities like power, nitrogen, UPS system instrument air, etc. are
available prior to startup.
viii)
5.2
DEWATERING
5.2.1
General
Dewatering of a pipeline section shall be done to facilitate EGP / caliper pigging. During the
dewatering operation the major quantity of hydrotest water shall be removed from the main
pipeline and distribution network. It is the responsibility of the Contractor to develop suitable
dewatering procedure and submit for Companys approval.
The disposal of the water shall be performed such that no harm is done to the environment.
5.2.2
Operational Requirements
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 5 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
Contractor shall provide a suitable compressor for oil-free air with sufficient capacity and
pressure.
Upon arrival of the pigs at the receiving end the Contractor in the presence of Companys
representative shall remove the pigs without delay.
5.2.2.2 Aboveground Piping Terminal
The dewatering operation of the piping work in the stations shall consist of physically draining
the water content in the piping work by opening low point drains and/or end flanges. If
required, air shall be used to push-off water from the pipes, The pipeline contractor shall
arrange suitable compressor for such purposes.
Flushing / Blowing of Aboveground Piping in the Terminal
Flushing / blowing of the above ground piping with water / air to remove debris / dirt / mud from
within the piping has to be performed by the pipeline contractor. Subsequent to water flushing,
to ensure complete cleanliness of the piping work, air blowing / cardboard blasting method has
to be adopted. All Instruments, control valves, plates etc. to be dismantled from the piping
work and any gap produced should be bridged with suitable temporary spool. Proper
supporting of the piping, during such flushing / blowing activities is to be ensured by the
pipeline contractor.
5.2.3
Acceptance Criteria
Before proceeding to the next stage of the inertisation operation Contractor shall ensure that
bulk of the water has been removed from the pipeline. Contractor shall specify when the
dewatering phase if finished and shall obtain approval of the company before proceeding to
the next inertisation phase.
5.3
Swabbing
5.3.1
General
The swabbing operation is meant to reduce the remaining water in the pipeline to bring the
pipeline into touch dry condition.
Swabbing operation shall be carried out to ensure that there is no free water left inside the
pipeline. For swabbing, suitable foam pigs shall be used by pipeline contractor and will be
suitable for traversing the whole length of the pipeline segment being swabbed. Before
starting swabbing operation, the pipeline contractor has to weight the swabbing pigs and
record. On arrival of the pigs at the receiving, the pipeline contractor to judge the weight
gained by the swabbing shall again weight the pigs. This is done by driving number of
swabbing pigs so that the weight increase in pig before and after the swabbing operation is
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 6 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
not more then 25%. The Contractor shall submit the detailed procedure along with the
duration of the swabbing operation and obtain approval of the company before starting the
operation.
5.3.2
Acceptance Criteria
The Contractor shall ensure that the swabbing operation is considered to be completed
when it is established that there is no free water left in the pipeline and the pipeline has
achieved a touch dry condition requirement of EGP. This shall be subject to companys
approval.
Note-1:
Note-2:
5.4
5.4.1
General
Equipments like Scraper Launcher, filters, Corrosion Inhibitor Dosing Tanks, Sump Tanks
and Scraper Receiver are to be checked for Internal cleanliness and shall be ensured by the
pipeline contractor.
5.4.2
Acceptance Criteria
The laying contractor has to demonstrate cleanliness of the internals of all equipment to the
satisfaction of the Owner / Consultant and obtain approval for final box up of the equipment.
5.4.3
MECON LIMITED
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TITLE
5.5
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
PROJECT
DOCUMENT NO.
Page 7 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
Drying
Unless otherwise stipulated the piping shall be dried with compressed air. The compressors
used for drying shall have an absorption drying units with adequate dew point outlet.
Valves shall be drained as much as possible in the half open position under air pressure
through the vent pipes under the supervision of and in consultation with the Owner /
Consultant. Manipulation of the valves without the supervision of the Owner / Consultant is
strictly forbidden. The blowing shall be continued until a constant dew point of -8C (or other
dew point as per TS) is measured. Subsequently, the pipe shall be closed for 24 hours. If
the dew point has not increased after 24 hours, the installation is considered dry.
The piping to be dried must have the necessary measuring devices to measure
constantly the temperature, pressure and dew point.
For faster drying, the Contractor may propose drying with heated Nitrogen. The temperature
shall be limited to + 50C.
5.6
Inertisation
During the inertisation operation, the air left in the pipeline shall be replaced by nitrogen
before admitting the product hydrocarbon that the pipeline will ultimately carry.
The inertisation operation shall start as soon as possible after the swabbing operation has
been completed and approved by the company. Contractor shall submit the detailed
purging procedure for approval for the company prior to its implementation.
Nitrogen needed for inertisation of the pipeline, shall be provided by the Contractor. The
maximum allowable oxygen content inside the pipeline shall be less than 1% by volume.
Multiple separation pigs with nitrogen slugs in between shall be used for pipeline
commissioning. At least three batches of nitrogen separated by four separation pigs shall
be used for inertisation of the pipeline during charging of gas in it. The combined nitrogen
column length to be used for inertisation should be at least 5% of the total pipeline length.
5.6.1
MECON LIMITED
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834002
TITLE
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
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6.0
COMMISSIONING
6.1
DOCUMENT NO.
Page 8 of 9
MEC/S/05/21/61
REVISION : 0
EDITION : 1
After completion of pre-commissioning activities and Owner approved safety start-up review
followed by liquidation of review punch list points, the pipeline contractor shall notify the
Owner / Consultant that the pipeline systems in totally are ready in all respects for
hydrocarbon-in. Ready for commissioning status shall be jointly assessed by Owner /
Consultant, composite work contractor, pipeline contractor.
After such joint assessment, if all the criteria are met, it will then be declared by the Owner
that the entire pipeline system has reached a stage of 'Ready for Commissioning'.
It should be noted that if the actual commissioning of the stations is taken up after idle time
of sufficient length, then before starting the rotating equipment again, revisioning of the
rotating equipments has to be done in presence of pump vendor(s). The pipeline contractor
has to provide all sorts of assistance during such revisioning activities.
6.2
7.0
DOCUMENTATION
Contractor shall submit for approval of the company the complete description, detailed
procedure and time schedule of all the dewatering, swabbing, flushing / blowing, drying
purging and commissioning operations, as applicable.
Documents shall also contain all procedures and safety plans to be followed while carrying
out the activities.
Upon successful completion of the work, Contractor shall prepare a final report of the work
which shall include necessary charts, diagrams, graphs, calculations, recordings, daily logs,
measurements, details of the operation, etc. Report shall also include all certificates of
calibration of instruments required together with records of calibration performed at site prior
to the start of any operation.
7.1
MECON LIMITED
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7.2
PRE-COMMISSIONING AND
COMMISSIONING OF PIPELINE
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DOCUMENT NO.
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EDITION : 1
Safety
Follow the safety practice during execution of pre-commissioning/ commissioning works as
detailed in the scope of work. Maintain and follow all safety practices equivalent or better
than those being practiced for the pipeline during pre-commissioning and commissioning
Rev. : 0
Edition : 1
SPECIFICATION
FOR
HEALTH, SAFETY
AND
ENVIRONMENT (HSE)
MANAGEMENT
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/65
REVISION : 0
EDITION : 1
CONTENTS
SL. NO.
DESCRIPTION
1.0
SCOPE
2.0
REFERENCES
3.0
4.0
5.0
RECORDS
ANNEXURE-A
ANNEXURE-B
ANNEXURE-C
ANNEXURE-D
ANNEXURE-E
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Feb. 2009
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/65
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit / Drawing
Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
1.0
DOCUMENT NO.
Page 1 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
SCOPE
This specification establishes the Healthy, Safety and Environment (HSE)
management requirement to be compiled with by the Contractors during
construction.
This specification is not intended to replace the necessary professional judgement
needed to design & implement an effective HSE system for construction activities
and the contractor is expected to exceed requirements given in this specification.
Requirement stipulated in this specification shall supplement the requirement of HSE
management given in relevant Act (S)/ legislations. General Condition of Contract
(GCC) Special Condition of Contract (SCC) and Job Specifications. Where different
documents stipulate different requirements, the most stringent shall be adopted.
2.0
REFERENCES
This document should be read in conjunction with following:
-
3.0
3.1
Management Responsibility
3.1.1
The Contract should have a document HSE policy to cover commitment of the
organization to ensure health, safety and environment aspects in their line of
operations
3.1.2
The HSE management system of the Contractor shall cover HSE requirement
including but not limited to what specified under clause 1.0 & 2.0 mentioned above
3.1.3
Contractor shall be fully responsible for planning and implementing HSE requirement
to the satisfaction of the company. Contractor as a minimum requirement shall
designate/deploy the following to co-ordinate the above:
No. Of workers deployed
Up to 250
MECON LIMITED
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DOCUMENT NO.
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EDITION : 1
Above 500
(for every 500 or less)
The Contractor shall ensure that the Health, Safety and Environment (HSE)
requirements are clearly understood & faithfully implemented at all levels, at each
and every site/ work place.
3.1.5
The Contractor shall promote and develop consciousness for Health, Safety and
Environment among all personnel working for the Contractor. Regular awareness
programs and fabrication shop/work site meeting shall be arranged on HSE activities
to cover hazards involved in various operations during construction.
3.1.6
Arrange suitable first aid measures such as First Aid Box, trained personnel to give
First Aid, Stand by Ambulance or Vehicle and install fire protection measures such
as: adequate number of steel buckets with sand and water and adequate fire
extinguishers to the satisfaction of OWNER/ MECON. In case the number of workers
exceeds 500, the Contractor shall position an ambulance /vehicle on full time basis
very close to the worksite.
3.1.7
The Contractor shall evolve a comprehensive planned and documented system for
implementation and monitoring of the HSE requirements. This shall submitted to
MECON LIMITED
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DOCUMENT NO.
Page 3 of 59
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REVISION : 0
EDITION : 1
OWNER & MECON for approval well in advance, prior to start of work. The
monitoring for implementation shall be done by regular inspection and compliance to
the observations thereof. The Contractor shall get similar HSE requirements
implemented at his sub-contractor (s) work site/ Office. However, compliance of HSE
requirement shall be the sole responsibility of the Contractor. Any review/ approval
by OWNER/ MECON shall not absolve the Contractor of his responsibility/ liability in
relation to all HSE requirements.
3.1.8
3.1.9
3.1.10
2.
Penalty Amount
For not using personal protective Rs. 250/- per day / item /
equipment (Helmet, Shoes, Goggles, person
Gloves, Full body harness, Face shield,
Boiler suit, etc.)
Working without Work Permit / Rs.5,000/- per occasion
Clearance
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
S.
No.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
DOCUMENT NO.
Page 4 of 59
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REVISION : 0
EDITION : 1
Penalty Amount
Unsafe electrical practices (not installing Rs.3,000/- per item per day.
ELCB, using poor joints of cables, using
naked wire without top plug into socket,
laying wire / cables
on the roads, electrical jobs by
incompetent person, etc.)
Working at height without full body Rs.1,000/ per case per day.
harness, using non-standard / rejected
scaffolding and not arranging fall
protection arrangement
as
required like Safety Nets.
Unsafe handling of compressed gas Rs. 100/- per item per day
cylinders (No trolley, jubilee clips double
gauge regulator, improper storage /
handling).
Use of domestic LPG for cutting
purpose.
No fencing / barricading of excavated
areas.
Not providing shoring / strutting / proper
slope and not keeping the excavated
earth at least 1.5 M away from
excavated area.
Non display of caution boards, list of
hospitals, emergency services available
at work locations.
Traffic rules violations like over speeding
of vehicles, rash driving, wrong parking,
not using seat belts, vehicles not fitted
with reverse warning alarms.
Absence of Contractor's top most
executive at site in the safety meetings
whenever called by MECON / Owner
Failure to maintain safety records by
Contractor Safety personnel.
Failure to conduct daily safety site
inspection, HSE meeting and HSE audit
at predefined frequencies.
Failure to submit the monthly HSE report
by 5th of subsequent month to Engineerin-Charge.
Poor House Keeping
Failure to report & follow up accident
(including Near Miss) reporting system.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
S.
No.
17.
18.
19.
20.
DOCUMENT NO.
Page 5 of 59
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REVISION : 0
EDITION : 1
Penalty Amount
Rs.1,000/- per occasion
To be decided by MECON /
Owner
This penalty shall be in addition to all other penalties specified else where in the
contract. The decision of imposing stoppage of work, its extent & monitory penalty
shall rest with MECON/OWNER & binding on the Contractor.
3.1.11
All fatal accidents and other personnel accidents shall be investigated by a team of
Contractors senior personnel for root cause and recommend corrective and
preventive actions. Findings shall documented and suitable actions taken to avoid
recurrences shall be communicated to OWNER / MECON. OWNER / MECON shall
have the liberty to independently investigate such occurrences and Contractor shall
extend all necessary help and co-operation in this regard. MECON / Owner shall
have to right to share the content of this report with the outside world.
3.2
House Keeping
3.2.1
Contractor shall ensure that a high degree of house keeping is maintained and shall
ensure the followings:
a.
All surplus earth and debris are removed/disposed off from the working site to
identified location (s).
b.
c.
All wooden scrap, empty wooden cable drums and other combustible packing
materials shall be removed from work place to identified location(s).
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REGD. OFF: RANCHI
834002
TITLE
3.3
DOCUMENT NO.
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EDITION : 1
d.
Roads shall be kept clear and materials like pipes, steel, sand, boulders,
concrete chips and bricks, etc. shall not be allowed in the roads to obstructs
free movement of men & machineries.
e.
f.
g.
h.
Utmost care shall be taken to ensure over all cleanliness and proper up keep
of the working areas.
i.
Trucks carrying sand, earth and pulverized materials etc. shall be covered
while moving within the plant areas.
j.
The contractor shall ensure that the atmosphere in plant area and on roads is
free from particulate matter like dust, sand, etc. by keeping the top surface
wet for ease in breathing.
k.
At least two exits for any unit area shall be assured at all times.
The Contractor shall provide safe means of access to any working place
including provision of suitable and sufficient scaffolding at various stages
during all operations of the work for the safety of his workmen, and OWNER/
MECON. Contractor shall ensure deployment of appropriate equipment and
appliances for adequate safety and healthy of the workmen and protection of
surrounding areas.
Contractor shall ensure identification of all Occupational Health, Safety &
Environmental hazards in the type of work he is going to undertake and enlist
mitigation measures. Contractor shall carry out Job Safety Analysis (JSA)
specifically for high risk jobs like working at height & in confined space, deep
excavations, radiography jobs, electrical installations, blasting operations,
demolishing / dismantling activities, welding / gas cutting jobs and submit the
findings to MECON / Owner. The necessary HSE measures devised shall be
in place prior to start of an activity by the contractor.
b)
The Contractor shall ensure that all their staff workers including their subContractor (s) shall wear Safety Helmet and Safety shoes. Contractor shall
also ensure use of safety belt, protective goggles, gloves etc. by the
personnel as per jobs requirements. All these gadgets shall conform to
relevant IS specification equivalent.
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REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
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REVISION : 0
EDITION : 1
The Contractor shall ensure that all their staff, workers and visitors including
their sub-contractor(s) have been issued (records to be kept) & wear
appropriate PPEs like nape strap
type safety helmets preferably with head
& sweat band with " cotton chin strap (made of industrial HDPE), safety
shoes with steel toe cap and antiskid sole, full body harness (C marked and
conforming to EN361), protective goggles, gloves, ear muffs, respiratory
protective devices, etc. All these gadgets shall conform to applicable IS
Specifications / C or other applicable international standards.
Owner may issue a comprehensive color scheme for helmets to be used by
various agencies. The Contractor shall follow the scheme issued by the
owner. All Safety / Fire personnel shall preferably wear red colour helmet so
that workmen can approach them for guidance during emergencies.
For shot blasting, the usage of protective face shield and helmets, gauntlet
and protective clothing is mandatory.
For offshore jobs/contracts, contractor shall provide PPEs (new) to MECON &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life
jacket at all time.
An indicative list of HSE standards/codes is given under Appendix-A.
The contractor shall issue height permit for working at height after verifying
and certifying the checkpoints as specified in the attached permit (Format No.
HSE-6). He shall also undertake to ensure compliance to the conditions of
the permit during the currency of the permit including adherence to personal
protective equipments.
The permit shall be issued initially for one week or expected duration of an
activity and extended further for the balance duration. This permit shall be
applicable in areas where specific clearance from Owner's operation Deptt. /
Safety Deptt. is not required. MECON field Engineers / Safety Officers / Area
Coordinators may verify and counter sign this permit (as an evidence of
verification) during the execution of the job.
In case work is undertaken without taking sufficient precautions as given in
the permit, MECON Engineers may cancel the permit and stop the work till
satisfactory compliance is arranged. Contractors are expected to maintain a
register for issuance of permit and extensions thereof including preserving
the used permits for verification during audits etc.
Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems
by his workers. Fall arresters are to be used while climbing / descending tall
structures. These arresters should lock automatically against the anchorage
line, restricting free fall of the user. The device is to be provided with a double
security opening system to ensure safe attachment or release of the user at
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 8 of 59
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REVISION : 0
EDITION : 1
any point of rope. In order to avoid shock, the system should be capable of
keeping the person in vertical position in case of a fall.
Contractor shall ensure that Full body harnesses conforming EN361 and
having authorized CC marking is used by all personnel while working at
height. The lanyards and life lines should have enough tensile strength to
take the load of the worker in case of a fall. One end of the lanyard shall be
firmly tied with the harnesses and the other end with life line. The harness
should be capable of keeping the workman vertical in case of a fall, enabling
him to rescue himself.
Contractor shall provide Roof Top Walk Ladders for carrying out activities on
sloping roofs in order to reduce the chances of slippages and falls.
c)
Contractor shall ensure that a proper Safety Net System shall be used at
appropriate locations. The safety net shall be located not more than 30 feet
(9.0 metres) below the working surface at site to arrest or to reduce the
consequences of possible fall of persons working at different heights.
d)
e)
The Contractor shall assign to his workmen, tasks commensurate with their
qualification, experience and state of health for driving of vehicles, handling
and erections of materials and equipments. All lifting equipments shall be
tested certified for its capacity before use. Adequate and suitable lighting at
every work place and approach there to shall be provided by the contractor
before starting the actual work/ operation at night.
Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes
(while in use) to minimize overloading risk. SLI shall have capability to
continuously monitor and display the load on the hook, and automatically
compare it with the rated crane capacity at the operating condition of the
crane. The system shall also provide visual and audible warnings at set
capacity levels to alert the operator in case of violations.
The contractor shall be responsible for safe operations of different
equipments mobilized and used by him at the workplace like transport
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REGD. OFF: RANCHI
834002
TITLE
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EDITION : 1
g)
All hazardous materials shall be labeled with the name of the materials, the
hazards associated with its use and necessary precautions to be taken.
The work place shall be checked prior to start of activities to identify the
location, type and condition of any asbestos materials which could be
disturbed during the work. In case asbestos material is detected, usage of
appropriate PPEs by all personnel shall be ensured and the matter shall be
reported immediately to MECON / Owner.
h)
Contractor shall ensure that during the performance of the work all hazards to
the health of personnel have been identified assessed and eliminated.
i)
j)
k)
l)
II)
Suitable facilities for toilet, drinking water, proper lighting shall be provided at
site and labor camps, commensurate with applicable Laws/Legislation.
n)
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REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
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EDITION : 1
recovered shall be stored and disposed of safely. In no way, toxic spills shall
be allowed to percolate into the ground. The contractor shall not use the
empty areas for dumping the wastes.
o)
All person deployed at site shall be knowledgeable of and comply with the
environmental laws, rules & regulation relating to the hazardous materials
substance and wastes. Contractor shall not dump, release or otherwise
discharge or dispose off any such materials without the authorization of
OWNER/ MECON.
Suitable scaffoldings shall be provided to workmen for all works that cannot
be safely done from the ground or from solid construction except such short
period work that can be safely done using ladders. When a ladder is used, an
extra workman shall be engaged for holding the ladder.
The contractor shall ensure that the scaffolds used during construction
activities shall be strong enough to take the designed load. Owner / MECON
reserves the right to ask the contractor to submit certification and or design
calculations from his Engineering regarding load carrying capacity of the
scaffoldings.
All scaffolds shall be inspected by a Scaffolding Inspector of the contractor.
He shall paste a GREEN tag on each scaffold found safe and a RED tag on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be
permitted to be used and RED ones shall immediately be removed from the
site.
All electrical installations / connections shall be carried out as per the
provisions of latest revision of following codes/standards, in addition to the
requirements of Statutory Authorities and IE / applicable international rules &
regulations:
-
SP 30 (BIS)
ii)
Shall deploy qualified & licensed electricians for proper & safe
installation and for regular inspection of construction power
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REGD. OFF: RANCHI
834002
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EDITION : 1
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
The following features shall also be ensured for all electrical installations
during construction phase by the contractor:
i)
ii)
The outgoing feeders shall be double or triple pole switches with fuses
/ MCBs. Loads in a three phase circuit shall be balanced as far as
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REGD. OFF: RANCHI
834002
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EDITION : 1
possible and load on neutral should not exceed 20% of load in the
phase.
iii)
iv)
v)
All single phase sockets shall be minimum 3 pin type only. All unused
sockets shall be provided with socket caps.
vi)
vii)
viii)
ix)
x)
xi)
Under ground road crossings for cables shall be avoided to the extent
feasible. In any case no under ground power cable shall be allowed to
cross the roads without pipe sleeve.
xii)
All cable joints shall be done with proper jointing kit. No taped /
temporary joints shall be used.
xiii)
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REGD. OFF: RANCHI
834002
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DOCUMENT NO.
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EDITION : 1
All cables and wire rope used for earth connections shall be
terminated through tinned copper lugs.
xv)
xvi)
xvii)
The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
For surface cleaning operations, sand blasting shall not be permitted even if not
explicitly stated elsewhere in the contract.
To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc
Welding shall not contain Thorium.
Appropriate respiratory protective devices shall be used to protect workmen from
inhalation of air borne contaminants like silica, asbestos, gases, fumes, etc.
Workmen shall be made aware of correct methods for lifting, carrying, pushing &
pulling of heavy loads. Wherever possible, manual handling shall be replaced by
mechanical lifting equipments.
For jobs like drilling / demolishing / dismantling where noise pollution exceeds the
specified limit of 85 decibels, ear muffs shall be provided to the workers.
To avoid upper limb disorders and backaches, Display Screen Equipments'
workplace stations shall be carefully designed & used with proper sitting postures.
Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how
to operate them safely & how to maintain good circulation in hands.
The contractor shall arrange health check up for all the workers at the time of
induction. Health check may have to be repeated if the nature of duty assigned to
him is changed necessitating health check or doubt arises about his wellness.
MECON / Owner reserve the right to ask the contractor to submit test reports.
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REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
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REVISION : 0
EDITION : 1
Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses,
Sun screen lotions, respirators, dust masks, etc. and rearranging / planning the construction
activities to suit the weather conditions.
Communication
All persons deployed at the work site shall have access to effective means of
communication so that any untoward incident can be reported immediately and assistance
sought by them.
All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
Unsuitable Land Conditions
Contractor shall take appropriate measures and necessary work permits / clearances if work
is to be done in or around marshy areas, river crossings, mountains, monuments, etc.
Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection
arrangements and shall posses communication facilities like cellular phones, wireless,
walkie-talkie. All divers used for seabed surveys, underwater inspections shall have required
authorized license, suitable life saving kit. Number of hours of work by divers shall be limited
as per regulations. MECON / Owner shall have the right to inspect the boat and scrutinize
documents in this regard.
TOOL BOX MEETING (TBM)
Contractor shall conduct daily TBM with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBM is to be
conducted by the immediate supervisor of the workers.
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REGD. OFF: RANCHI
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EDITION : 1
Signature
Section
Remarks, if any
The above record can be kept in local language, which workers can read. These records
shall be made available to MECON / Owner whenever demanded.
TRAINING
Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about
-
Records of the training shall be kept and submitted to MECON / Owner whenever
demanded.
For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner / MECON.
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REGD. OFF: RANCHI
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EDITION : 1
INSPECTION
The contractor shall carryout daily HSE inspection and record observations at a central
location. These inspection records shall be freely accessible to Owner / MECON
representatives. The contractor shall also assist Owner / MECON representatives during the
HSE inspections conducted by them.
ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING PLANT
As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant :
a)
Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined
Space from Owner in the prescribed format.
b)
The contractor shall monitor, record and compile list of his workers entering the
operational plant/unit each day and ensure & record their return after completing the
job.
c)
Contractor's workers and staff members shall use designated entrances and
proceed by designated routes to work areas only assigned to them. The workers
shall not be allowed to enter units' area, tanks area, pump rooms, etc. without work
authorization permit.
d)
e)
The contractor shall submit a list of all chemicals / toxic substances that are intended
to be used at site and shall take prior approval of the Owner.
f)
g)
Proper barricading / cordoning of the operational units / plants shall be done before
starting the construction activities. No unauthorized person shall be allowed to
trespass. The height and overall design of the barricading structure shall be finalized
in consultation with the Owner and shall be got approved from the Owner.
h)
Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i)
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j)
Emergency evacuation plan shall be worked out and all workmen shall be apprised
about evacuation routes. Mock drill operations may also be conducted.
k)
Flammable gas test shall be conducted prior to any hot work using appropriate
measuring instruments. Sewers, drains, vents or any other gas escaping points shall
be covered with flame retardant tarpaulin.
l)
Respiratory devices shall be kept handy while working in confined zones where there
is a danger of inhalation of poisonous gases. Constant monitoring of presence of
Gas / Hydrocarbon shall be done.
m)
Clearance shall be obtained from all parties before starting hot tapping, patchwork
on live lines and work on corroded tank roof.
n)
o)
Welding spatters shall be contained properly and in no case shall be allowed to fall
on the ground containing oil. Similar care shall be taken during cutting operations.
p)
The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust
pipe and got it approved from Safety Department of the Owner.
q)
Plant air should not be used to clean any part of the body or clothing or use to blow
off dirt on the floor.
r)
Gas detectors should be installed in gas leakage prone areas as per requirement of
Owner's plant operation personnel.
s)
HSE PROMOTION
The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops / seminars / training programmes, celebrating HSE awareness weeks
& National Safety Day, conducting quizzes & essay competitions, distributing pamphlets,
posters & material on HSE, providing incentives for maintaining good HSE practices and
granting bonus for completing the job without any lost time accident.
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REVISION : 0
4.0
4.1
On Award of Contract
EDITION : 1
The Contractor shall prior to start of work submit his Health. Safety and Environment
Manual of procedure and HSE Plans for approval by OWNER/MECON. The
Contractor shall participate in the pre-start meeting with OWNER/MECON to finalize
HSE plans including the following.
-
4.2
4.2.1
Arrange all HSE permits before start of activities (as applicable) like her work,
confined space, work at heights, storage of Chemicals/explosives materials
and its use and implement all precautions mentioned therein
Submit timely the completed check list on HSE activities, Monthly HSE report,
accident report, investigation report, etc. as per OWNER/MECON
requirements. Compliance of instructions on HSE shall be done by Contractor
and informed urgently to OWNER/MECON.
Display at site office and work locations caution boards, list of hospitals for
emergency services available.
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834002
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5.0
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EDITION : 1
RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following
reporting formats:
1.
2.
3.
4.
5.
6.
7.
8.
9.
HSE-1
HSE-2
HSE-3
HSE-4
HSE-5
HSE-6
HSE-7
HSE-8
HSE-9
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EDITION : 1
ANNEXURE-A
A.
SP:53
Safety code for the use, Care and protection of hand operated tools.
IS: 818
Code of practice for safety and health requirements in electric and gas
welding and cutting operations
IS: 1179
IS: 1860
Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 2925
IS: 3016
Code of practice for fire safety precautions in welding and cutting operations.
IS: 3043
IS: 3764
IS: 3786
Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents.
IS: 3996
IS: 4082
IS: 4770
IS: 5121
IS: 5557
IS: 5983
Eye protectors
IS:6519
IS: 7293
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EDITION : 1
IS: 8519
IS: 9167
Ear protectors
IS: 11006
IS:11016
General and safety requirements for machine tools and their operation
IS: 11057
IS: 11226
IS: 11972
IS: 13367
IS: 13416
B.
Safety Glasses
Safety Shoes
Hand Gloves
BS 1651
Ear Muffs
Hard Hat
Goggles
ANSI Z 87.1
Face Shield
ANSI Z 89.1
Breathing Apparatus :
BS 4667, NIOSH
ANSI Z 49.1
Safe handling of
compressed Gases
in cylinders
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EDITION : 1
ANNEXURE-B
DETAILS OF FIRST AID BOX
SL.
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
DESCRIPTION
Small size Roller Bandages, 1 inch wide (Finger Dressing small)
Medium size Roller Bandages, 2 inch wide (Hand and Foot Dressing)
Large size Roller Bandages, 4 inch wide (Body Dressing Large)
Large size Burn Dressing (Burn Dressing Large)
Cotton wool (20 gms packing)
Antiseptic Solution Dettol (100 ml.) or Savlon
Mercurochrome Solution (100 ml.) 2% in water
Ammonia Solution (20 ml.)
A Pair of Scrissors
Adhesive Plaster (1.25 cm x 5 m)
Eye pads in Separate Sealed Packet
Tourniqut
Safety Pins
Tinc. Iodine / Betadin (100 ml.)
Ointment for burns (Burnol 20 gms.)
Polythene Wash cup for washing eyes
Potassium Permanganate (20 gms.)
Tinc. Benzoine (100 ml.)
Triangular Bandages
Band Aid Dressing
Iodex / Moov (25 gms.)
Tongue Depressor
Boric Acid Powder (20 gms.)
Sodium Bicarbonate (20 gms.)
Dressing Powder (Nebasulf) (10 gms.)
Medicinal Glass
Duster
Booklet (English & Local Language)
Soap
Toothache Solution
Eye Ointment
Vicks (22 gms.)
Forceps
Cotton Buds (5 nos.)
Note Book
Splints
Lock
Life Saving/Emergency/Over-the Counter Drugs
QUANTITY
6 Pcs.
6 Pcs.
6 Pcs.
4 Pkts.
4 Pkts.
1 Bottle
1 Bottle
1 Bottle
1 Piece
1Spool
4 Pcs.
1 No.
1 Dozen
1 Bottles
1 Bottole
1 No.
1 Pkt.
1 Bottole
2 Nos.
5 Pcs.
1 Bottole
1 No.
2 Pkt.
1 Pkt.
1 Bottole
1 No.
1 No.
1 No. each
1 No.
1 No.
1 Bottle
1 Bottle
1 No.
1 Pkt.
1 No.
4 Nos.
1 Piece
As decided at site
Box size : 14 x 12 x 4
Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.
MECON LIMITED
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EDITION : 1
ANNEXURE C
TYPE OF FIRES VIS--VIS FIRE EXTINGUISHERS
Fire
Water
Foam
Inflammable
liquids
like alcohol, diesel,
petrol, edible oils,
bitumen
Legend :
x
Fire Extinguishers
CO2
Dry Powder
Multi Purpose
(ABC)
Can control
minor
surface fires
Can control
minor
surface fires
Can be used
Not to be used
Note : Fire extinguishing equipment must be checked atleast once a year and after every use by
an authorized person. The equipment must have an inspection label on which the next
inspection date is giver:. Type of extinguisher shall clearly be marked on it.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 24 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
ANNEXURE D
Indicative List of Statutory Acts & Rules Relating to HSE
-
The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules.
The Building and Other Construction Workers (Regulation of Employment and Condition of
service) Act
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 25 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
ANNEXURE E
TYPE OF HAZARD
EFFECT OF HAZARD
Personal injury
Pit Excavation up
to 3.0m
Earth
Collapse
Contact with
buried electric
cables
Gas/ Oil
Pipelines
Suffocation /
Breathlessness
Buried
Electrocution
Explosion
PREVENTIVE MEASURES
Provide guard
rails/barricade with
warning signal.
Provide escape
ladders.
Maintain sufficient
angle of repose.
Provide slope not
less than 1:1 and
suitable bench of
0.5m width at every
1.5m depth of
excavation in all soils
except hard rock.
Battering/benching
the sides.
Obtain permission
from competent
authorities, prior to
excavation, if
required.
Start digging
manually to locate
the exact position of
buried utilities and
thereafter use
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Pit Excavation
beyond 3.0m
Narrow deep
excavations for
pipelines, etc.
Same as
above plus
Flooding due
to excessive
rain/
underground
water
Digging in the
vicinity of
existing
Building/
Structure
Page 26 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
Can cause
drowning situation
Building/ Structure
may collapse
Loss of health &
wealth
Movement of
vehicles /
equipments
close to the
edge of cut.
Same as
above plus
Frequent
cave-in or
slides
Flooding due
to Hydrostatic
testing
PREVENTIVE MEASURES
mechanical means.
Prevent ingress of
water
Use under-pining
method
Construct retaining
wall side by side
Barricade the
excavated area with
proper lighting
arrangements
Maintain at least 2m
distance from edge
of cut and use stop
block to prevent
over-run.
Strengthen shoring
and strutting
May arise
drowning situation
Rock excavation by
blasting
Improper
handling of
explosives
Uncontrolled
explosion
Battering/benching
of sides
Provide escape
ladders
Same as above plus
Bail out accumulated
water
Maintain adequate
ventilation
Ensure proper
storage, handling &
carrying of
explosives by trained
personnel.
Comply with the
applicable explosive
acts & rules.
Allow only authorized
persons to perform
blasting operations.
Smoking and open
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Rock excavating by
blasting (Contd)
Piling Work
Page 27 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
PREVENTIVE MEASURES
flames are to be
strictly prohibited.
