TABLE OF CONTENTS

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

SECTION - 1 GENERAL TECHNICAL SPECIFICATIONTABLE OF CONTENTS
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 INTENT OF SPECIFICATION...................................................................................3 SCOPE OF WORK FOR ERECTION........................................................................3 TERMINAL POINTS..................................................................................................6 EXCLUSIONS FROM THE BIDDER'S SCOPE OF WORK........................................6 PERFORMANCE TEST............................................................................................7 PROJECT INFORMATION........................................................................................7 APPROVED SUB VENDORS/MAKES.......................................................................7 TAGGING..................................................................................................................7 PAINTING..................................................................................................................7 QUALITY ASSURANCE, TESTING AND INSPECTION.............................................7 DOCUMENTATION.................................................................................................10

ANNEX-1.1 PROJECT INFORMATION.......................................................................................14 ANNEX- 1.2 BILL OF MATERIAL................................................................................................17 ANNEX- 1.3 PIPING CLASSIFICATION.....................................................................................32 ANNEX - 1.4 LIST OF SUB-VENDOR...........................................Error! Bookmark not defined. ANNEX- 1.5 PAINTING ...........................................................................................04 SHEETS

SECTION 1 1.0.0 GENERAL TECHNICAL SPECIFICATION INTENT OF SPECIFICATION

1.1.0 This specification covers the minimum technical requirements and essential particulars for Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports Erection, Laying, inspection & testing at site, cleaning & painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc. 1.2.0 Services shall be rendered in conformity with proven design principles, taking into account the current technology. The requirements of the contract must be fulfilled in its entirety. The services shall be rendered inclusive of all appliances and interconnecting arrangements with other supplies, necessary for installation of all accessories, needed for proper and reliable continuous operation and for satisfactory maintenance and repair. 1.3.0 In so far as data on the execution of services as contained in drawings, but none in specification and vice versa, such data shall be deemed to be contained in both. Contradictions, if any, between drawings and specifications and within various sections of the specification shall be brought to the attention of the Purchaser/Consultant by the Bidder and the correct requirement shall be obtained. 1.4.0 It is mandatory for the bidder's to furnish along with the bid the deviations if any, whether major or minor in the „Schedule of Deviations' only. In the absence of the deviations listed in the „Schedule of Deviations', the offer shall be deemed to be in full conformity with the specification not withstanding anything else stated elsewhere in the offer, data sheet, etc. The hidden deviations or stated / implied deviations in the offer shall not be acceptable OR binding on the Purchaser. 1.5.0 All materials supplied under this contract shall be new and unused.

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

requirement.

2.0.0

SCOPE OF WORK FOR ERECTION

2.1.0 The scope of work covered under this specification include but not limited to preparation of relevant drawings, specifications, documents and getting them approved by the Consultant and statutory authorities for necessary clearances, Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc. as detailed in the scope of work. 2.2.0 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.3.0 2.3.1 Scope of supply All handling equipment, machinery, tools, consumables etc., required for fabrication work to be carried out at site. All handling equipment, machinery, tools, consumables etc., required for erection of LP piping. Piping supports for the above ground piping complete with all accessories. Consumables and chemicals required for the piping and fittings fabrication, erection, cleaning and testing works. Temporary piping material and supports for piping system, cleaning and testing. Gasket for all flanges and Hume pipe for Buried pipe. Required hardware (like bolts, nuts, clamps, U- clamps etc.) Painting of piping. Wrapping and Coating tape for Buried piping. Scope of services Fabrication, Erection & Commissioning of LP Piping: Receipt of material from site stores, Handling at site, Pipes and fittings (free issue by owner), Fabrication of miter bends (above 300NB / The plate material will be free issued by owner), supply and Fabrication of Supports, Erection, Laying, Inspection & Testing at site, Cleaning & Painting, Wrapping and Coating, site supervision, calibration and commissioning at site for LP piping & fittings, valves, Expansion joints supports and specialties etc... as detailed in the scope of work. 2.3.2 The Bidder shall be responsible for examining all the consignments and notify the Project Manager immediately of any damage, shortage, discrepancy etc. The Bidder shall submit to the Project Manager every week a report detailing all the receipts during the week. However, the Bidder shall be solely responsible for any shortages or damage in transit, handling and/or in storage and erection of the equipment/ material at the site. Any demurrage, wharf age and other such charges claimed by the transporters, etc shall be to the account of the Bidder. The Bidder shall maintain an accurate and exhaustive record detailing out the list of all equipment / material received by him for the purpose of erection and keep such record open for the inspection of the Owner/ Project Manager at anytime. The equipment/material stored shall be properly protected and the same shall be moved to the actual location at an appropriate time so as to avoid any kind of damage to them. The Bidder shall ensure that all the packing materials, and protection devices used for the various equipment / material during transit and storage are removed before the same are installed. The packing materials and protection devices shall remain the property of the Owner and shall be handed over by the Bidder to the Owner after the completion of works. The Bidder shall be responsible for making arrangement for suitable indoor storage facilities to store required equipment/ material. In general, all the electrical equipment/ material such as motors, control gears and consumables like electrodes, lubricants etc. shall be stored in the closed storage space. The Project Manager, in addition, may direct the Bidder to move certain other materials that in his opinion will require indoor storage to the designated indoor storage areas, which the Contractor shall strictly comply with.

2.3.3

2.3.4 2.3.5

2.3.6

calibration and handing over in a planned manner and within the schedule of stipulated time. 2. The erection supervisors shall be present during and shall supervise the unloading of equipment and materials from vehicles. hauling.3.18 All the tests as specified in this specification.3.3.21 Field Supervision: The Bidder shall furnish the services of one or more construction / erection supervisors for resident supervision of all erection work. 2.3. materials.3.0.3. 2.13 After completion of job arrange to clear the area of work of all loose materials.3. 2.2.3. erection and testing of the LP piping. calibration & measuring instruments etc. tools equipment etc. experienced in the fabrication. The Bidder will be required to submit drawings and engineering data in accordance with the schedule and requirements specified herein to assure compliance with the overall construction and operating schedule. 2. equipment & tools etc.3. cleaning. 2. as specified herein. and placing the piping into successful operation.10 The scope includes fabrication design of pipes & accessories which includes preparation of fabrication and spool drawings. start up. The service representatives shall be technically competent. 2. 2.3.11 Obtaining necessary approvals from various agencies as applicable. Also update Purchaser's construction drawings to incorporate all the modifications carried out and get same certified as 'as-built' drawings by the Project Manager. the Project Manager will have the right to get them moved to the area earmarked for the Bidder at the Bidder's cost. 2.3. 2. storing.2 this section of the specification. erection. 2.23 Design Conference: The Bidder's design engineer shall attend a design conference at a time and place prescribed by the Owner to discuss matters relative to the execution of this Contract. filler wires. The erection quantities involved are listed in Annex 1. consumable. The Bidder's design engineer shall attend additional design conferences as required by the Owner thereafter to expedite the work.7 If the materials belonging to the Bidder are stored in areas not acceptable to the Owner. Monthly progress report including reconciliation statement of free issue materials at the end of the month.24 Quality Assurance and Quality Control: As specified in Cl. 2. All the materials stored in the open or dusty location must be covered with suitable weather proof and flame proof covering of material wherever applicable. Time is the essence of contract in completing each phase of the work so that the plant can be in commercial operation on the specified date. 2. oxygen. tools and tackles.3. material and complete erection equipment including cranes/hoists.11. the Bidder shall submit a documented Quality Assurance and Quality Control program capable of providing assurance that all involved equipment. .3. testing.3. sequence of erection. and Owner review of drawings and data in his Engineering Schedule and Procurement / Production / Shipping Schedule.3. 2. the Bidder shall furnish the services of one or more technical service representatives.17 All pre-commissioning and commissioning activities.12 Providing all man power. trained. welding electrodes. scraps. and authorized to perform the work stipulated.3.3.8 2. and services meet requirements of the contract documents. Any damage or deterioration of the material while in the custody of the Bidder shall be recovered by the Owner from the Bidder.25 Submission of Daily.16 The onsite construction / erection / installation work shall be in accordance with the requirements specified in this specification.3.14 Assisting the Purchaser in successful commissioning of the system by providing skilled/unskilled personnel. processing. and testing. acetylene.0 of this specification.20 The Bidder shall allow not less than 30 days for mailing. 2.15 Participation in design conferences.22 Technical Services: In addition to the resident field supervision specified herein before.3.9 2. 2.19 Welding of pipes /flanges at terminal points shall be included under the scope of this package and required to be done by the Bidder. Weekly. to enable execution of job including final testing.