Scattering of
stone pieces
in atmosphere
Entrapping of
persons/
animals.
Misfire
May explode
suddenly
Failure of piledriving
equipment
Noise
pollution
Can cause
deafness
and psychological
imbalance
Extruding rods
/ casing
Working in the
vicinity of
LiveElectricity
Can cause
electrocution /
asphyxiation
(B) CONCRETING
Air pollution
by cement
Handling of
ingredients
Protruding
reinforcement
rods.
Earthing of
electrical
mixers,
May affect
Respiratory
System
Hand s may get
injured
Feet may get
injured
Can cause
electrocution /
asphyxiation
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Super-structure
Page 28 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
vibrators, etc.
not done
Falling of
materials from
height
Continuous
pouring by
same gang
Cause tiredness
of workers and
may lead to
accident.
Revolving or
concrete
mixer/
vibrators
Parts of body or
clothes may get
entrapped.
Same as
above plus
Deflection in
props or
shuttering
material
Shuttering / props
may collapse and
prove fatal
Passage to
work place
Improperly tied
and designed
props / planks
may collapse
Curtailment
and binding of
rods
Carrying of
rods for short
distance/ at
Workers may
injure their hands
and shoulders
(C)
REINFORCEMENT
DOCUMENT NO.
PREVENTIVE MEASURES
electrical circuit
before
commencement of
work.
Remove surplus
material immediately
from work place
Ensure lighting
arrangements during
night hours.
Provide adequate
rest to workers
between subsequent
pours.
Ensure proper
mechanical locking
of vibrator
Avoid excessive
stacking on
shuttering material
Rectify immediately
the deflection noted
during concreting
Provide suitable
pads on shoulders
and use safety
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Page 29 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
heights
DOCUMENT NO.
PREVENTIVE MEASURES
gloves.
Ensure proper
staging.
Use measuring
devices tape,
measuring rods, etc.
Checking of
clear distance/
cover with
hands
Hitting
projected rods
and standing
on cantilever
rods
Falling of
material from
height
Transportation
of rods by
trucks /
trailers
Protruded rods
may hit the
persons
(D) WELDING
AND GAS
CUTTING
Welding
radiates
invisible
ultraviolet and
infrared says
Improper
placement of
oxygen and
acetylene
cylinders
Radiation can
damage eyes and
skin.
Explosion may
occur
Leakage /
cuts in hoses
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
DOCUMENT NO.
Page 30 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
Opening-up of
cylinder
Cylinder may
burst
Welding of
tanks,
container or
pipes storing
flammable
liquids
Explosion may
occur
PREVENTIVE MEASURES
oil on oxygen line
connections and
copper fittings on
acetylene lines
(E)
RADIOGRAPHY
Ionizing
Radiation
Radiations may
react with the skin
and can cause
cancer, skin
irritation,
dermatitis, etc.
Transportation
and Storage
of
Radiography
source
Same as above
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Loss of Radio
isotope
Page 31 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
Same as above
PREVENTIVE MEASURES
storage room with
lock and key
arrangement. The pit
should be approved
by BARC/AERB
Radiography source
should never be
carried either in
passenger bus or in
a passenger
compartment of
trains.
BARC/AERB have to
be informed before
source movement.
Permission from
Director General of
Civil Aviation is
required for booking
radio isotopes with
airlines.
Inform
BARC/AERB(*)
(*)
(F) ELECTRICAL
INSTALLATION
AND USAGE
Short
circuiting
Can cause
Electrocution or
Fire
Atomic Energy
Regulatory Board
(AERB), Bhabha
Atomic Research
Centre (BARC)
Anushaktinagar,
Mumbai 400 094
Use rubberized hand
gloves and other
PPE
Dont lay wires under
carpets, mats or
door ways.
Allow only licensed
electricians to
perform on electrical
facilities
Use one socket for
one appliance
Ensure usage of only
fully insulated wires
or cables
Dont place bare wire
ends in a socket
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
DOCUMENT NO.
Page 32 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
Overloading
of Electrical
System
Bursting of
system can occur
which leads to fire
Improper
laying of
overhead and
underground
transmission
lines / cables
Can cause
electrocution and
prove fatal
PREVENTIVE MEASURES
Ensure earthing of
machineries and
equipments
Do not allow
open/bare
connections
Provide all
connections through
ELCB
Protect electrical
cables / equipments
from water and
naked flames
Check all
connections before
energizing.
Ensure approved
cable size, voltage
grade and type.
Do not allow
unauthorized
connections.
Do not lay
unarmored cable
directly on ground,
wall, roof of trees
Maintain at least 3m
distance from HT
cables
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
(G) FIRE
PREVENTION
AND
PROTECTION
Small fires
can become
big ones and
may spread to
the
surrounding
areas
Page 33 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
Cause burn
injuries and may
prove fatal.
PREVENTIVE MEASURES
fine sand overlying
by brick soling
Provide proper
sleeves at crossings/
intersections
Confine smoking to
Smoking Zones
only
Dont obstruct
assess to Fire
extinguishers
Maintain lightening
arrestors for
elevated structures
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
DOCUMENT NO.
Page 34 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
Improper
selection of
Fire
Extinguisher
It may not
extinguish the fire
Improper
storage of
highly
inflammable
substances
Same as above
PREVENTIVE MEASURES
locations.
Ensure usage of
correct fire
extinguisher meant
for the specified fire
(for details refer
Appendix-C)
Do not attempt to
extinguish Oil and
electric fires with
water. Use foam
cylinders/CO2/sand
or earth.
Maintain safe
distance of
flammable
substances from
source of ignition
Restrict the
distribution of
flammable materials
to only min.
necessary amount
Construct specifically
designed fuel
storage facilities
Keep chemicals in
cool and dry place
away from hat.
Ensure adequate
ventilation
Before welding
operation, remove or
shield the flammable
material properly
Store flammable
materials in stable
racks, correctly
labeled preferably
with catchments
trays.
Wipe off the spills
immediately
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
(H) VEHICULAR
MOVEMENT
Short
circuiting of
electrical
system
Crossing the
Speed Limits
(Rash driving)
DOCUMENT NO.
Page 35 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
Same as above
Can cause
Electrocution
Personal injury
PREVENTIVE MEASURES
Do not allow
open/bare
connections
Provide all
connections through
ELCB
Ensure earthing of
machineries and
equipments
Adverse
weather
condition
Same as above
Consuming
alcohol before
and during he
Same as above
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
(I) PROOF
TESTING
(HYDROSTATIC/
PNEUMATIC
TESTING
DOCUMENT NO.
Page 36 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
driving
operation
Falling objects
/ Mechanical
failure
Bursting of
piping
Collapse of
tanks
Tanks flying
off
PREVENTIVE MEASURES
alcohol or driving.
Ensure effective
braking system,
adequate visibility for
the drives, reverse
warning alarm.
Proper maintenance
of the vehicle as per
manufacturer
instructions
Prepare test
procedure & obtain
CONSULTANT/
Owners approval
Provide separate
gauge for
pressurizing pump
and
piping/equipment
Check the calibration
status of all pressure
gauges, dead weight
testers and
temperature
recorders
Take dial readings at
suitable defined
intervals and ensure
most of them fall
between 40-60% of
the gauge scale
range
Provide safety relief
valve (set at
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
(J) WORKING AT
HEIGHTS
Person can
fall down
Page 37 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
May sustain
severe injuries or
PREVENTIVE MEASURES
pressure slightly
higher than test
pressure) while
testing with
air/nitrogen
Ensure necessary
precautions,
stepwise increase in
pressure, tightening
of bolts/ nuts,
grouting, etc. before
and during testing
Pneumatic testing
involves the hazard
of released energy
shored in
compressed gas.
Specific care must
therefore be taken to
minimize the chance
of brittle failure
during a pneumatic
leak test. Test
temperature is
important in this
regard and must be
considered when the
designer chooses
the material of
construction
A pressure relief
device shall be
provided, having a
set pressure not
higher than the test
pressure plus the
lesser of 345 KPa
(50 psi) or 10% of he
test pressure. The
gas used as test
fluid, if not air, shall
be nonflammable
and nontoxic.
Provide guard
rails/barricade at the
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Material can
fall down
Page 38 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
prove fatal
TYPE OF HAZARD
DOCUMENT NO.
PREVENTIVE MEASURES
work place
Obtain a permit
before starting the
work at height above
3 meters
Provide adequate
working space (min.
0.6 m)
Tie/weld working
platform with fixed
support
Avoid movement on
beams
(K) CONFINED
SPACES
Suffocation /
drowning
Unconsciousness,
death
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
DOCUMENT NO.
Page 39 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
Presence of
foul smell and
toxic
substances
Inhalation can
pose threat to life.
Ignition /
flame can
cause fire
Person may
sustain burn
injuries or
explosion may
occur
PREVENTIVE MEASURES
etc.
Fulfill conditions of
the permit.
Check for
hydrocarbon and
Aromatic
compounds before
entering a confined
space
Keep fire
extinguishers at a
hand distance
Remove surplus
material and scrap
immediately
Do not smoke inside
a confined space
Do not allow gas
cylinders inside a
confined space
Use low voltage
(24V) lamps for
lighting
Use tools with air
motors or electric
tools with max.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
(L) HANDLING
AND LIFTING
EQUPMENTS
DOCUMENT NO.
Page 40 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
Failure of load
lifting and
moving
equipments
Can cause
accident and
prove fatal
Overloading
of lifting
equipments
Can cause
electrocution and
fire
PREVENTIVE MEASURES
voltage of 24V
Remove all
equipments at the
end of the day
Check periodically
oil, brakes, gears,
horns and tyre
pressure of all
moving machinery
Ensure certification
by applicable
authority.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Overhead
electrical
wires
Page 41 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
Can cause
electrocution and
fire
PREVENTIVE MEASURES
capacity, boom and
angle of erection
(M)
SCAFFOLDING,
FORMWORK AND
LADDERS
Person can
fall down
Person may
sustain severe
injuries and prove
fatal
Failure of
scaffolding
material
Same as above
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
Material can
fall down
Page 42 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
TYPE OF HAZARD
DOCUMENT NO.
Persons working
at lower level gets
injured.
PREVENTIVE MEASURES
for max. load
carrying capacity
Scaffolding planks
shall not be less than
50x250 mm full
thickness lumber or
equivalent. These
shall be cleared or
secured and must
extend over the end
supports by at least
150mm and not
more that 300 mm
(N) STRUCTURAL
WORKS
Personal
negligence
and danger of
fall
Lifting /
slipping of
Same as above
Remove excess
material and scrap
immediately
Carry the tools in a
tool-kit bag only
Provide safety nets
Do not take rest
inside rooms built for
welding machines or
electrical distribution
system
Avoid walking on
beams at height
Wear helmet with
chin strap and safety
belts when working
at height
Use hand gloves and
goggles during
grinding operations
Cover or mark the
sharp and projected
edges
Do not stand within
the operating radius
of cranes
Do not stand under
the lifted load
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
ACTIVITY
(O) PIPELINE
WORKS
DOCUMENT NO.
Page 43 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
EFFECT OF HAZARD
Erection /
lowering
failure
PREVENTIVE MEASURES
Control longer
pieces lifted up by
cranes from both
ends
Remove loose
materials from height
Ensure tightening of
all nuts and bolts
Use appropriate
PPEs
Other
Same as above
TYPE OF HAZARD
material
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 44 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Contractor
Owner
Report No.
Job No
:_______________________
:________________________
:________________________
:_______________________
ITEM
HOUSEKEEPING
Waste containers provided and used
Sanitary facilities adequate and clean
Passageways and Walkways clear
General neatness of working areas
Others
PERSONNEL PROTECTIVE EQUIPMENT
Goggles; Shields
Face protection
Hearing protection
Safety shoes
Hand protection
Respiratory Masks etc.
Safety Belts
Safety Helmet/Hard Hat
Others
EXCAVATIONS/OPENINGS
Openings properly covered or barricaded
Excavations shored
Excavations barricaded
Overnight lighting provided
Others
WELDING & GAS CUTTING
Gas cylinders chained upright
Cables and hoses not obstructing
Screens or shields used
Flammable materials protected
Fire extinguisher(s) accessible
Others
SCAFFOLDING
Fully decked platforms
Guard and intermediate rails in place
YES
NO
REMARKS
ACTION
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
SL.
NO.
c)
d)
e)
f)
6
a)
b)
c)
d)
e)
7
a)
b)
c)
d)
e)
f)
g)
h)
8
a)
b)
c)
d)
e)
9
a)
b)
c)
d)
10
a)
b)
c)
d)
e)
f)
g)
11
a)
b)
c)
d)
DOCUMENT NO.
Page 45 of 59
MEC/S/05/21/65
REVISION : 0
ITEM
Toe boards in place
Adequate shoring
Adequate access
Others
LADDERS
Extension side rails 1m above
Top of landing
Properly secured
Angle + 70 from horizontal
Others
HOISTS, CRANES AND DERRICKS
Condition of cables and sheaves OK
Condition of slings, chains, hooks and eyes OK
Inspection and maintenance logs maintained
Outriggers used
Signs/barricades provided
Signals observed and understood
Qualified operators
Others
MACHINERY, TOOLS AND EQUIPMENT
Proper instruction
Safety devices
Proper cords
Inspection and maintenance
Others
VEHICLE AND TRAFFIC
Rules and regulations observed
Inspection and maintenance
Licensed drivers
Others
TEMPORARY FACILITIES
Emergency instructions posted
Fire extinguishers provided
Fire-aid equipment available
Secured against storm damage
General neatness
In accordance with electrical requirements
Others
FIRE PREVENTION
Personnel instructed
Fire extinguishers checked
No smoking in Prohibited Areas
Hydrants Clear
EDITION : 1
YES
NO
REMARKS
ACTION
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
SL.
NO.
e)
12
a)
b)
c)
d)
e)
f)
g)
h)
i)
13
a)
b)
c)
14
a)
b)
c)
d)
15
a)
b)
c)
d)
e)
16
a)
b)
c)
d)
e)
f)
g)
17
a)
b)
c)
DOCUMENT NO.
Page 46 of 59
MEC/S/05/21/65
REVISION : 0
ITEM
Others
ELECTRICAL
Use of 3-core armoured cables
Usage of 'All insulated' or 'double insulated' electrical
tools
All electrical connection are routed through ELCB
Natural Earthing at the source of power (main DB)
Continuity and tightness of earth conductor
Covering of junction boxes, panels and other
energized wiring places
Ground fault circuit interrupters provided
Prevention of tripping hazards
Others
HANDLING AND STORAGE OF MATERIALS
Properly stored or stacked
Passageways clear
Others
FLAMMABLE GASES AND LIQUIDS
Containers clearly identified
Proper storage
Fire extinguishers nearby
Others
WORKING AT HEIGHT
Erection plan and work permit obtained
Safety nets
Full body harness and lanyards; chute lines
Health Check record available for workers going up?
Others
CONFINED SPACE
Work permit obtained
Test for toxic gas and sufficient availability of oxygen
conducted
At least one person outside the confined space for
monitoring deputed
Availability of sufficient means of entry, exit and
ventilation
Fire extinguishers and first-aid facility ensured
Lighting provision made by using 24V lamps
Proper usage of PPEs ensured
RADIOGRAPHY
Proper storage and handling of source as per BARC /
AREB guidelines
Working permit obtained
Cordoning of the area done
EDITION : 1
YES
NO
REMARKS
ACTION
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
SL.
NO.
d)
e)
f)
18
a)
b)
c)
d)
e)
f)
g)
h)
19
a)
b)
c)
d)
e)
f)
g)
DOCUMENT NO.
Page 47 of 59
MEC/S/05/21/65
REVISION : 0
ITEM
EDITION : 1
YES
NO
REMARKS
ACTION
___________________
Signature of Resident
Engineer with Seal
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 48 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Fatal
First-Aid case
CAUSE OF ACCIDENT
NATURE OF INJURY/DAMAGE
DATE:
To
SIGNATURE OF CONTRACTOR
WITH SEAL
:
:
OWNER..
RCM/SITE-IN-CHARGE, MECON
1 COPY
3 COPIES
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 49 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Site:________________________
Date:_______________________
Work Order / LOI No. :______________
NATURAL OF INJURY/DAMAGE
DATE:
To
SIGNATURE OF CONTRACTOR
WITH SEAL
:
:
OWNER..
RCM/SITE-IN-CHARGE, MECON
1 COPY
3 COPIES
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 50 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
INCIDENT REPORTED BY
LOCATION
DATE:
To
YES
NO
SIGNATURE OF CONTRACTOR
WITH SEAL
:
:
OWNER..
RCM/SITE-IN-CHARGE, MECON
1 COPY
3 COPIES
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 51 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
ITEM
UPTO
PREVIOUS
MONTH
THIS
MONTH
a)
DATE:
To
Y/N
Y/N
Y/N
OWNER
RCM/, MECON (2 COPIES)
CUMULATIVE
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 52 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Sr. No.:
Date:
Nature of Work :
Exact location of work :
Duration of work: from ... to
The following items have been checked and compliance shall be ensured during the
currency of the permit:
-----------------------------------------------------------------------------------------------------------------------------Sl.
ITEM
DONE
NOT REQD.
-----------------------------------------------------------------------------------------------------------------------------1.
Equipment/Work Area inspected
2.
3.
ELCB provided
4.
5.
6.
7.
8.
9.
10.
11.
12.
------------------------------------------------------------------------------------------------------A.
Following personal protective equipment are provided ( mark) and used as relevant
Safety helmet/Gloves/Goggles/Shoes/Face Shield/Life Line/Safety Belt/Safety Harness.
B.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 53 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
C.
Permit shall be issued for maximum one week only (Monday to Sunday).
D.
E.
After completion of the work, used permits shall be preserved for record purposes.
F.
Sl.
No.
Validity
Period
From
To
Work time
From ..Hrs.
To .Hrs.
Initiator
(Supervisor of
Contractor)
Issuing
Authority
(Safety
Officer)
of Contractor
Verification
by
CONSULTANT
with date
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 54 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Sr. No.:
Date:
Nature of Work :
(A)
Has the equipment been ?
Y NR
Y NR
isolated from
water flushed &/or
power / steam / air
steamed
isolated from liquid
Manways open &
or gases
ventilated
depressurized &/or
cont. inset gas flow
drained
arranged
blanked / blinded /
adequately cooled
disconnected
(B)
Expected Residual Hazards
Y NR
Y NR
lack of O2
combustible gas /
liquid
corrosive
pyrophoric iron /
chemicals
scales
Heat / stream /
high humidity
frost
(C)
Protective Measures
Y NR
gloves
protective clothing
Grounded air
educater / blower /
AC
Fire fighting
arrangements
NR
radiation sources
removed
Proper lighting
provided
NR
H2S / toxic gases
electricity / static
ionizing radiation
Y
ear plug / muff
NR
NR
goggles / face
shield
personal gas alarm
rescue equipment /
team
communication
equipment
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 55 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
No. of
Persons
Allowed
Name of
Persons
allowed
Signature
Contractors
Supervisor
Contractors
Safety
Officer
Time
From
To
Signatur
e
Workman
Permit Closure :
(A)
(B)
(C)
Entry
was closed
stopped
Remarks, if any :
key transferred
Manways barricaded
will continue on
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 56 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Sr. No.:
Date:
Name of Contractor :
Job No. :
Location of work
Source Strength
The following items have been checked & compliance shall be ensured during currency of the
permit :
S.
Item Description
No.
1.
Safety regulations as per BARC/AERB ensured while source in use/ in transit &
during storage.
2.
Area cordoned off.
3.
Lighting arrangements for working during nights ensured.
4.
Warning signs / flash lights installed.
5.
Cold work permit taken (if applicable)
6.
PPEs like film badges, dosimeters used.
Done
Permission is granted.
Permit is valid from _________ AM/PM ____________ Date to ________ AM/PM ____________
Date
Name :
Designation :
Date :
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 57 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Permit renewal :
Permit extended upto
Date
Time
Additional precautions
required, if any.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 58 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Sr. No.:
Date:
Name of Contractor :
Job No. :
Name of Contractor
Location details of dismantling / demolition with sketch : (Clearly indicate the area)
The following items have been checked & compliance shall be ensured during currency of the
permit :
S.
Item Description
No.
1.
Services like power, gas supply, water, etc. disconnected.
2.
3.
4.
5.
6.
7.
(Contractors Supervisor)
Permission is granted.
(Permit issuing authority)
Name :
Date :
Done
Not
Applicable
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 59 of 59
MEC/S/05/21/65
REVISION : 0
EDITION : 1
Completion Report :
Dismantling / Demolishing is completed on __________ Date at __________ Hrs.
Materials / debris transported to identified location
Tagging completed (as applicable)
Services like power, gas supply, water, etc. restored
SPECIFICATION
FOR
QUALITY ASSURANCE SYSTEMS
REQUIREMENTS
MECON LIMITED
DELHI - 110 092
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 1 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION 0
CONTENTS
Sl.No.
Description
Page No.
1.0
INTRODUCTION
2.0
DEFINITIONS
1-2
3.0
2-4
4.0
4-7
ATTACHMENTS
TITLE
NUMBER
FORMAT 00001
FORMAT 00002
PREPARED BY
CHECKED BY
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APPROVED BY
MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
1.0
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 2 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
INTRODUCTION
This specification establishes the Quality Assurance Requirements to be met by
the sub-contractors (including turnkey Contractors) and their sub-vendors.
In case of any conflict between this specification and other provisions of the
contract/ purchase order, the same shall be brought to the notice of MECON,
at the stage of bidding and shall be resolved with MECON, prior to the
placement of order.
2.0
DEFINITION
Bidder
For the purpose of this specification, the word Bidder means the person(s),
firm, company or organisation who is under the process of being contracted by
MECON/ Owner for delivery of some products (including service). The word is
considered synonymous to supplier, contractor or vendor.
Correction
Action taken to eliminate the detected non-conformity.
Refers to repair, rework or adjustment and relates to the disposition of an
existing non-conformity.
Corrective Action
Action taken to eliminate the causes of an existing non-conformity, defect or
other undesirable situation in order to prevent recurrence.
Preventive Action
Action taken to eliminate the causes of a potential non-conformity, defect or
other undesirable situation in order to prevent its recurrence.
Process
Set of inter-related resources and activities which transform inputs into
outputs.
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 3 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
Special Process
Processes requiring pre-qualification of their process capability.
3.0
3.1
3.2
MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 4 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
4.0
4.1
The bidder shall nominate an overall incharge of the contract titled as Project
Manager for the scope of work of agreed contract. The name of this person
shall be duly intimated to MECON including all subsequent changes, if any.
MECON shall correspond only with the project manager of the bidder on all
matters of the project. The project manager of the bidder shall be responsible
for co-ordination and management of activities with bidders organisation and
all sub-vendors appointed by the bidder.
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 5 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
After award of work, the bidder may review augmentation of manpower and
resources deployment chart (submitted earlier), detail it out, if so consented
by MECON/ Owner and resubmit the same as issued for effective
implementation of the project.
4.2
The bidder shall plan the contract scope of work on quality plan format such
that no major variation is expected during delivery of contract scope of work.
These quality plan shall be made on enclosed format complete in all respect.
The quality plan shall be assumed to be detailing bidders understanding and
planning for the contract/ offered scope of work. The bidder shall plan the
type of resources including various work methodology which he agrees to
utilize for delivery of contract scope of work.
4.3
4.4
4.5
For all documents which the bidder is likely to utilise for delivery of contract
scope of work, a system must exist which assures that latest/ required
version(s) of the document(s) is available at all location/ point of use.
4.6
In case the bidder decides to sub-contract any part/ full of the contract scope
of work (without prejudice to main Contractual condition), the bidder shall :
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 6 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
Bidder shall establish adequate methodology such that the materials supplied
by the Owner/ MECON shall be adequately preserved, handled and made use
of for the purpose for which they are provided.
4.8
All output delivered against contract scope of work shall be suitably identified
in such a manner that either through identification or some other means,
sufficient traceability is maintained which permits effective resolution of any
problem reported in the outputs.
4.9
4.10
All inspections carried out by the bidders surveillance/ inspection staff shall be
conformity to quality plans and/ or inspection and test plans. All inspection
results shall be duly documented on controlled/ agreed forms such that results
can be co-related to specific product, that was inspected/ tested.
4.11
All inspection, measuring & test equipments (IMTEs) shall be duly calibrated as
per National/ International standards/ codes and only calibrated and certified
IMTEs shall be utilized for delivery of contract scope of work.
4.12
All outputs/ products delivered against contract scope of work shall be duly
marked such that their inspection status is clearly evident during all stages/
period of the contract.
4.13
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 7 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
4.14
4.15
4.16
Bidder shall prepare sufficient records for various processes carried out by him
for delivery of contract scope of work such that requirements of this
specification are objectively demonstrable. In case MECON/ Owner finds that
enough objective evidence/ recording is not available for any particular
process, bidder shall be obliged to make additional records so as to provide
sufficient objective evidence. The decision of MECON/ Owner shall be final
and binding on such issues.
4.17
4.18
For all special processes, bidder shall deploy only qualified performers.
Wherever MECON/ Owner observes any deficiency, the bidder shall arrange
the adequate training to the performer(s) before any further delivery of work.
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MECON LIMITED
REGD. OFF : RANCHI (BIHAR)
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 8 OF 9
REQUIREMENTS
MEC/S/05/62/66
REVISION
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FORMAT - 00002
No. :
Date :
Location of Work :
Item of Work :
Details of Observation(Deficiency)
Date :
Distribution (before resolution) :
Project Manager
Chief Business Executive
Owner
MECON
MECON Inspection
New Delhi
Resident Construction
Manager, MECON Site
Date :
Distribution (before resolution) :
Chief Business Executive
Project Manager
MECON
Owner
Name of Signature
MECON Inspection
New Delhi
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\66 quality assurance system\Specification - Quality Assurance Plan - Reqd. - 66.doc
Resident Construction
Manager, MECON Site
FORMAT 00001
Bidders Quality Plan
Activity Description
Note: 1)
2)
Project Name :
General
Procedure
Number
Code of
Conformance
Performing Functions
Performer
Checker
Reviewer/
Approver
Audit Function
Audit Scope
Owners/ MECON
Review/ Audit
Requirement
The bidder ensures that the filled up format conforms to minimum requirements on Quality Plan/ Quality Assurance, specified by MECON on drawings/ standards/ specifications/ write-up.
The bidder confirms that document is issued for information/ approval of Owner/ MECON for the project implementation
C:\Documents and Settings\hcl\Desktop\Specs\WORKS\66 quality assurance system\Specification - Quality Assurance Plan - Reqd. - 66.doc
Rev. : 0
Edition : 1
SPECIFICATION
FOR
DOCUMENTATION FOR PIPELINE
CONSTRUCTION
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/69
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
RECORDS
3.0
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Jan. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 1 of 1
MEC/S/05/21/69
REVISION : 1
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 1 of 6
MEC/S/05/21/69
REVISION : 0
EDITION : 1
1.0
SCOPE
1.1
This specification covers the minimum requirements of various records, reports and
drawings for all aspects of pipeline construction to be prepared by Contractor and
submitted to the Company at intervals as described in this specification and as
directed by Company.
1.2
1.3
This specification shall be read in conjunction with the conditions of all specifications
and document included in the Contract between Company and Contractor.
2.0
RECORDS
Contractor shall submit daily, weekly, monthly and after completion to the Company,
various records and reports for Companys documentation purpose during and
immediately after the construction. This shall as minimum include, but not limited to
the following :
2.1
Daily
2.2
Weekly
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
2.3
Page 2 of 6
MEC/S/05/21/69
REVISION : 0
EDITION : 1
Monthly
2.4
DOCUMENT NO.
Further, Contractor shall supply (for approval if required to the Company with
document such as but not limited :
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 3 of 6
MEC/S/05/21/69
REVISION : 0
EDITION : 1
2.5
3.0
3.1
General
Contractor shall prepare as-built drawings of all by or on behalf of Company issued
drawings and of all Contractor work drawings including vendor drawing, such as but
not limited to :
For Pipeline Section :
-
Route Maps
Alignment Sheets
Detail Drawings (road, railway, minor water crossings, major water crossings,
valley crossings)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 4 of 6
MEC/S/05/21/69
REVISION : 0
EDITION : 1
As-Built Drawings
Contractor shall prepare a complete set of as-built drawings. From the start of
construction, Contractor shall on daily basis process any changes in two sets of
drawings. Deleted parts shall be indicated in red, new parts in blue, remarks in
green and unchanged parts in yellow. Said drawings shall be kept at site and be
available to Company at all times. Contractor shall prepare as-built drawings
based on these data. On completion of the work, one revised film transparency of all
drawing made as-built by Contractor containing the as-built information shall be
handed over to Company as well as one complete set of CD ROM/ floppy diskettes
as specified by Company.
Contractor shall prepare and submit a specimen of the layout of the drawings for
Companys approval.
The required measurement for as-built drawing shall be executed by Contractor by
experienced, qualified surveyors.
The surveyors shall daily take care of all measurement required such as but not
limited to:
-
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 5 of 6
MEC/S/05/21/69
REVISION : 0
EDITION : 1
Type of rock
Type of blasting and ripping.
Sand padding.
Type of road pavement.
Details of bank protection, number of insulators, seals.
Contractor shall also prepare isometric drawings of all installation (facilitates) etc. for
which the data as mentioned in or required for the Pipe and Welding Book can be
identified and these drawings can also be used for material accounting.
3.3
Nameplates of Equipment
All permanent equipment supplied and installed by Contractor shall be provided with
plates by Contractor. All texts shall be submitted to Company for approval before
plates may be manufactured.
3.4
Pipe Book
Every page of the pipe and Welding Book shall mention:
-
Alignment sheet number and atleast the location thereon of two welds on every page
of the pipe Book.
Further,
-
Diameter of pipeline
Length of each pipe
Wall thickness
Pipe number
Heat number, certificate number
Cut and re-numbered pipe ends
Coating type
Date of stringing
Date of welding
Weld number
Welder number
Direction of working
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
DOCUMENT NO.
Page 6 of 6
MEC/S/05/21/69
REVISION : 0
EDITION : 1
In order to achieve this, Contractor shall identify all pipe elements. Sample format of
Pipe Book shall be submitted for Company approval.
3.5
As-Built Documents
Contractor shall prepare all documents in the prescribed format as indicated below.
In addition to the hard copies, softcopies of final documents shall also be submitted
in electronic media i.e. CD / DVD format.
Software used for the preparation of these documents shall be as follows:
Type document
a)
Reports/ Documents
b)
Drawings
Software
MS Office
Auto CAD
For the purpose of preparation of as-built drawings, Contractor shall update the
Issued for construction drawings issued by the Company. It shall be the
Contractors responsibility to covert the drawings furnished by the Company in hard
copy into CAD drawings including scanning, digitising and converting the drawings
into a suitable format compatible with the AutoCAD and above. As-built drawings
shall be prepared only on AutoCAD drawings.
SPECIFICATION
FOR
CALIPER PIGGING
MECON LIMITED
DELHI - 110 092
CONTENTS
Sl. No.
Description
Page No.
1.0
INTENT
2.0
OBJECTIVE
3.0
SCOPE OF WORK
4.0
5.0
6.0
7.0
8.0
9.0
PIG TRACKING
10.0
MARKER DEVICES
11.0
DEFECT VERIFICATION
12.0
ABNORMAL SITUATIONS
13.0
WORK REPORT
14.0
INTENT
The intent of this specification is to setforth the requirements of the
caliper pigging. The specification is not intended to be all-inclusive and the
use of this specification will not absolve the contractor of his responsibility
of generating valid, interpretable and physically verifiable data.
2.0
OBJECTIVE
The objective of the present pigging programme to access the internal
geometry of the following pipelines and detect significant geometry
defects if any, which may affect safe operation of the pipeline.
The relevant technical specifications of the pipeline including launcher and
receiver details in the Annexure.
3.0
SCOPE OF WORK
To achieve the above objective, contractors SCOPE OF WORK includes
running of adequate numbers of foam pigs, cleaning pigs (magnet, brush,
commination of brush and magnet, scraper, pin wheel etc.), gauge pig
and caliper pig.
Further the scope of work comprises supply of skilled personnel, all
equipment e.g. foam pigs cleaning pigs, gauging pig, caliper pigs, pig
locating and pig tracking devices, spares consumables, communication
and transportation including their mobilisation and demobilisation. It is
expressly understood that this do not limit the scope of work of the
CONTRACTOR in any way. The quantities to be mobilized for different
equipment (different types of pigs pig tracking device, marker device)
accessories, spare and consumables need to be carefully evaluate by the
CONTRACTOR taking in to the consideration that caliper pigging of various
Page 1 of 9
pipelines in the scope of work should be carried out without any constraint
and turn around time.
The contractor shall submit the details of each type of pig including foam,
gauge cleaning and caliper for approval of MECON/ GAIL, which he
proposes to use. Pigs shall be launched in the pipeline only after their
design and size has been approved by MECON/ GAIL. Due care shall be
taken not to damage internal coating by the contractor, while proposing
the pigs for internally coated pipeline.
The detailed scope of work shall be, but not limited to under
-
4.0
5.0
Page 2 of 9
6.0
7.0
7.1
The
Page 3 of 9
about the degree of cleanliness of pipeline and provide detailed daily site
report for each run in the approved format before commencing the
subsequent run. Choice of the type of cleaning pig has been left to the
contractor. Contractor may deploy brush cleaning pig, magnetic cleaning
pig, combination of brush and magnet, scrapper pig etc. the cleaning pigs
should be able to pass over negotiate lateral tees or bends on the pipeline
8.0
Page 4 of 9
Tees/ off-takes.