Plate for fabricated pipe and fittings.0.5.0 TERMINAL POINTS Terminal point has been indicated in the P&I Drawings (All Terminal point details are preliminary only and which shall be finalised after award of the contract). type and details of support for lines will be indicated in the Piping / G.1. arranging for the Inspector to visit site and obtain necessary approvals and certificates for the erected pipe work etc. The list of drawings indicated above is furnished else where in this tender document.4.26 Any other activities found necessary for the successful completion of the job.3 2.0 . Symbol and Legends. c.4. c.2. Pipe Support materials.3. Plot Plant. 2. Any alteration in pipe routing / supporting required to suit the site condition shall be done by the Contractor to the satisfaction of the Project Manager at no extra cost. drawing support details wherever not shown in GA drawing. This includes getting approval of the welders from the above authorities. roads.2. The final drawings will be made available to the contractor progressively after the award of contract. 4. d.0. All valves.4. EXCLUSIONS FROM THE BIDDER'S SCOPE OF WORK Mechanical • Erection of Piping beyond battery limits.1. b. buildings.5 2.2 Coordinating for approvals from the statutory authorities like Inspector of Explosives CCOE (if required) and for calibration from Weights & Measures Department etc. Equipment layout drawings.4.A.(required stubs and fitting to be provided by bidder as indicated in the P & ID'S Supply of pipes and fittings (other than fabricated from the plate material). Standard piping support details.4. Piping layout drawings. P&ID Drawings. Consumables Supply of all consumables required for commissioning and performance test shall be included in the scope and the same shall be supplied by the successful Bidder at appropriate time. However these are tentative and indicative only. Isometric / 2D drawings. pipe racks/ pipe 2. All fabrication drawings for piping shall be developed by the Contractor and submit to the Project Manager for approval. b.1 Drawings Purchaser shall provide the following drawings & documents a.(structural materials only) All specialties their counter flanges along with fastener and gaskets.4 2. but required for the piping stability the Contractor shall carry out supporting with the approval of Project Manager after developing necessary support drawings. Location.0 4. 3.0 2.4. All instruments with their accessories.0 4. d. 2.0 Civil • All Civil Engineering works such as RCC foundation. expansion joints their counter flanges along with fastener and gaskets. & others for the system under their purview.0 3.

incoming raw material inspection. as well as the terminal boards.0.0. within the appropriate time period as specified to demonstrate the achievement of guaranteed parameters. All tests shall be carried out in accordance with the relevant international standards unless otherwise specified or approved by the Purchaser. components and selection of Sub. TESTING AND INSPECTION 10. after award of contract. Performance test will be carried out.1.0 The makes of all material/equipment/ instruments under this specification shall be subject to Purchaser's approval in the event of order. source inspection.0 PAINTING 9.0 QUALITY ASSURANCE. etc. 10.0 TAGGING 8.0 Encasement for the buried piping. The tag shall be of engraved plate of sufficient rigidity and figures and letters embossed and painted. • 5.5 of this specification. instruments and control equipment.1 of this section of the specification. the Bidder shall adopt suitable quality assurance programme to control such activities at all points necessary. Approval.trenches etc. f) Control of calibration and testing of measuring and testing equipment. c) The procedure for purchase of materials. A quality assurance programme of the Bidder shall generally cover the following: a) Bidders organisation structure for the management and implementation of proposed quality assurance programme. all apparatus. rejection or addition of makes shall not have any cost implication to the Purchaser after award of contract.0. The inscription shall be approved by the Purchaser/Consultant. parts. verification of materials purchased.1 To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Bidder's works or at his Sub-Vendor's premises or at the Purchaser's site or at any other place of work are in accordance with the specifications. PERFORMANCE TEST Guarantee requirements In addition to compliance with the requirements of the Specification. signal tapping points.Vendor's services including Vendor analysis.1.0 Quality Assurance Programme 10. etc.0. b) Qualification data of his key personnel.0. g) System for indication and appraisal of inspection status.1. motors.0.1. Such nameplates or labels shall be of white non. d) System for shop manufacturing including process controls and fabrication and assembly controls.hygroscopic material with engraved black lettering. . Purchaser reserves the right to accept/ reject any make or sub-vendor or add new makes/ sub-vendors for the project. installed in the latter shall be provided with permanently attached tag bearing the Purchaser's coding together with relevant text clearly inscribed.0 7. cubicles.0 PROJECT INFORMATION Project Information is furnished in Annex 1. h) System for quality audits. the Bidder shall meet the specific guarantees of performance as required and as stated in the specification. The language of inscription shall be English.1. Bidder shall furnish a list of makes/ sub-vendors/ sub-contractors along with his bid. 6.0 5. e) Inspection and test procedure both for manufacture and field activities. 8.0 The painting specification for all the piping shall be as specified in Annex 1...1..0 Components whose identity is important for operation and maintenance of the plant viz. 9. The method of implementation and labeling will be informed for all components after award of contract. Such programmes shall be outlined by the Bidder and shall be finally accepted by the Purchaser after discussions before the award of Contract. APPROVED SUB VENDORS/MAKES 7.

and method used to verify that the inspection and testing points. 10. however. The cost of all such tests as well as third party inspectors shall be borne by the Bidder. k) System for maintenance of records. if used.2 The Purchaser shall be given reasonable notice of all tests and shall have the right to witness all tests. verification sketches.4 The cost of all inspections at site by other regulatory institutions shall be borne by Bidder and . h) Stress relief time temperature charts.2 The Bidder shall furnish the quality plan for erection and commissioning activities indicating stage wise all tests and inspections.3 Testing/inspection procedures as detailed herein is to give a basic quality control programme to be followed by the Bidder and are in no way comprehensive and in no way form a complete quality assurance programme.0 General Requirements for Testing and Inspection 10. storage & delivery.i) j) System for handling. g) Non-destructive examination result reports. 10.2. inspections etc. prejudice the right of Purchaser to reject the equipment if it does not comply with specifications when erected or does not give complete satisfaction in service.3. d) Material mill test reports on components as specified by the specification.3. shall upon request be made readily available. f) Sketches and drawings used for indicating the methods of traceability of the radiographs to the location on the equipment. c) Welder identification list. b) Welder and welding operation qualification certificates. At the time of Purchaser's visit all quality documentation pertaining to test.3. Such quality plan shall be subject to the approval of the Purchaser.3 The Purchaser or his authorized representative may periodically check the work and the Constructor's method of operation to assure that quality control practices are being followed. 10. safety and reliability point of view shall also be included. e) The inspection plan with verification. 10.3. inspection plan check points. 10. 10.2. procedures and acceptance norms to be adopted for each piece of equipment under this specification.2. and shall have access to the works of Bidder and Sub-Vendor at all times for the purpose of carrying out system audits. listing welder's and welding operator's qualification procedure and welding identification symbols. qualifications. i) Factory test results for testing required as per applicable codes and standards referred in the specification.2.2. a) All non-destructive examination procedures.1 All equipment covered under these specifications shall be subject to inspection and tests by the Purchaser/his authorized representative or third party during erection and commission. System for authorising release of manufactured product to the Purchaser. conducting quality surveillance witnessing of tests and inspections etc. performed satisfactorily. The approval of the Purchaser or passing of such inspection of test will not. 10.1 The Bidder shall be required to submit the following Quality Assurance Documents as required. Any other inspection stages not mentioned in these clauses but required as per the Bidder's quality assurance programme or the Purchaser shall be deemed to be included. stress relief and weld/repair procedure actually used during fabrication.. and l) A quality plan detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component furnished. in the inspection plan were.0 Quality Assurance Documents 10. Any tests necessary from operation. 10.3.4 All reports of tests and inspections as per Quality Control Practices and Quality Plans shall be furnished to the Purchaser.