The caliper pig should have minimum capability to identify and detect the
defects of following threshold.
Dent
Ovality
Location accuracy
Axial 3.0m
Circumferential : 12
PIG TRACKING
The movement of any type of pig (Except, foam pig) put into the line
during caliper pigging shall be required to be monitored along the pipeline
length from launcher to receiver trap. The BIDDER shall detail out the
complete methodology of pig tracking proposed to be deployed by him
including complete technical details of the equipment and device proposed
to be used for this purpose.
It is proposed that pig tracking would be done in a discrete manner at
least 5 to and 10 km - interval on each pipeline at preselected locations.
The exact KM chainage of these locations shall be decided at site in
consultation with the Contractor and CONSULTANT/ COMPANY.
10.0
MARKER DEVICES
The contractor shall submit the details of marker devices, which he
proposes to place for relocating the defect accurately in the field, when
the same has been identified as a result of Caliper survey.
Page 5 of 9
DEFECT VERIFICATION
At the discretion of the COMPANY/ CONSULTANT identify at least two
verification dig sites for each pipeline jointly with MECON and GAIL from
the recorded data and provide MECON/ GAIL with their distance from the
nearest pipeline feature or reference marker to facilitate location of defect
in the field.
The contractor shall depute his representative to observe the verification
at verification sites for proving that filed log detected anomalies conform
to sizing including linear and circumferential positions.
12.0
ABNORMAL SITUATIONS
The objective of this section is to write down foreseeable abnormal
circumstances for taking appropriate measures, should such a condition
arise during implementation of project.
The following abnormal condition have been foreseen by the Comapny.
However, if the BIDDER foresees any other abnormal condition, he is free
to make a mention of the same in his technical BID offer:
12.1
Tool Failure
CONTRACTOR is required to get valid interpretable and verifiable data for
pipeline. In case CONTRACTORS equipment fails to perform electronic
Page 6 of 9
Stuck-Up Tool
The BIDDER shall details out a contingency plan in his BID as proposed by
him in case any of the pigs get stuck up. The plan shall identify procedure
for exactly locating the stuck up pig, detail procedure for retrieval of pig,
equipment, including support facilities required to retrieve the pig.
If pig do not move from stuck up location, by any measure, then the
pipeline section shall have to be cut for retrieval of Pig. Necessary
erection, fabrication and modification of pipe with new pipe piece after
retrieval of pig shall be done by Contractor. The cost for this works shall
be borne by Contractor on actuals. After fabrication & erection, pigging
contractor shall run Gauge pig to check internal restriction, if any.
Locating the stuck up pig and its retrieval shall be the responsibility of the
CONTRACTOR.
13.0
WORK REPORT
The work report shall be prepared and submitted in hard copy (4 sets)
and Electronics media (2 sets)
The work report shall consist of following as a minimum.
-
Equipment description
List of installations
Page 7 of 9
14.0
Specification of foam pigs, cleaning pigs, gauge pig and caliper pig
for pipelines with and without internal coating respectively.
Page 8 of 9
Rev. : 0
Edition : 1
SPECIFICATION
FOR
FIELD JOINT COATINGS OF PIPELINE
FOR HDD CROSSING
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CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
4.0
APPLICATION PROCEDURE
5.0
INSPECTION
6.0
TESTING
7.0
8.0
9.0
DOCUMENT
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Binita Brahma)
(Sunil Kumar)
(A.K. Johri)
May 2009
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AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit / Drawing
Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
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1.0
SCOPE
1.1
General
DOCUMENT NO.
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1.2.1
The Contractor shall supply wrap around heat shrinkable sleeves which is composed
of two parts such as adhesive coated wrap around and a curable modified epoxy
primer alongwith applicator pads.
1.2.2
The supply of wrap around heat shrinkable sleeve shall be under Contractors scope.
1.2.3
The Contractor shall provide all skilled/ unskilled personnel required for execution of
this work.
1.2.4
The joint coating operation starting from cleaning and surface preparation till
application of joint coating and wrapping of the pipe joints shall be performed under
the supervision of skilled personnel who are well versed in the work.
1.2.5
Contractor shall at his own cost provide a fully equipped laboratory and test facilities
with adequate inventory to carry out tests required for procedure qualification and
during regular production, for testing of joint coating system.
2.0
REFERENCE DOCUMENTS
2.1
Provision of the following documents/ codes shall generally be followed for standard
of specification and workmanship.
a)
b)
c)
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2.2
In case of conflict between the requirements of this specification and that of above
referred documents/ codes, the requirements of this specifications shall govern.
3.0
3.1
General
This scope covers the minimum requirement of materials, equipment required for
installation of field joint coating by wraparound fibre-reinforcement heat-shrinkable
sleeve used for corrosion protection and sealing of field joints in pipelines that are
forced through the soil by Horizontal Directional Drilling technique. The sleeves shall
be suitable for 3LPE/FBE coated pipes operating up to 60C continuously.
3.1.1
3.1.2
For HDD Joint Coating fiber glass reinforced heat shrinkable sleeve certified
to Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX shall be
used. Directional drilling kit, multilayer sleeve system or equivalent to be
approved by Owner / Engineer.
b)
Only coating material C-60 Class as per EN 12068 and DVGW certified
(wrapping tape and heat shrinkable material) will be accepted for all material
to be coated.
c)
d)
e)
A clamping belt
Sleeve Backing
The heat shrinkable sleeves shall be manufactured from minimum 1.0 mm thick
radiation cross linked, thermally stabilized, UV -resistant heat-shrinkable fabric,
composed of a fibre glass reinforcement and polyolefin fibres, embedded in a
polyolefin matrix.
3.1.3
Sleeve Adhesive
The inner surface of the sleeves shall be coated with a controlled thickness of
minimum 1mm of adhesive which in combination with the modified epoxy primer, will
bond to and seal to the steel pipe and common yard applied medium temperature
yard coatings.
3.1.4
Epoxy Primer
The Epoxy primer shall be a solvent free, modified two components liquid epoxy type
primer, which is applied to cleaned and dry steel surface. When the sleeve coatings,
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comes in contact with the liquid primer during installation, a strong bond is formed
upon full curing of the system.
3.2
3.2.1
Test
Method
ISO 4675
Condition
ISO 175
Chemical
resistance
Requirement
Below 40C
3.2.2
Followed by test
for bursting
strength
Thermal ageing
ISO 3303
ISO 188
150C
Followed by test
for bursting
strength
ISO 3303
23C
168 hrs.
1100 N Min.
1700 N Min.
Adhesive material
Property
Softening point
Peel Strength
Peel Strength
After immersion for 4
weeks
at 23C~NaOH pH12
H2SO4
pH2 ground water
solution:1.2% H3PO4
1.6% KOH
Test
Method
ASTM
E28
DIN
30672
DIN
30672
Condition
Requirement
85C minimum
23C. CHS*
100 mm/ min.
60C
23C. CHS*
100 mm/ min.
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Test
Method
Property
Condition
Requirement
1.2NaCl
1.0% Fe2O3
3.2.3
DIN
30672
23C. CHS*
100 mm/ min.
60 N/cm minimum
Shear strength
ISO 4587
23C. CHS*
50 mm/ min.
200 N/cm2
minimum
Corrosive effect
ASTM D
2671
120C.
16 hrs.
No corrosion
Primer Material
Property
Test Method
Condition
Requirement
ASTM
D1084
23 +/- 0.50 C
Part A: 2 rpm, spindle
#6
Part B: 20rpm, spindle
#3
23C
Density
Mixing ratio
Shear
strength
By weight
By volume
ISO 4587
23C. CHS*
50 mm/ min.
100:40
100:60
1000 N/cm2 minimum
Functional Properties
Sl.
No.
a)
b)
c)
Test Method
Condition
Requirement
Impact
resistance
Penetration
resistance
DIN 30672
23C.
Class C
60C.
Class C
Specific
coating
resistance
DIN 30672
No holidays when
tested at 20 KV
Minimum 70% of
original resistance
thickness left; no
holidays when tested at
20 KV
108 Ohm sq. m
minimum; no oxidation
on pipe surface
Property
DIN 30672
23C.
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d)
e)
f)
g)
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Property
Test Method
Condition
Requirement
Cathodic
disbondment
resistance
Resistance to
split
propagation
Resistance to
circumferentia
l edge loading
Resistance to
local edge
loading
(chisel test)
ASTM G42
60C.
30 days
15 mm increase in
radius of disbondment
max.
No cut propagation
TEST
METHOD-1*
TEST
METHOD-2*
50 KN minimum
TEST
METHOD-3*
6 KN minimum
*Test Methods
3.3
Test Methods
3.3.1
3.3.2
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During the pushing or pulling operation, any obstacle protruding from the smooth
pipe surface is loaded by the surrounding soil that passes by. This test simulates the
shear forces that are exerted on to the sleeve by rigid soil type.
3.3.3
I5mm
35mm
View AA
Figure- 1 Chisel
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3.4
3.4.1
3.4.2
3.4.3
a.
b.
Contractor shall ensure that the coating materials supplied by him are properly
packed and clearly marked with the following :-
Manufacturers name
Batch Number
b.
c.
3.4.4
3.5
Storage of Materials
Material shall be stored in sheltered storage by the Contractor in the manufacturers
original packing and away from direct sunlight and in accordance with
manufacturers instructions.
4.0
APPLICATION PROCEDURE
4.1
General
a)
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b)
Contractor shall provide and maintain mobile facilities which contains all
necessary tools, propane torches, epoxy primer pumps, silicon rollers, testing
instruments, equipment, and spares for cleaning, coating, repairs, inspection
and testing.
c)
Contractor shall furnish sufficient number of the following equipment and the
required spares as a minimum for inspection and testing purpose for each
crew :
-
4.2
DOCUMENT NO.
Fully automatic full circle adjustable holiday detector with audio and
visual output signal for inspection of coating.
Portable Tensile Strength Tester
Digital Thermometer
Solid state digital thickness gauge for measuring thickness of joint
coating.
The Contractor shall thoroughly clean and dry the joint surface by power tool
cleaning in accordance with SSPC-SP1. The complete procedure and details
of equipment used shall be prepared by the Contractor for Owners approval
prior to commencement of joint coating work.
b)
Prior to cleaning operation, Contractor shall visually examine the joint surface
area and shall ensure that all defects, flats and other damages have been
repaired or removed.
c)
d)
e)
f)
The abrasive blast material shall be free of impurities and inclusions, water
and oil. All abrasives shall be removed after blast by brush or vacuum type
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cleaner prior to applying joint coating. The abrasive shall be stored in a dry
condition and maintained dry during use.
4.3
g)
The compressed air for blasting shall be free of water and oil. Contractor to
verify air cleanliness at the start of the work and every four hours thereafter.
Separators and the traps shall be provided at the compressor and blasting
station. Separators and traps shall be checked daily for effective moisture
and oil removal during coating operations.
h)
The ends of existing line pipe protective coating shall be inspected and
chamfered. Unbonded portions of the coating shall be removed and then
suitably trimmed. Portions where parent coating is removed shall be
thoroughly cleaned as specified.
i)
Procedure
a)
b)
c)
d)
All pipe joint surfaces shall be thoroughly examined before the application of
the coating in order to ensure that the surfaces are free of oil, grease, rust,
mud, earth or any other foreign matter.
e)
Liquid epoxy primer shall be applied on the joints immediately after the
completion of heating operation.
f)
The heat shrink sleeve is then wraparound the joint while the primer is still
wet and shall overlap the existing pipe coating by minimum 100 mm on each
side.
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g)
The wraparound sleeve is shrunk on pipe joint with a propane torch moved
back and forth over the surface when heated above 125C, the sleeve shall
shrink tightly around the substrate on to the wet-primer. At the time of
application of the primer, th pipe surface temperature shall be at least 60C at
every point. To check this, approved temperature indicators shall be used .
temperature indicating crayons shall not be used.
h)
The wraparound sleeve shall be entirely wrapped around the pipe positioning
the closure patch off to one side of the pipe in 10m or 2 Oclock position, with
edge of the undergoing layer facing upward and an overlap of min. 100 mm.
i)
j)
Application of Wear Cone - The leading edge will be given an extra wear
cone. Start by heating the leading edge area of the main sleeve to 700C.
Wrap the leading edge sleeve over the transition Mill coating. Ensure that the
closure is placed away from the main sleeve closure Shrink the leading edge
sleeve.
k)
Application of Metal Belt - The metal belt shall be applied over the wear cone
sleeve. The metal belt will be tightened using the strapper tool supplied by
the manufacturer.
l)
m)
The installed sleeve shall not be disturbed until the adhesive has solidified.
5.0
INSPECTION
5.1
For wraparound coating, a visual inspection shall be carried out for the following :
-
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5.2
Holiday Inspection
5.2.1
The Holiday Detector used shall be checked and calibrated daily with an accurate
D.C. voltmeter. The detector electrode shall be in direct contact with the surface of
coating to be inspected.
5.2.2
The entire surface of the joint section shall be inspected by means of a full circle
Holiday Detector approved by OWNER set to DC Voltage of at least 25 kV for
wraparound sleeves. Inspection of the heat shrink sleeve coating shall be conducted
only after the joint has cooled below + 50C.
5.2.3
5.2.4
An installed sleeve with more than two holiday shall be stripped and a new one be
installed.
6.0
TESTING
a)
OWNER reserves the right to test one out of every 30 joint coating subject to
a minimum of 2 joints. CONTRACTOR shall provide all assistance in
removing and testing of field joint coatings. From each test sleeve, one or
more strips of size 25 mm x 200 mm shall be cut one perpendicular to the
pipe axis and slowly peeled off. This test shall be conducted between either
sleeve and metal or sleeve and mill coating as per direction of Owner/
Engineer-in-charge.
b)
The required peel strength shall be 60 N/cm (min.) at 23C. The system shall
fail only in the adhesive layer. No failure either in adhesion to steel or
adhesion to backing shall be permitted. The adhesive layer that remains on
the pipe surface shall be free of voids resulting from air or gas inclusion.
c)
If the sleeve taken away for test does not meet the requirement of clause 6.0
(b), the adjacent two sleeves do not meet the requirements of clause 6.0 (b)
the field joint coating shall be stopped until OWNER is satisfied with
application methods.
d)
For the test tensile strength, two parallel incisions spaced 1 CM. Apart are
made right down to the surface of the steel. A further incision shall then be at
right angles to the first angles to the first two incisions. With the aid of a 1 cm.
Wide knife the coating is lifted over a length of about 2 cm. And clamped into
the tensile tester, where upon a uniform pull is exerted at an angle of 90
degree. The tensile strength shall be more than a 2500psi.
e)
Coating thickness shall be checked by non destructive method for each field
joint.
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7.0
7.1
test to the complete satisfaction of the OWNER, already completed field joint
coatings.
stop joint coating until remedial measures are taken against the causes of
such failures, to the complete satisfaction of the OWNER.
7.2
7.3
CONTRACTOR shall, at his own cost repair all areas where the coating has been
removed for testing by the OWNER or by the CONTRACTOR to the complete
satisfaction of the OWNER.
7.4
The upright edges of the damaged areas shall be chamfered, in addition to the steel
shall be free from rust, dirt, oil and grease. The coating around the damaged area
shall be roughened. After thorough mixing (in accordance with the recommendations
of the manufacturer) the filler shall be applied, to sufficient Thickness with the aid of
stooping knife, whilst observing ample overlap hardening. The material will require
the approval of OWNER.
7.5
After the coating work on welded joints and repairs to the coating have been
completed, The coating area as a whole shall be tested with spark-tester before pull
back/ lowering/jacking the pipeline.
7.6
8.0
8.1
Any defect or damage in pipe coating observed till incorporation on permanent works
shall be rectified by the Contractor at his risk and cost. However, for repair of
damaged coating observed during taking over of Owner supplied pipe, if any, shall
be paid extra in accordance with the relevant items of Schedule of Rates.
8.2
Field repair of coated pipes shall be carried out by using same type of wraparound
sleeves used for joint coating.
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8.3
The repair procedure shall be same as specified herein above for application of anticorrosion field joint coating on welded pipe.
9.0
DOCUMENTATION
9.1
Prior to start the coating works at site Contractor shall furnish following Owner/
Consultants approved documents in addition to that mentioned in clause no. 3.4 of
this specification.
-
9.2
Final submission of all documents after finish the work shall be as per relevant
specification & SCC enclosed with the tender or as per direction of Engineer-incharge.
Rev. : 0
Edition : 1
SPECIFICATION
FOR
PIPELINE CROSSINGS USING HORIZONTAL
DIRECTIONAL DRILLING METHOD
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CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
4.0
CONSTRUCTION
5.0
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Jan. 2009
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AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
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1.0
SCOPE
1.1
1.2
1.3
Contractor shall, execute the work in compliance with laws, by laws, ordinance and
regulations. Contractor shall provide all services, labour, inclusive of supervision
thereof, supply of all materials (excluding Owner supplied Material), equipment ,
appliances etc..
1.4
Contractor shall take full responsibility for the stability and safety of all operation and
methods involved in the work.
1.5
Contractor shall be deemed to have inspected and examined the work area and its
surroundings and to have satisfied himself as far as practicable with the surface
conditions, hydrological and climatic conditions, the extent and nature of the work
and materials necessary for the completion of the work, and the means of access to
the work area.
1.6
Contractor shall be deemed to have obtained all necessary information with regard
to risks, contingencies and all other circumstances, which may influence the work.
1.7
Contractor shall, in connection with the work, provide and maintain at his own costs
all lights, guards, fencing, as necessary or directed by Owner or their representative.
1.8
For the purpose of this specification, the following definitions shall hold.
-
The words `Should, May and Will are non mandatory, advisory, or
recommendatory.
1.9
2.0
REFERENCE DOCUMENTS
Reference has been made in this specification to the latest edition (edition enforce at
the time of issue of enquiry) of the following codes, standards and specifications :
a.
ASME B 31.4
Pipeline
Transportation
Systems
Hydrocarbons and Other Liquids.
for
Liquid
b.
ASME B 31.8
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c.
OISD 226
d.
e.
In case of conflict between the requirements of this specification and the above
referred documents, the requirements of this specification shall govern.
3.0
3.1
The limits of each crossing shall be determined by the Contractor on the basis of
crossing profile based on survey drawings, design, equipment, installation technique
and site condition. Contractor shall furnish all engineering design calculation and
crossing drawings etc. to owner for their approval prior to execution of the work.
3.2
Within the entire limits of crossing, the minimum cover to top of coated pipe shall be
as specified in the Special Conditions of Contract (SCC).
However, wherever the drilled length for a crossing includes the crossings of
obstacles such as roads, railroads, cannals, streams, etc. The following minimum
requirements of cover to the pipe shall be satisfied unless specified otherwise in the
scope of work in SCC.
For Road Crossing
In case the pipeline crosses other utilities, viz., other pipelines, sewers, drain pipes,
water mains, telephone conduits and other underground structures, the pipeline shall
be installed with at least 500 mm free clearance from the obstacle or as specified in
the drawing or such greater minimum distance as may be required by authorities
having jurisdiction. Also in all cases, the minimum covers specified above shall be
maintained within the entire limits of crossing.
3.3
The entry and exit points of the pipeline at ground level shall not come within the
limits of crossing as defined in the crossing drawings.
3.4
Contractor shall carry out calculations for determining the maximum permissible
overburden on pipe, to check that the empty pipeline is safe from collapse at any
point along the drilled crossing section. Contractor shall submit these calculations to
Owner for approval.
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Pipeline Axis
The plane containing the pipeline route axis shall be perpendicular to the horizontal
plane. There shall be no bending of the pipeline route axis at depths shall lower
than 2 meters below ground level.
3.6
3.6.1
to optimise the crossing design in terms of pipeline stresses and power requirement
3.6.2
Contractor shall indicated what maximum shear stress in the pipeline coating will
result from his choice of above parameters and other characteristics described in this
section.
3.6.3
Contractor shall furnish all calculations for Owners approval. If shear stress in pipe
coating is, in the opinion of Owner, beyond the permissible limits, Contractor shall
revise his choice of parameters to reduce shear stress on pipe coating to permissible
value.
3.7
Contractor shall determine in the minimum allowable elastic bend radius for pipe
from the following consideration:
3.7.1
3.7.2.
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3.7.4
The minimum allowable radius of curvature for the pipeline shall be the highest value
of the minimum pipeline elastic radius as computed from the considerations outlined
in clause 2.7.1
to 2.7.3 above after correction for drilling inaccuracies or
multiplication by the factor 1.85. whichever results in the highest permissible value
of minimum elastic bend radius.
3.7.5
Contractor shall submit all calculations for Companys approval alongwith procedure.
3.8
3.8.1
3.8.2
Contractor shall furnish all calculation and specify the number of required supports,
description of the supports, their co-ordinates and capacity in metric tons.
3.8.3
Contractor shall also furnish a drawing of the launching ramp indicating the pipeline
configuration.
3.8.4
The distance between each roller shall also be specified and justified.
3.9
Contractor shall, based on result of design and engineering carried out by him,
prepare construction drawings for the crossing and shall submit the same for
Owners approval. Construction drawings shall indicate the pipeline profile with levels
furnished at sufficient intervals for proper control during construction. Other relevant
details viz., entry and exit angles, radius of bends, etc. shall also be indicated.
Contractor shall also calculated the total length of pipeline required as well as the
maximum tension required on the pull head of the rig.
3.10
All construction works shall be carried out in accordance with the construction
drawings approved by Owner.
3.11
Before commencement of any field work, Contractor shall furnish for Owners
approval all design calculations and construction drawings as stipulated in the above
clauses.
4.0
CONSTRUCTION
Contractor shall comply with all the conditions and requirements issued by
Authorities having jurisdiction in the area where the work is to be performed.
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If no public road exists, Contractor shall arrange on his own for access to his work
area at no extra cost to owner.
4.1.0
Installation Procedure
4.1.1
Contractor shall, before commencing any work at site, submit for Owners approval a
detailed installation procedure.
4.1.2
b)
c)
Details of Equipment :
Contractor shall furnish the complete list of all equipment to be deployed for
preparation of pipe string and installation of crossing. Technical
characteristics and capacity of each equipment including instrumentation,
monitoring and control equipment shall be furnished in details.
d)
e)
f)
g)
Method of installation covering all steps of construction, viz. Rig up, Pilot
hole, Back-Reaming, Pulling Down, Backfilling etc.
h)
i)
4.1.3
The time schedule shall be in accordance with overall time schedule for the project.
4.1.4
4.2
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radiographic inspection of joints and joint coating of the string shall be performed in
accordance with the respective applicable specifications included in the Contract
document.
4.3
Pre-testing
4.3.1
Contractor shall hydrostatically pre-test the complete pipe string of each crossing
before installation as per approved procedure for a minimum period of 24 hours.
4.3.2
After pre-testing, joint coating of the welds shall be done as per specification for
specific field joint coating of pipeline for HDD crossing included in the contract
document
4.3.3
The section of the pipeline corresponding to the crossing shall, before installation, be
subjected to hydrostatic test pressure as stipulated in the Special Conditions of
Contract. During the test, Contractor shall check all welds for leakage. Failure, if any,
during the test shall be rectified by the Contractor.
4.4
Gauging
4.4.1
Before pre and post installation hydrostatic testing, Contractor shall prove the
diameter of the pipeline by passing a gauging pig through the pipeline. The gauging
pig shall have a diameter equal to 95% of the nominal internal diameter of the pipe.
Contractor shall supply and install all temporary scraper launchers/ receivers and
other equipment, piping and materials and consumables required for the purpose.
4.5
Installation
4.7.1
4.7.2
The lateral offset of the actual exit point of the pilot hole from the calculated and
theoretical exit point shall not exceed half per cent (0.5%) of the length of the
crossing.
4.7.3
The length tolerance shall not exceed one per cent of the crossing length, subject to
the condition that the actual exit point shall not be within the limits of crossing as
defined in the approved drawings.
4.7.4
Back reaming shall be done separately from the pipeline pulling operation. The size
of the back-reamed hole shall be adequate (approximately 1.5 times the pipeline
diameter) to allow enough clearance for a smooth pull-back of the pipeline.
4.7.5
Contractor shall be responsible for maintaining the drilled hole till such time the
pipeline is pulled in.
4.7.6
During pulling operation, the buoyancy of the pipeline shall be controlled by suitable
approved methods so as to maintain the buoyancy as close as possible to zero
during pull-back in order to reduce friction forces of the pipeline in the hole.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 7 of 11
MEC/S/05/21/75
REVISION : 0
EDITION : 1
4.7.7
Bentonite slurry of specified viscosity shall be pumped into the hole, preventing the
wall from collapsing and protecting the pipeline coating.
4.6
4.6.1
Before pull-back operation, megger test shall be done for the entire pipeline
(externally corrosion coated) string made for crossing by HDD method.
4.6.2
After pull-back operation to ensure the integrity of pipeline coating, again megger
test shall be done for the bored string before tied-in to the mainline pipe. The
megger value before & after pulling operation of the pipeline string shall be nearly
same and acceptable to Owner.
4.6.3
However, if, in Owners opinion, the integrity of external corrosion coating of bored
pipeline string is not established by above (Clause No. 3.6.1 & 3.6.2), then further in
order to ensure the integrity of coating of the bored pipeline string, megger test of
the coating shall be carried out in accordance with the following steps:
4.6.4
a)
The test must be carried out before the bored pipe is tied-in to the mainline
pipe
b)
c)
d)
e)
Impress a current into the bored pipe start at Zero amp. and increase slowly
until the bored pipe potential is depressed to 1.5 V with respect to the
reference electrode.
f)
Note the current from the digital multimeter and calculate the current
density.
g)
The desirable value of calculated current density should be less than 70 micro
ampere per square meter of drilled pipe surface in contact with the soil.
If Contractor again fails to establish the integrity of coating of the bored pipeline
string and the same is not acceptable to Owner, the above works shall not be
continued further until the cause analysed and rectified by the Contractor to the
entire satisfaction of Owner.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 8 of 11
MEC/S/05/21/75
REVISION : 0
EDITION : 1
4.7
4.7.1
The complete crossing section shall be tested after installation. The test pressure
shall be as stipulated in the Special Conditions of Contract. After temperature
stabilisation, pressure shall be retained in the pipeline for a period of 6 hours and
recorded by manothermograph. The hydrostatic testing shall be carried out in
accordance with approved procedures and specification detailed elsewhere in the
document.
4.7.2
Test Procedure
Contractor shall prepare for Company's approval a hydrostatic test procedure manual
for pre-testing and post-installation testing of pipeline. The test procedure manual
shall include, but shall not be limited to, the following items:
a.
For the pipe section to be tested, a diagram indicating all fittings, vents,
valves, temporary connections, relevant elevations and ratings. The diagram
shall also indicate injection locations and intake and discharge lines.
b.
c.
d.
The type and sequence of pigs and the pig tracking system for cleaning and
removal of air pockets, pig inspection procedures, including procedure to be
followed in case the gauging pig indicates damage.
e.
Procedures for levelling and stabilization after filling and for pressurization
and to allow for temperature stabilization.
f.
g.
h.
i.
Procedure for safe dewatering the pipeline section after testing, including a
complete description of all proposed equipment and instruments (including
spares), their location and set-up, the type and sequence of pigs and the pig
tracking system along with the pig specifications.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
j.
DOCUMENT NO.
Page 9 of 11
MEC/S/05/21/75
REVISION : 0
EDITION : 1
4.7.3
Contractor shall furnish all necessary equipment & instrumentation for performing
the work including all temporary piping, hydro test header and scraper launcher /
receiver etc.
4.7.4
The test medium shall be fresh water to be arranged by the Contractor. The water to
be used shall be filtered, shall not be contaminated, and free from sand of silt.
Contractor shall submit laboratory test reports of water used for testing. Contractor
shall provide Company approved corrosion inhibitors, oxygen scavengers and
bactericides to be added to the test water. Contractor shall furnish and install all
temporary piping, which may be necessary to connect from source of water to its
pumps and manifolds / tankage.
4.7.5
Before filling operation, Contractor shall clean the pipeline by air driven pigs provided
with spring loaded brushes and cups to remove all mill scale, rust / sand from the
internal of pipe sections.
4.7.6
The hydrostatic test shall be considered as positive if pressure has kept a constant
value throughout the test duration, except for changes due to temperature effects,
and there is no abrupt pressure drop throughout the test duration.
If test section fails to maintain the specified test pressure after isolation, Contractor
shall determine by search the location of leakage or failure. All leaks and failures
within the pipe wall or longitudinal seam shall be repaired by replacement of entire
joint or joints in which leakage or failure occurs. In those cases where leaks occur in
circumferential welds the method of repair shall be determined by Company.
Contractor shall comply with instructions of the Company whether to replace a
section of the line pipe that includes the line leak or whether to repair the
circumferential weld. This repair should, however, meet the requirements of welding
specification contained herein. Where failures occur in pipeline field bends, bends
shall be replaced with same degree of bends. After completion of repairs, the
hydrostatic test shall be repeated in full, as per the approved procedures.
All work of reinstating line pipe, to replace failures, shall be done in accordance with
the specifications contained herein.
Contractor shall haul and stockpile all damaged and defective pipes to storage
locations designated by the Company. All cracks and splits resulting nom failures
shall be coated with an application of grease to preserve the characteristics of
failures nom corrosion. Joints of failed pipes shall be marked with paint, with a tag
indicating failure details, date and location of failure and pressure at which failure
occurred.
4.7.7
After completion of successful hydrotest of the above portion, the pipeline shall be
capped and buried. Pipeline end position on the banks shall be marked on the
ground by installing location markers on both banks approved by Company.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
4.8
DOCUMENT NO.
Page 10 of 11
MEC/S/05/21/75
REVISION : 0
EDITION : 1
4.9
Fencing
Wherever specified, Contractor shall supply all materials and install G.I. Wire Chain
link security fencing of size 10 m x 10 m x 25 m high with lockable steel gate around
the pipe ends and test stations for temporary C.P. on both sides of each river
crossing.
4.10
4.11
Final Clean up
4.11.1
After completion of construction, Contractor shall clear the site of all balance material
and debris and bentonite slurry. All balance pipe lengths shall be returned to Owners
designated stock yard(s). Site/ ROW shall be cleared to the complete satisfaction of
the land owners and authorities having jurisdiction. All such works shall be done at
no extra cost to Owner. The Owner shall be indemnified against any/ all claims
arising as a result thereof.
4.11.2
Contractor shall arrange for safe disposal of all surplus soil and bentonite slurry &
corrosion inhibited test water so as to avoid any harm to the environment /
occupants at locations duly approved by authorities and pollution control boards
having jurisdiction and/or as instructed by Company without any extra cost.
5.0
DOCUMENTATION
5.1
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
5.2
Page 11 of 11
MEC/S/05/21/75
REVISION : 0
EDITION : 1
Permits obtained from authorities having jurisdiction for the various works.
Plan & profile of the drilled hole along with the water level variations.
Records of hydrostatic pre-testing and final testing.
Record of Non Destructive Testing of welds.
Clearance certificates form the landowners and Authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline RoU and work areas.
Clearance certificate from the land owners and authorities having jurisdiction
regarding satisfactory clean-up and restoration of the pipeline ROW and work
sites.
After completion of construction, Contractor shall prepare and furnish six sets of
copies and two sets of reproducible of `As-built for the crossings. As built drawings
shall , as a minimum include the following information
5.3
DOCUMENT NO.
TECHNICAL SPECIFICATION
FOR
LONG RADIUS BENDS
MECON LIMITED
DELHI
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 1 OF 8
MEC/TS/05/62/015
REVISION 1
CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIAL
4.0
MANUFACTURE
5.0
6.0
7.0
WARRANTY
8.0
DOCUMENTATION
Revision No.
PREPARED BY :
Date
Revised by
CHECKED BY :
Checked by
Approved by
APPROVED BY :
MECON LIMITED
DELHI
TITLE
1.0
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 2 OF 8
MEC/TS/05/62/015
REVISION 1
SCOPE
This specification covers long radius steel pipe bends to be manufactured in
accordance with the requirements of MSS-SP (Manufacturers Standardisation
Society Standard Practice) 75, latest edition, to be used in pipeline system
handling Natural Gas. The selection of options permitted by MSS-SP-75 shall be
as described below. All applicable requirements contained in the MSS-SP-75
shall be fully valid unless cancelled, replaced or amended by more
requirements as stated in this specification. In case of conflict between the
requirements of this specification and MSS-SP-75, the requirements of this
specification shall govern.
2.0
REFERENCE DOCUMENTS
Reference has also been made in this specification to the latest edition of the
following codes, standards and specifications.
a)
ANSI B31.8
b)
c)
ASME Sec IX
d)
API Spec. 5L
Line Pipe
e)
ASTM Part-I
MATERIALS
3.1
Bends shall be fabricated from bare steel line pipe (to be issued as free issue
item by Purchaser). The details of free issue line pipe material is given
separately in LR Bend Data Sheet & Purchase Requisition.
MECON LIMITED
DELHI
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 3 OF 8
MEC/TS/05/62/015
REVISION 1
3.2
All mechanical properties of the bends after finishing shall be same as pipe
specification as referred in section 3.1. The following tests shall be conducted
on finished bends and test procedures shall be as per pipe specification as
referred in para 3.1.
3.2.1
One transverse tensile test will be conducted to establish the yield strength,
ultimate tensile strength and elongation of :
a)
b)
3.2.2
One all weld tensile test will be conducted (wherever applicable) to establish
yield strength, ultimate tensile strength and elongation of weld material on
bend.