4 Quality assurance document for erection of piping system 11. 11. V code requirements. The personnel shall be qualified with Practice SNT-TC-1A of the American Society of Non-destructive Testing or equivalent. 11.0 DOCUMENTATION 11. results evaluation.2.2.0. his duly authorised representative shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its Fabrication or erection and if part of the works is being fabricated or assembled on other premises or works.1 All welding procedures adopted for performing welding work shall be qualified in accordance with the requirements of Section IX of ASME code. 10.2. 1 and Sec. Category I A I A I A A A .6 Final welding procedure for piping.1. 10.6.1. the preheat temperature maintained.2.7 Any other details if required by purchaser/Owner.1.5 List of tests the Bidder proposes to carry out at site after installation including those pertaining to their sub-contractor. 11.5 The Purchaser.1. the post-weld heat treatment given.2.3.6 A bar chart indicating fabrication.4. 11.3 Time schedule for erection.6.1 Duly filled-in technical data and prices as per specified schedules.6.2.2 Test procedures and details of test to be conducted.2. 11. data / documents to be furnished by the successful Bidder The following drawings.1 Piping fabrication/spool piece details. 11. 11. 11. tests and welders performance details for the work performed under these specifications shall be maintained by the Bidder and be made available to the Purchaser on request. the welding current and voltage used during qualification of welding procedures.4 List showing auxiliary piping furnished for all equipments. 11. Each non-destructive examination shall be recorded in a report which summarises methods and equipment used.3 Technical data sheet and GA drawings for supply items 11.0 Drawings. 11. thickness. the Bidder shall obtain for the Project Manager and for his duly authorised representative permission to inspect.6.7 A comprehensive write-up or brochure on the details of facilities / man power available with the Bidder. date and identification of personnel employed.2 List of drawings/documents attached. 10.5.5 Fabrication procedure for piping 11.0 Drawings.0 Non-destructive Examination 10. the joint details.2. and commissioning.8 Type and Routine Test certificates. 10.2.accordingly included in his lumpsum price in the Bid.3 All records of the welding procedures. 11. testing and commissioning activities. data / documents to be submitted along with tender 11. 11.1.0 All non-destructive examinations shall be performed in accordance with written procedure to meet ASME Sec. the welders qualifications. installation. testing. data / documents shall be submitted for the approval / review of the Purchaser / Consultant by the successful Bidder. 10. material test certificates for major components.0 Welding Procedure 10.2 These welding procedures shall clearly state the type of material.1.1. Description 11.1.

3. As-built drawings for all equipment/systems supplied under this contract and works executed under this contract incorporating all changes/modifications upto the time of commissioning / handling over to the Purchaser/consultant. Detailed interface schedule for all terminal points identifying terminal point no. Documents as listed in respective sections of Technical specification. fixing arrangement required.4. weight of each component for packing and shipment. Detailed write-up for shop tests Test certificates for type/routine tests.2 The contractor shall submit drawings/ documents as per the no.5 The furnishing of detailed engineering data and drawings by the Contractor shall be in accordance with the time schedule finalised during pre-award meeting.0 General a. notings. Contract network schedule Detailed painting specification. design flow. 11. n. The review of these documents / data / drawings by the Contractor/Purchaser will cover only general conformance of the data / drawings / documents to the specifications and contract.Note: Category-A : For Approval Category-I : For Information/Reference. The review and / or approval by the Contractor/Purchaser shall not relieve the Purchaser/ Contractor of any of this responsibilities and liabilities under this contract.4. 11. e.1 All drawings shall be made in latest Autocad version. pressure and temperature at the terminal points QAP for all manufactured and sub contracted items.4. If standard catalogue pages are submitted the applicable items shall be indicated therein. 11. the dimensions required for installation and interconnections with other equipment and materials.4. 11. size.3 All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail indicating the type. c. standard acceptance tests and performance tests Field Quality Plans h. Drawings/data to be required/submitted to statutory authorities o. size. the external connection. type of connection. markings and writings on the drawing shall be in English. 11. Title block to be issued by Contractor after award of contract.0 Drawings/ Documents Submission 11.4 Each drawing submitted by the Contractor shall bear a title block at the right hand bottom corner with clear mention of the name of the Contractor/Purchaser. clearance and spaces required between various portions of equipment. material.6 After the approval of the drawings. 11. interfaces with the equipment provided by others and external connections of the dimensions as reviewed. further work by the Contractor shall be in strict accordance with these approved drawings and no deviation shall be permitted without the written approval . All titles.4.4. j. b. k. g.4. Storage instructions for all equipment i. Installation drawings and manuals for all equipment/systems Detailed write-up on all pre-commissioning and commissioning activities.. arrangement. Detailed write-up for site performance tests Integrated operation and maintenance manuals for the complete plant as well as for all individual equipment m. d. f. l. of copies listed below: To PLL : 7 copies To Consultant : 4 copies 11. All the dimensions shall be in metric units.

a) b) c) d) Erection strategy Sequence of erection Erection instructions Critical checks and permissible deviation / tolerances . The Instruction Manuals shall comprise of the following.of the Contractor/Purchaser. 11. i) Information that shall be submitted for the approval to the Contractor/Purchaser before proceeding further and ii) Information and would be submitted for Contractor's/Purchaser's information only. For this. The Engineering Information Schedule shall be prepared monthwise.1 The Contractor shall submit every month a work progress and Exception Report giving the status of work information including a) A list of drawings / data which remains unapproved for more than four (4) weeks after the date of first submission.4.6. if any. The manual shall be specifically compiled for this project and subject to approval by Purchaser.0 Instruction Manuals The Contractor shall submit to the Owner/Purchaser.2 The draft format for this report shall be furnished to the Contractor/Purchaser within four (4) weeks of the award of the contract. The Contract shall not be considered to be completed for purposes of taking over until the final Instructions manuals have been supplied to the Owner/Purchaser. the Contractor will update all original drawings and documents for the equipment / system to "as built" conditions. A) Erection Manuals The erection manuals shall be submitted atleast three (3) months prior to the commencement of erection activities of particular equipment / system. c) Master list of drawings (computer output). which shall then be discussed and finalized with the Contractor/Purchaser. 11. The schedule should allow adequate time for proper review and incorporation of changes / modifications. the same shall not be reviewed and returned to the Contractor for re-submission. 11. b) Drawings which were not submitted as per agreed schedule. The erection manual should contain the following as a minimum. commissioning and testing. The information shall be categorised into the following parts.7. b) Drawings must be checked by the Contractor prior to submission to the Purchaser.6. a Detailed Engineering Information Submission Schedule shall be tied up with the Contractor. In case. the contractor shall furnish a detailed list of engineering information alongwith the proposed submission schedule. drawings are found to be submitted without proper checking by the Contractor. 11. The list would be a comprehensive one including all engineering data / drawings / information for all bought out items and manufactured items.7 As Built Drawings a) After final acceptance of individual equipment / system by the Contractor/Purchaser.5. draft Instruction Manuals for all the work covered under the Contract by the end of six (6) months from the date of his acceptance of the Letter of Award. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performance and progress.0 Engineering Information Submission Schedule Prior to the award of Contract. The Instruction manuals shall contain full details required for erection.0 Work Progress and Exception Report 11.6. 11. to meet the contract without affecting the equipment delivery schedule.

e) f) g) h) i) j) k) l) List of tool. tackles etc. . Bills of Materials Procedure for erection Procedure for initial checking after erection Procedure for testing and acceptance norms Procedure / Check list for pre-commissioning activities Procedure / Check list for commissioning of the system Safety precautions to be followed in electrical supply distribution during erection.

0 8.0 KM Chandrapur (Maharashtra).3 0C 29 0C 50 °C 14.8 °C 33.0 7.8 0C 21.75 for tanks 48.0 km 0. recorded Average Annual rain fall Period of Monsoon (Avg) Showers FFL + 224.0 (a ) (b ) (c) 12.0 2.5mm.0 4. 0 3.0 11.0 Owner Project Title Location Power station site Elevation above Mean Seal Level (MSL) Latitude /Longitude Nearest Railway station Nearest Town Distance from Nearest State Highway Nearest Airport Nearest Sea Port Road Approach Seismic data Seismic intensity Zone Importance factor Temperature Maximum / Minimum temperature Daily maximum mean temperature Daily minimum mean temperature Maximum Dry bulb temperature Minimum Dry bulb temperature Wet Bulb Temperature Design temperature for elec equipment/device/System Relative Humidity Monthly Maximum Relative Humidity Maximum mean Relative Humidity Monthly minimum Relative Humidity Minimum mean Relative Humidity Design relative humidity for Electrical equipment/Device/System Rain fall Max.8 0C 42.5 Km from SH-264 Nagpur Visakhapatnam (East coast) NH-3&NH-6.1 5. and SH-264 AsperIS-1893.5 m TG hall 1 9 ° 5 8 ' N/ 7 9 ° 1 8 'E Tadali Railway Station of Warora Branch of Central Railway and the distance is about 3.0 10.0 (a ) (b ) (c) 84% 65% 21% 46% 95% 1276. 0 (a) (b) (c) (d) 12. II 1. India. 3.0 9. 0 (a) (b) (c) (d) (e) (f) (g) 13. 0 6. .8 0 C 4.1.3 0C and 2.

11 18. 3 phase. AC supply (Effectively earthed) 240V. 1 Phase. Unless otherwise specified.2 17.4 Wind data Maximum wind speed Climatic conditions Auxiliary power supply AC Motors above 160 kW AC Motors 0. DC emergency drives.6kV. 3 4 wire. EHV System 400000 V (±)10% . For control of switchgear. wire. switchyard equipment. solidly grounded system.5% ± 10% 17.) and 415 V switchgear outgoing feeder modules controls.5 240V. AC AC supply (Medium supply (Effectively 240V. Any other AC or DC voltage required shall be derived from the same. 17. 3 phase.6 220V DC Supply : UPS supply 240V AC. etc. crane control.3 17. switchyard and generator protection panels. space heating panels and space heating of motors of rating 30kW and above Control Circuit of local panels (like compressor control. For Instrumentation and Control 44 m/s.15.18 kW Plant lighting. 3 earthed) phase.15% ±1% ± 10% + 5% to .10 Unless otherwise specified all electrical system shall be designed for the following voltage and frequency variations: AC system Voltage variations Frequency variation Combined Voltage and Frequency Variation DC system a) Voltage variation (220 V) + 10% to.8 17.9 (a) (b) (c) 17. . All auxiliary equipment to be supplied against this specification shall be suitable for operation on the following supply 6.1 17.7 17. AC supply (Effectively earthed) 17. 1 Phase. AC supply system (Derived from 415/240V step down transformer) 17. DC emergency lights. 50 Hz (+)5% to (-)5%.18 kW to including 160 kW AC Motors Below 0.0 17. resistance earthed) 400V. etc.0 16. utility power sockets.0 UPS Electrical Voltage levels a.0 17. 1 Phase.

c. 3 phase. 50 kA for one second . 50 Hz d. c. For motors above 160 kW For motors from 0.6 kV system 415 volts system 40 kA for 1 (One) second 40 kA for 3 (Three) second. 50 Hz. 240 V (±)10% volts. 50 Hz 415 Volt.18 For all MOV motors Fault Level 20. d.b.0 Electric Equipment Voltage Rating a. DC Voltage h. 50 Hz 10% (Absolute sum) 220 (+)10% to (-) 15% volts. Auxiliary supply for lighting Combined voltage & frequency variation g.0 a.6 kV. f. solidly grounded system. 400. 3 phase. 50 Hz (+)5% to (-)5%. MV System LV System 6600 V (±)10% volts. 415 V (±)10% volts. 1 phase. low resistance grounded system.18 upto 160 kW For motors less than 0. 3 phase. 50 Hz system 6. 1 phase. 3 phase. 50 Hz Solidly earthed 240 Volt. 50 Hz (+)5% to (-)5%. 50 Hz low resistance grounded system 415 Volt. 3 phase. b. ungrounded system 230 volts (±)10% volts. 1 phase. c. b. UPS Voltage 19. 230 V (±)10% volts. 1 phase. Control Voltage e.000 volts system 6.

Galvanised Mild Steel -IS 1239 Part1.No. Galvanised Mild Steel -IS 1239 Part 2. 1 150 168.No. Galvanised Mild Steel -IS 1239 Part 2.2 BILL OF MATERIAL System : ITEM: PIPE Instrument Air system SL. Galvanised Medium Grade 2 ENDS BW REMARKS 2 100X50 114. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2.30 MATERIAL Mild Steel -IS 1239 Part 2.40 Heavy Grade 5 Threaded ITEM: CONCENTRIC REDUCER SL. Galvanised Medium Grade 4 ENDS BW REMARKS 2 100 114.30 MATERIAL Mild Steel -IS 1239 Part 1. 4 25 33.ANNEX-1.32X33.30 MATERIAL Mild Steel -IS 1239 Part 2.40 Heavy Grade 28 Threaded ITEM: EQUAL TEE SL. Galvanised Mild Steel -IS 1239 Part 2. 1 150 168. Galvanised Mild Steel -IS 1239 Part 2.30X114.30 MATERIAL Mild Steel -IS 1239 Part 2.32 Heavy Grade 5 Threaded 4 25 33.40 Heavy Grade 550 Threaded 5 15 21.30 Medium Grade 120 BW 3 50 60.No. ERW. Galvanised Mild Steel -IS 1239 Part1.40 Heavy Grade 3 Threaded .32 Heavy Grade 470 Threaded One end of pipe to be provided with Threaded full coupling threaded.30 Medium Grade 4 BW 3 50 60.5D SL.34 Heavy Grade 7 Threaded ITEM : 90° ELBOW 1. ERW.40 Heavy Grade 3 BW 4 50X25 60. Galvanised Mild Steel -IS 1239 Part 2. ERW. Galvanised Mild Steel -IS 1239 Part1. One end of pipe to be provided with Threaded full coupling threaded. Galvanised Medium Grade 720 ENDS BW REMARKS 2 100 114.32 Medium Grade 5 BW 3 100X25 114. Galvanised Mild Steel -IS 1239 Part1. 1 150 168.No.32 Heavy Grade 4 Threaded 4 25 33.30X33. ERW.30 Medium Grade 16 BW 3 50 60. Galvanised Mild Steel -IS 1239 Part 2. One end of pipe to be provided with Threaded full coupling threaded. Galvanised Mild Steel -IS 1239 Part 2. ERW. Galvanised Medium Grade 9 ENDS BW REMARKS 2 100 114.30X60. 1 150X100 168.