3.2.3
3.2.4
4.0
MANUFACTURE
4.1
MECON LIMITED
DELHI
TITLE
4.2
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 4 OF 8
MEC/TS/05/62/015
REVISION 1
When bending, the weld wherever applicable shall be located at approx. 10 from
the neutral zone, measured at outside of the bend as indicated in figure below.
10
W E LD H ER E
OR
HERE
B E N D IN G P L A N E
BEND
10
4.3
4.4
4.5
4.6
The cooling of the bend immediately after bending shall be an interval cooling,
alternatively with water and air at a minimum pressure of 2 atmospheres.
4.7
The procedure shall be such which shall not require any additional heat
treatment after bending. If such a heat treatment is required, it is permitted only
after the written approval of purchaser and shall be carried out at Manufacturers
expense.
4.8
Bulges, dents and flat areas shall not appear within 100mm from end of the bend.
For the remaining part of the bend these deviations from the original contour of
the pipe are permitted but the same shall be repaired, provided these deviations
shall not exceed 6.5% of nominal wall thickness in height/ depth and the same
shall not extend (in any direction) over a distance of more than 25% of nominal
diameter.
4.9
The excess weld material wherever applicable at the inside of the bend shall be
removed over a distance of 100mm at both ends.
4.10
Tolerances
The dimensions of bends shall be controlled to make sure that they are
manufactured according to the tolerances indicated below over and above the
requirements of MSS-SP-75
MECON LIMITED
DELHI
TITLE
4.10.1
4.10.2
4.10.3
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 5 OF 8
MEC/TS/05/62/015
REVISION 1
Bend Angle
Bend Radius
1% of bending nominal
Diameter
The manufacturer shall check the wall thickness of the pipe before and after
bending along the outside radius either at distances approximately equal to
pipe diameter or 300mm whichever is less. The measured wall thickness shall
be atleast equal to :
tmin
0.95 (tnom. -
t)
tnom
4.10.4
Wrinkles
Measurements of the outside diameter shall be taken in the plane of the bend
at locations where wrinkles are present (OD max.) and at locations where
wrinkles are not present (OD min,). The acceptance limit shall be as defined
below.
OD max. OD min
------------------------- < 1%
OD nom.
MECON LIMITED
DELHI
TITLE
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 6 OF 8
MEC/TS/05/62/015
REVISION 1
5.0
5.1
The manufacturer shall perform all inspection and tests as per the
requirements of this specification and MSS-SP-75 prior to shipment at his
works. Such inspection and tests shall be, but not limited to, the following :
a)
b)
c)
d)
e)
f)
g)
5.2
MECON LIMITED
DELHI
TITLE
5.3
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 7 OF 8
MEC/TS/05/62/015
REVISION 1
Test Certificates
The Manufacturer shall produce the Certificates (in original) for all, but not
limited to, the following :
a)
b)
c)
d)
In case any of the above said certificates are not available during the final
inspection, the supply shall be considered incomplete.
6.0
6.1
6.2
All loose and foreign material i.e. rust, grease, etc. shall be removed from
inside and outside of the bends.
6.3
All bends except bevelled ends shall be coated internally and externally with a
thin film of zinc chromate red oxide paint for protection against corrosion
during transit and storage. The coating shall be easily removable in the field.
Manufacturer shall furnish the details for the same.
6.4
Both ends of all bends shall be suitably protected to avoid any damage during
transit by means of metallic bevel protectors.
6.5
Order Number
Package Number
Manufacturers Name
Size (Inches) and wall thickness (mm)
MECON LIMITED
DELHI
TITLE
7.0
STANDARD SPECIFICATION
SPECIFICATION NO.
PAGE 8 OF 8
MEC/TS/05/62/015
REVISION 1
WARRANTY
Purchaser will be reimbursed by Manufacturer for any bend furnished on this
order that fails under field hydrostatic test if such failure is caused by a defect
in the bend which is outside the acceptance limits of this specification. The
reimbursement cost shall include bend cost, labour cost and equipment rental
for searching, excavation, cutting out and installation of replaced bend in
position. The field hydrostatic test pressure will not exceed that value which
will cause a calculated hoop stress equivalent to 100% of specified minimum
yield strength of the attached pipe.
8.0
DOCUMENTATION
8.1
8.2
8.3
a)
b)
c)
Within one week of placement of order the Manufacturer shall submit four
copies, of the manufacturing process and quality assurance plan for pipe and
bends.
Once the approval has been given by Purchaser any change in material and
method of manufacture and quality control shall be notified to Purchaser
whose approval in writing of all such changes shall be obtained before the
bends are manufactured.
8.4
Within four weeks from the approval date Manufacturer shall submit one
reproducible and six copies of the documents as stated in para 8.3 of this
specification.
8.5
Prior to shipment, the Manufacturer shall submit one reproducible and six
copies of test certificates as listed in para 5.3 of this specification.
Rev. : 0
Edition : 1
SPECIFICATION
FOR
SEAMLESS FITTINGS & FLANGES
[SIZE UPTO DN 400 mm (16) NB]
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
CONTENTS
SL.NO.
DESCRIPTION
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MANUFACTURERS QUALIFICATION
4.0
MATERIALS
5.0
6.0
7.0
TEST CERTIFICATES
8.0
9.0
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Shalini Singh)
(Sunil Kumar)
(A.K. Johri)
Dec. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
AMENDMENT STATUS
Sl.
No.
Clause / Paragraph /
Annexure / Exhibit / Drawing
Amended
Page
No.
Revision
Date
By
Verified
(Name)
(Name)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
1.0
DOCUMENT NO.
Page 1 of 5
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
SCOPE
This specification covers the minimum requirements for the design, manufacture and
supply of following carbon steel flanges and fittings of size upto DN 400 mm (16") to
be installed in onshore pipeline systems handling non-sour hydrocarbons in liquid or
gaseous phase including Liquefied Petroleum Gas (LPG) :
-
2.0
REFERENCE DOCUMENTS
2.1
Reference has been made in this specification to the latest edition (edition enforce at
the time of issue of enquiry) of the following Codes, Standards and Specifications :
ASME B31.4
Pipeline
Transportation
Systems
Hydrocarbons and Other Liquids
for
Liquid
ASME B31.8
ASME B16.5
ASME B16.9
ASME B 16.11
ASME B 16.48
ASME Sec IX
ASTM A 370
MSS-SP-25
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
MSS-SP-97
DOCUMENT NO.
Page 2 of 5
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
2.2
3.0
MANUFACTURER'S QUALIFICATION
Manufacturer who intends bidding for fittings must possess the records of a
successful proof test, in accordance with the provisions of ASME B16.9 / MSS-SP-75
as applicable.
4.0
MATERIAL
4.1
The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed.
Material for flanges and fittings shall comply with the material standard indicated in
the Purchase Requisition. In addition, the material shall also meet the requirements
specified hereinafter.
4.2
Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance
with the following formula:
CE = C
Mn
+ ------- +
6
Cr + Mo + V
--------------------5
Ni + Cu
--------------15
For flanges and fittings specified to be used for Gas service or LPG service, Charpy
V-notch test shall be conducted on each heat of steel. Unless specified otherwise,
the Charpy V-notch test shall be conducted at 0C in accordance with the impact test
provisions of ASTM A 370 for flanges and fittings.
The average absorbed impact energy values of three full-sized specimens shall be
27 joules. The minimum impact energy value of any one specimen of the three
specimens analysed as above, shall not be less than 22 Joules.
When Low Temperature Carbon Steel (LTCS) materials are specified for flanges and
fittings in Purchase Requisition, the Charpy V-notch test requirements of applicable
material standard shall be complied with.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 3 of 5
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
4.4
For flanges and fittings specified to be used for Gas service or LPG service,
Hardness test shall be carried out in accordance with ASTM A 370. Hardness testing
shall cover at least 10% per item, per size, per heat, per manufacturing method. A
full thickness cross section shall be taken for this purpose and the maximum
hardness shall not exceed 248 HV10.
4.5
In case of RTJ (Ring Type Joint) flanges, the groove hardness shall be minimum 140
BHN. Ring Joint flanges shall have octagonal section of Ring Joint.
5.0
5.1
Flanges such as weld neck flanges and blind flanges shall conform to the
requirements of ASME B16.5.
5.2
Spectacle blind and spacer & blind shall conform to the requirements of ASME B
16.48.
5.3
Fittings such as tees, elbows, reducers, etc. shall be seamless type and shall
conform to ASME B16.9 for sizes DN 50 mm (2") to DN 400 mm (16") (both sizes
included) and ASME B 16.11 for sizes below ON 50 mm (2").
5.4
5.5
Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.6
Flanges and fittings manufactured from bar stock are not acceptable.
5.7
All butt weld ends shall be bevelled as per ASME B 16.5 / ASME B 16.9 / MSS-SP97 as applicable.
5.8
5.9
Stub-in or pipe to pipe connection shall not be used in the manufacture of tees.
Tees shall be manufactured by forging or extrusion methods. The longitudinal weld
seam shall be kept at 90 from the extrusion. Fittings shall not have any
circumferential joint .
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 4 of 5
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
6.0
6.1
The Manufacturer shall perform all inspections and tests as per the requirement of
this specification and the relevant codes, prior to shipment at his works. Such
inspections and tests shall be, not but limited to the following :
6.2
a)
All flanges and fittings shall be visually inspected. The internal and external surfaces
of the flanges and fittings shall be free from any strikes, gauges and other
detrimental defects.
b)
Dimensional checks shall be carried out on finished products as per ASME B16.5 for
flanges, ASME B16.48 for spacers and blinds and ASME B16.9 / MSS-SP-97 as
applicable for fittings and as per this specification.
c)
d)
All finished wrought weld ends subject to welding in field, shall be 100% tested for
lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall
not be acceptable.
Purchaser's Inspector reserves the right to perform stage wise inspection and
witness tests, as indicated in clause 6.1 of this specification at Manufacturer's Works
prior to shipment. Manufacturer shall give reasonable notice' of time and shall
provide, without charge, reasonable access and facilities required for inspection, to
the Purchaser's Inspector.
Inspection and tests performed / witnessed by Purchaser's Inspector shall in no way
relieve the Manufacturer's obligation to perform the required inspection and tests.
7.0
TEST CERTIFICATES
Manufacturer shall furnish the following certificates:
a)
b)
c)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
DOCUMENT NO.
Page 5 of 5
MEC/TS/05/21/025
REVISION : 0
EDITION : 1
the specified minimum yield strength for the pipe with which the fitting is to be
attached without impairment of serviceability.
8.0
8.1
After all inspection and tests required have been carried out; all external surfaces
shall be thoroughly cleaned to remove grease, dust and rust and shall be applied
with standard mill coating for protection against corrosion during transit and storage.
The coating shall be easily removable in the field.
8.2
Ends of all fittings and weld neck flanges shall be suitably protected to avoid any
damage during transit. Metallic or high impact plastic bevel protectors shall be
provided for fittings and flanges. Flange face shall be suitably protected to avoid any
damage during transit.
8.3
All flanges and fittings shall be marked as per applicable dimension / manufacturing
standard.
9.0
DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized below.
Number of Copies (Hard copies / soft copies etc.) shall be as indicated in
CONTRACT document / Material Requisition.
9.1
9.2
Prior to shipment, the Manufacturer shall submit test certificates as listed in clause
7.0 of this specification.
9.3
TECHNICAL SPECIFICATION
FOR
ASSORTED PIPES
\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\59A assorted pipe spec\Specification for Assorted Pipes 59A.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
ASSORTED PIPES
REV-0
PAGE 1 OF 9
CONTENTS
Sl.No.
Description
1.0
GENERAL
2.0
IBR PIPES
3.0
HYDROSTATIC TEST
4.0
ANNEXURE-I :
Page No.
HYDROSTATIC TEST
Prepared By :
Checked By :
\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\59A assorted pipe spec\Specification for Assorted Pipes 59A.doc
Approved By :
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
ASSORTED PIPES
REV-0
PAGE 2 OF 9
1.0
GENERAL
1.1
1.2
Testing
1.2.1
Test reports shall be supplied for all mandatory tests as per the applicable
material specifications. Test reports shall also be furnished for any
supplementary tests as specified in the MR & Clauses 1.10 & 1.11.
1.2.2
1.3
Manufacturing Processes
1.3.1
1.3.2
1.4
1.5
a)
Seamless and E.R.W. pipes shall not have any circumferential seam
joint in a random length. However, in case of E.FS.W. pipe, in one
random length one welded circumferential seam of same quality as
longitudinal weld is permitted. This weld shall be at least 2.5 m
from either end. The longitudinal seams of the two portions shall
be staggered by 90. Single random length in such cases shall be 5
to 7m.
b)
\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\59A assorted pipe spec\Specification for Assorted Pipes 59A.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
ASSORTED PIPES
REV-0
PAGE 3 OF 9
1.6
Pipe with screwed ends shall have NPT external taper pipe threads
conforming to ASME/ ANSI B1.20.1 upto 1.5 NB & IS:554 for 2 to 6 NB.
1.7
Pipe with bevelled ends shall be in accordance with ASME B16.25. Weld
contours shall be as follows:
Material
Carbon Steel (Except Low
Temp. Carbon Steel)
Alloy Steel Stainless Steel &
Low Temp. Carbon Steel
Wall Thickness
Upto 22mm
> 22mm
Upto 10 mm
>10 mm & Upto 25 mm
> 25 mm
Weld Contour
Figure 2 Type A
Figure 3 Type A
Figure 4
Figure 5 Type A
Figure 6 Type A
1.8
Gavanished pipes shall be coated with zinc by hot dip process conforming
to IS:4736/ ASTM A 153.
1.9
1.10
1.10.1
For all austenitic stainless steel pipes, intergranular corrosion test shall
have to be conducted as per following:
ASTM A262 practice B with acceptance criteria of 60 mils/ year
(max.)
OR
ASTM 262 practice E with acceptance criteria of No cracks as
observed from 20X magnification & Microscopic structure to be observed
from 250X magnification.
1.10.2
1.10.3
For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall
be drawn from each solution annealing lot; one set corresponding to
highest carbon content and the other corresponding to the highest pipe
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1.12
1.13
Specified heat treatment for carbon steel & alloy steel and solution
annealing for stainless steel pipes shall be carried out after weld repairs.
Number of weld repairs at the same spot shall be restricted to maximum
two by approved repair procedure.
1.14
2.0
IBR PIPES
2.1
IBR Documentation
2.1.1
2.1.2
For materials 1 Cr- Mo (ASTM A335 Gr. P11/ A691 Gr. 1 Cr) & 2
Cr-1Mo (ASTM A335 Gr.P22/ A691 Gr. 2 Cr.), from III-A approved
by IBR shall include the tabulation of Et , Sc & Sr values for the entire
temperature range given below. Et , Sc & Sr values shall be such that
throughout the temperature range
where,
SA
:
Et
:
Et / 1.5
Sr / 1.5
Sc
Sa
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SA (psi)
Material
Sc
Sr
REV-0
PAGE 5 OF 9
500
600
650
700
750
800
850
900
950
1000
1050
1100
17200
18900
17900
16700
18300
17900
16200
18000
17900
15600
17600
17900
15200
17300
17900
15000
16800
17800
14500
16300
14500
12800
15000
12800
9300
9900
10800
6300
6300
7800
4200
4200
5100
2800
2800
3200
Note:
SA values given above are as per ASME B31.3-1999. Values shall be as per
the latest edition prevailing.
2.2
For carbon steel pipes under IBR, the chemical composition shall conform
to the following;
Carbon (max.)
Others (S, P, Mn)
:
:
0.25%
As prescribed in IBR regulation.
HYDROSTATIC TEST
Refer Annexure I.
4.0
4.1
4.2
Pipes under IBR, CRYO, & NACE shall be painted in red stripes, light
purple brown stripes & canary yellow stripes, respectively, longitudinally
throughout the length for easy identification.
4.3
Paint or ink for marking shall not contain any harmful metal or metallic
salts such as zinc, lead or copper which cause corrosive attack on heating.
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4.4
Pipes shall be dry, clen and free from from moisture, dirt and loose
foreign materials of any kind.
4.5
4.6
4.7
Both ends of the pipe shall be protected with the following material:
Plain end
Bevel end
Threaded end
:
:
:
Plastic cap
Wood, Metal or Plastic cover
Metal or Plastic threaded cap
4.8
4.9
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ANNEXUREI
3.0
HYDROSTATIC TEST
3.1
3.2
3.2.1
Carbon Steel
Material Standard
ASTM A 106 Gr. B
API 5L Gr. B, Seamless
API 5L, E.R.W.
API 5L, Spiral
ASTM A333 Gr.3 & 6, Seamless
ASTM A 333 Gr. 3 & 6, E.R.W.
b)
Material Standard
Test Pressure Standard
ASTM A335 GR.P1, P12, P11, P22, P5, ASTM A 530
P9
ASTM A268 TP 405, TP410
ASTM A530
c)
Material Standard
Test Pressure Standard
ASTM A312 Gr.TP304, 304L, 304H, 316, ASTM A 530
316L, 316H, 321, 347
d)
ASTM
ASTM
ASTM
ASTM
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e)
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3.2.2
PAGE 8 OF 9
ASTM B725
ASTM B517
ASTM B514
API 5L Gr.B
ASTM A 671 Gr.CC65, 70 (Cl.32)
ASTM A 672 Gr.C60, 65, 70 (Cl.12,22)
ASTM A 671 Gr.CF60, 65, 66, 70 (Cl.32)
ASTM A 691 Gr. Cr, 1Cr, 1 Cr, 2
Cr, 5Cr, 9Cr (Cl.42)
P=2ST/ D
S=90% of SMYS (except for API 5L
Gr.B)
S=85% of SMYS for API 5L Gr.B
T=Nominal Wall Thickness
D=O.D. of Pipe
b)
Size
2
3
4
6
Material Gr.1:
Material Gr.2:
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c)
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Material Standard
Test Pressure Standard
ASTM A358 TP 304L, 304, 304H, P = 2ST/D
316L, 316, 316H, 321, 347 S = 85% of SMYS
(Classes 1, 3 & 4)
T = Nominal Wall Thickness
D = O.D. of Pipe
ASTM A358 TP 304L, 304, 304H, P = 2ST/D
316L, 316, 316H, 321, 347 S = 72% of SMYS
(Classes 2 & 5)
T = Nominal Wall Thickness
D = O.D. of Pipe
3.2.3
\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\59A assorted pipe spec\Specification for Assorted Pipes 59A.doc
Rev. : 0
Edition : 1
SPECIFICATION
FOR
BALL VALVES
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
ABBREVIATIONS :
ASME
ASTM
API
BHN
DN
Nominal Size
HAZ
LC
LO
MSS-SP
NDT
NPS
RTJ
SSPC
Members
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
BALL VALVE
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
CONTENTS
Sl.No.
Description
Page No.
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
5.0
6.0
7.0
TEST CERTIFICATES
8.0
9.0
10.0
DOCUMENTATION
11.0
GUARANTEE
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(SHALINI SINGH)
(GURDEEP SINGH)
(A.K. JOHRI)
Oct. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/002
REVISION : 1
EDITION : 1
AMENDMENT STATUS
Sl.
No.
1.
Clause / Paragraph /
Annexure / Exhibit /
Drawing Amended
Cl. No. 4.6
Page
No.
Rev.
By
Date
Name
April 09
Gurdeep
Singh
Verified
Sig.
Name
KK De
Sig.
MECON LIMITED
REGD. OFF: RANCHI
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TITLE
BALL VALVE
DOCUMENT NO.
Page 1 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
1.0
SCOPE
This specification covers the minimum requirements for design, manufacture, testing
and supply of carbon steel ball valves of size DN 50mm (2) and above and ANSI
class 150 to 900 to be used in on-shore pipeline systems handling non-sour
hydrocarbons in liquid or gaseous phase, including Liquid Petroleum Gas (LPG).
This specification does not cover ball valves for sour hydrocarbon (liquid/ gas)
service as defined in NACE standard MR-01-75.
2.0
REFERENCE DOCUMENTS
2.1
All valves shall be manufactured and supplied in accordance with the Twenty Second
Edition, January,2002, or the latest edition of American Petroleum Institute (API)
Specification 6D / ISO 14313 : 1999, with additions and modifications as indicated in
the following sections of this specification.
2.2
Reference has also been made in this specification to the latest edition of the
following Codes, Standards and Specifications :
ASME B 16.5
ASME B 16.25
ASME B 16.34
ASME B16.47
ASME B 31.3
ASME B 31.4
ASME B 31.8
ASME Sec.VIII/IX
ASTM A 370
ASTM B 733
API 6FA
API 607
API 1104
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MEC/TS/05/21/002
REVISION : 0
EDITION : 1
2.3
BS:6755 (Part-II)
MSS-SP-6
MSS-SP-44
SSPC-VIS-1
ASMEB 16.10
In case of conflict between the requirements of this specification, API 6D and the
Codes, Standards and Specifications referred in clause 2.2 above, the requirements
of this specification shall govern. Order of precedence shall be as follows :
Data Sheets
This Specification
API 6D Specification
Other Referred Codes & Standards
Manufacturers Standard
3.0
MATERIALS
3.1
Material for major components of the valves shall be as indicated in Valve Data
Sheet. Other components shall be as per Manufacturers standard (suitable for the
service conditions indicated in Data Sheet) and shall be subject to approval by
Purchaser. In addition, the material shall also meet the requirements specified
hereinafter.
3.2
Carbon steel used for the manufacture of valves shall be fully killed.
3.3
The Carbon Equivalent (CE) of valve end connections which are subject to further
field welding by Purchaser, shall not exceed 0.45% (as calculated by the following
formula) on check analysis for each heat of steel used:
CE = C
3.4
Mn
Cr + Mo + V
Ni + Cu
+ -------- + ---------------------- + --------------6
5
15
For Valves specified to be used for Gas service or LPG service, Charpy V-notch test,
on each heat of base material shall be conducted as per API 6D Clause 7.5, for all
pressure containing parts such as body, end flanges and welding ends as well as
bolting material for pressure containing parts. Unless otherwise, the Charpy V-notch
test shall be conducted at 0 C. Test procedure shall conform to ASTM A370. The
average absorbed energy value of three full sized specimens shall be 27 J. The
minimum impact energy value for any one specimen of the three specimens analysed
as above, shall not be less than 22 J.
MECON LIMITED
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MEC/TS/05/21/002
REVISION : 0
EDITION : 1
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data
Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable
material standard shall be complied with.
3.5
For all such valves where carbon steel is used as ball material, the ball shall have 75
micrometer (0.003 inch) thick Electroless Nickel Plating (ENP) as per ASTM B733 with
following classification : SC2, Type II, Class 2. The hardness of plating shall be
minimum 50 RC.
3.6
When specified in Valve Data Sheet, hardness test shall be carried out on each heat
of base material for all pressure containing parts of the valve. A full thickness crosssection shall be taken for this purpose and the maximum hardness shall not exceed
248 HV10 based on minimum four measurements representing the entire thickness.
3.7
All process-wetted parts, metallic and non-metallic, shall be suitable for the fluids and
service specified by the Purchaser. The service gas composition shall be as given in
Annexure-I.
3.8
Non-metallic parts of the valves (including O-rings, soft seals etc.) intended for
hydrocarbon gas service shall be resistant to explosive decompression.
4.0
4.1
Valve design shall meet the requirements of API 6D and other referred codes and
shall be suitable for the service conditions indicated in Valve Data Sheet. The ASME
Boiler & Pressure Vessel Code, Section VIII, Division 1, shall be used to design the
valve body. Allowable stress requirements shall comply the provisions of ASME
B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be
considered in valve design. However, the minimum wall thickness shall not be less
than the minimum requirement of ASME B16.34. The Manufacturer shall have a valid
license to use API 6D monogram for manufacture of ball valves.
4.2
Valve body shall be either fully welded or bolted. Valve body joints with threads are
not permitted.
4.3
4.4
Valves shall be Full Bore (FB) or Reduced Bore (RB) as indicated in Valve Data Sheet.
Full bore valves shall be suitable for the passage of all types of pipeline scraper and
inspection pigs on regular basis without causing damage to either the valve
component or the pig. The full bore valve shall provide an unobstructed profile for
pigging operations in either direction. Full bore valves shall be designed to minimize
accumulation of debris in the seat ring region to ensure that valve movement is not
impeded. In case of reduced bore valves, the nominal valve size indicated in Valve
Data Sheet corresponds to the end connection. Nominal valve size of reduced bore
shall be as per Table below:
MECON LIMITED
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MEC/TS/05/21/002
REVISION : 1
EDITION : 1
Nominal Valve
Size
Nominal Valve
Nominal Valve
Nominal Valve
Size for Reduced
Size
Size for Reduced
Bore
Bore
DN mm (NPD inches) DN mm (NPD inches) DN mm (NPD inches) DN mm (NPD inches)
50 (2)
50 (2)
600 (24)
500 (20)
80 (2)
50 (2)
650 (26)
550 (22)
100 (4)
80 (3)
700 (28)
600 (24)
150 (6)
100 (4)
750 (30)
600 (24)
200 (8)
150 (6)
800 (32)
650 (26)
250 (10)
200 (8)
850 (34)
700 (28)
300 (12)
250 (10)
900 (36)
750 (30)
350 (14)
250 (10)
950 (38)
800 (32)
400 (16)
300 (12)
1000 (40)
850 (34)
450 (18)
350 (14)
1050 (42)
900 (36)
500 (20)
400 (16)
1200 (48)
1050 (42)
550 (22)
450 (18)
4.5
Ball mounting shall be trunnion/ pivot type or as indicated in Valve Data Sheet. Valve
design shall minimize the possibility of debris ingress into the trunnion as far as
practicable. Ball mounting either trunnion or floating may be as follows :
Sl. No.
Rating
1.
2.
3.
150
300
600
Up to 8
Up to 4
Nil
Trunnion Mounted
Design
More than 8
More than 4
2 & Above
4.6
Valve seats shall have metal to metal contact. O-rings or other seals, if used for drip
tight sealing, shall be encased in a suitable groove in such a manner that it can not
be removed from seat ring and there is no extrusion during opening or closing
operation of valve at maximum differential pressure corresponding to valve class
rating. The seat rings shall be so designed as to ensure sealing at low as well as high
differential pressures. Seat design with PTFE insert is not acceptable.
4.7
Valves shall have double block and bleed feature to facilitate complete flushing,
draining and venting of the valve body cavity.
4.8
For valves to be used in liquid service, the body cavity over-pressure shall be
prevented by self relieving seat rings/assemblies. A pressure relief hole in the ball is
not permitted. Self relieving seat rings shall relieve at a body cavity differential
pressure not exceeding 50% of the valve class rating pressure.
4.9
MECON LIMITED
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MEC/TS/05/21/002
REVISION : 0
EDITION : 1
4.10
Full Bore Valves of nominal size DN 200mm(8) & above and Reduced Bore Valves of
nominal size DN 250mm(10) & above shall have provision for secondary sealant
injection under full line pressure for seat and stem seals. All sealant injection
connections shall be provided with a needle valve, a grease fitting and non-return
valve. Valve design shall have a provision to replace the sealant injection fitting
under full line pressure. Location and arrangement of sealant points shall be as per
Figure-1 (Annexure-II).
4.11
Valves shall be provided with vent and drain connections. Location and arrangement
of vents and drains alongwith provision of valves shall be as per Figure-1 (AnnexureII).
4.12
Valve design shall ensure repair of stem seals / gland packing under full line
pressure.
4.13 a)
Valve ends shall be either flanged or butt welded or one end flanged and one end
butt welded as indicated in Valve Data Sheet. Flanges of the flanged end cast/
forged body valves shall be integrally cast/forged with the body of valve. Face-toface/ end-to-end dimensions shall conform to API 6D. Face-to-face and end-to-end
dimensions for valve sizes not specified in API 6D shall be in accordance with ASME
B 16.10. Face-to-face and end-to-end dimensions not shown in API 6D or in ASME B
16.10 shall be as per Manufacturer Standard and shall be subject to approval by
Company.
b)
c)
Flanged end shall have dimensions as per ASME B16.5 for valve sizes upto DN
600mm (24 inches) excluding DN 550mm (22 inches) and as per MSS-SP-44 / ASME
B 16.47 series A for valve sizes DN 550mm (22 inches) & for DN 650mm (26 inches)
and above. Flange face shall be either raised face or ring joint type as indicated in
Valve Data Sheet. Flange face finish shall be serrated or smooth as indicated in Valve
Data Sheet. Smooth finish when specified shall be 125 to 200 AARH. In case of RTJ
flanges, the groove hardness shall be minimum 140 BHN.
Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe to
which the valve has to be welded shall be as indicated in Valve Data Sheet. Valves
shall be without transition pups. In case significant difference exists between
thickness of welding ends of valve and connecting pipe, the welding ends of valve
shall have bevel preparation as per ASME B31.4 or ASME B31.8, as applicable.
4.14
Design of weld end valves shall be such that during field welding operations, the soft
seals or plastic components of the valve (where ever used) are not liable to be
damaged. The manufacturer shall furnish necessary field welding instructions and
post-weld test procedure to demonstrate integrity and leak-tightness of valves after
field welding operations.
4.15
Valves shall be provided with ball position indicator and stops of rugged construction
at the fully open and fully closed positions.
MECON LIMITED
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MEC/TS/05/21/002
REVISION : 0
EDITION : 1
4.16
Full Bore Valves of nominal size DN 200mm(8) and Reduced Bore Valves of
nominal size DN 250mm(10) shall be equipped with support foot and lifting lugs.
Tapped holes and eye bolts shall not be used for lifting lugs. Height of support foot
shall be kept minimum. The location and size of support foot / lifting lugs shall
ensure unrestrictive operation of vent / drain valves.
4.17
Valve design shall be such as to avoid bimetallic corrosion between carbon steel and
high alloy steel components. Suitable insulation shall be provided as required.
4.18
When indicated in Material Requisition, valves shall have locking devices to lock the
valve either in full open (LO) or full close (LC) positions. Locking devices shall be
permanently attached to the valve operator and shall not interfere with operation of
the valve.
4.19
Valves shall be of fire resistant design as per API 607/BS:6755 (Part-II)/API 6FA, as
indicated in Valve Data Sheet.
4.20
4.21
Valves shall be suitable for either buried or above ground installation as indicated in
Valve Data Sheet.
4.22
When stem extension requirement is indicated in Valve Data Sheet, the valves shall
have the following provisions :
a)
Valves provided with stem extension shall have water proof outer casing.
Length of stem extension shall be as indicated in Valve Data Sheet. The
length indicated corresponds to the distance between centreline of the valve
opening and the top of mounting flange for valve operating device (gear
operator / power actuator as applicable).
b)
Vent and drain connections and sealant injection lines shall be terminated
adjacent to the valve operator by means of suitable piping anchored to the
valve body. Pipe used shall be API 5L Gr. B/ ASTM A 106 Gr. B, with Sch.
160. Fittings shall be ASTM A 105/ ASTM 234 Gr. WPB, Socket Welded, ANSI
class 6000.
c)
Stem extension and stem housing design shall be such that the complete
assembly will form a rigid unit giving a positive drive under all conditions with
no possibility of free movement between valve body, stem extension or its
operator.
d)
Outer casing of stem extension shall have 3/8 or NPT plugs at the top
and bottom, for draining and filling with oil to prevent internal corrosion.
MECON LIMITED
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MEC/TS/05/21/002
REVISION : 0
EDITION : 1
4.23
Operating Devices
a)
Valves shall have a power actuator or manual operator as indicated in Valve Data
Sheet. In case of manual operator, valve sizes < DN 100mm (4 inches) shall be
wrench operated and valve sizes DN 150mm (6 inches) shall be gear operated.
Each wrench operated valve shall be supplied with wrench. Valve design shall be
such that damage due to malfunctioning of the operator or its controls will only
occur in the operator gear train or power cylinder and that damaged parts can be
replaced without the valve cover being removed.
b)
The power actuator shall be in accordance with the Purchaser specification issued for
the purpose and as indicated in Valve and Actuator Data Sheet. Operating time shall
be as indicated in Valve Data Sheet. Valve operating time shall correspond to full
close to full open/full open to full close under maximum differential pressure
corresponding to the valve rating. For actuated valves, the actuator torque output
shall be 1.25 times the break torque required to operate the ball valve under the
maximum differential pressure corresponding to the valve class rating.
c)
For manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall conform to API 6D requirements and be such that under
maximum differential pressure, the total force required to operate the valve does not
exceed 350 N. Manufacturer shall also indicate the number of turns of hand wheel
(in case of gear operators) required for operating the valve from full open to full
close position.
d)
e)
Gear operators, when provided, shall have a self locking provision and shall be fully
encased, in water proof/ splash proof/ dust proof/ weather proof enclosure and shall
be filled with suitable grease.
f)
Operating devices shall be designed for easy operation of the valve under maximum
differential pressure corresponding to the valve rating.
4.24
All welds shall be made by welders and welding procedures qualified in accordance
with the provisions of ASME Section IX. The procedure qualification shall include
impact test and hardness test and shall meet the requirements of clauses 3.4 and
3.6 of this specification, respectively.
4.25
All welds shall be stress relieved in accordance with ASME Section VIII.
4.26
Repair by welding is not permitted for fabricated and forged body valves. However
repair by welding as per ASME B16.34 is permitted for cast body valves. Such repairs
shall be carried out at casting suppliers care only. Repair shall be carried out before
any heat treatment of casting is done. Repair welding procedure qualification shall
include impact test and hardness test and shall meet the requirements of clauses
3.4, 3.5 & 3.6 of this specification, respectively.
MECON LIMITED
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MEC/TS/05/21/002
REVISION : 0
EDITION : 1
4.27
The tolerance on internal diameter and out of roundness at the ends for welded end
valves shall be as per applicable connected pipe specification as indicated in Valve
Data Sheet.