40 60. 4 10% Margin has been considered for all piping & all Fittings. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Heavy Grade / 3000# 2 ENDS Threaded REMARKS 1 Pipe size. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later.30X21. .3 114.34 MATERIAL Mild Steel -IS 1239 Part 2.30 X114. Galvanised Mild Steel -IS 1239 Part 2.34 Mild Steel -IS 1239 Part 2.30X60. 1 2 3 4 5 6 MATERIAL ENDS Medium Grade REMARKS 150X100 168.30X33. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2.No. Galvanised Mild Steel -IS 1239 Part 2. thickness and Quantity details have been indicated preliminary and which shall be finalised later.40 60.40X21.34 33. 2 Fitting size. 1 Note: 15 21.ITEM : UN EQUAL TEE SL. Galvanised 8 2 2 3 4 8 BW BW BW Threaded Threaded Threaded Medium Grade Medium Grade Heavy Grade Heavy Grade Heavy Grade ITEM : HALF COUPLING SL.30X33. Galvanised A 105.30 100X50 100X25 50X25 50X15 25X15 114.No.

Galvanised Mild Steel -IS 1239 Part1. Galvanised Mild Steel -IS 1239 Part 2.5D SL. ERW. Galvanised Medium Grade 8 ENDS BW REMARKS 2 65 73. Galvanised Mild Steel -IS 1239 Part1.90 MATERIAL Mild Steel -IS 1239 Part 2.40 Heavy Grade 1550 Threaded 6 15 21.40 Heavy Grade 7 Threaded .No. One end of pipe to be provided with Threaded full coupling threaded. 1 80 88. Galvanised Mild Steel -IS 1239 Part 2. One end of pipe to be provided with Threaded full coupling threaded.02 60.90 MATERIAL Mild Steel -IS 1239 Part1.System : ITEM: PIPE Service Air system SL. ERW. Galvanised Mild Steel -IS 1239 Part1.26 Heavy Grade 2 Threaded 5 25 33.90 73. Galvanised Mild Steel -IS 1239 Part 2. One end of pipe to be provided with Threaded full coupling threaded. Galvanised Mild Steel -IS 1239 Part1. ERW. 1 2 3 4 5 80 65 50 40 25 88. Galvanised Mild Steel -IS 1239 Part 2.32 Heavy Grade 2 Threaded 4 40 48. Galvanised Mild Steel -IS 1239 Part 2. ERW. ERW.26 Heavy Grade 450 Threaded 5 25 33. Galvanised Mild Steel -IS 1239 Part 2.No.32 48. 1 80 88. 4 40 48.02 Heavy Grade 3 BW 3 50 60.26 33. Galvanised Mild Steel -IS 1239 Part1. Galvanised Mild Steel -IS 1239 Part 2.32 Heavy Grade 435 Threaded One end of pipe to be provided with Threaded full coupling threaded.40 MATERIAL Mild Steel -IS 1239 Part 2.02 Heavy Grade 90 BW 3 50 60. ERW.No. Galvanised Medium Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 16 8 6 7 40 ENDS BW BW Threaded Threaded Threaded REMARKS ITEM: EQUAL TEE SL. Galvanised Medium Grade 500 ENDS BW REMARKS 2 65 73. Galvanised Mild Steel -IS 1239 Part 2.34 Heavy Grade 6 Threaded ITEM: 90° ELBOW 1.

40 Heavy Grade 5 Threaded 7 50X 15 60. thickness and Quantity details have been indicated preliminary and which shall be finalised later.90 X 60.32 Medium Grade 1 BW 3 88. Galvanised Mild Steel -IS 1239 Part 2.32 X 33.26 X 33.02 Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2.32 X 48.90 X 33. Galvanised 2 88.40 Heavy Grade 3 Threaded Note: 1 Pipe size. NB 3 80X 40 OD in mm 88. Mild Steel -IS 1239 Part 2.34 Heavy Grade 2 Threaded For Pressure I ndicator 8 40X 25 48.40 Heavy Grade 2 SW 6 48.34 Heavy Grade 2 SW For Pressure I ndicator ITEM: CONCENTRIC REDUCER SL.90 X 60. 2 ENDS BW REMARKS 4 80X 50 88. 4 10% Margin has been considered for all piping & all Fittings.ITEM : UN EQUAL TEE SL.90 X 73.4X21. Galvanised Mild Steel -IS 1239 Part 2.32X21. Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later. 3 Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system. Galvanised Mild Steel -IS 1239 Part 2.No.26 Heavy Grade 1 Threaded 6 50X 25 60.40 Medium Grade 3 BW 4 60. .26 Heavy Grade 1 SW 5 60.26 X 33. Galvanised Mild Steel -IS 1239 Part 2. 2 Fitting size. Galvanised Mild Steel -IS 1239 Part 2.32 X 48. 1 MATERIAL ENDS Medium Grade 2 BW REMARKS 80X65 80X50 80X25 50X40 50X25 40X25 25X15 88. Galvanised Medium Grade Nos. Galvanised Mild Steel -IS 1239 Part 2.26 MATERIAL THK.32 Medium Grade 2 BW 5 50X 40 60.No.90 X 48. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2.40 Heavy Grade 4 SW 7 33.32 X 33. Galvanised Mild Steel -IS 1239 Part 2.

ERW. MATERIAL ENDS REMARKS 1 200 219.Potable Water System ITEM : PIPE SL. Galvanise Mild Steel -IS 1239 Part 1.26 33.WPB 4.No.32 48. Galvanised Mild Steel -IS 1239 Part 1. One end of pipe to be provided with full coupling threaded.90 73. Galvanise Mild Steel -IS 1239 Part 1. Galvanise Mild Steel -IS 1239 Part 1.5D SL.5D SL.02 MATERIAL Mild Steel -IS 1239 Part 2.26 500 Threaded 6 25 33. Galvanised Mild Steel -IS 1239 Part 2.5 2 BW 2 3 4 5 6 80 65 50 40 25 88. Galvanise Mild Steel -IS 1239 Part 1.08 MATERIAL IS 3589 Fabricated from IS 2062 Gr. ERW. Galvanise 4.5 50 ENDS BE REMARKS 2 80 88.No.02 60.40 Mild Steel -IS 1239 Part 2. 5 40 48.40 10 Threaded 7 15 21. Galvanised Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 14 23 24 27 5 BW BW Threaded Threaded Threaded ITEM : 45° ELBOW 1. ERW.02 1100 BW 4 50 60. ERW. One end of pipe to be provided with full coupling threaded. Galvanised Mild Steel -IS 1239 Part 2. 1 65 73. One end of pipe to be provided with full coupling threaded. Galvanised Mild Steel -IS 1239 Part 2.32 2 Threaded One end of pipe to be provided with full coupling threaded. ERW. Galvanised Mild Steel -IS 1239 Part 2.B Mild Steel -IS 1239 Part 1.90 Heavy Grade Heavy I Grade Heavy I Grade Heavy I Grade Heavy I Grade Heavy I Grade 880 BW 3 65 73. ERW.08 A 234 Gr.System .34 5 Threaded ITEM : 90° ELBOW 1.No. 1 200 219. Galvanised Heavy Grade 2 ENDS BW REMARKS .