4.28
When indicated in Material Requisition, valves shall have locking device to lock the
valve either in full open (LO) or full close (LC) positions. Locking devices shall be
permanently attached to the valve operator and shall not interfere with operation of
the valve.
4.29
Valve stem shall be capable of withstanding the maximum operating torque required
to operate the valve against the maximum differential pressure corresponding to
applicable class rating. The combined stress shall not exceed the maximum allowable
stresses specified in ASME Section VIII, Division I. In case of power actuated valves,
the valve stem shall be capable of withstanding maximum output of the power
actuator.
5.0
5.1
The Manufacturer shall perform all inspection and tests as per the requirements of
this specification and the relevant codes, prior to shipment, at his works. Such
inspection and tests shall be, but not limited to, the following:
5.1.1
All valves shall be visually inspected. The internal and external surfaces of the valves
shall be free from any strikes, gouges and other detrimental defects. The surfaces
shall be thoroughly cleaned and free from dirt, rust and scales.
5.1.2
Dimensional check on all valves shall be carried out as per the Purchaser approved
drawings.
5.1.3
5.1.4 a)
b)
Body castings of all valve shall be radiographically examined on 100% of the surface
of critical areas as per ASME B16.34. Procedure and acceptance criteria shall be as
per ASME B16.34. The extent of radiography shall be as follows:
ANSI
class 150
All sizes
Nil
ANSI
class 300
Nil
100%
All sizes
100%
MECON LIMITED
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Page 9 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
All castings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B.16.34.
c)
All valves, with body fabricated from plates made or by forgings, shall be
ultrasonically examined in accordance with the procedure and acceptance standard
of Annexure E of ASME B16.34. All forgings shall be wet magnetic particle inspected
100% of the internal surfaces. Method and acceptance shall comply with ASME B
16.34
d)
5.1.5
Full inspection by radiography shall be carried out on all welds of pressure containing
parts. Acceptance criteria shall be as per ASME B 31.4 or ASME B31.8, as applicable,
and API 1104.
5.1.6
5.1.7 a)
All finished wrought weld ends subject to welding in field shall be 100%
ultrasonically tested for lamination type defects for a distance of 50mm from the
end. Laminations shall not be acceptable.
b)
Weld ends of all cast valves subject to welding in field shall be 100% radiographically
examined and acceptance criteria shall be as per ASME B16.34.
c)
After final machining, all bevel surfaces shall be inspected by dye penetrant or wet
magnetic particle methods. All defects longer than 6.35 mm are rejected, as are
defects between 6.35 mm and 1.59mm that are separated by a distance less than 50
times their greatest length. Rejectable defects must be removed. Weld repair of
bevel surface is not permitted.
5.1.8
All valves shall be tested in compliance with the requirements of API 6D. During
pressure testing, valves shall not have sealant lines and other cavities filled with
sealant, grease or other foreign material. The drain, vent and sealant lines shall be
either included in the hydrostatic shell test or tested independently. Test pressure
shall be held for at least 30 minutes. No leakage is permissible during hydrostatic
testing. The body cavity self-relieving feature meeting the requirements of clause 4.8
of this specification shall also be checked.
5.1.9
A supplementary air seat test as per API 6D shall be carried out for all valves. A
bubble tight seal is required without the use of any sealant. No leakage is allowed.
Test pressure shall be held for at least 15 minutes.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 10 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
5.1.10
Manufacturer who intends bidding, must submit at bid stage, certificate and report
for successful fire type-tests for valves in accordance with API-607/ BS EN 10497 /
API 6FA, as applicable in Valve Data Sheet.
Failure to comply with this requirement shall be a cause of rejection of the offer.
5.1.11
5.1.12
Power actuated valves shall be tested after assembly of the valve and actuator at the
valve Manufacturers works. At least five open-close-open cycles without internal
pressure and five open-close-open cycles with maximum differential pressure shall be
performed on the valve actuator assembly. The time for full open to full close shall
be recorded during testing.
If required, the actuator shall be adjusted to ensure that the opening and closing
times are within the limits stated in Actuator Data Sheet issued for the purpose.
Hand operator provided on the actuator shall also be checked after the cyclic testing,
for satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five(5) valves
of the same size, rating and the actuator model/ type. In case the tests do not meet
the requirements, retesting / rejection of the lot shall be decided by Purchasers
Inspector.
5.1.13
Subsequent to successful testing as specified in clause 5.1.11 and 5.1.12 above, one
(1) valve out of the total ordered quantity shall be randomly selected by the
Company Representative for cyclic testing as mentioned below :
a)
b)
Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.
In case this valve fails to pass these tests, the valve shall be rejected and two more
valves shall be selected randomly and subjected to testing as indicated above. If
both valves pass these tests, all valves manufactured for the order (except the valve
that failed) shall be deemed acceptable. If either of the two valves fails to pass these
tests, all valves shall be rejected or each valve shall be tested at the option of
manufacturer.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 11 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
Previously carried out test of similar nature shall be considered acceptable if the
same has been carried out by Manufacturer in last two years. Valves of two sizes
below and two sizes above the size of valve previously tested, and rating similar or
one rating lower of valve tested previously, shall be qualified.
5.1.14
Checks shall be carried out to demonstrate that the dissimilar metal used in the
valves are successfully insulated as per the requirement of clause 4.17 of this
specification.
5.1.15
When indicated in Valve Data Sheet, valves shall be subjected to anti-static testing
as per supplementary test requirement of API 6D.
5.2
Purchaser reserves the right to perform stage-wise inspection and witness tests as
indicated in clause 5.1 above at Manufacturers works prior to shipment.
Manufacturer shall give reasonable access and facilities required for inspection to the
Purchasers Inspector.
Purchaser reserves the right to require additional testing at any time to confirm or
further investigate a suspected fault. The cost incurred shall be to Manufacturers
account.
In no case shall any action of Purchaser or his Inspector relieve the Manufacturer of
his responsibility for material, design, quality or operation of valves.
Inspection and tests performed/ witnessed by the Purchasers Inspector shall in no
way relieve the Manufacturers obligation to perform the required inspection and
tests.
6.0
6.1
Purchasers Inspector shall perform inspection and witness tests on all valves or as
indicated in the Quality Assurance Plan (QAP) attached with this specification.
6.2
The hydrostatic testing and cyclic opening and closing of the valves with the
operator shall be witnessed by Purchasers Inspector.
7.0
TEST CERTIFICATES
7.1
b)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 12 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
c)
d)
e)
All other test reports and certificates as required by API 6D and this
specification.
The certificates shall be valid only when signed by Purchasers Inspector. Only those
valves which have been certified by Purchasers Inspector shall be despatched from
Manufacturers works.
8.0
8.1
Valve surface shall be thoroughly cleaned, freed from rust and grease and applied
with sufficient coats of corrosion resistant paint. Surface preparation shall be carried
out by shot blasting to SP-6 in accordance with Steel Structures Painting Council
Visual Standard SSPC-VIS-1. For valves to be installed underground, when
indicated in Valve Data Sheet, the external surfaces of the buried portion of valves
shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry
film thickness of 300 microns.
8.2
Manufacturer shall indicate the type of corrosion resistant paint used, in the
drawings submitted for approval.
8.3
All valves shall be marked as per API 6D. The units of marking shall be metric
except Nominal Diameter which shall be in inches. Marking shall be done by diestamping on the bonnet or on the housing. However, for buried valves the marking
shall be done on the above ground portion of the stem housing only.
8.4
Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by a
coat of grease or other suitable material. All valves shall be provided with suitable
protectors, for flange faces, securely attached to the valves. Bevel ends shall be
protected with metallic or high impact plastic bevel protectors.
8.5
All sealant lines and other cavities of the valve shall be filled with sealant before
shipment.
8.6
8.7
Order Number
Manufacturers Name
Valve Size and Rating
Tag Number
Serial Number
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 13 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
9.0
9.1
Manufacturer shall furnish list of recommended spares and accessories for valves
required during start-up and commissioning and supply of such spares shall be
included in the price quoted by Manufacturer.
9.2
Manufacturer shall furnish list of recommended spares and accessories required for
two years of normal operation and maintenance of valves.
9.3
Manufacturer shall quote for spares & accessories as per Material Requisition.
10.0
DOCUMENTATION
10.1
b)
Sectional drawing showing major parts with reference numbers and material
specification. In particular, a blow-up drawing of ball-seat assembly shall be
furnished complying the requirement of clause 4.5 of this specification.
c)
Reference list of similar ball valves manufactured and supplied in last five
years indicating all relevant details including project, year, client, location,
size, rating, service etc.
d)
Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for power actuated valves.
e)
f)
g)
h)
Details of support foot, including dimensions and distance from valve centre
line to bottom of support foot.
i)
Quality Assurance Plan enclosed with this tender duly signed, stamped and
accepted.
j)
k)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 14 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
l)
IMPORTANT
The drawings to be submitted alongwith the bid shall be in total compliance
with the requirement of technical specification and data sheets of the
valves with no exception & deviation.
10.2
Within two weeks of placement of order, the Manufacturer shall submit six copies of,
but not limited to, the following drawings, documents and specifications for
Purchasers final approval :
a)
b)
Assembly drawings with overall dimensions and features. Drawing shall also
indicate the number of turns of hand wheel (in case of gear operators)
required for operating the valve from full open to full close position and the
painting scheme. Complete dimensional details of support foot (where
applicable) shall be indicated in these drawings as referred to in clause 10.1
above.
c)
d)
e)
f)
10.3
Within 30 days from the approval date, Manufacturer shall submit to Purchaser one
reproducible and six copies of the approved drawings, documents and specifications
as listed in clause 10.2 above.
10.4
Prior to shipment, Manufacturer shall submit one reproducible and six copies of the
following:
a)
b)
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
BALL VALVE
DOCUMENT NO.
Page 15 of 15
MEC/TS/05/21/002
REVISION : 0
EDITION : 1
10.5
11.0
GUARANTEE
11.1
Manufacturer shall guarantee that the materials and machining of valves and fittings
comply with the requirements in this specification and in the Purchase Order.
11.2
Manufacturer is bound to replace or repair all valve parts which should result
defective due to inadequate engineering or to the quality of materials and
machining.
11.3
11.4
Any defect occurring during the period of Guarantee shall be attended to by making
all necessary modifications and repair of defective parts free of charge to the
Purchaser as per the relevant clause of the bid document.
11.5
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
(NB 2)
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MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 1 of 13
CONTENTS
Sl.No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
4.0
5.0
6.0
7.0
TEST CERTIFICATES
8.0
10
9.0
10
10.0
DOCUMENTATION
11
11.0
GUARANTEE
12
Page No.
PREPARED BY :
CHECKED BY :
APPROVED BY :
Gurdeep Singh
A.K. Sarkar
A.K. Johri
Date
Date
Date
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
1.0
REV-2
Page 2 of 13
SCOPE
This specification covers the minimum requirements for design, manufacture and supply
of carbon steel plug valves of size DN 50mm (2") and above and ANSI Class 150# thru
900# for use in onshore pipeline systems handling non sour hydrocarbons in liquid phase
or gaseous phase including Liquefied Petroleum Gas (LPG).
2.0
REFERENCE DOCUMENTS
2.1
All valves shall be manufactured and supplied in accordance with the Twenty Second
Edition, January, 2002, or the latest edition of American Petroleum Institute (API)
Specification 6D, twenty first edition, 1994 including supplement 1 & 2 thereof with
additions and modifications as indicated in the following sections of this specification.
2.2
Reference has also been made in this specification to the latest edition of the following
Codes, Standards and Specifications :
ASME B 16.5
ASME B 16.25
Buttwelding ends
ASME B 16.34
ASME B16.47
ASME B 31.3
ASME B 31.4
ASME B 31.8
ASME Sec.VIII
ASTM A 370
ASTM B 733
API 6FA
API 1104
BS:6755 (Part-II)
MSS-SP-6
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MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
2.3
REV-2
Page 3 of 13
MSS-SP-44
SSPC-VIS-1
In case of conflict between the requirements of this specification, API 6D and the
Codes, Standards and Specifications referred in clause 2.2 above, the requirements of
this specification shall govern. Order of precedence shall be as follows :
Data Sheets
This Specification
API 6D Specification
Other Referred Codes & Standards
Manufacturers Standard
3.0
3.1
Material for major components of the valves shall be as indicated in Valve Data Sheet.
Other components shall be as per Manufacturer's standard which will be subject to
approval by Purchaser.
3.2
Carbon steel used for the manufacture of valves shall be fully killed.
3.3
Chemical composition (check analysis) of valve end connection which are subject to
further welding by Purchaser shall meet the following requirements for each heat of steel
used:
a)
Carbon
:
0.22% (max.)
b)
Manganese
:
1.70 % (max.)
c)
Silicon
:
0.55 % (max.)
d)
Phosphorus
:
0.030 % (max.)
e)
Sulphur
:
0.030 % (max.)
Total percentage of Vanadium, Niobium and Titanium shall not exceed 0.20. Residual
elements shall not exceed the following limits :
a)
Nitrogen
:
0.019 %
b)
Nickel
:
0.30 %
c)
Copper
:
0.20 %
d)
Aluminum
:
0.070 %
e)
Chromium
:
0.15 %
f)
Molybdenum
:
0.05 %
Carbon equivalent (CE) as calculated by the following shall not exceed 0.45%.
CE = C
Mn
Cr + Mo + V
Ni + Cu
+ -------- + ---------------------- + --------------6
5
15
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MECON LIMITED
Delhi
3.4
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 4 of 13
For valves specified for Gas Service or high vapour pressure liquid service, charpy VNotch test on each heat of base material shall be conducted as per API 6D, for all
pressure containing parts such as body, end flanges and welding ends as well as the
bolting material for pressure containing parts. Unless specified otherwise in Valve Data
Sheets, the Charpy impact test shall be conducted at 0C. The Charpy impact test
specimen shall be taken in the direction of principal grain flow and notched perpendicular
to the original surface of plate or forging.
Unless specified otherwise in Valve Data Sheets, the minimum average absorbed
energy per set of three specimens shall be 27 J with an individual minimum per
specimen of 22 J.
3.5
For valves specified for Gas Service or high vapour pressure liquid service, the hardness
of base material of body and principal parts of the valve such as plug, stem, etc., shall
not exceed 22 RC.
3.6
Plug for valve size DN 200mm (8) and above or as specified in Valve Data Sheets shall
have Electroless Nickel Plating (ENP) or equivalent. The hardness of plating shall be
minimum 50 RC. Manufacturer shall ensure that the adhesive strength of plating is
sufficient so as to prevent peeling of plating during operation of the valve.
3.7
All process-wetted parts, metallic and non-metallic, shall be suitable for the fluids and
service specified by the Purchaser. The service gas composition when applicable shall be
as given in Annexure-I.
4.0
4.1
The Manufacturer shall have a valid license to use API 6D monogram for manufacture of
Plug Valves.
4.2
Valve pattern shall be short, regular or venturi as specified in the following table:
Class
150
300
600
900
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 5 of 13
4.3
Valve shall have an inherent feature using line pressure to ensure that the line pressure
cannot cause taper locking of the plug/ plug movement into taper i.e. valves shall be of
pressure balanced design.
4.4
Cover shall be bolted to the body and screwed connections are not acceptable.
4.5
Soft seats to achieve a seal between plug and body are not permitted.
4.6
All valves shall have provisions for secondary sealant injection under full line pressure for
seat and stem seals. Sealant injection points shall be provided with a ball type check
valve or needle valve to replace the sealant injection fitting under full line pressure.
4.7
Valves shall have vent and drain connections as per API 6D.
4.8
When specified in the Valve Data Sheet, valves shall be designed to withstand a
sustained internal vacuum of at least one milli-bar in both open and closed position.
4.9
Valve design shall ensure repair of gland packing under full line pressure.
4.10
a)
Valve ends shall be either flanged or butt welded or one end flanged and one end butt
welded as indicated in Valve Data Sheet. Flanges of the flanged end cast/ forged body
valves shall be integrally cast/forged with the body of valve. Face-to-face/ end-to-end
dimensions shall conform to API 6D.
b)
Flanged end shall have dimensions as per ASME B16.5 for valve sizes upto DN 600mm
(24 inches) excluding DN 550mm (22 inches) and as per MSS-SP-44 for valve sizes DN
550mm (22 inches) & for DN 650mm (26 inches) and above. Flange face shall be either
raised face or ring joint type as indicated in Valve Data Sheet. Flange face finish shall be
serrated or smooth as indicated in Valve Data Sheet. Smooth finish when specified shall
be 125 to 200 AARH. In case of RTJ flanges, the groove hardness shall be minimum 140
BHN.
c)
Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe to
which the valve has to be welded shall be as indicated in Valve Data Sheet. Valves
shall be without transition pups. In case significant difference exists between
thickness of welding ends of valve and connecting pipe, the welding ends of valve
shall have bevel preparation as per ASME B31.4 or ASME B31.8, as applicable.
4.11
Valves shall be provided with position indicator and stops at the fully open and fully
closed positions.
4.12
Valves of size DN 200mm (8) and above shall be equipped with lifting lugs. Tapped
holes and eye bolts shall not be used for lifting lugs.
4.13
Valves shall have locking devices to be locked either in full open or full close position
when indicated in the Valve Data Sheets. Locking devices shall be permanently attached
to the valve operator and shall not interfere with operation of the valve.
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 6 of 13
4.14
Valves shall be of fire safe design as per BS:6755 (Part-II)/ API 6FA, if indicated in Valve
Data Sheet.
4.15
Valves shall be suitable for either buried or above ground installation as indicated in the
Valve Data Sheet.
4.16
Valves with stem extension, when indicated in Valve Data Sheet shall have following
provisions :
a)
b)
c)
d)
e)
4.17
Valves provided with stem extension shall have water proof outer casing. Length
of stem extension shall be as indicated in the Valve Data Sheet. The length
indicated corresponds to the distance between the centreline of the valve opening
and the top of the mounting flange for valve operating device (gear operator/
power actuator as applicable).
Vent and drain connections shall be terminated adjacent to the valve operator by
means of suitable piping anchored to the valve body. Pipe used shall be API 5L
Gr. B/ ASTM A106 Gr. B, with Sch. 160. Fittings shall be ASTM A105/ ASTM A
234 Gr. WPB, Socket Welded, ANSI class 6000.
Sealant injection lines shall be extended and terminated adjacent to the valve
operator in manner as indicated in (b) above.
Stem extension and stem housing design shall be such that the complete
assembly will form a rigid unit giving a positive drive under all conditions with no
possibility of free movements between valve body stem extension or its operator.
Outer casing of stem extension shall have 3/8" or " NPT plugs at the top and
bottom, for draining and filling with oil to prevent internal corrosion.
Operating Devices
a)
b)
The power actuator shall be in accordance with the specification issued for the
purpose and as indicated in the valve and actuator data sheet. Operating time
shall be as indicated in valve data sheet. Valve operating time shall correspond to
full close to full open / full open to full close under maximum differential pressure
corresponding to the valve rating. For actuated valves, the actuator torque shall
be atleast 1.25 times the maximum torque required to operate the valve under
maximum differential pressure corresponding to the valve class rating.
c)
Operating device shall be designed for easy operation of valve under maximum
differential pressure corresponding to the valve rating.
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 7 of 13
d)
For manual operation of all valves, the diameter of the hand wheel or the length
of operating lever shall be such that under the maximum differential pressure, the
total force required to operate the valve does not exceed 350 N. Manufacturer
shall also indicate the number of turns of hand wheel (in case of gear operator),
required to operate the valve from full open to full close position.
e)
f)
Gear operators, if specified, shall have a self locking provision and shall be fully
encased in waterproof/ dustproof/ weatherproof/ splashproof enclosure and shall
be filled with suitable grease.
4.18
Repair by welding is not permitted for fabricated and forged body valves. However repair
by welding as per ASME B16.34 is permitted for cast body valves. Repair shall be carried
out before any heat treatment of casting is done. Repair welding procedure qualification
shall also include impact test and hardness test when required as per Clause 3.4 and 3.6
of this specification and shall meet the requirements as specified therein.
4.19
The tolerance on internal diameter and out of roundness at the ends for welded ends
valves shall be as per connected pipe specification as indicated in the Valve Data Sheet.
4.20
Valve stem shall be capable of withstanding the maximum operating torque required to
operate the valve against the maximum differential pressure corresponding to applicable
class rating. The combined stress shall not exceed the maximum allowable stresses
specified in ASME section VIII, Division-1.
For Power Actuated Valves, the valve stem shall be designed for maximum output torque
of the selected power actuator (including gear box, if any) at the valves stem.
5.0
5.1
The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment at his works. Such inspection and
tests shall be, but not limited to, the following :
5.1.1
5.1.2
Dimensional check shall be carried out as per the Purchaser approved drawings.
5.1.3
5.1.4
a)
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
b)
REV-2
Page 8 of 13
Valves castings shall be radiographically examined at the cover and body portion,
seat location, flanged body ends and circumference of ends to be field welded.
Procedure and acceptance criteria shall be as per ASME B16.34. The extent of
radiography shall be as follows :
ANSI Class 150 -
All Sizes
DN 400mm (16")
DN 450mm (18")
Nil
-
All Sizes
100%
Nil
100%
All castings shall be wet magnetic particle inspected 100 % of the internal
surfaces. Method and acceptance shall comply with ASME B16.34.
c)
5.1.5
5.1.6
a)
b)
c)
Weld ends of all cast valves shall be 100% radiographically examined and
acceptance criteria shall be as per ASME B16.34.
After final machining all bevel surfaces shall be inspected by dye penetrant, or
wet magnetic particle methods. Any defects longer than 6.35mm shall be rejected
and also defects between 6.35mm and 1.59mm that are separated by a distance
less than 50 times their greatest length. Weld repair of bevel surface is not
permitted. Rejectable defects must be removed.
All finished wrought weld ends subject to welding in the field shall be 100%
ultrasonically tested for lamination type defects for a distance of 50mm from the
end. Laminations shall not be acceptable.
5.1.7
All valves shall be tested in compliance with the requirements of API 6D. Hydrostatic
shell testing shall ensure that the whole of the shell is subjected to the test pressure. If
necessary, the empty shell shall be pressure tested prior to assembly of the plug. The
drain, vent and sealant lines shall be either included in the hydrostatic shell test or tested
independently. No leakage is permissible during hydrostatic testing.
5.1.8
A supplementary air seat test as per API 6D shall be carried out for all valves. No leakage
is allowed. Test pressure shall be held for at least 15 minutes.
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MECON LIMITED
Delhi
5.1.9
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 9 of 13
Manufacturer who intends bidding must submit at bid stage, certificate and report for
successful fire safe tests for all types of valves in accordance with BS:6755 (Part-II)/ API
6FA, as applicable in Valve Data Sheet.
Failure to comply with the requirement shall be a cause of rejection of the offer.
5.1.10
5.1.11
Power actuated valves shall be tested after assembly at the valve Manufacturer's works.
Actuator shall be capable to allow minimum five consecutive "opening" and "closing"
cycles. To achieve this, the Manufacturer shall provide "closing" and "opening"
operations. This test shall be conducted on one valve out of a lot of five valves of the
same size, rating and actuator type. In case the test result dose not meet the
requirements, retesting/ rejection of the lot shall be as decided by Purchaser's Inspector.
The actuator shall be adjusted to ensure that opening and closing time is within the limits
stated in Actuator Data Sheet issued for the purpose.
The hand operator installed on the actuator shall also be checked after the cyclic testing,
for satisfactory manual over-ride performance.
5.2
Purchaser reserves the right to perform stagewise inspection and witness tests as
indicated in para 5.1 at Manufacturer's works prior to shipment. Manufacturer shall give
reasonable access and facilities required for inspection to Purchaser's Inspector.
Purchaser reserves the right to request additional testing at any time to confirm or further
investigate a suspected fault. If the suspected fault is confirmed, the cost incurred shall
be to Manufacturer's account.
In no case shall any action of Purchaser or his representative relieve the Manufacturer of
his responsibility for material, design, quality or operation of valves.
Inspection and tests performed/ witnessed by the Purchaser's Inspector shall in no way
relieve the Manufacturer's obligation to perform the required inspection and tests.
6.0
6.1
Purchaser's Inspector shall perform inspection and witness test on all valves as indicated
in the Quality Assurance Plan (QAP) attached with this specification.
6.2
The hydrostatic testing and cyclic opening and closing of the valves with the operator
shall be witnessed by Purchaser's Inspector.
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
7.0
TEST CERTIFICATES
7.1
REV-2
Page 10 of 13
a)
Mill test certificates relevant to the chemical analysis and mechanical properties of
the materials used for valve construction as per the relevant standards.
b)
c)
d)
e)
Test reports on operation of valves conforming to clause 5.1.10 and 5.1.11 of this
specification.
f)
All other test reports and certificates as required by API 6D and this specification.
The certificates shall be valid only when signed by Purchaser's Inspector. Only those
valves which have been certified by Purchasers Inspector shall be dispatched from
Manufacturer's works.
8.0
8.1
Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by
shot blasting to SP 6 in accordance with "Steel Structures Painting Council - Visual
Standard - SSPC-VIS-1". For the valves to be installed underground, when indicated in
Valve Data Sheet, external surfaces of the buried portion of valves shall be painted with
three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300
microns.
8.2
Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings
submitted for approval.
8.3
All valves shall be marked as per API 6D. The units of marking shall be metric except
Nominal Diameter which shall be in inches. Marking shall be done by die-stamping on the
bonnet or on the housing. However for buried valves the marking shall be done on the
above ground portion of the stem housing only.
8.4
Valve ends shall be suitably protected to avoid any damage during transit. All threaded
and machined surfaces subject to corrosion shall be well protected by a coat of grease or
other suitable material. All valves shall be provided with suitable protectors, for flange
faces, securely attached to the valves. Bevel ends shall be protected with metallic bevel
protectors.
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 11 of 13
8.5
All sealant lines and other cavities of the valves shall be filled with sealant before
shipment.
8.6
8.7
Packages shall be marked legibly, with suitable marking ink, the following.
a)
b)
c)
d)
e)
Order Number
Manufacturer's Name
Valve Size and Rating
Tag Number
Serial Number
9.0
9.1
Manufacturer shall recommend and quote separately the spares for valves required for
commissioning and two years of normal operation. List of such spares without price shall
be indicated alongwith technical bid and separately with price.
9.2
Manufacturer shall recommend and quote unit price separately for the accessories (like
wrench, sealant injector, etc.), sealant and special tools required for maintenance of
valves.
10.0
DOCUMENTATION
10.1
At the time of bidding, the bidder shall submit the following documents :
a)
b)
Sectional drawing showing major parts with reference numbers and material
specification.
c)
Reference list of similar plug valves manufactured and supplied in last five years,
indicating all relevant details including project, year, client, location, size rating,
service, etc.
d)
Torque curves for the power actuated valves alongwith break torque and
maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for power actuated valves.
e)
f)
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 12 of 13
g)
Details of support foot, including dimensions and distance from valve centre
line to bottom of support foot.
h)
Quality Assurance Plan enclosed with this tender duly signed, stamped and
accepted.
IMPORTANT
The drawings to be submitted alongwith the bid shall be in total compliance
with the requirement of technical specification and data sheets of the valves
with no exception & deviation.
10.2
Within two weeks of placement of order, the manufacturer shall submit six copies of, but
not limited to, the following drawings, documents and specifications for approval :
a)
Design drawings and relevant calculations for pressure containing parts and other
principle parts.
b)
Detailed sectional arrangement drawing showing all parts with reference numbers
and materials specification.
c)
Assembly drawings with overall dimensions & clearances required and showing all
features. Drawing shall also indicate the numbers of turns of handwheel (in case
of gear operator) required for operating the valve from full open to full close
position and the painting scheme.
d)
e)
f)
Manufacture of valves shall commence only after approval of the above documents. Once
approval has been given by Purchaser, any change in design, material and method of
manufacture shall be notified to the Purchaser, whose approval in writing for all changes
shall be obtained before the valves are manufactured.
10.3
Within 30 days from the approval date, Manufacturer shall submit one reproducible and
six copies of the approved drawings, documents and specification as listed in clause 10.2
of this specification.
10.4
Prior to shipment, Manufacturer shall submit one reproducible and six copies of following
:a)
Test certificates as listed in clause 7.0 of this specification.
b)
Manual for installation, erection instructions, maintenance and operation
instructions, including a list of recommended spares for the valves.
10.5
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
PLUG VALVES
REV-2
Page 13 of 13
11.0
GUARANTEE
11.1
Manufacturer shall guarantee that the materials and machining of valves and fittings
comply with the requirements in this specification and in the Purchase Order.
11.2
Manufacturer is bound to replace or repair all valve parts which should result defective
due to inadequate engineering or to the quality of materials and machining.
11.3
11.4
Any defect occurring during the period of Guarantee shall be attended to by making all
necessary modifications and repair of defective parts free of charge to the Purchaser as
per the relevant clause of the bid document.
11.5
D:\old data\Vijyant\Spec master\Final Spec\SUPPLY ITEMS\03 PLUG VALVE\003 - Plug Valves - TS-R2.doc
Page 1 of 7
(A)
1.0
General
1.1
1.2
1.3
For heavy valves, provision for lifting shall be made by way of lugs, eyebolts,
or similar standard devices.
1.4
Unless otherwise stated, all flanged valves shall have end flanges integral
with valve body. Weld on flanges are not acceptable. Flange finish shall be
serrated finish 250 AARH (250 AARH to 500 AARH) or 125 AARH (125
AARH to 250 AARH) or 63 MRH (32 AARH to 63 AARH) as per valve
specification sheet.
1.5
For all weld end valves, with bevel end as per ANSI B 16.25, the bevel
contour shall be as follows:
Wall Thickness
Weld Contour
Upto 22 mm
> 22 mm
Upto 10 mm
> 10 mm & upto 25 mm
> 25mm
Figure
Figure
Figure
Figure
Figure
Material
Carbon Steel (Except Low
Temp. Carbon Steel)
Alloy Steel
Stainless Steel &
Low Temp Carbon Steel
2
3
4
5
6
Type A
Type A
Type A
Type A
1.6
If an overlay weld-deposit is used for the body seat ring, seating surface, the
seat ring base material shall be at least equal to the corrosion resistance of
the materials of the shell.
1.7
For valve body/ bonnet, forging is acceptable where castings are specified but
not vice versa.
1.8
1.9
Stem shall be forged or machined from a forged bar. Castings are not
permitted except integral stem.
1.10
1.11
1.12
Flange dimensions of steel, alloy steel and stainless steel flanged valves
shall conform to ANSI B 16.5 for sizes up to 24 and API 605 for size 26
and above.
1.13
Flange dimensions for cast iron flanged valves shall conform to ANSI B
16.1 for size up to 24 class 125 and API 605 with flat face for sizes
greater than 24.
1.14
API 602
BS 5352
API 600
BS 1873
BS 1868
BS 5156
BS5155/AWVVA C504
1.15
Wherever stellite is specified, it means facing of seat and disc are welded by
Cr-Co-W alloy. Stellite facing shall maintain minimum hardness of 375 BHN at
high temperature.
1.16
All weld end valves shall have bevel ends as per ANSI B 16.25.
1.17
If an overlay weld deposit is used for the body seat ring or seating surface,
the seat ring base material shall be at least equal to corrosion resistance of
the material of the shell.
1.18
By Pass
-
1.19
:
:
:
:
:
:
on
on
on
on
on
on
sizes
sizes
sizes
sizes
sizes
sizes
26 and above
16 and above
6 and above
4 and above
4 and above
3 and above
Contractor shall supply the by-pass valve duly tested and fitted to the
main valve. By-pass attachment to the main valve body shall not be
screwed. All fillet welds for by-pass installation shall be 100%
examined by DP / MP test.
Spiral wound bonnet gasket is to be provided with inner / outer ring except
when encapsulated gaskets type body bonnet joints are employed. Outer ring
may be avoided in case of non-circular spiral wound gasket used in 150#
Page 3 of 7
valve provided the outermost layer of spiral touches the bolts ascertaining the
centering.
1.20
1.21
Pressure Test
-
Valves covered under API codes shall be tested as per API 598 unless
otherwise specified in the applicable valve code.
For all austenitic stainless valves, inter-granular corrosion test shall have to
be conducted as per following: -
1.22
1.23
For the IGC test as described in 1.16.1 & 1.16.2 two sets of samples shall be
drawn from each solution treatment lot, one set corresponding to highest
carbon content and other set corresponding to the highest rating/ thickness.
2.0
OPERATION
2.1
Valve Types
Gate & Diaphragm Valves
Globe Valves
Butterfly Valves
150
300
600
900
1500
2500
900
1500
2500
150
300
of some grades of
etc.) ASTM A 262
shall have to be
E photograph of
Page 4 of 7
2.2
Gear operator shall be as under with position indicators for open / close
positions, with limit stops.
For Gate / Globe / Diaphragm Totally enclosed bevel gear in
Valves
grease case with grease nipples/
plug
For Butterfly Valves
Totally enclosed helical worm gear
or combination of helical worm and
spur gear in grease case with
grease nipples/ plugs.
2.3
2.4
Butterfly valves even with wrench or lever operators shall have open and
closed position indicators with limit stops.
2.5
Hand wheel diameter shall not exceed 750 mm and effort to operate shall not
exceed 35 kg at hand wheel periphery. In case these limits cannot be
satisfied for any valve, a gear operation shall be provided.
3.0
3.1
All valves and valves operators shall be subject to stage wise and final
inspection by third party inspection agency (at Contractors cost).