ITEM : EQUAL TEE SL. 1 2 3 4 MATERIAL ENDS Heavy Grade Heavy Grade Heavy Grade Heavy Grade 3 7 4 11 BW BW BW Threaded REMARKS 80X65 80X50 65X50 50X40 88. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2. 4 10% Margin has been considered for all piping & all Fittings.32 48.32 73.No. .08 88. Galvanised 4.90 73.9X60. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system.No. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2.WPB Mild Steel -IS 1239 Part 2.5 Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 2 9 2 3 2 5 ENDS BW BW BW Threaded Threaded Threaded REMARKS ITEM : CONCENTRIC REDUCER SL.26 33.No. Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later.02 X 60.9X73. 1 Note: 25 33. 2 Fitting size.26 Mild Steel -IS 1239 Part 2. Galvanised ITEM : END CAP SL.02 60.40 MATERIAL A 234 Gr.32 60.02 88. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Mild Steel -IS 1239 Part 2. Galvanised Heavy Grade 5 ENDS Threaded REMARKS End Cap for Drain and Ven 1 Pipe size. Galvanised Mild Steel -IS 1239 Part 2.40 MATERIAL Mild Steel -IS 1239 Part 2. 1 2 3 4 5 6 200 80 65 50 40 25 219.32 X 48. Thickness and Quantity details have been indicated preliminary and which shall be finalised later.

30 88. ERW Mild Steel -IS 1239 Part1.90 60. ERW Mild Steel -IS 1239 Part1.32 48. 1 2 3 200 100 80 MATERIAL 219.90 60.90 Mild Steel.IS 1239 Part 2 4.IS 1239 Part 2 Mild Steel. ERW 4.08 114.90 60. 1 2 3 200 100 80 MATERIAL 219. 1 80 MATERIAL 88. One end of pipe to be provide i with socket welded full coupling.System : ITEM : PIPE Service water system SL.5 Medium Grade Medium Grade Heavy Grade Heavy Grade Heavy Grade ENDS 11 13 24 4 44 5 BW BW BW BW SW SW REMARKS 4 5 6 50 40 25 ITEM : 45° ELBOW 1.30 88.5 Medium Grade Medium Grade Heavy Grade Heavy Grade Heavy Grade ENDS 2 1 1 4 3 REMARKS BW BW BW BW SW SW 4 5 6 50 40 25 5 .08 114.B Mild Steel -IS 1239 Part 1.IS 1239 Part 2 Medium Grade ENDS 2 BW REMARKS ITEM : EQUAL TEE SL.IS 1239 Part 2 Mild Steel.26 Heavy Grade 800 Plain End One end of pipe to be provide i with socket welded full coupling.5 Medium Grade Medium Grade Heavy Grade 700 350 800 30 ENDS BE BE BE BW REMARKS - 4 50 5 40 48.IS 1239 Part 2 Mild Steel.5D SL.IS 1239 Part 2 Mild Steel. 6 25 33.WPB Mild Steel.IS 1239 Part 2 Mild Steel .IS 1239 Part 2 Mild Steel.IS 1239 Part 3 4.No.32 48.WPB Mild Steel.32 IS 3589 Fabricated from IS 2062 Gr.40 Heavy Grade 10 Plain End ITEM : 90° ELBOW 1.No.5D SL.No.40 A 234 Gr. ERW Mild Steel -IS 1239 Part1. 1 2 3 200 100 80 MATERIAL 219.IS 1239 Part 2 Mild Steel.26 33.40 A 234 Gr.26 33.IS 1239 Part 2 Mild Steel.No. ERW Mild Steel -IS 1239 Part1.30 88.08 114.

IS 1239 Part 2 Mild Steel. 1 25 33.26 A 234 Gr.No.40 MATERIAL Mild Steel -IS 1239 Part 2 Heavy Grade 5 ENDS SW REMARKS End cap for vent and drain.32X48.26 A 234 Gr.No. 4 10% Margin has been considered for all piping & all Fittings.08X114.31 88.26 88. .26 88. Note: 1 Pipe size. 1 2 3 4 5 MATERIAL ENDS 4.5 Medium Grade Medium Grade Medium Grade Heavy G rade 3 2 3 4 1 BW BW BW BW SW REMARKS 200X100 100X80 100X40 80X40 50x40 219.ITEM : UNEQUAL TEE SL.IS 1239 Part 2 Mild Steel.No.90 114.40 MATERIAL Mild Steel -IS 1239 Part 2 / A 105 #3000 5 END SW REMARKS ITEM : END CAP SL.3X48.3 114.IS 1239 Part 2 Mild Steel. 2 Fitting size. Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later.90X48.3 114.No.WPB Mild Steel.IS 1239 Part 2 Mild Steel.5 Medium Grade Medium Grade Medium Grade Medium Grade 6 1 2 1 8 BW BW BW BW BW REMARKS 200X100 100X80 100X40 80X50 80X40 219.90X48.3X88. Thickness and Quantity details have been indicated preliminary and which shall be finalised later.IS 1239 Part 2 Mild Steel.IS 1239 Part 2 ITEM : CONCENTRIC REDUCER SL.26 60. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system.WPB Mild Steel. 1 2 3 4 5 MATERIAL ENDS 4.3X88.08X114. 1 25 33.90 114.IS 1239 Part 2 ITEM : HALF COUPLING SL.3X48.90X60.IS 1239 Part 2 Mild Steel.

00 406.30 114. ERW Mild Steel -IS 1239 Part1.20 609.WPB A 234 Gr.3 5.02 60.5 Medium Grade Medium Grade END 5 12 6 6 2 26 19 29 7 BW BW BW BW BW BW BW BW BW REMARKS Miter Bend Miter Bend Miter Bend Miter Bend Miter Bend . ERW 7.90 73.B Fabricated from IS 2062 Gr.60 508.3 5.30 114.40 355.3 6.IS 1239 Part 2 Mild Steel.05 219.B Mild Steel -IS 1239 Part 1.30 88.40 355.6 5 4.60 273.60 273.1 6.B IS 3589 Fabricated from IS 2062 Gr.B A 234 Gr.40 Heavy Grade 25 Plain End 14 15 21.5 Medium Grade i Medium Grade i Medium Grade i Heavy Grade Heavy Grade 106 248 31 16 10 648 677 632 23 85 67 25 END BE BE BE BE BE BE BE BE BE BE BE Plain End REMARKS One end of pipe to be provide d with socket welded full coupling.No.1 6.30 MATERIAL Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr. ERW Mild Steel -IS 1239 Part1.3 6. One end of pipe to be provide d with socket welded full coupling.20 609.34 Heavy Grade 25 Plain End ITEM : 90° ELBOW 1.30 MATERIAL IS 3589 Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.B Fabricated from IS 2062 Gr.B IS 3589 Fabricated from IS 2062 Gr.3 6. ERW Mild Steel -IS 1239 Part1.60 508.6 5 4.No.3 6.WPB Mild Steel. ERW Mild Steel -IS 1239 Part1. ERW Mild Steel -IS 1239 Part1.System : Plant water system ITEM : PIPE SL.08 168. ERW Mild Steel -IS 1239 Part1. 13 25 33.B IS 3589 Fabricated from IS 2062 Gr. 1 2 3 4 5 6 7 8 9 700 600 500 400 350 250 200 150 100 711.B IS 3589 Fabricated from IS 2062 Gr.IS 1239 Part 2 7.5D SL. One end of pipe to be provide d with socket welded full coupling.08 168.B Fabricated from IS 2062 Gr.05 219. 1 2 3 4 5 6 7 8 9 10 11 12 700 600 500 400 350 250 200 150 100 80 65 50 711.B Fabricated from IS 2062 Gr.00 406.