However, Company reserves the right to depute its authorized /
representative in addition to third party inspection agency. Minimum 15
days notice shall be given to Company for all shop inspection and testing.
3.2
All the mandatory shop tests and inspection required by the respective data
sheet and applicable standards & codes etc. shall be carried out.
3.3
The extent of inspection by shall be as under. However the exact extent with
hold points shall be decided during review of the inspection plan to be
submitted to Company as part of the post-order documentation.
3.4
Page 5 of 7
3.5
4.0
4.1
SIZE RANGE
RADIOGRAPHY
150#
150#
300#
300#
600# and above
24 and below
26 and above
16 and below
18 and above
All sizes
Nil
100%
Nil
100%
100%
MATERIAL
All
4.2
5.0
IBR VALVES
5.1
All valves described as IBR Valves shall be in accordance with the latest IBR
(Indian Boiler Regulations) as well as the other requirements specified in the
specification.
5.2
For BW / SW end carbon steel valves under IBR, the chemical composition
shall conform to the following:
Carbon (Max.)
Others (S, B, Mn)
:
:
0.25%
As per IBR
For all IBR Valves, test certificate in form III-C shall be furnished duly
signed by IBR inspection authority or an IBR approved representative.
5.4
6.0
MARKING
6.1
Page 6 of 7
Each valve shall have a corrosion resistant tag giving size and valve tag/code
no. securely attached on the valve body.
6.3
Paint or ink used for marking shall not contain any harmful metal or metal
salts such as zinc, lead or copper which may result in corrosive attack on
heating.
6.4
Carbon steel valves shall be painted with two coats of red oxide zinc
chromate primer.
6.5
All alloy steel high temp valves shall be painted with heat resistant silicone
paint suitable for intended temperature.
7.0
DESPATCH
7.1
Valves shall be dry, clean and free from moisture, dirt and loose
foreign material of any kind.
7.2
7.3
7.4
:
:
:
7.5
7.6
Page 7 of 7
Edition : 1
SPECIFICATION
FOR
INSULATING JOINTS
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 1 of 1
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
CONTENTS
Sl.No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
5.0
6.0
TEST CERTIFICATES
7.0
8.0
GUARANTEE
9.0
DOCUMENTATION
PREPARED BY:
CHECKED BY:
APPROVED BY:
ISSUE DATE :
(Amit Lavania)
(A.K. Gupta)
(A.K. Johri)
Oct. 2008
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 1 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
1.0
SCOPE
This specification cover the basic requirements for design manufacture, testing and
supply of carbon steel insulating joints to be installed in onshore pipeline systems
handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas
(LPG).
2.0
REFERENCE DOCUMENTS
2.1
Reference has been made in this specification to the latest edition of, the following
Codes, Standards and Specifications.
2.2
a)
ASME B 31.8
b)
ASME B 31.4
c)
ASME B 16.5
d)
ASTM A 370
e)
ANSI B 16.25
f)
ASME Section
g)
API 1104
h)
SSPC-VIS-1
i)
MSS-SP-53
j)
MSS-SP-75
k)
NACE RP 0286
In case of conflict between the requirements of this specification and any code,
Standard and Specification referred in Clause 2.1 above. Order of precedence shall be
as follows :
Data Sheets
This Specification
Manufacturers Standard.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 2 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
3.0
MATERIALS
3.1
Material for the pressure containing parts of the insulating joints shall be as indicated
in the data sheets. Material for pups shall be equivalent or superior to the material of
connecting pipeline which is indicated in the data sheets. Other part shall be as per
manufacturer's standard suitable for the service condition indicated in Insulating Joint
Data Sheets and shall be subject to approval by purchaser.
All process-wetted parts, metallic & non-metallic shall be suitable for the
commissioning fluids & service specified by the purchaser. Manufacturer shall confirm
that all wetted parts are suitable for treated water/seawater environment, which may
be used during field testing.
3.2
Insulating joints which are subject to field welding by purchaser, shall have carbon
equivalent (CE) not exceeding 0.45 based on check analysis for each heat of steel
calculated according to the following formula :
CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15
3.3
When specified in the IJ Data Sheet, charpy V-notch test shall be conducted on each
heat of base material, weld metal and heat affected zone of all pressure containing
parts such as body, welding ends in accordance with the impact test provisions of
ASTM A 370 at a temperature of 0 C. The charpy impact test specimens shall be taken
in the direction of principal grain flow and notched perpendicular to the original surface
of the plate of forging. Average impact energy value of three full sized specimens shall
be 27 joules. Minimum impact energy value of any one specimen shall not be less than
80% of the average impact energy specified. No specimen shall exhibit less than 80%
shear area.
When Low Temperature Carbon Steel (LCTS) materials are specified in Datasheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material
standard shall be complied with.
3.4
3.5
When specified in data sheet, hardness test shall be carried out as per ASTM A370 for
each heat of steel used. The maximum hardness of base metal, weld metal and heat
affected zone of all pressure parts shall be 248 HV10, unless specified otherwise.
3.6
Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP
0286.
4.0
4.1
Mechanical
4.1.1
Insulating joints shall be of integral type fabricated by welding and with pups on either
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 3 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
side as shown in data sheet. A corrosion allowance as indicated in data sheet shall be
considered in design. Bolted and threaded joints are not acceptable. Insulating Joints
of design, not having closing welds, are not acceptable.
4.1.2
All materials used for the manufacture of the insulating joint shall be in accordance
with clause 3.0 of this Specification.
4.1.3
Insulating joints shall be designed using the design principles of ASME Section-VIII Div.
1. The design shall be checked for the following two cases:
Case-I :
The allowable stress in this case shall be less than or equal to 95% of SMYS of
insulating joint material.
All design parameters shall be as per Insulating Joint Data Sheet. Detailed calculations
shall be submitted for Purchasers approval.
4.1.4
Insulating joint design and materials shall be capable of being vacuum tested to 1
millibar.
4.1.5
The joint between pipe pup pieces and main forging shall be full penetration butt weld
type. Weld design shall be such as resulting in a weld joint factor of 1.0.
4.1.6
Butt weld ends shall have ends as per ASME B16.25. However, end preparation for
butt welding ends having unequal thickness with respect to connecting pipe, shall be
as per ASME B31.4/ B31.8 as applicable.
4.1.7
The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall
be removed for a distance of at least 50mm from each end.
4.1.8
Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal
bore shall be same as that of connecting pipe including its tolerances.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 4 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
4.1.9
The insulating joint shall be formed by sandwiching and locking in positions the
insulating material in a bell and spigot type of joint. The joint shall be assembled in
such a way that its various components are firmly locked in position and the completed
joint is capable of withstanding stresses due to designed operating conditions and field
hydrostatic testing.
4.1.10
4.1.11
All welds shall be made by welders and welding procedures qualified in accordance
with the provisions ASME section IX. The procedure qualification shall include impact
test and hardness test and shall meet the requirements of clause 3.3, 3.5 of this
specification.
4.1.12
Repair welding on parent metal is not allowed. Repair of welds shall be carried out
only after specific approval by purchaser's representative for each repair. The repair
welding shall be carried out by welders and welding procedures duly qualified as per
ASME section IX and records for each repair shall be maintained. Repair welding
procedure qualification shall also include impact test & hardness test when required
as per Cl. No. 3.3 & 3.5 of this specification & shall meet the requirements as
specified therein.
4.1.13
The Tolerance on Internal diameter at the welding end shall be as per applicable
connected pipe specification as indicated in the datasheet.
4.1.14
Out of roundness measured at the root face of the welding ends shall not be more
than 0.5% of the specified inside diameter.
4.2
Electrical
4.2.1
The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts.
4.2.2
Two cleats as shown in data sheet shall be provided on the pups on either side of the
insulating joint for connecting 10 mm2 and 50 mm2 cables for measurement/ shorting
purposes. Cleats shall be attached to the insulating joint by welding.
5.0
5.1
The manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment at his works. Such inspection
and tests shall be, but not limited to the following:
5.1.1
All insulating joints shall be visually inspected. The internal & external surfaces shall be
free from any strikes, gauges & other detrimental & defects. The surfaces shall be
thoroughly cleared & free from dirt, rust & scales.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 5 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
5.1.2
Dimensional checks shall be carried out as per the purchaser approved drawings.
5.1.3
5.1.4
100% radiography shall be carried out on all butt & repair welds of pressure
containing parts. Acceptance limits shall be as per API 1104.
Welds, which in purchaser's Representative opinion cannot be inspected by
radiographic methods, shall be checked by ultrasonic or magnetic particle
methods. Acceptance criteria shall be as per ASME Section VIII Appendix-12
and Appendix-6 respectively.
b)
All finished weld ends shall be 100% ultrasonically tested for lamination type
defects for a distance of 5Omm from the ends. Any lamination larger than 6.35
mm shall not be acceptable.
c)
d)
All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle
inspection and 6mm shall be examined 100% by UT. Acceptance criteria for
MPI & UT shall be as per ASME Sec.VIII Appendix-6 & Appendix-12
respectively.
5.1.5
5.1.6
After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for 10
minutes. The tightness shall be checked by immersion or with a frothing agent. No
leakage will be accepted.
5.1.7
Dielectric Test
5.2
a)
b)
Insulating joint before and after the hydrostatic test, shall be tested for
dielectric integrity for one minute at 5000 V A.C., 50 cycles and the leakage
current before and after hydrostatic test shall be equal. Testing time voltage
and leakage shall be recorded and certified. No repair shall be permitted to the
insulating joints failed in the above-mentioned tests.
Purchaser reserves the right to perform stage wise inspection and witness test as
indicated in Para 5.1 at Manufacturer's works prior to shipment. Manufacturer shall
give reasonable notice of time and shall provide without charge reasonable access and
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 6 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
TEST CERTIFICATES
6.1
7.0
7.1
Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and
applied with sufficient coats of corrosion resistant paint. Surface preparation shall be
carried out by shot blasting to SP-6 in accordance with "steel structures painting
council - Visual standard SSPC-VIS-l.". External surfaces of burried insulating joints
shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry
film thickness of 300 microns.
Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings
submitted for approval.
7.2
Insulating joints shall be marked with indelible paint with the following data:a.
b.
c.
d.
e.
f.
g.
h.
Manufacturer's name
Suitable for _____ inch nominal diameter pipeline
End thickness in mm
Material
Design Pressure/ Hydrostatic Test Pressure
ANSI Class Rating
Tag No.
Year of Manufacture
7.3
Insulating joints shall be suitably protected to avoid any damage during transit.
Metallic or high-impact plastic bevel protectors shall be provided to weld ends.
7.4
Only those insulating joints which have been inspected and certified by Purchaser shall
be shipped.
MECON LIMITED
REGD. OFF: RANCHI
834002
TITLE
INSULATING JOINTS
DOCUMENT NO.
Page 7 of 7
MEC/TS/05/21/009
REVISION : 0
EDITION : 1
8.0
GUARANTEE
8.1
The manufacturer shall guarantee that the materials used comply with the
requirements of this specification.
8.2
Manufacturer shall replace or repair insulating joints found defective due to inadequate
engineering or quality of material.
8.3
Manufacturer shall replace the insulating joint without delay if the defect or
malfunctioning can not be eliminated.
8.4
Any defects occurring within 12 months from the date of installation or within 30
months from the date of despatch, whichever is earlier, shall be repaired making all
necessary modifications and repair of defective parts free of charge to the purchaser.
9.0
DOCUMENTATION
9.1
9.2
9.3
Within three weeks of placement of order, the Manufacturer shall submit four copies of
but not limited to the following drawings, documents and specifications for approval.
a)
b)
c)
Once the approval has been given by purchaser any changes in design, material and
method of manufacture shall be notified to the Purchaser whose approval in writing of
all changes shall be obtained before the insulting joint are manufactured.
9.4
Within four weeks from the approval date Manufacturer shall submit one reproducible
and six copies of the approved drawings, documents and specifications as listed in 9.3
of this specification.
9.5
Prior to shipment, the manufacturer shall submit one reproducible and six copies of the
test certificates as listed in Clause 6.0 of this specification.
Rev. : 0
Edition: 0
SPECIFICATION
FOR
Y / T TYPE STRAINERS
MECON LIMITED
DELHI - 110 092
D:\LPG\TS\STRAINER\STRAINER011.doc
TITLE
Y/T TYPE
STRAINER
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
AMENDMENT STATUS
Sl.
No.
Page
No.
PREPARED BY :
D:\LPG\TS\STRAINER\STRAINER011.doc
CHECKED BY :
APPROVED BY :
Rev-2
Rev-3
Rev-4
ISSUE DATE :
Y/T TYPE
STRAINER
TITLE
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
CONTENTS
Sl.
No.
Description
1.0
GENERAL
Page No.
02
2.0
02
3.0
DESIGN
03
4.0
TECHNICAL REQUIREMENTS
03
5.0
04
6.0
05
7.0
06
8.0
07
9.0
10.0
INFORMATION/ DOCUMENTS/DRAWINGS
TO BE SUBMITTED WITH OFFER
WARRANTY
07
08
PREPARED BY :
CHECKED BY :
APPROVED BY :
ISSUE DATE :
(SHESH RAM)
(G. V. WALIMBE)
(A. K. JOHRI)
JULY 2008
D:\LPG\TS\STRAINER\STRAINER011.doc
TITLE
Y/T TYPE
STRAINER
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
1.0
GENERAL
1.1
1.2
1.3
1.4
Strainer model offered shall be from the existing regular manufacturing range
of the strainer vendor. Vendor's / manufacturer's catalogue and general
reference list shall be furnished along with the offer.
1.5
2.0
2.1
2.2
2.3
D:\LPG\TS\STRAINER\STRAINER011.doc
TITLE
Y/T TYPE
STRAINER
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
2.4
Supply of recommended spare parts needed for start-up and commissioning and
special tools or fixtures, if any.
2.5
2.6
2.7
3.0
DESIGN
3.1
Following standards and codes (latest edition) shall be followed for design,
fabrication, testing etc. of the equipment.
ASME SEC. II & ASTM
ASME SEC. VIII DIV. I
ASME SEC. IX
ANSI B 16.5
ANSI B 16.9
ANSI B 16.11
:
:
:
:
:
:
Material specification
Boiler and pressure vessel code
Welding and brazing qualifications
Pipe flanges
Butt-welded fittings.
Forged steel fittings socket welded
and threaded.
3.2
4.0
TECHNICAL REQUIREMENTS
4.1
The equipment shall be of the type as mentioned in the data sheet; and shall
meet the duty requirements and performance parameters as mentioned
therein.
4.2
4.3
Effective free area of basket shall be minimum 3 times of the inlet nozzle area.
4.4
D:\LPG\TS\STRAINER\STRAINER011.doc
TITLE
Y/T TYPE
STRAINER
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
4.5
Dimensions of flanges including shell flanges, nozzle flanges and blind cover
flanges shall be as per ANSI B 16.5. Larger flanges not covered by ANSI shall
be as per MSS-SP-44.
4.6
Drain and vent connections wherever provided shall be with matching blind
cover flanges alongwith necessary gaskets, bolts and nuts.
4.7
Pressure parts joined by butt, Welds shall be with full penetration welds.
Where both sides welding is not accessible, root run by tungsten Inert gas
process or backing strip, shall be used to ensure full penetration. Backing, strip
if used shall be removed after welding.
4.8
Fabricated body shall be post weld heat treated, whenever it is required due to
service requirement or due to code requirements. Body shall be post weld heat
treated as a complete unit and no welding shall be permitted after the post
weld heat treatment is completed.
5.0
5.1
5.2
following:
Hydrostatic test at a pressure not less than 150% of design pressure for
the body.
Any other tests as per data sheets / codes / standards and covered under
approved QAP.
D:\LPG\TS\STRAINER\STRAINER011.doc
Y/T TYPE
STRAINER
TITLE
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
5.3
Any or all the tests, at purchaser's option, shall be witnessed by purchaser/ its
authorised inspection agency. However, such inspection shall be regarded as
check-up and in no way absolve the vendor of his responsibility
5.4
6.0
6.1
All exposed carbon steel parts to be painted shall be thoroughly cleaned from
inside and outside to remove scale, rust, dirt and other foreign materials by
wire brushing and sand blasting as applicable. Minimum acceptable standard
in case of power tool cleaning shall be St.3 and in case of blast cleaning shall
be Sa 2 as per Swedish Standard SIS 0055900.
6.2
6.3
6.4
6.5
(Description).
i) Normal Industrial
Surface
Preparation
Sa 2
Primer
Finish
D:\LPG\TS\STRAINER\STRAINER011.doc
Surface
:
Preparation
Sa 2
agent
Y/T TYPE
STRAINER
TITLE
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
Primer
Finish :
Surface
:
Preparation
Sa 2
7.0
7.1
All packaging shall be done in such a manner as to reduce the volume. The
equipment shall be dismantled into major components suitable for shipment
and shall be properly packed to provide adequate protection during shipment.
All assemblies shall be properly match marked for site erection.
7.2
Attachments, spare parts of the equipment and small items shall be packed
separately in wooden-cases. Each item shall be appropriately tagged with
identification of main equipment, item denomination and reference number of
the respective assembly drawing.
7.3
7.4
D:\LPG\TS\STRAINER\STRAINER011.doc
TITLE
Y/T TYPE
STRAINER
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
of manufacture etc.
8.0
8.1
Vendor shall provide spare parts needed for start-up and commissioning.
Vendor shall furnish a separate itemized priced list of recommended spares for
one as well as two (2) years normal operation and maintenance. Lists shall
include part number, part description, serial number and normal delivery lead
time. Vendor shall ensure listed parts are available for shipment at the time of
equipment shipment.
8.2
8.3
All spare parts furnished by Vendor should be wrapped and packaged so that
they will be preserved in original as new condition under the normal conditions
of storage to be anticipated in India. Spare parts shall be properly tagged and
coded so that later identification as to intended equipment usage will be
facilitated. They shall be packaged separately clearly marked as "spare parts"
and shipped at the same time as the equipment. Packing lists shall be
furnished so that the parts can be handled without uncrating, if required.
Start-up spares shall be packed and identified separately.
8.4
Vendor shall provide two sets of special tools or fixtures as required, for
installation / erection, operation & maintenance and disassembly of the
furnished equipment.
8.5
All such tools shall be permanently tagged with information pertaining to their
use. Any special drawings or instructions pertaining to the use of such tools
shall be included in the instruction manual.
9.0
D:\LPG\TS\STRAINER\STRAINER011.doc
TITLE
Y/T TYPE
STRAINER
DOCUMENT NO.
MEC/TS/05/21/010
Rev.0
Edition: 0
9.1
9.2
10.0
WARRANTY
Vendor shall have final and total responsibility for the design and mechanical
performance of all equipment supplied under this specification. Vendor shall
warrant the equipment furnished by him and the performance of the said
equipment in accordance with this specification and with warranty
requirements given elsewhere in bid package.
D:\LPG\TS\STRAINER\STRAINER011.doc
STANDARD SPECIFICATION
FOR
FIRE DETECTION AND
ALARM SYSTEM
CONTENTS
1.0
SCOPE
2.0
3.0
SITE CONDITIONS
4.0
GENERAL REQUIREMENTS
5.0
6.0
7.0
8.0
9.0
ENGINEERING REQUIREMENTS
10.0
11.0
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MEC/TS/05/21/081H
MECON LIMITED
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
1.0
SCOPE
1.1
2.0
2.1
The fire alarm system and the components used shall confirm to the
latest edition of the following and also the other Indian and international
Standards as applicable.
2.1.1
IS-5
2.1.2
IS-513
2.1.3
IS-2175
2.1.4
IS-2189
2.1.5
IS-3700
2.1.6
IS-3826 Part-I
2.1.7
IS-5469
2.1.8
IS-5780
2.1.9
IS-11360
2.1.10
BS-5839
Part-2
2.1.11
NFPA 72
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
2.1.12
LPC
2.2
2.3
3.0
SITE CONDITIONS
3.1
All the equipments shall be suitable for the site conditions specified in the
enquiry document / data sheets. If not specifically mentioned therein, a
design ambient of 55`C and an altitude not exceeding 1000m above
mean sea level shall be considered with a minimum temperature of (-)5`C
for battery sizing.
4.0
GENERAL REQUIREMENTS
4.1
4.2
Power Supply
The Fire Alarm System shall be suitable to receive the power supply as
given below:
a)
b)
Voltage
Frequency
:
:
TS FDA - 2
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
Further distribution shall be vendors responsibility. Any voltage, other than
the above shall be internally derived by the vendor within the system.
4.1.2
5.0
5.1
5.1.1
5.1.2
TS FDA - 3
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.2.2
5.2.1
5.2.1.1
Central fire alarm panel shall gather information from various Zonal Alarm
panels regarding the status of activation of detectors / manual call points
etc. on an overall basis.
5.2.1.2
Central fire alarm panel shall house starter control(s) for siren(s), in order
to generate an alarm audible in the entire plant in the event of fire.
5.2.1.3
If specified in the enquiry document / data sheets, the central fire alarm
panel shall have provision for signals, alarms etc. as specified under
clauses 5.2.5.1.
5.2.4
5.2.2
5.2.2.1
5.2.2.2
5.2.2.3
5.2.2.4
Test facility through common Test push button shall be provided for
TS FDA - 4
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
complete functional test of each group of logic circuits, audio and visual
flasher circuit, lamps etc.
5.2.2.5
The annunciation circuit design shall ensure that momentary short circuit
in the lamp circuit does not adversely affect the performance of the
system. Visual and audible alarm circuits shall be independent i.e. the
failure of one will not affect the other.
5.2.2.6
5.2.2.7
The field contact wiring will be carried out by using multicore, copper
conductor, PVC insulated and armoured cable which may be running close
to power cables. Hence the logic circuitry shall be designed with
sufficiently high signal-to noise ration to avoid spurious actuation due to
noise induced in the field wiring because of proximity with power cables.
Adequate noise filters and time delay shall be incorporated at the input
stages to reduce the effect of the noise.
5.2.2.8
A minimum of two lamps shall be provided in parallel for each fire loop to
increase the reliability of the visual alarm.
5.2.2.9
Fire alarm loop card shall be capable to receive the signal from break
glass box, Heat, UV, IR, ionisation, optical type detector, heat sensing
cable, linear beam detector and any combination thereof.
5.2.2.10
Whenever the fire is detected in any zone, both audible and visual
(flashing) alarm shall be raised in the fire alarm panel indicating the
corresponding location of fire zone. On pressing the ACCEPT push
button, the audible alarm shall stop and the lamp shall glow steadily. The
panel shall be brought to normal condition by pressing RESET push
button (only after the field conditions are normalised). It shall be possible
to manually initiate the audio alarm in addition to automatic operation.
If specified in the material requisition / data sheet, the system shall be
provided with a siren to be located at a suitable location in the plant. The
controls for the siren shall form an integral part of the Fire Alarm Panel.
The starter for the siren shall be direct-on-line type, weather proof shall
be in an IP-55 enclosure, suitable for outdoor installation. The enclosure
shall be epoxy painted fire red, to shade 536 of IS-5.
5.2.3
5.2.3.1
Zonal Fire Alarm Panel shall gather information from various detectors /
manual call points connected to its loop. It shall monitor the status of
detectors, cable faults etc.
TS FDA - 5
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
Zonal Fire Alarm Panel shall have provision to annunciate the fire/fault
signals received from the detector/manual call points connected to its
loops. LEDs shall be provided for visual annunciation and electronic
hooters as audible alarm.
5.2.3.2
Additionally LEDs shall be provided for power ON, fault, fire, multiple
alarm indication etc. Push buttons shall be provided for alarm accept,
hooter reset, LED test etc. Power ON switch shall be provided.
5.2.3.3
Zonal Fire Alarm Panel shall generate output contacts for signals to repeat
alarm panels, central fire alarm panel etc. It shall generate potential free
contacts for energisation of hooters, exit signs, tripping of owners AHU
and pressurisation system etc.
5.2.3.4
5.2.4
5.2.4.1
5.2.4.2
5.2.4.3
Repeat alarm panels shall derive power from the associated fire alarm
panel.
5.2.5
5.2.5.1
In addition to the initiation of fire alarm, zonal, central fire alarm panels
shall have the facility for following status signals, status alarms and
shutdown signals if specified in data sheets / drawings.
TS FDA - 6
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
i.
ii. Selector switches for primary or secondary clean agent/CO2 supply for
each skid / protected area.
iii. Manual push button for discharge of clean agent/CO2 in each
protected area (after alarm and 30 seconds time delay).
iv. Clean agent/CO2 discharge inhibit push button for each protected
area.
v. Deluge valve activation push buttons, deluge valve test push buttons
and deluge valve activated status lamps.
vi. Shutdown signals to various air handling units relative to the zone of
fire.
vii. Fire water pumps running indications.
viii. Fire water pumps start push buttons.
ix. Controls of sirens.
x. Repeat alarm signal to various control rooms.
xi. Repeat alarm signal to mimic panel.
xii. Repeat alarm signal to repeat alarm panel.
xiii. Status of Battery Conditions.
5.3
5.3.1
5.3.1.1
5.3.1.2
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
Visual Display Units (VDU), key boards, printers etc. located at central /
various locations in the plant.
5.3.1.3
CFAP shall have the facility to scan the data received from the DGFAPs
and shall send necessary information to the respective DGFAPs, repeat
alarm panels, VDUs etc. through bi-directional communication network.
5.3.1.4
5.3.1.5
CFAP shall be designed specifically for fire alarm and protection system
applications and shall provide status, alarm, shutdown signals in
predefined manners, initiate alarms, synchronise all activities, provide
repeat alarms and other signals as specified.
5.3.1.6
The CFAP shall have non-volatile memory for reliability and shall permit
reprogramming by authorised personnel.
5.3.1.7
The CFAP shall provide various event initiated programmes (EIP). EIP
shall be initiatred by any of the following user defined parameters; day,
time, alarm, return to normal, change of status and hardware failure.
The system shall provide multi levels of command priority to assure that
high level commands are not overriden by lower level commands.
5.3.1.8
CFAP shall have the facility to display the affected area on the VDU and
provide the instructions to suppress the cause. High resolution graphic
software shall be provided for display. The graphics shall have many
layers of penetration. The VDU shall either be touc screen type or menu
driven using mouse/keyboard. However, instead of graphic display, VDU
with only text display shall be provided, if specified in the data sheets.
5.3.1.9
5.3.1.10
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.3.1.11
5.3.1.12
Monitor screen shall have dedicated areas for the following functions:
-
5.3.1.13
Alarms and all other changes of status shall be displayed on the screen
area reserved for this information. The following information shall be
provided as a minimum:
-
On receipt of alarm, an audible alarm shall sound and the condition and
detector type shall flash until acknowledged by the operator. Return to
normal shall also be annunciated and shall require operator
acknowledgement.
5.3.1.14
The system shall have multiple levels of priority for displaying alarms.
Should multiple alarms occur, the first received, highest priority alarm
shall be displayed on the screen until acknowledged by the operator.
Then the next highest priority alarm shall be displayed until acknowledged
etc. Should a higher priority alarm occur, the higher priority alarm shall
replace the lower priority alarm on the screen and the lower priority alarm
shall be retained in memory and re-displayed after the higher priority
alarm is acknowledged.
TS FDA - 9
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.3.1.15
The system shall provide sufficient memory so that no alarm shall be lost.
A message highlighted in reverse video, shall advise the operator when
other unacknowledged alarms are present in the system.
5.3.1.16
The VDU keyboard shall use function keys with English descriptions to
initiate all system functions. Typing abbreviations or using unlabeled or
numerical function buttons is unacceptable. When a function key is
pressed, the monitor shall lead the operator through the function by
asking him to choose one of several clearly defined options (menu
penetration). When a specific detector must be addressed, a distinct
numerical keypad shall be used to speedup and simplify the operation. On
command from the operator, system reports either shall be displayed on
the VDU screen or output on the printer, as desired by the operator.
5.3.1.17
Multiple levels of access to the system shall be provided for operators and
supervisors via user defined passwords. The following functions shall be
provided for each levels:
a)
-
b)
-
5.3.1.18
Printer used in the system shall provide real time records of the system
events and provide system reports on demand.
5.3.1.19
TS FDA - 10
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.3.1.20
The system printer (PTR) shall be a letter quality dot-matrix printer, 132
character wide and shall have a 96 character set. The printer shall have a
microprocessor controlled bi-directional logic seeking head. The printing
speed shall not be less than 300 cps in draft mode.
5.3.1.21
5.3.1.22
5.3.1.23
5.3.1.24
Printer shall use fanfold paper and shall accomodate an original and two
copies. Paper shall be tractor fed. Each page shall be automatically timed,
dated and page numbered to detect unauthorised removal.
5.3.1.25
Printer shall be desk top unit and shall be styled to match the VDU.
5.3.1.26
The printer shall have an indicator to alert the operator that pape has run
out.
5.3.1.27
The printer shall have a self test feature to verify printer operability even
when off line.
5.3.1.28
5.3.1.29
The central processing unit, along with PCs and their peripherals shall be
housed in a console type enclosure made out of minimum 16 guage CRCA
sheets..
TS FDA - 11
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.3.1.30
All cabling between the central processing unit, PCs and their peripherals
shall be in the vendors scope. Arrangements shall be made within the
console enclosure for distribution of power supply to various equipments.
5.3.2
5.3.2.1
5.3.2.2
5.3.2.3
The DGFAP shall have its own microprocessor and non-volatile memory.
5.3.2.4
The DGFAP shall have the facility to transfer all data to CFAP. It shall be
possible to re-programme the operations at site. The DGFAP shall have
the capability of stand alone operation in case of communication failure
with the CFAP/other DGFAPs.
5.3.2.5
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
-
5.3.2.6
5.3.2.7
All the data gathering panels shall have alarm verification capability.
5.3.2.8
5.3.2.9
DGFAP shall provide indications for communication with the CFAP, as well
as, alarm and trouble conditions in the sensor loops.
5.3.3
5.3.3.1
5.3.3.2
Repeat alarm panel shall be capable to receive signals from either the
CFAP or the DGFAP and shall have provision to annunciate the same using
audio-visual annunciation.
5.3.3.3
5.3.3.4
5.3.3.5
Additionally LEDs shall be provided for power ON, fault, fire, multiple
alarm indication etc. Push buttons shall be provided for alarm accept and
hooter reset, as well as, for LED test. Switch shall be provided for power
ON.
TS FDA - 13
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.3.3.6
Repeat alarm panel shall derive power from the associated fire alarm
panel.
5.3.4
Data Highway
5.3.4.1
5.3.4.2
Alternately, optical fibre cables, may be used as data highway. The fibres
shall be as per latest CCITT recommendation for single mode optical
fibres and shall be laid in slots/tubes filled-up with moisture resistant jelly.
Polymer coated aluminium tape around the cable core shall provide a
moisture barrier. Optical fibre cables shall have an inner polyethylene
sheath with corrugated steel tape armouring and a polyethylene outer
sheath.
5.4
5.4.1
5.4.2
Equipment Mounting
TS FDA - 14
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.4.2.1
All apparatus, instruments and alarm facias mounted on the panel front
shall be flush mounted type. The panel wiring shall not be terminated
directly on the base connector of PCBs. It shall either be terminated
through a separate terminal block or multipin connectors. Routine
calibration and adjustments shall be accessible from the front of the panel
without having to remove any wiring or causing loss of the panel function.
In addition, total removal of the instrument(s) and replacement with a
spare shall be possible from the front of the panel.
5.4.2.2
All annunciator components except the alarm horn and auxiliary contact
relays (if used) shall be mounted integrally in a protective enclosure.
Sufficient spare terminals shall be provided to accommodate all spare /
future alarm points in the display. Access shall be provided to permit
checking and / or changing the wiring at these terminal strips.
5.4.2.3
Lamps shall be capable for removal and replacement from the panel front
via individual snap out windows or a swing out hinged door on which all
windows are mounted.
5.4.2.4
There shall be separate hooters for faults/ malfunction and fire alarm
having distinct audible tones.
5.4.2.5
5.4.2.6
Cable entry shall be from bottom unless otherwise specified in the enquiry
document / data sheet. A terminal strip shall be provided for incoming /
outgoing cables. Supporting facilities shall be provided for clamping the
cables.
5.4.3
5.4.3.1
Wiring within the panel shall be in slotted plastic raceways enclosed with
cover. Interconnecting wiring shall be done with 1 sq. mm. Cross-section,
copper conductor, PVC insulated, 660V wires. Power circuit wiring shall be
with minimum 2.5 sq.mm. cross section, copper conductor. Panels shall
be supplied completely pre-wired including spare points of modules /
controllers etc. so that only field termination is required before
energisation.
TS FDA - 15
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.4.3.2
5.4.3.3
5.4.4
Cable Glands
5.4.4.1
All the cable glands for outdoor application shall be weatherproof, nickel
plated brass and double compression type, whereas those for indoor
application shall be single compression type.
5.4.4.2
5.4.5
Earthing
5.4.5.1
5.4.6
Name Plates
5.4.6.1
All name plates for panel shall be engraved out of 3 ply (black-whiteblack) lamicoid sheets or anodised aluminium. Back engraved perspex
sheet nameplates will also be acceptable. Engraving shall be done with
square groove cutters. Hard paper or self-adhesive plastic tape
nameplates will not be acceptable.
5.4.6.2
All panels mounted equipments (e.g. lamps, push buttons, switches PCBs
etc.) shall be provided with suitable nameplates.
TS FDA - 16
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
5.4.6.3
5.4.6.4
5.4.7
Painting
5.4.7.1
5.4.7.2
6.0
6.1
General Specifications
6.1.1
All the detectors shall be plug-in type and shall have twist lock action
fitting. An LED shall be incorporated which shall normally flicker indicating
alertness and should turn steady when a fire is sensed, enabling
immediate identification of the affected detector.
6.1.2
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
recess mounting. Junction boxes for detector mounting shall be complete
with terminal block, etc. Additional terminals shall be provided to fit end
of line resistance, wherever applicable.
6.1.3
The detectors, which employ a Radio Active source shall be such that the
strength of the Radio Active material shall not exceed 1 micro curie.
6.1.4
6.1.5
All the detectors shall have inbuilt safety device to monitor the removal
and pilferage of the detector.
6.1.6
All the detectors shall be on the approved list of Loss Prevention Council,
Under Writers Laboratory (USA) / Factory Mutual (USA) / Tariff Advisory
Committee.
6.1.7
6.2
All automatic detectors for microprocessor based fire alarm system shall
be analogue addressable type. The analogue addressable detectors shall
be continuously monitored to measure any change in their sensitivity due
to the environment (dirt, dust, temperature, humidity etc.). These
detectors shall give an advance indication to the panel regarding the need
for maintenance. The analogue reading sent by the detectors shall be
sensed and if there is a rapid increase, an alarm shall be generated.
However, if there is a gradual increase in the analogue reading, a
maintenance alert shall be generated by the DGFAP. It shall be possible to
generate maintenance reports from DGFAP.
6.3
All analogue addressable detectors shall preferably have the facility to set
the addresses from the DGFAP. Alternately dip switches in the detector
base shall be used for setting the detector address.
6.4
Manual call points/break glass boxes for microprocessor based fire alarm
system shall be addressable type. Each device shall have its own address
TS FDA - 18
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
module which shall send a status signal to the DGFAP regarding its state
of actuation.
6.5
Heat Detectors
6.5.1
6.5.2
The rate of rise element shall be carefully calibrated to ignore any normal
fluctuation in temperature, but to respond quickly when the temperature
rise is 9`C or more per minute.
6.5.3
6.5.4
The detector shall be self-restoring type ensuring repeated use and easy
maintenance.
6.6
6.6.1
6.6.2
The radioactive source used in the detector shall not emit beta and
gamma rays and the strength of Radioactive material shall not be more
than 1 micro curie.
6.6.3
6.6.4
The sensitivity of the detector shall not vary with change in ambient
temperature, humidity, pressure or permissible voltage variation. Its
performance shall not be affected by an air current of 5 meter per
second. It shall have an inbuilt arrangement such that puffs of smoke or
hot air pockets do not inadvertently trigger the alarm. The detector shall
TS FDA - 19
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
be protected against dust accumulation / ingress. It shall have insect
resistant screen to prevent nuisance alarms. All detectors shall be
identical in construction, design and characteristics to facilitate easy
replacement.
6.7
6.7.1
6.8
UV Flame Detector
6.8.1
6.8.2
6.9
IR Detectors
6.9.1
6.9.2
6.10
6.10.1
TS FDA - 20
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
6.10.2
6.11
6.11.1
Heat sensing cable shall be analogue type. It shall consist of four copper
conductors, each covered with a colour coded, negative temperature coefficient material. The cores shall be twisted together and protected by an
outer sheath of high temperature flame retardent PVC insulation. External
mechanical protection shall be provided over the sensor cables. Vendor
shall provide control unit for each 10 mtr. Length of the sensor cable.
6.12
6.12.1
The break glass box shall be fabricated out of 14 gauge cold rolled sheet
steel. Alternately the break glass box may be made of die cast aluminium
alloy such as LM6. It shall have IP-55 enclosure and weatherproof
construction suitable for outdoor installation. The break glass box shall
have a minimum dimension of 100x100x80mm.
6.12.2
The box shall be fabricated in such a way so that it can be mounted, flush
to the wall or on the surface without any modification. Two nos. 19mm
knock outs shall be provided at the bottom of the box to facilitate the
cable/conduit entry. The glass shall cover at least 30cm2 area and shall
have a thickness not exceeding 2mm.
6.12.3
The break glass box shall have a push button element kept in pressed
condition by a glass sheet fitted in the front of the box.
6.12.4
The break glass box enclosure shall be painted with fire red colour (shade
536 of IS-5) epoxy painting and an inscription Break Glass in Case of
Fire, shall be painted in white letters or rivetted on the enclosure by a
steel nameplate. A suitable nickel plated brass hammer, duly chained to
the box with stainless steel chain shall be provided with each box for
TS FDA - 21
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
breaking the glass. Each box shall have a distinct identification number
boldly painted on it.
6.12.5
If specified in the enquiry documents / data sheets, the break glass box
shall have a suitably wired telephone hand set to facilitate communication
between the break glass box and the central annunciation panel. In such
a case the telephone hand set mounted on hook switch shall be provided
in a separate lockable weather proof enclosure.
6.13
Response Indicator
6.13.1
6.13.2
6.14
Exit Signs
6.14.1
Exit signs shall be fabricated out of 16 gauge cold rolled sheet steel. This
shall be suitable for wall mounting or hanging from ceiling.
6.14.2
Fire Exit / No Fire Exit shall be displayed on opposite of the exit sign by
means of 5mm dia. Red LEDs or back-lit text. It shall derive power from
data gathering cum fire alarm panel and shall operate on DC power
supply.
6.15
Hooters
6.15.1
The unit shall consist of solid state circuitry on a printed circuit board, a
loudspeaker and a flashing lamp housed in a weatherproof dust tight, wall
mounting type enclosure. The hooters shall, at least, have 102db(A)
output measured at 1 meter distance. The nit shall derive power from the
TS FDA - 22
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
fire alarm panel and operate on DC power. In the event of fire, the hooter
shall raise pulsating audio alarm and the lamp shall flash.
6.16
Flashing Lights
6.16.1
The unit shall consist of solid state circuitry on a printed circuit board and
a red caped incandescent lamp and audio unit housed in a dust tight, wall
/ ceiling mounting type enclosure. It shall derive power from the data
gathering cum fire alarm panel and operate on DC supply.
6.16.2
Flashing lights shall be installed in the enclosed areas where clean agent /
CO2 is to be dumped. In the event a signal for clean agent / CO2 release is
given, the lamp shall start blinking with a warning sound enabling
operating personnel to evacuate the area. The audio unit (hooter) shall
have 102 db (A) output measured at 1 meter distance.
6.17
6.17.1
This unit shall consist of pull type release and inhibit switches clean agent
/ CO2 . The unit shall be fabricated out of 18 gauge cold rolled sheet
suitable for wall mounting. Switches shall be pulled to release or inhibit
clean agent / CO2 .
Release switches shall have inscription:
PULL TO RELEASE CLEAN AGENT / CO2
And inhibit switches shall have inscription:
PULL TO RELEASE CLEAN AGENT / CO2
6.18
Zener Barrier
6.18.1
6.18.2
TS FDA - 23
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
6.18.3
Wherever zener barriers are provided, in safe area outside the zonal panel
or DGFAP, they shall be housed in their own enclosure and shall be dust
and vermin proof, weatherproof with IP-55 degree of protection as a
minimum.
6.19
6.19.1
6.19.2
On occurrence of a fault (short circuit), the isolator shall cut power to all
devices installed beyond the isolator in the loop.
6.19.3
The fault isolator shall have the capability to continuously check the
faulted side of the loop to determine if the fault still exists. On
rectification of the fault, the isolator shall automatically reset itself.
6.19.4
In case the fault isolator nearest to the fault does not activate first, the
isolator shall query other isolators nearest to the short circuit and then
de-activate/restore itself. The restoration shall continue along the loop
until only the isolator closest to the fault is left activated.
6.19.5
6.19.6
6.20
Sirens
6.20.1
6.20.2
The decibel level of the siren shall, at least be, 132db(A) at 1 meter, to
meet the audibility requirement for the above range. Unless otherwise
specified, Sirens shall operate at 240V, 3ph. AC. Sirens shall be housed in
TS FDA - 24
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
weatherproof enclosure and shall be supplied along with direct-on-line
starters. Power supply for sirens shall be derived from a source with
battery back-up as specified in clause 4.1.2.
7.0
7.1
In general the CFAP, DGFAPs, Zonal fire alarm panels, mimic panels and
repeat alarm panels shall be located in control room environment which is
non-hazardous. However, if specified in the enquiry document/data
sheets, the enclosure for the detectors, panels and other equipment shall
have flameproof construction, conforming to IS-2148 and shall be suitable
for installation in hazardous areas classified as Zone-1 and/or Zone-2,
with gas group IIB or as specified in the material requisition/data sheet.
All equipment for hazardous area installation shall be complete with cable
glands as specified in clause 5.4.4.2.
7.2
7.3
For analogue addressable fire alarm systems, manual call points, address
interface units, automatic detectors etc. which are to be installed in
hazardous area shall preferably have flame proof construction to permit
the use of class-A, style-6 fault tolerant wiring as per NFPA-72, without
employing T-tapping. As an alternative,intrinsically safe address interface
units, automatic detectors etc. may be permitted provided they are wired
beyond zener barriers, located in non-hazardous area. Fire Alarm Circuit
beyond zener barrier shall be intrinsixcally safe type confirming to IS5780.
7.4
7.5
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
8.0
8.1
In the case of conventional fire alarm system, clean agent / CO2 dumping
area shall be divided at least into two zones for fire detection purposes.
The detectors shall be installed in cross zoning manner. Signals for clean
agent / CO2 release shall be sent only when at least two zones have
detected the fire. The blinking lights shall operate in the affected area.
Two type of detectors in cross zones shall be provided in each dumping
area.
On detection of fire (Min. two detectors), a signal from zonal Fire Alarm
Panel shall be generated which shall open the valves for dumping clean
agent / CO2 .
8.2
8.3
Clean agent / CO2 can be released or inhibited by the Clean Agent/ CO2
release and inhibit switch located outside the protected area or from the
fire alarm panel. The contact for clean agent / CO2 release alarm shall be
taken from the pressure switch provided in the clean agent / CO2
manifold. Provision in F.A. panel shall be kept to wire pressure switch
contacts.
9.0
ENGINEERING REQUIREMENTS
9.1
The vendor shall perform basic and detailed engineering activities, unless
specified otherwise in the material requisition/data sheets.
9.1.1
9.1.1.1
For conventional fire alarm systems basic engineering shall include the
development of block-diagram furnished by MECON/Owner.
TS FDA - 26
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
9.1.1.2
9.1.2
9.1.2.1
9.1.2.2
10.0
10.1
10.2
All routine tests as specified by the applicable codes and standards shall
be carried out at the manufacturers work under his care and expense.
10.3
TS FDA - 27
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR FIRE DETECTION AND
ALARM SYSTEM
MECON LIMITED
MEC/TS/05/21/081H
10.4
10.5
11.0
11.1
All the equipment shall be divided into several sections for protection and
ease of handling during transportation. The equipment shall be properly
packed for transportation by ship/rail or trailer. The panel shall be
wrapped in polythene sheets before being placed in crates to prevent
damage to finish. Crates shall have skid bottom for handling. Special
notations such as Fragile, This side up, Centre of gravity, Weight etc.
shall be clearly marked on the package together with Tag nos. P.O. Nos.
etc.
11.2
The equipment may be stored outdoors for long periods before erection.
The packing shall be completely suitable for outdoor storage in areas with
heavy rains/high ambient temperature.
TS FDA - 28
STANDARD
SPECIFICATION
FOR
MEDIUM VELOCITY WATER SPRAY SYSTEM
Page 1 of 5
MECON LIMITED
Delhi
TECHNICAL
SPECIFICATION MEDIUM
VELOCITY WATER SPRAY
SYSTEM
MECON LIMITED
MEC/TS/05/21/081K
1.0
1.1
GENERAL
This specification lays down the broad technical specification for the medium velocity
water spray system to be provided for various areas as specified in SOR, specifications.
For fluids flashing at below 65o C (150o F), extinguishments is always not possible or
even desirable and for these, Medium Velocity Water Sprayers need to be installed to
provide cooling, controlling the burning and/or exposure protection to protect
processing blocks, processing equipments, structures, flammable liquid and gas
vessel, piping and equipment LPG bottling plants, spot protection etc..
1.2
SCOPE
This specification covers design, supply, fabrication, erection, testing and
commissioning complete with all mechanical and electrical items as elaborated in the
following paragraphs. The system shall consist of the following as mechanical part of
the system.
2.0
Fittings and valves viz. sluice valve, non-return valve, float valve, drain valve
etc.
SPRAY NOZZLE
Page 2 of 5
MECON LIMITED
Delhi
TECHNICAL
SPECIFICATION MEDIUM
VELOCITY WATER SPRAY
SYSTEM
MECON LIMITED
MEC/TS/05/21/081K
It is normally open water discharging device called Sprayers which, when supplied
with water under pressure will distribute the water in a special, directional pattern
peculiar to the particular device. These nozzles are made in a range of orifice sizes
with varying discharge angles so that discharge can be controlled for optimum
protection.
b)
DELUGE VALVE
Deluge valve is quick opening valve, which admits water automatically to a system of
projectors or sprayers and is operated by a system of detectors and/or sprinklers
installed in the same areas as nozzles.
c)
DETECTION SYSTEM
In case of water spray systems, detection systems are required for activating the
Deluge system for spot protection (outdoors and indoors).
For the above protections, sprinklers are found in extensive application in view of
their reliability. However the contractor can recommend / suggest other types of
detection systems. The design of detection system by sprinklers varies from risk to
risk in case of water spray systems and shall be governed in accordance with TAC
guidelines for rules of water spray systems.
The system shall comprise water supply at high pressure, adequate number of spray
nozzles and quartzoid bulb detectors to be located at strategic points, deluge valve,
piping, audio-visual alarm system, control panel etc. Water shall be tapped from
nearby sprinkler line. Water from static water tank shall be pumped to the system by
means of the main pump to obtain the required minimum pressure at the remotest
nozzle. Provision for 100% standby pump set to meet the emergency requirement
shall be made. The delivery side of the pump shall be connected through a set of back
pressure valves and stop valves to the Emulsifier System. These pumps shall have
automatic starting facility, which will start the pumps whenever the delivery pressure
drops below a preset valve.
High velocity water spray nozzles shall be installed all around the transformers. The
number, spacing and discharge angles shall be so decided as to give effective
coverage.
The quartzoid bulb heat detectors shall be placed on all sides of the transformer. The
detectors shall be planned to be mounted on independent pipe line of compressed air.
The heat sensing quartzoid bulb detectors shall shatter at 79 deg. C in case of a fire,
creating a drop in the air pressure in the detector pipe line.
Page 3 of 5
MECON LIMITED
Delhi
TECHNICAL
SPECIFICATION MEDIUM
VELOCITY WATER SPRAY
SYSTEM
MECON LIMITED
MEC/TS/05/21/081K
Under normal condition the system shall be kept in automatic mode. Due to leakage of
water in the system, the water level in the tank shall fall resulting in pressure drop in
the system. This shall actuate the pressure switch to start the pump. The jockey pump
shall be automatically started by the actuation of level switch. When the water level
rises beyond a preset level, the jockey pump shall be stopped automatically by the
actuation of the level switch.
In case of fire, the temperature will rise and the gas inside the quartzoid bulb detector
will expand to shatter the bulb. Water will then be released through the detector
openings reducing the pressure rapidly. This will cause the deluge valve clack to get
lifted by the hydraulic thrust on the downside of the deluge valve, which in turn shall
allow water to get sprayed through the nozzles. This will result in rapid fall in pressure
in the water line, which will actuate the pressure switch to start the main electrically
driven pump. In case of power failure the pressure shall drop further to actuate the
pressure switch for starting the standby pump.
3.0
3.1
3.2
3.3
SPRAY NOZZLES
High velocity water spray nozzles shall be installed all around the transformer in such a
manner that the entire surface of the transformers is encompassed for uniform spray
of water. For this a piping cage shall be erected around the transformer. The number,
spacing and discharge angles of the nozzles shall be so decided as to give effective
coverage with an optimum discharge of water (11 l/sq.m/minute) to minimise the
extent of damage to the equipment.
Page 4 of 5
MECON LIMITED
Delhi
TECHNICAL
SPECIFICATION MEDIUM
VELOCITY WATER SPRAY
SYSTEM
MECON LIMITED
MEC/TS/05/21/081K
3.4
VALVES
All the valves shall be provided with matching flanges, bolts, nuts, gaskets, washers
etc. Gate valves shall conform to the relevant class of IS: 780/ IS: 2906 while nonreturn valves shall be as per IS: 5312. All the valves shall be provided with proper
support.
3.5
Page 5 of 5
MECON LIMITED
Delhi
STANDARD SPECIFICATION
FOR
DELUGE VALVE
MECON LIMITED
MECON LIMITED
Delhi
CONTENTS
1.0
SCOPE
2.0
3.0
DESIGN REQUIREMENT
4.0
MATERIAL OF CONSTRUCTION
5.0
6.0
7.0
TS-DV- 1
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
SCOPE
This standard lays down requirements regarding construction, material, shape, and
method of operation, performance and test of automatic deluge valve for fire water
distribution.
2.0
3.0
DESIGN REQUIREMENT
3.1
3.2
Rated Flow
M3/hr
Working Pressure
Kg/cm2 g.
2(50)
3 (75)
4(100)
6(150)
8(200)
10 to 30
30 to 50
51 to 80
81 to 150
151 to 300
7.0
7.0
7.0
7.0
7.0
to
to
to
to
to
10.5
10.5
10.5
10.5
10.5
3.3
The deluge valve shall be provided with solenoid operated air release valve for
remote operation. If deluge valve in located in hazardous area, alarm switch shall be
intrinsically safe and flameproof.
4.0
MATERIAL OF CONSTRUCTION
4.1
For non saline water service, the material of construction shall be as follows:
TS-DV- 2
MECON LIMITED
Delhi
Body
:
Seat
:
Clapper
:
Clack
:
Diaphragm spindle & hinged pin
:
Test and drain valve
:
Installation stop valve & outlet valve :
Check Valve
:
Diaphragm & Seat Rubber
:
MECON LIMITED
4.2
For saline water service, aluminium bronze material shall be used in place of cast
iron.
5.0
5.1
The deluge valve unit shall be provided with a clack to keep the valve close through
a diaphragm unit.
5.2
The deluge valve shall also be fitted with an integral test and drain manifold. It shall
consist of 50mm test and drain valve, air body drain valve and a drip valve.
5.3
The test valve shall allow water to flow through the deluge valve to drain during
testing of deluge valve and to drain water from distribution pipe after fire. At open
position the valve clack shall be held against its seating by an internal compression
spring of sufficient strength to keep it in closed position till the pressure acting on
underside of it does not exceed approx. 0.3 Kg/cm2. The clack will open at pressure
exceeding 0.3 Kg/cm2.
5.4
The drain valve shall drain all the water from the deluge valve body and the outlet
connections during maintenance of the deluge valve. The drain pipe work is to be
designed to periodically check the rate of flow available in the system to satisfy the
requirements appropriate to the hazard class for which the deluge valve is provided.
Flow measurement shall be checked with differential pressure.
Water operated alarm motor gang shall be connected to the test and drain valve so
that it gives an alarm as the deluge valve opens.
5.5
On detector pipe work manifold, test valve shall be provided at one end while on air
supply pipe one air pressure regulator, check valve and gate valve shall be provided.
Both detector pipe work and air supply line shall be terminated with flanged ends.
Piping shall be GI to IS 1239 medium grade. Instrument air shall be supplied at a
specified pressure by the owner. Vendor shall supply suitable air pressure regulator.
In addition to above an electric pressure switch shall be provided to give alarm at
Low air pressure and fire condition. Low air pressure alarm shall be set at
1.7Kg/cm2 while for fire it shall be set at 0.7Kg/cm2. When fire occurs and deluge
TS-DV- 3
MECON LIMITED
Delhi
MECON LIMITED
Installation stop valve and outlet valve above deluge valve shall be as per IS:780
class PN 1.6. In addition following provision shall be made:
Both the valve must be strapped (not chained) and padlocked in open position at all
normal times. End flanges of both the valves shall be flat face, dimensions
confirming to ANSI B 16.5 150 lb rating.
5.7
The deluge valve shall be tested for operation / opening at set pressure and
operation of the alarms at set pressures.
5.8
For testing and setting of deluge valve, a priming valve and a vent shall be provided
with deluge valve assembly. At all normal times and when testing the deluge valve
according to various tests required, the body of the deluge valve shall remain full of
water.
5.9
Pressure guage shall be fitted immediately above the deluge valve on water supply
line. Another pressure guage shall be provided on detector pipe work manifold.
Pressure gauge shall be bourdon type and shall be weather proof to NEMA-4. Vendor
shall specify the range of the pressure gauge and also submit detailed specification /
data sheet of the instrument.
5.10
The complete valve assembly shall be of good workmanship and furnish and shall be
free from burrs and sharp edges. All waterways shall have smooth finish.
5.11
6.0
6.1
Owner / MECON shall have access at all reasonable times to the manufacturers
works where the deluge valve assembly are being manufactured or being tested.
TS-DV- 4
MECON LIMITED
Delhi
MECON LIMITED
6.2
Deluge valve assembly shall be clearly permanently marked with the purchasers
name, design and test pressure.
7.0
7.1
The vendor shall furnish the following information alongwith the offer and for
approval, prior to fabricationa)
b)
c)
d)
e)
f)
7.2
Following information shall be furnished by the vendor along with the supply of the
deluge valve :
7.2.1
Instruction books for the guidance of the user including both the operating and
normal maintenance procedures. The books shall include an itemised and illustrated
part list / spare parts list giving reference no. of all the wearing parts.
7.2.2
TS-DV- 5
MECON LIMITED
Delhi
STANDARD
SPECIFICATION
FOR
LANDING VALVE
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
SCOPE :
The specification covers the general requirement regarding the material, design and
construction, performance, test and type of landing valve.
The single / double outlet landing valve mainly consists of landing valve with complete
set.
2.0
MATERIAL:
SL. NO.
ITEM / COMPONENT
MATERIAL OF CONSTRUCTION
1.
Valve body
2.
3.
Valve spindle
4.
Handle wheel
5.
6.
Gland packing
7.
Spring
8.
Tooth
9.
Blank cap
ABS plastic
The materials shall be as per IS: 5290. The various alternatives available in the BIS
for landing valve body are aluminium alloy, LeadTin-Bronze and stainless steel.
TS-LV- 1
MECON LIMITED
Delhi
MECON LIMITED
However, materials selection shall be as per data sheet (if available) / Companys
approval.
Flanges for hydrant valve shall have dimensions conforming to ANSI B 16.5 150 lbs
rating flat slip-on type or MS plate flange as per IS 6392 table 17.
3.0
Water mains coming to post shall be of 150 & 100mm M.S construction and
provided with Double outlet landing valve.
2.
3.
Only oblique hydrants with outlet angled towards floor shall be used. The
hydrant couplings shall be of the instantaneous spring lock (female) type of
60mm dia and valves shall be of the slow down type.
4.0
Performance Requirements
4.1
4.2
4.3
Flow Test
Test shall be discharged through the valve assembly and its flow shall be measured
using flow meter or V-notch. The flow shall not be less than 900 LPM for Type A and
1800 LPM for Type B at 7MN/m2 (7kgs/cm2) provided feed to the valves is not less
than these figures.
5.0
5.1
All parts shall be of good finish, clear of burrs and sharp edges. All castings shall clean
TS-LV- 2
MECON LIMITED
Delhi
MECON LIMITED
and sound and shall be free from plugging, welding or repair of any defects.
The valve top except the face of the flange and the instantaneous outlet shall be
painted fire red of shade no. 536 of IS: 5. The outside of instantaneous outlet shall
be highly polished. The hand wheel shall be painted black. Paints shall conform to
IS: 2932: 1974.
6.0
6.1
All steel components subject to direct water contact shall be hot dipped galvanised to
minimum thickness of 0.12mm. The thickness of coating shall be measured as per IS
3203. External surfaces and non-ferrous components may be wetted with lead tin alloy
by electrical deposition process.
6.2
The stand post and its arms, valve top except the face of the flange and the
instantaneous outlet from outside shall be painted with three coats of anti corrosive
fire red paint of shade No. 536 of Is 5. The outside of instantaneous outlet shall be
highly polished. The hand wheel shall be painted black. Paints shall confirm to Is 2932.
Internal surface shall be painted with three coats of chlorinated rubber based rasin
paint or zinc chromate paint.
7.0
Marking
1.
Each assembled valve shall be clearly and permanently marked on the valve
body as follows:
a)
b)
c)
d)
8.0
Inspection
There shall be provision for inspection by third party inspection agency at contractors
cost. The agency shall have access at all reasonable times to the manufacturers
works, where hydrants are being manufactured and / or tested. However specifically
prior call for inspection shall be communicated for performance test of hydrants.
TS-LV- 3
MECON LIMITED
Delhi
STANDARD SPECIFICATION
FOR
WATER CUM FOAM MONITOR
MECON LIMITED
MECON LIMITED
Delhi
1.
SCOPE
2.
MATERIAL
3.
4.
HYDRAULIC PERFORMANCE
5.
6.
7.
TEST
8.
MARKING
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
SCOPE
This specification covers the general requirements regarding the material, design and
construction, performance and test for stand post type
water cum foam monitor.
2.0
3.0
MATERIAL
2.1
Monitor body, swivel joints, worm wheel, base flange and change over valve
assembly shall be made of copper alloy confirming to IS:8442 Cl. 3.3.1. Body
shall be of C.S. pipe heavy grade to IS: 1239 and base flange shall be of M.S.
to IS 226 or IS 6392.
2.2
Foam and water barrel shall be extruded aluminium pipe to IS:1285. Water
barrel can be from M.S. seamless pipe to IS:1239 heavy grade.
2.3
Water nozzle shall be made from aluminium alloy to IS:617 designation 4450
when water barrel is made from extruded aluminium pipe. It shall be made
from copper alloy as specified in IS: 8442 Cl. 3.3.1 when water barrel is of
MS pipe to IS: 1239 H. gr.
2.4
Pick up tube shall be made from rubber hose with chrome plated brass
strainer.
2.5
Worm gear for traverse mechanism shall be made from phosphorus bronze or
copper alloy as per Cl. 3.3.1 of IS: 8442.
2.6
Nuts and bolts for base flange and change over valve shall confirm to
IS:1367 Cl.10.9 and 12 respectively while gasket shall be of CAF 40 to
IS:2712.
2.7
Drain valve shall confirm to IS: 778 class 2. Locks on swivels shall be made of
brass to IS:291.
3.2
3.3
The monitor shall be provided with a change over valve along with its
assembly for instantaneous switch over of discharge from water to foam or
vice versa as desired. The valve shall be lever operated type.
TS-WM-1
MECON LIMITED
Delhi
4.0
5.0
3.4
A foam inductor shall be provided behind the air intake chamber of foam
maker in foam monitor. A flexible rubber pick up tube of 3m length having
strainer at the inlet shall be provided. A foam compound control valve
capable of metering and inducing 3% to 6% of foam compound shall also be
provided.
3.5
The monitor shall be mounted on a 100mm (4) N.B. flat face slip on type
flange confirming to ANSI B 16.5 150lbs rating. Bolts and nuts for base flange
shall have dimension confirming to ANSI B 16.5 Gasket shall be full face 3mm
thick with drilling dimension same as for flange.
3.6
Near the base flange a drain connection shall be provided with a 15mm
(1/2) NB drain valve at the end of pipe. The drain pipe shall be long enough
to drain water away from the base flange.
3.7
3.8
The inner surface of the nozzle shall be finished smooth and polished for the
converging length of the nozzle.
HYDRAULIC PERFORMANCE
4.1
4.2
The horizontal ranges for water and foam jet shall be 60m and 45m
respectively while the vertical throw shall be 30m and 20 to 25m respectively.
6.0
MECON LIMITED
All the parts shall have good workmanship and finish. All burrs and sharp
edges shall be removed particularly water way foam way and nozzle shall
have smooth finish.
All steel components subject to direct water or foam contact shall be hot
dipped galvanized to a minimum thickness of 0.12mm. The thickness of
coating shall be measured as per IS:3203. External surfaces and non ferrous
components may wetted with lead tin alloy by electrical deposition process.
6.2
Monitors steel part shall be painted with fire red colour confirming to IS: 5
shade no. 536 and the paint shall confirm to IS:2932 and copper alloy part
shall be polished.
TS-WM-2
MECON LIMITED
Delhi
7.0
8.0
MECON LIMITED
TEST
7.1
7.2
MARKING
8.1
Each monitor shall be clearly and permanently marked with the following:
a)
b)
c)
TS-WM-3
MECON LIMITED
Delhi
STANDARD SPECIFICATION
FOR
HOSE CABINET
MECON LIMITED
MECON LIMITED
Delhi
CONTENTS
1.0
SCOPE
2.0
DESCRIPTIONS
3.0
MATERIAL OF CONSTRUCTION
4.0
TS-PE-CO2-6.8- 1
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
SCOPE
This standard lays down overall requirements regarding construction, material,
design, shape and fixing arrangements of fire hose cabinet to be installed near fire
hydrants and to be used for keeping fire fighting accessories.
2.0
DESCRIPTION OF CABINET
2.1
Depending upon place of installation to suit the requirement, hose cabinets shall be
of two sizes and types for accommodating delivery hose, jet nozzle with branch pipe,
or universal branch pipe, fireman axe (if required). The two types of hose cabinets
have been defined as Type-A and Type-B.
2.2
Type-A hose cabinets are suitable for wall mounting installations. They shall be able
to accommodate, one 63mm delivery hose having length 15m with end male /
female coupling, one jet nozzle with branch pipe or alternately one universal branch
pipe.
2.3
Type-A cabinet shall have single panel glass door. Necessary hangers and brackets
for proper keeping / positioning of delivery hose, nozzles and branch pipe or
universal branch pipe inside shall be provided with the cabinet.
2.4
Type-B hose cabinet shall be of self-supporting type and shall be suitable for
outside installation. They shall be capable to accommodate two 63mm delivery
hoses of 15m length with end couplings, two jet nozzles with branch pipe or two
universal branch pipes.
2.5
Type-B hose cabinet shall have double panel glass door. Necessary hangers and
brackets for proper keeping / positioning of delivery hose, nozzles and branch pipe
or universal branch pipe inside shall be provided with the cabinet.
2.6
Both types of hose cabinets shall be provided with handle type lock, a small recess
to keep cabinet key under glass cover, a small hammer secured to the cabinet with a
chain to break open the key glass cover.
3.0
MATERIAL OF CONSTRUCTION
3.1
The hose cabinet shall be made of 16 gauge M.S. sheet suitably welded with single /
double MS door frame glass covered, depending upon the type of hose cabinet.
Glass shall be fitted to the door with gasket and rubber bidding so that it fits
securely.
3.2
Door of the hose cabinet shall be provided with standard handle type lock Godrej,
Mortise or equivalent with prior approval of owner / MECON.
3.3
Hammer shall be made of M.S. whereas Chain for securing purpose of hammer shall
be made of G.I.
3.4
Angle iron or M.S. round pipe of suitable size as per instruction of owner / MECON
shall be provided for supporting Type-B cabinet.
TS-PE-CO2-6.8- 2
MECON LIMITED
Delhi
MECON LIMITED
3.5
Universal branch pipe shall confirm to IS: 2171. End coupling jet nozzle and branch
pipe shall confirm to IS:903.
4.0
4.1
Each hose cabinet shall be painted with 3 coats of anti-corrosive paint of fire red
colour from outside and white paint from inside. Each cabinet shall be clearly and
permanently marked as following:
i.
ii.
iii.
iv.
TS-PE-CO2-6.8- 3
MECON LIMITED
Delhi
MECON LIMITED
SPECIFICATION
FOR
NON-PERCOLATING FLEXIBLE
FIRE-FIGHTING DELIVERY HOSE
WITH COUPLING
MECON LIMITED
Delhi
1.0
MECON LIMITED
Scope :
This specification covers the general requirement regarding the material, design and
construction, performance and test for non-percolating flexible fire fighting delivery
hose with gunmetal male & female type instantaneous coupling.
2.0
Material:
2.1
The material for Delivery hose shall be rubberised fabric lined as per IS: 636 TYPE A.
2.2
The material for Male and Female instantaneous type coupling shall be of Gunmetal as
per IS: 903.
3.0
3.1.
The hose shall be constructed from a circular woven jacket having a waterproof
rubberised fabric lining on the inside, facing the waterway.The jacket shall be seamless
and compactly woven from good quality cotton yarn or from yarn made from suitable
synthetic fibre of polyamide or polyester type of good quality or from their
combinations.
3.2.
Fire hose with outer coating/covering shall be manufactured using synthetic yarn only.
3.3.
3.4.
If cotton yarn is used in the construction of jacket, this shall be rootproofed as per IS:
636 and method as per IS: 11662.
3.5.
The average mass of hose per metre length shall not exceed 0.425kg.
3.6.
The delivery hose couplings shall be of 63mm and consist of male half and female
half coupling assembled with washer as per IS: 903.
4.0
Performance Requirements
4.1
The delivery hose pipe shall be tested for kink, hydrostatic burst pressure, change in
length and diameter, adhesion, abrasion resistance, moisture absorption and heat
resistance as per methods and parameters mentioned in IS: 636.
4.2
5.0
5.1
The jacket shall be practically free from dirt, knots, lumps, irregularities of the yarn and
TS-HOSE-1
MECON LIMITED
Delhi
MECON LIMITED
Inner lining shall be of rubberised fabric and shall be generally smooth and practically
free from pitting and other imperfections.
5.3
All fittings shall be of good workmanship, finish, clear of burrs and sharp edges. All
forgings and castings shall be clean and sound and shall be free from porosity,
blowholes, scales, cracks and other imperfections and shall not be repaired or filled so
as to hide casting defects.The water way of the fillings shall have a smooth finish.