1 50 60.WPB Mild Steel.IS 1239 Part 2 Mild Steel.90 73. 1 2 80 65 MATERIAL CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) #150 #150 4 2 END 3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING MATERIAL 80 65 A 105 A 105 #150 #150 4 2 END Flat face Flat face REMARKS Flange Code ASMEB16.90 MATERIAL Fabricated from IS 2062 Gr. 1 2 ITEM: END CAP SL.40 273.No. 1 2 ITEM: GASKET SL.IS 1239 Part 2 6.IS 1239 Part 2 Mild Steel.5 2 25 33. 10 11 12 13 80 65 50 25 88.60X406.No. 1 2 3 4 5 600 X 400 250 X 200 200X150 150X100 100X80 609.No.40 Heavy Grade 25 Threaded .30 168.08X168. 1 2 3 4 250 100 80 65 273.30X114.IS 1239 Part 2 5 Medium Grade Medium Grade Medium Grade 1 6 6 5 END BW BW BW BW REMARKS ITEM: UNEQUAL TEE SL.90 73.No.B A 234 Gr.05X219.No.SL.IS 1239 Part 2 Mild Steel.02 MATERIAL A 234 Gr.IS 1239 Part 2 Mild Steel.IS 1239 Part 2 Mild Steel.05 114.40 MATERIAL Mild Steel.WPB Mild Steel.5 Medium Grade Medium Grade 1 1 2 1 1 END BW BW BW BW BW REMARKS ITEM : SORF FLANGE ( Header Flange) SL.5 Flange Code ASMEB16.30 88.30 33.30 114.6 REMARKS - ITEM : BLIND FLANGE( Header Flange) SL.5 Flange Code ASMEB16.02 60.3 5 4.IS 1239 Part 2 Mild Steel.No.30 MATERIAL Mild Steel -IS 1239 Part 2 Mild Steel -IS 1239 Part 2 Heavy Grade 15 END Threaded REMARKS 80 65 MATERIAL A 105 A 105 #150 #150 4 2 END Flatface Flat face REMARKS Flange Code ASMEB16.IS 1239 Part 2 Medium Grade Medium Grade Heavy Grade Heavy Grade 15 31 10 15 END BW BW SW SW REMARKS ITEM: EQUAL TEE SL.08 219.No.WPB A 234 Gr.30X88.

1 QTYIN Nos. 1 50 60.30 MATERIAL Mild Steel -IS 1239 Part 2 / A 105 Mild Steel -IS 1239 Part 2 / A 105 Mild Steel -IS 1239 Part 2 / A 105 #3000 15 END SW REMARKS 2 25 33.20 MATERIAL Fabricated from IS 2062 Gr.No.NO.40 #3000 25 SW 3 15 33. Pipe size and Pipe thickness details have been indicated preliminary and which shall be finalised later. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system.40 #3000 30 SW ITEM DISHED END COVER SL. Fitting size and thickness details have been indicated preliminary and which shall be finalised later. . 1 END BW REMARKS Torispherical Note: 1 Pipe length. 1 700 711.ITEM HALF COUPLING SL. 7.B SCH/ THK. 2 No Fittings. 4 10% Margin has been considered for all piping & all Fittings.

System :
ITEM : PIPE

DM Feed water system

SL.No. 1 50 60.30

MATERIAL A312TP304, ERW 40 35

END Plain End

REMARKS One end of pipe to be provide with socket welded full coupling. One end of pipe to be provide with socket welded full coupling. One end of pipe to be provide with socket welded full coupling.

2

25

33.40

A312TP304,ERW

40

10

Plain End

3

15

21.30

A312TP304, ERW

40

16

Plain End

ITEM : 90° ELBOW

SL.No. 1 2 50 25 60.30 33.40

MATERIAL A182Gr.F304 A182Gr.F304 #3000 #3000 6 8

END SW SW

REMARKS

ITEM : HALF COUPLING

SL.No. 1 2 ITEM : END CAP SL.No. 1 25 33.40 25 15 33.40 21.30

MATERIAL A182Gr.F304 A182Gr.F304 #3000 #3000 14 30

END SW SW

REMARKS

MATERIAL A182Gr.F304 #3000 14

END NPT

REMARKS

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

ITEM : PIPE SL.No. 1 400 406.40 MATERIAL END 5S 35 BE REMARKS -

A312TP304, ERW

2

250

273.00

A312TP304, ERW

10S

70

BE

3

200

219.10

A312TP304, ERW

10S

40

BE

4

150

168.30

A312TP304, ERW

10S

710

BE

-

5

100

114.30

A312TP304, ERW

10S

435

BE

6

80

88.90

A312TP304, ERW

10S

20

BE

-

ITEM: 90° ELBOW 1.5D

SL.No. 1 2 3 4 5 6 400 250 200 150 100 80 406.40 273.00 219.10 168.30 114.30 88.90

MATERIAL A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 5S 10S 10S 10S 10S 10S 6 9 10 67 30 12

END BW BW BW BW BW BW

REMARKS

-

-

ITEM : EQUAL TEE

SL.No. 1 2 3 4 400 200 150 100 406.40 219.10 168.30 114.30

MATERIAL A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 5S 10S 10S 10S 2 2 2 1

END BW BW BW BW

REMARKS

-

ITEM : UNEQUAL TEE

SL.No. NB 1 2 3 4 400 X 250 250 X 200 250X150 150 X 100 OD in mm 406.40 X 273.00 273.00 X219.10 273.00X168.30 168.30X114.30

MATERIAL THK. A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 A 403 Gr. WP304 5S 10S 10S 10S Nos.(Rev. 0A) 8 2 1 15

END

REMARKS

BW BW BW BW

-

-

ITEM : CONCENTRIC REDUCER

SL.No. 1 2

MATERIAL

END 10S 10S 7 2 BW BW

REMARKS -

250X150 100X50

273.00X168.30 114.30X60.3

A 403 Gr. WP304 A 403 Gr. WP304

ITEM : SOFF FLANGE ( Header Flange) SL.No. 1 2 3 400 250 200 MATERIAL END #150 #150 #150 2 1 2 Flat face Flat face Flat face REMARKS Flange Code ASME B16.5 Flange Code ASME B16.5 Flange Code ASME B16.5

A182Gr. F304 A182Gr. F304 A182Gr. F304

4

150

-

A182Gr. F304

#150

4

Flat face

Flange Code ASME B16.5

ITEM : BLIND FLANGE SL.No. 1 2 3 4 ITEM : GASKET SL.No. 1 400 MATERIAL CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) CNAF (Compressed Non asbestos fibre) #150 2 END
3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING 3MM THICKNESS SELF CENTERING FLAT RING

MATERIAL 400 250 200 150 -

END #150 #150 #150 #150 2 1 2 4 Flat face Flat face Flat face Flat face

REMARKS Flange Code ASME B16.5 Flange Code ASME B16.5 Flange Code ASME B16.5 Flange Code ASME B16.5

A182Gr. F304 A182Gr. F304 A182Gr. F304 A182Gr. F304

REMARKS -

2 3 4 Note:

250 200 150

#150 #150 #150

1 2 4

-

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

System : Effluent System
ITEM: PIPE SL.No. 1 2 3 4 300 150 65 50 323.80 168.30 88.90 60.32 MATERIAL IS 3589 Fabricated from IS 2062 Gr.B Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW Mild Steel -IS 1239 Part1, ERW 6.3 Heavy Grade Heavy Grade Heavy Grade 1400 745 2290 1800 ENDS BE BE BE Plain End One end of pipe to be provided with socket welded full coupling. One end of pipe to be provided with socket welded full coupling. One end of pipe to be provided with socket welded full coupling. REMARKS -

5

40

48.26

Heavy Grade

5319

Plain End

6

25

33.40

Heavy Grade

25

Plain End

ITEM: 90° ELBOW 1.5D

SL.No. 1 2 3 4 5 6 300 150 65 50 40 25 323.80 168.30 88.90 60.32 48.26 33.40

MATERIAL A 234 Gr.WPB Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 6.3 Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 20 30 30 30 30 20

ENDS BW BW BW SW SW SW

REMARKS

-

ITEM: EQUAL TEE

SL.No. 2 3 4 5 6 150 65 50 40 25 168.30 88.90 60.32 48.26 33.40

MATERIAL Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 2 Mild Steel- IS 1239 Part 3 Heavy Grade Heavy Grade Heavy Grade Heavy Grade Heavy Grade 5 5 5 5 5

ENDS BW BW SW SW SW

REMARKS

-

Note: 1 Pipe size.40 MATERIAL Mild Steel -IS 1239 Part2 Heavy Grade 25 ENDS SW REMARKS End cap for vent and drain.No. 4 10% Margin has been considered for all piping & all Fittings. 2 Fitting size.ITEM: HALF COUPLING SL. 1 25 33. . Thickness and Quantity details have been indicated preliminary and which shall be finalised later. 1 25 33.No. . Pipe thickness and Quantity details have been indicated preliminary and which shall be finalised later.40 MATERIAL Mild Steel -IS 1239 Part 2 / A 105 #3000 25 END SW REMARKS - ITEM: END CAP SL. Counter flanges for all flanged valves along with Fasteners and Gaskets are considered in valve vendor scope of supply for this system.