6.0
6.1
Packing
The hoses may be dusted with French Chalk as per IS: 380 on the inside and shall be
packed and delivered in a length of 15M in neat, clean and dry condition in
Polyethylene bags.
6.2
Marking
A)
Fire Hose
Beginning at a point not less than one metre from each end, each length of
hose shall be marked with clear and indelible letters at least 20mm in height
indicating :
a)
b)
c)
d)
B)
Delivery Couplings
The male and female instantaneous couplings shall be separately, clearly and
permanently marked with following information:
a)
b)
c)
d)
TS-HOSE-2
MECON LIMITED
Delhi
STANDARD
SPECIFICATION
FOR
PORTABLE EXTINGUISHERS
MECON LIMITED
MECON LIMITED
Delhi
MECON LIMITED
SCOPE
This standard lays down requirements regarding construction, material, shape,
anticorrosive treatment and test for ordinary dry powder type fire extinguisher.
2.0
ANTICORROSIVE
PRINCIPLE
The method of expulsion of dry powder shall be as per IS: 2171 (latest
edition) with either of the method of operation specified therein. Vendor shall
indicate clearly the method adopted for operation.
4.0
CAPACITY
Nominal capacity of the extinguisher and the dry powder contents of the
assembled body or dry powder container shall be as follows when charged
with dry powder conforming to IS: 4308 (latest edition.)
TS PEDCP - 1
MECON LIMITED
Delhi
MEC/TS/05/21/081D/A
NOM. CAPACITY OF
EXTINGUISHER ( KG)
1
2
5
10
1
2
5
10
Only dry powder confirming to IS: 4308 (latest edition) shall be used for
charging the extinguisher.
5.0
ACCESSORIES
Each extinguisher shall be supplied with a suitable wall bracket or holder into
which it may be mounted and from which it may be removed for use in an
emergency and screws and spanner as may be necessary. Extinguishers shall
be supplied with all accessories, initial charge etc.
6.0
MARKING
Each extinguisher shall be clearly and permanently marked with the information
specified in IS: 2171 along with BIS certification mark and purchasers name.
Each extinguisher shall be painted fire red and clearly marked with following:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
7.0
INSPECTION
Third party inspection agency at Contractors cost shall have access at all
reasonable times to the Manufacturers work where extinguishers are being
manufactured and / or tested. Samples from lots under a quality control
system shall be done as per Appendix B of IS: 2171. The cylinder shall be
hydraulically tested for 30kg/cm2 of pressure.
TS PEDCP - 2
MECON LIMITED
Delhi
MECON LIMITED
STANDARD SPECIFICATION
FOR
PORTABLE FIRE
EXTINGUISHERS
CARBON DI OXIDE TYPE (6.8KG)
MECON LIMITED
Delhi
MECON LIMITED
SCOPE
This standard lays down requirements regarding construction, material, shape, and
method of operation, performance and test of portable fire extinguisher of carbon
dioxide type.
2.0
MATERIAL,
SHAPE,
CONSTRUCTION,
PERFORMANCE, CONTENTS AND TESTS
2.1
The construction, material, shapes, method of operation, performance, and test shall
comply with IS: 2878 (latest edition) with ISI mark and approved by C.C.E. Nagpur.
2.2
Nominal size.
2.2.1
The extinguisher shall be following nominal sizes in kg: 1,2,3,4,5 and 6. The sizes
being denoted as per clause 4.11 of IS: 2878.
2.4
Carbon Di-oxide gas used shall conform to IS: 307 and extinguisher shall be filled as
per IS 2878 CI. 6.0.
2.5
The cylinder shall be made of cold drawn seamless steel cylinders as per IS: 7285
and fitted with screw down type high pressure control valve as per IS: 3224 with a
provision of safety release. Riveted joints will not be acceptable.
2.6
The extinguishers shall be fitted with discharge tube with swivel joint of atleast 1m
length with elect. non-conductor discharge horn.
3.0
APPROVALS
3.0
4.0
MARKING
4.1
Each extinguisher shall be clearly and permanently marked as per IS: 2878 along
with BIS certification mark and following:
i.
ii.
iii.
iv.
v.
vi.
vii.
METHOD
OF
OPERATION,
TS-PE-CO2-6.8- 1
MECON LIMITED
Delhi
5.0
MECON LIMITED
ACCESSORIES
Each extinguisher shall be supplied with M.S. bracket and spanner as may be
necessary. The details of the same shall be submitted. The extinguisher shall be
complete with wall mounting brackets and screws.
5.0
INSPECTION
6.1
Third party inspection agency at Contractors cost shall have access at all reasonable
times to the manufacturers work where extinguishers are being manufactured and /
or tested.
TS-PE-CO2-6.8- 2
MECON LIMITED
Delhi
STANDARD SPECIFICATION
FOR
FIRE BUCKETS
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
Scope
The specification covers the general requirement regarding the material,
shape, design, dimensions, manufacture, finish and tests of galvanised mild
steel fire bucket.
2.0
Material
2.1
2.2
Rod used for top & bottom handles shall be of mild steel confirming to IS:
226.
2.3
Wires used for stiffening of top rim shall be of mild steel, confirming to IS:
280.
2.4
Inside
b)
Outside
c)
3.0
3.1
The shape and dimensions of the fire bucket shall be as per IS: 2546.
3.2
The body of fire bucket shall be in two halves and to be joined together by
butt welding. Top rim of the body shall be wired and uniformly beaded
without gaps. Thickness of body shall be 1.0 mm & dia of beading wire 3.55
mm.
3.3
Bottom sheet of fire bucket shall be 1.0 mm thick and dished. It shall be
joined to the body by butt welding to avoid raw edge on the inside of the
bucket.
TS BKT - 1
MECON LIMITED
Delhi
MECON LIMITED
3.4
Thickness of mild steel sheet for ears shall be 2.8 mm and shall be fitted to
the body at the top by welding with the flat head on the side.
3.5
Top & bottom handle shall be of mild steel rod of 10.0 mm dia. The grip
shall have no sharp edges.
4.0
Performance Test
4.1
The bucket shall be fully filled with water and kept for 15 minutes, there
shall not be any leakage for the period.
4.2
The dry empty bucket with its top facing upward shall be pressed down the
water in a water tank of suitable size vertically. In such a way that top of
the bucket shall be minimum 6.0 mm above the water level. Water shall not
enter inside the bucket.
4.3
After taking out the bucket, the bucket shall be reversed and pressed inside
the water tank vertically. There shall not be any air bubble seen escaping
through the water.
5.0
5.1
5.2
All gas welds shall clean and sound and shall be free from porosity, blowholes, scales and brittleness.
5.3
6.0
Marking
Each fire bucket shall be clearly and permanently marked with the following
information:
a)
b)
c)
TS BKT - 2
MECON LIMITED
Delhi
STANDARD
SPECIFICATION
FOR
FIREMAN'S AXE
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
Scope
The specification covers the general requirement regarding the material, shape,
dimensions and construction of fireman's axe.
2.0
Material
2.1
Axe head shall be of steel made by forging. The chemical composition and
requirements of steel shall be as per IS: 926.
2.2
2.3
The axe handle shall be insulated. The insulated handle shall be of vulcanised
rubber.
3.0
2.
The axe head shall be soundly forged to shape and the steel handle
shall be welded to the head.
3.
The pick and the blade shall be well and evenly hardened and tempered.
4.
4.0
Performance Test
4.1
The cutting edge of the axe shall not show any sign of damage when tested for
single heavy blow as per the procedure mentioned in IS:926.
4.2
The cutting edge of the axe shall receive no damage when tested for load and
buckling as per IS:926.
4.3
5.0
5.1
5.2
All forgings shall clean and sound and shall be free from porosity, blow-holes,
scales and cracks.
TS AXE - 1
MECON LIMITED
Delhi
6.0
MECON LIMITED
Marking
1.
Each axe shall be clearly and permanently marked with the following
information:
a)
b)
c)
d)
TS AXE - 2
MECON LIMITED
Delhi
MECON LIMITED
STANDARD
SPECIFICATION
FOR
GAS FLOODING SYSTEM
Page 1 of 11
MECON LIMITED
Delhi
1.0
1.1
GENERAL
MECON LIMITED
Fire in strategically important places like computer rooms, control rooms, switch gear
rooms, data storage rooms, server rooms, museum, data storage archives, libraries,
laboratories etc. is a serious hazard to highly precious and irretrievable items and
properties. Occurrence of fire besides leading to personnel injuries and property
damage also leads to loss of productivity and precious time. The primary cause of fire
may be due to short circuit / overheating of certain components somewhere in the
areas. Since most of the areas are unmanned and completely closed, fire inside is not
visible and accessible from outside till it becomes too big, dangerous and
unmanageable.
Fire suppression with conventional water-based systems such as hydrant or sprinkler
system can damage the assets permanently. Therefore for these costly & critical areas,
the Fire Protection System envisaged calls for early detection of fire and quenching the
same by flooding the area with gas based fire suppression system besides giving out
an audio visual alarm. The system considers and addresses possible Fire Hazards
within the protected volume at the incipient stage and provide for highest degree of
protection and minimum extinguishing time..
1.2
SCOPE
1.2.1
This specification for clean agent (environment friendly) based fire suppression system
covers design, supply, fabrication, erection, testing and commissioning complete with
all mechanical and electrical items as elaborated in the specification. The system shall
consist of the following as mechanical / electrical / instrumentation / hardware /
software part of the system.
Gas agent
Discharge Nozzle(s)
Check valves
Mounting brackets
Page 2 of 11
MECON LIMITED
Delhi
MECON LIMITED
Discharge hoses
Electrical Cables from alarm initiating devices to the panels with required
conduits as per the direction of purchaser / consultant.
Detectors
1.2.2
The system shall have an interfacing with Main Fire Alarm & Control Panel of the plant.
In case of fire in the concerned panel, indication & alarm should come in Main Fire
Alarm & Control Panel.
2.0
REQUIREMENTS
REQUIREMENTS
2.1
The bidder shall be either Original Equipment Manufacturer (OEM) or any one of the
approved International / National Distributor authorised and certified by the parent
company for manufacture and / or marketing of their Fire Protection Systems.
2.2
The distributor shall have an established relationship with the OEM and they should
hold the distributorship prior to submission of bid.
2.3
The bidder should have received technical training on design, installation and
commissioning of the systems from the principal and training certificate to this account
from the principals should be submitted.
2.4
The OEM / Bidder shall give a certificate stating that their system as a whole along
with equipments, components, flow calculation software etc. is approved by UL / FM /
ULC / LPCB.
2.5
The gas being used for the system shall have a Chief Controller of Explosives, Nagpur
Certified filling station in India. The filling station should also be UL approved. The
filling station should have Gas Chromatography facility to test the purity and chemical
properties of the gas, if required.
FROM
BIDDERS
AND
SPECIFIC
TECHNICAL
Page 3 of 11
MECON LIMITED
Delhi
MECON LIMITED
2.6
The system flow calculation shall be carried out on certified software, suitable for the
Seamless Steel Cylinder being offered for the project. Such system flow calculations
shall also be approved by UL / FM / LPCB / ULC. The system flow calculation software
developed The system flow calculation software developed for Welded Cylinder
parameters, and subsequently modified to suit the Seamless Cylinder parameters, shall
not be admissible unless the modifications too, are tested, certified and listed by UL /
FM / LPCB/ULC.
2.7
The system shall UL/FM/LPCB/ULC certified technology that allows for a higher
capacity to overcome frictional losses and allow for higher distances of the agent flow
and also allow for better agent penetration in enclosed electronic equipments such as
Server Racks/ Electrical Panels etc.
2.8
All system components shall be new and of current manufacture. These shall be
installed in accordance with local codes. Systems containing components that have a
dated life span and need periodical replacement shall not be acceptable.
2.9
The bidder shall provide all documentation such as Cylinder Manufacturing Certificates,
Test and Inspection Certificates and Fill Density Certificates.
2.10
The tender drawings and Schedule of Quantities enclosed are for basic guidance of the
bidder. It shall be the responsibility of the individual bidder to ensure the completeness
of the gas flooding system as per area and volume of the protected risk.
2.11
The Contractor shall specifically prepare all the shop drawings. These drawings shall
show the quantity, location, and marking of all system components included. The
drawings shall also describe and indicate the routing of all piping, wiring for detectors
and conduit layouts.
2.12
3.0
3.1
Gas based flooding system (Clean Agent System) mainly consists of pressurized Gas
cylinder filled with clean gas (FM200 / NAF / HFC227/ Inert Gas / Halon replacement
system etc.) and automatic detection (through smoke and heat detectors) and release
of extinguishing media / suppression agent. The suppression system shall provide for
high-speed release of Gas on the concept of total Flooding of the enclosed areas. A
Uniform extinguishing concentration shall be maintained inside the protected area all
over as applicable and approved by the manufacturer/NFPA 2001/UL/LPCB/ULC.
3.2
Design Concentration
v/v%
Design Concentration
Kg/m3
Page 4 of 11
MECON LIMITED
Delhi
per
MECON LIMITED
3.3
The system discharge time shall be 10 seconds or less, in accordance with NFPA
standard 2001. Sub floor and the ceiling void to be included in the protected volume.
Care should be taken to locate all agent storage containers as close to the protected
area as possible to ensure complete liquid discharge of the suppression agent within
10 seconds.
3.4
The Fire Suppression System shall include a detection and control system provision for
both pre-alarm and automatic agent release. The detection and control system that
shall be used to trigger the Fire suppression shall employ cross zoning of Laser and
Multi-criteria smoke detectors. A single detector in one zone activated, shall cause in
alarm signal to be generated. Another detector in the second zone activated, shall
generate a pre-discharge signal and start the pre-discharge condition.
3.5
The discharge nozzles shall be located in the protected volume in compliance to the
limitation with regard to the spacing, floor and ceiling covering etc. The nozzle
locations shall be such that the uniform design concentration will be established in all
parts of the protected volumes. Aluminum / Brass Discharge nozzles shall be used to
disperse the clean gas agent. The nozzles shall be brass / Aluminum with female
threads and available in sizes as advised by the OEM system manufacturer. Each size
shall come in two styles: 180 and 360 dispersion patterns. The nozzles provided shall
be UL listed /LPC/ULC/Vds approved. The final number of the discharge nozzles shall
be according to the OEMs patented and certified software, which shall also be UL / FM
/ LPCB / ULC approved.
3.6
In the event of fire, the signal through detectors reaches Gas Release Panel. The Gas
discharge shall be activated by an output directly from the Gas Release Control Panel,
which will activate the solenoid valve and the gas stored in the cylinder will get
released through the discharge nozzles located in the protected volume. The Gas agent
is stored in the container as a liquid. The drop of pressure in the cylinder followed by
reduction in the weight of the gas cylinder due to discharge of gas will activate an
audio-visual alarm unit which will be interfaced / connected with the main fire control
system.
3.7
The required gas quantity and size of the cylinder is selected based on the volume
(Cu.M.) of the protected area. The gas should be environment friendly and should not
leave any residue, has less refilling cost, local availability and no damage to protected
equipment after fire suppression.
4.0
EQUIPMENT DETAILS
The main features of the system are:-
Page 5 of 11
MECON LIMITED
Delhi
MECON LIMITED
4.1
4.1.1
A self-activating pressure valve and a cyfen tube inside the cylinder shall be fitted to
the cylinder through which the piping shall be connected. The valve shall contain a
pressure regulator, to retain gas pressure in the cylinder.
4.1.2
In the event of detection by Smoke / Heat Detectors, the Control Panel will energise
solenoid valve (electric operated) or pneumatically operated device which releases
the agent through the pneumatic operated pressure valve.
4.1.3
The storage cylinders offered shall be Seamless type (UL listed), meant for exclusive
use in the above gas systems, with FM/UL/LPCB/ULC component approval. Welded
cylinders are not permitted.
4.1.4
The storage cylinders shall be made of Manganese steel DS658 using hot spinning
process and heat-treated at 860`Centigrade for 30 minutes. These cylinders should
have satisfactorily undergone air leakage test, bend test etc.
4.1.5
The cylinders should have concave bottom and neck threading to IS:3224-1979 14TPI
Type-4.
4.1.6
The design drawings etc. including the cylinders shall be approved by CCOE, Nagpur.
4.1.7
The cylinders shall confirm to IS:7285 specifications, inspected and certified by BIS for
permission for filling the gas.
4.1.8
The cylinders shall be individually numbered and subject to hydrostatic stretch test at a
pressure of 250 Kg/Cm2 as required under rules 39 to 42 of the Gas Cylinder Rules
1981.
4.1.9
Gas storage cylinders shall be provided with a safety rupture disc. An increase in
internal pressure due to high temperature shall rupture the safety disc and allow the
content to vent before the rupture pressure of the container is reached. The contents
shall not be vented through the discharge piping and nozzles.
4.1.10 Gas containers shall be equipped with a pressure gauge to display internal pressure.
The gauge shall be an integral part of the container and shall be color-coded for fast
Page 6 of 11
MECON LIMITED
Delhi
MECON LIMITED
MULTI-CRITERIA DETECTOR
4.2.1
The Multi-criteria detector shall have multi sensor, which combines optical, and heat
detection along with microprocessor controls with analogue communications. The
detectors shall have 2 auto learn sensitivity settings, 3 fixed photo thermal settings and
thermal only detection mode, Twin LED for 360deg visibility.
4.2.2
The technical parameters for smoke and heat detector should be as follows:
Supply Voltage
Average Quiescent Current at 24V
Average Quiescent Current at 9V
Alarm Current at 24V
Alarm Current at 9V
Alarm Indication
Normal Operating Temperature
Max wind continuous
:
:
:
:
:
:
:
:
9 to 33V
45A
21A
52A
17A
red LED
-20 to +60C
10 m/s
4.3
4.3.1
The Manual Release Valve is intended for activation of the Gas system manually. The
releasing of Gas Cylinder(s) shall also be possible through direct mechanical
actuation, providing a means of discharge in the event of total electrical malfunction.
It shall consist of a Ball valve actuator mechanism. The valve shall be operated by
pulling out the locking pin and turning the knob to the "ON position to actuate the
system instantaneously.
4.3.2
The manual release device fitted on the Gas Cylinder(s) shall be of a manual lever
type and a faceplate with clear instruction of how to mechanically activate the
system. In all cases, gas cylinders shall be fitted with a manual mechanical operating
facility that requires two-action actuation to prevent accidental actuation.
4.3.3
Manual Gas Discharge stations and Manual Abort Stations, in conformance to the
requirements put forth in NFPA 2001 shall be provided.
4.4
4.4.1
Master Control Unit / Gas Release Panel shall be Micro Controller based intelligent /
Addressable control panel with battery charger and stand-by batteries located in
control room. The PCBs controls, Displays, switches etc. shall be housed in this
prefabricated anodised aluminium structure. It should be capable of monitoring the
status of Solenoid valve and overall Gas flooding system in all the preset different
zones on continuous basis.
4.4.2
The Panel shall have 2 x 40 character LCD display and have a capacity of 198 devices
per loop .The panel should have LED indications for all zones, complete with internal
Page 7 of 11
MECON LIMITED
Delhi
MECON LIMITED
sounder and alarm/fault indications The panel shall be capable of enhanced features
such as inbuilt printer and auto dialer interface, by addition of extra cards/ field
modules on the motherboard.
4.4.3
The system shall operate on 230V-AC and shall have battery backup for atleast 6
hours. GRP shall communicate with all the audio-visual alarm units once in every 70
Msec to understand their status. If there is any fault / fire condition sensed by the
Smoke / Heat detector, the GRP will indicate zone area.
4.4.4
In case there is loss of gas in any Gas cylinder, the system shall give fault indication.
4.4.5
The GRP shall have LED indicators for power on, zone wise indication for fire, zone
wise indication for fault, bigger fire indication, test & isolate condition, Gas cylinder
status, power backup status, charger on, battery low conditions etc.
4.4.6
It should also have switches for lamp / alarm test, buzzer mute, and power on and fire
acknowledgement.
4.4.7
Release of Gas agent shall be accomplished by an electrical output from the Gas
Release Panel to the solenoid valve and shall be in accordance with the requirements
set forth in the current edition of the National Fire Protection Association Standard
2001.
4.5
4.5.1
The Audio-Visual Alarm Unit is located at the respective zones at convenient place near
the panels fitted with Gas flooding system. This unit shall also be micro controller
based and shall be housed in prefabricated anodised aluminium rack.
4.5.2
The unit shall monitor the status of all the Gas cylinders and the piping system
installed inside the rooms to be protected. In case of fire, there shall be loud audiovisual alarm and the sound level shall be 100db.
4.5.3
The unit works on 24 V DC supply provided from the master control unit. It should
have LED indication for power on, fault, Gas cylinder status, power backup status and
also switches for lamp / alarm test, buzzer mute and fire acknowledgement. The AVA
Unit shall respond to the Master Control Unit / Gas Release Panel based on the
commands received.
4.6
4.6.1
The main control unit shall be provided with a power backup so that it is operational in
case of 230V-AC power supply failure. The power backup shall not be less than four
hours. Two nos. of 12 Volts maintenance free Batteries backup of Exide make
connected in series (24V) shall be provided to the system.
Page 8 of 11
MECON LIMITED
Delhi
MECON LIMITED
4.6.2
Built in battery charging facility shall be provided using high quality charging ICs. The
system shall continuously maintain the status of the battery. If the battery level
becomes less than the predefined level of 20volt, the charging circuit will start charging
the battery. At that time, charger on indication shall be displayed on the MCU.
4.6.3
In case the battery voltage becomes less than 18 volt, it should give a battery low
indication and also charger on indication. When battery voltage reaches 27 volt, the
charger circuit shall display the fully charged indication. When the system works on
emergency battery backup, the battery backup working indication should glow.
4.7
4.7.1
Standard fittings of reputed manufacturers should be used for completing the job. All
the Major components of the Gas suppression system shall be supplied by one single
manufacturer under the same brand name to the extent possible.
.
4.8
ELECTRICAL CABLES
4.8.1
Electrical cables as per Indian Standard specification shall be used for inter connection
of the master control unit to audio visual alarm unit, from audio visual alarm unit to
various Gas / Clean agent cylinders. Cables shall be made up of 3 nos. twisted pair
copper wire of 1.5 sq.mm. Cables shall be routed through M.S. conduit pipes, which
shall be painted red.
4.9
4.9.1
The weight monitoring system shall be designed to monitor the weight of the Clean
agent gas filled in the cylinders. It shall have load cell of high quality and precision
with associated electronics and a cylindrical ring for holding the cylinder in place.
4.9.2
The load cell shall operate in the 5` Centigrade to 70` Centigrade range. The temp.
affect on the span should not be more than 0.006% and the effect on tare shall be
0.008%. The safe overload provision is 200% of the rated capacity of 100 Kgs. The
protection class code is IP-68. The system shall use beam type load cell.
4.9.3
In the event of reduction in the weight of the gas in the cylinder (either due to
leakage or release of gas) beyond the preset limit (1.5Kg in the preset condition),
the electronic circuitry provided in the unit shall activate the respective audio visual
alarm unit and annunciates the occurrence of fault or fire.
5.0
TESTING
5.1
The Fire panel and Detectors will be tested as per the testing procedure of
Intelligent Fire Alarm and Detection System.
Page 9 of 11
MECON LIMITED
Delhi
MECON LIMITED
5.2
The alarm will be generated from the fire alarm panel and the gas release panel
should start the timer and the signal to valves.
5.3
The gas release panel will also be tested for its functioning of the manual override
and the manual discharge.
5.4
The valves will be removed from the cylinder and the actuation of valves will be
tested for its performance.
5.5
The bidder has to provide required quantity of colored nitrogen gas for testing the
release of gas in each area.
5.6
The bidder will provide testing with one cylinder of Gas for testing the complete
system & quenching the fire. After testing the bidder will refill and fix the cylinder in
the main system at no additional cost.
5.7
Acceptance for the System installation, inclusive of the piping and requisite cabling
shall be strictly in accordance with the installation acceptance guidelines as put forth in
the NFPA 2001. The bidder shall be required to carry out a simulation test [with the
Electrical Solenoid on the Gas bank (/ Cylinder) disenabled / disengaged so as to
prevent discharge of gas], and prove the functionality of the System.
6.0
7.0
WARRANTY
System shall be warranted for parts and labour for a period of one (1) year from the
date of commissioning of the system. The Contractor shall specify the maintenance to
be performed during the warranty period to maintain warranty conditions.
8.0
8.1
All materials, equipments, piping, valves, fittings etc. dimensional standards, tolerance,
prices of manufacture and testing procedure shall be in accordance with the latest
revision of relevant Indian, British, American standards wherever applicable.
8.2
The material used and equipment supplied shall be new and the best of their kind and
shall comply with the latest revisions of all relevant standards. The tenderer shall
indicate in his tender the relevant standards to which the equipment, piping, fittings,
etc. offered by him shall comply with. The latest revisions of applicable standards
indicated in the technical specification shall be used for the design, manufacture,
inspecting and testing of the items covered in this specification. The following codes
Page 10 of 11
MECON LIMITED
Delhi
MECON LIMITED
DESIGN CRITERIA
FOR GAS BASED FIRE SUPPRESSION SYSTEM
System Design for the Control Room of size: 12.5M x 20M X 3.15 Mtr. hight
S.No.
1.
2.
Description
Overall Room Dimensions including all rooms to
be protected approx. (Mtrs)
Total Volume (M3)
Calculation
12.5M x 20M X 3.15 Mtr.
hight
788
3.
4.
5.
Design Temperature
6-8 or as recommended
by Gas agency
0.441 or as
recommended
21 deg C
6.
To be furnished by bidder
7.
To be furnished by bidder
Page 11 of 11
MECON LIMITED
Delhi
TECHNICAL SPECIFICATION
FOR
FIRST AID HOSE REEL
MECON LIMITED
MECON LIMITED
Delhi
CONTENTS
1.0
SCOPE
2.0
DESCRIPTION
3.0
4.0
SIZE
5.0
OPERATING INSTRUCTIONS
6.0
MARKING
7.0
INSPECTION
TS-LV- 1
MECON LIMITED
MECON LIMITED
Delhi
1.0
MECON LIMITED
SCOPE :
The specification covers the requirements regarding constructional details, Material and
test for first aid hose reel intended for installation in buildings as Emergency fire
fighting component / equipment.
2.0
DESCRIPTION:
The hose reel shall comply to IS: 884 ( latest edition ).
3.0
3.1
The construction, material and test shall be as per IS: 884 ( latest edition ).
3.2
3.3
A suitable guide or hose runner as per IS: 884 Cl. 6.1.7 shall be provided.
3.4
When installing hose reel outside building dust cover as per IS: 884 Cl. 6.2 shall be
provided.
3.5
3.6
4.0
SIZE
It shall carry 20mm bore 40 m long hose.
5.0
OPERATING INSTRUCTIONS
A metal plate showing in clear legible letters, the instructions for operating the first
aid hose reel shall be fixed preferable near the bracket for nozzle.
6.0
MARKING
Each hose reel shall be clearly and permanently marked with the following
information along with Purchasers name.
a. Manufacturers name or trade mark.
b. Year of manufacture
c. Instruction for use
d. The letters Ref. IS: 884 and
e. Length and size of tube carried on hose reel.
TS-LV- 2
MECON LIMITED
Delhi
7.0
MECON LIMITED
INSPECTION
Third party inspection agency at Contractors cost shall have access at all reasonable
times to the manufacturers works where the first aid hose reel or its components
are being manufactured, assembled and / or tested.
TS-LV- 3
MECON LIMITED
Delhi
MECON LIMITED
TECHNICAL SPECIFICATION
FOR
STAND POST TYPE FIRE HYDRANT
FIRST AID HOSE REEL
MECON LIMITED
Delhi
CONTENTS
STAND POST TYPE WITHOUT PUMPER CONNECTION
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
SCOPE
CODES AND STANDARDS
MATERIAL
DESCRIPTION
WORKMANSHIP AND FINISH
TESTING
PAINTING
MARKING
INSPECTION
SCOPE
CODES AND STANDARDS
MATERIAL
DESCRIPTION
WORKMANSHIP AND FINISH
TESTING
PAINTING
MARKING
INSPECTION
TS-SPH- 1 -
MECON LIMITED
MECON LIMITED
Delhi
MECON LIMITED
SCOPE :
This standard lays down the requirements of type, shape, materials, dimensions
and test for vertical stand post type fire hydrant to be installed on fire water main with
an isolation valve.
2.0
3.0
MATERIAL :
3.1
Hydrant vertical post and hydrant arms shall be from pipe conforming to IS: 1239
heavy grade and shall be with welded construction.
3.2
3.3
3.4
3.5
Bolts and nuts for flanges shall comply to IS: 1367 clause 10.9 and 12.0
respectively while gasket 2 mm thick full face shall be made of CAF 40 to IS:
2712.
4.0
DESCRIPTION :
4.1
The hydrant shall be of stand post type. The vertical post shall be of 100 mm diameter
with two horizontal hydrant arms each 80 mm diameter on which independent
hydrant valve shall be fixed. Hydrant valve shall comply to IS: 5290 type B.
4.2
63 mm coupling to hydrant valve shall comply to IS: 903 except that the lug shall be
twist release type.
TS-SPH- 2 -
MECON LIMITED
Delhi
4.3
MECON LIMITED
All flanges for hydrant valve and base shall have drilling dimensions conforming to
ANSI B 16.5 # 150 lbs rating flat face, slip on type.
5.0
5.1
All parts shall be of good workmanship and finish. All parts and sharp edges shall be
removed. The water ways shall have smooth finish.
5.2
Wherever IS has been specified the latest edition of the same shall be followed.
6.0
TESTING :
Hydrant assembly with hydrant valves closed shall be satisfactorily tested and
proved water tight under a hydraulic pressure of 18.0 kg / cm2.
7.0
PAINTING :
7.1
The stand post and its arms shall be painted with three coats of anti corrosive fire red
paint conforming to IS: 2932 from outside while internal surface shall be painted with
three coats of chlorinated rubber based resin paint or zinc chromate paint. The
paint shall conform to shade no. 536 of IS: 5 and IS: 2982.
All steel parts coming in direct contact with water shall be hot dipped galvanized to a
7.2
thickness of not be less than 0.12 mm. The thickness of the coating shall be measured
as per IS: 3203. External surfaces and non-ferrous components may be coated with
lead-tin alloy by electrical deposition process.
8.0
MARKING :
8.1
8.2
The assembly shall also be marked with the required BIS marking.
TS-SPH- 3 -
MECON LIMITED
Delhi
MEC/TS/05/21/081N
9.0
INSPECTION :
Third party inspection agency at Contractors cost shall have access at all
reasonable
times
to
the
manufacturers
TS-SPH- 4 -
work
where
hydrants
are
being
MECON LIMITED
Delhi
MECON LIMITED
SCOPE :
This standard lays down the requirements of type, shape, materials, dimensions
and test for vertical stand post type fire hydrant to be installed on fire water main with
an isolation valve.
2.0
3.0
MATERIAL :
3.1
Hydrant vertical post and hydrant arms shall be from pipe conforming to IS: 1239
heavy grade and shall be with welded construction.
3.2
3.3
3.4
3.5
63 mm coupling to hydrant valve shall comply to IS: 903 while blind cap with its lugs
shall be of gun metal complying to IS: 318 Gr. II. Chain shall be of mild steel.
3.6
Bolts and nuts for flanges shall comply to IS: 1367 clause 10.9 and 12.0
respectively while gasket 2 mm thick full face shall be made of CAF 40 to
IS:2712.
4.0
DESCRIPTION :
4.1
The hydrant shall be of stand post type. The vertical post shall be of 100
mm
TS-SPH- 5 -
MECON LIMITED
Delhi
4.2
MECON LIMITED
63 mm coupling to hydrant valve shall comply to IS: 903 except that the lug shall be
twist release type.
4.3
The vertical post shall have 100 mm outlet as pumper connection and provided with a
blind cap. The 100 mm outlet shall have round male threads conforming to IS: 902
and blind up shall have round female matching threads. The cap shall be provided with
four fixing lugs and 500 mm long M.S. chain.
4.4
All flanges for hydrant valve and base shall have drilling dimensions conforming to
ANSI B 16.5 # 150 lbs rating flat face, slip-on type.
5.0
5.1
All parts shall be of good workmanship and finish. All parts and sharp edges shall be
removed. The water ways shall have smooth finish.
5.2
Wherever IS has been specified the latest edition of the same shall be followed.
6.0
TESTING :
Hydrant assembly with hydrant valves and pumper connection closed shall be
satisfactorily tested and proved water tight under a hydraulic pressure of 18.0 kg/cm2.
7.0
PAINTING :
7.1
The stand post and its arms shall be painted with three coats of anti corrosive fire red
paint conforming to IS: 2932 from outside while internal surface shall be
painted with three coats of chlorinated rubber based resin paint or zinc chromate paint.
7.2
All steel parts coming in direct contact with water shall be hot dipped galvanized to a
thickness of not less than 0.12 mm. The thickness of the coating shall be measured as
per IS: 3203. External surfaces and non-ferrous components may be coated with leadtin alloy by electrical deposition process.
8.0
MARKING :
8.1
TS-SPH- 6 -
MECON LIMITED
Delhi
MEC/TS/05/21/081N
b. Year of manufacture
c. Purchasers name
d. IS: 5290 on hydrant valve
8.2
The assembly shall also be marked with the required BIS marking.
9.0
INSPECTION :
Third party inspection agency at Contractors cost shall have access at all
reasonable
times
to
the
manufacturers
TS-SPH- 7 -
work
where
hydrants
are
being