IS 1239 (Heavy Grade / Medium Grade ). B7.1 3MM THICKNESS SELF CENTERING FLAT RING CNAF (Compressed Non asbestos fibre) / Class 150 ASME B16.3 5.9 4. Galvanised & NUTS A194 Gr.1 /ASME B 18. * .67 3.2.3 5. Pipe thickness details have been indicated preliminary and subject to change.32 4.Pressure & Temperature have been indicated preliminary and subject to change. °C 50 IS-1239 ( Part -I) THREADED END/ BUTTWELD Mild Steel .2 Design Press. ERW.5 150 168.ANNEX-1.02 4.5 80 88.8 100 114. (bar g ) 10.5/ASMEB 18.4 Design Pres.21 THREADED END//BUTTWELD TO MATCH PIPE THICKNESS IS-1239 (Part.2/ASME B1. (bar g ) 10. Galvanised/Class 150 ASMEB 16.5 20 26. Galvanised ASTMA105.4 Design Temp.2 ) Mild Steel IS -1239.5 Service Air Distribution System CHART 1 Description Instrument Air Distribution Lines Pipes Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness (mm) Standard End type Material Flanges Material End Type /Facing /Class Standard Bolts / Nuts Type Material /Class Standard Gaskets Type Material /Class Standard Fittings End type Class / Thick Standard Material 15 21.2 25 33.4 4 Design Temp.26 4 50 60. Galvanised THREADED END / RAISED FACE /Class 150 ASMEB16. °C 50 32 42.2.5 FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos. .) BOLTS A193Gr. 2.3 PIPING CLASSIFICATION PIPING CLASSIFICATION Corrosion Allowance -1 mm Instrument Air Distribution System NON IBR Hydrotest Pressure Factor -1.5 Description Service Air Distribution Lines 65 73.16 4 40 48. Galvanised Note: 1. 2H.34 3.

2/ASME B1.5 12 3.0 mm DM Feed Water System Description DM Water Transfer Pump Suction line DM Water Transfer Pump Discharge lines Hot Well Make up Pump Suction lines Hot Well Make up Pump Discharge lines Design Press.4 200 Description Colony Potable Water Pump suction lines Colony Potable Water Pump discharge lines NON IBR Hydrotest Pressure Factor -1.9 ASTM A 234 Gr. 2H.2 Design Press.4 4 32 42. Galvanised ASTMA105. (bar g ) 3.5 Design Temp.5 3.6 25 33. Galvanised/Class 150 ASMEB 16.5 80 88. Galvanised Note: 1.8 100 114. °C 50 50 219. B7.16 4 40 48. * .5 5. 2.34 3.32 4. Galvanised THREADED END / FLAT FACE / Class 150 ASMEB16. ( Bar g 3.21 BUTT WELDED END /BEVELED END WITH ZINC RICH ELECTRODE TO MATCH PIPE THICKNESS ASMEB 16.3 5.5 16.2 20 26.5 Potable Water System Design Pres. Galvanised IS-1239 ( Part -I) THREADED END/ BUTT END Mild Steel – IS 1239 (Heavy Grade).5 DM Feed Water System Design Press.5 10 CHART 2 Design Temp.5 FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.5 3.32 CHART 3 Design Temp.B . Galvanised & NUTS A194 Gr.5 5. WPB. °C 50 50 50 50 Description DM Cooling Water Make up Pump Suction lines DM Cooling Water Make up Pump Discharge lines Boiler Fill Pump Suction lines Boiler Fill Pump Discharge lines NON IBR Hydrotest Pressure Factor -1.5 65 73. Galvanised 15 21.9 4. (bar g ) 3.3 IS-3589 BUTT WELDED END /BEVELED END WITH ZINC RICH ELECTRODE IS 3589 Fabricated from IS 2062 Gr. PIPING CLASSIFICATION Corrosion Allowance .02 4. Pipe thickness details have been indicated preliminary and subject to change.PIPING CLASSIFICATION Corrosion Allowance -1 mm Potable Water System Description Plant Potable Water Pump suction lines Plant Potable Water Pump discharge lines Potable Water Distribution lines Pipes Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness (mm) Standard End type Material Flanges Material End Type /Facing /Class Standard Bolts / Nuts Type Material /Class Standard Gaskets Type Material /Class Standard Fittings End type Class / Thick Standard Material THREADED END TO MATCH PIPE THICKNESS IS-1239 (Part-2) Mild Steel IS-1239. °C 50 50 50 50 60.5/ASMEB 18. °C 50 50 50 50 .08 6.) BOLTS A193Gr.1 3MM THICKNESS SELF CENTERING FLAT RING CNAF (Compressed Non asbestos fibre) / Class 150 ASME B16.5 3.2.26 4 Design Temp.67 3.1 /ASME B 18.Pressure & Temperature have been indicated preliminary and subject to change.3 5.4 150 168. ERW.2. ( Bar g ) 3.

Design Pressure & Design Temperature have been indicated preliminary and subject to change.40 12.4 5.30 6.2 & A 194 Gr.0 0 10.1 3MM THICKNESS SELF CENTERING FLAT RI NG CNAF (Compressed Non asbestos fibre) / Class 150 ASME B16.00 609.02 80 88.3589 AWWA C200 / AWWA M11 .5 4.16 40 48.05 400 406.40 5S ASMEB36.30 6.30 6.20 1824.Pipes Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness (mm) Standard End type Material 15 21.2.00 2600 2624.32 65 73.30 6.19M PLAIN END BUTT WELDED END / BEVELED END STAINLESS STEEL ASTM A 312 TP 304.26 50 65 80 88.4 273.40 32 42.2.08 250 273.00 1200 1800 2200 2224.3 200 219.B8M / Class 150 ASMEB 16.00 1400 1422.60 6.30 457.00 I S .12 39 ( Pa r t.67 25 33. PIPING CLASSIFICATION NON IBR CHART 4 Pipes Nominal Diameter (NB) Outside Diameter (mm) Pipe Thickness Standard 15 21.5 FULLY THREADED BOLTS / HEAVY HEXAGONAL NUTS (2 Nos.34 20 26.30 168.30 450 500 600 700 800 812.05 323.60 711.2/ASME B1.34 3.20 508. B8M Cl.4 0 6.2 25 33.32 73.26 50 60.08 6.30 250 300 350 400 406.WP304 SLIP ON / FLAT FACE / Class 150 Flanges Material End Type /Facing /Class Standard Bolts / Nuts Type Material /Class Standard Gaskets Type Material /Class Standard Fittings End type Class / Thick Standard Material Note: 1.2 20 26.80 7.10 1000 1016.1 /ASME B 18.00 10.30 5.30 6.I ) IS .16 40 48.02 4.4 40 32 42. Pipe thickness details have been indicated preliminary and subject to change.) ASTM A 193 Gr. F304 BUTT WELDED END / BEVELED END TO MATCH PIPE THICKNESS ASMEB 16.9 ASTMA403Gr.00 12.9 100 114.00 60.20 6.00 12.5 114. 2.3 10S 150 168.80 355.8 100 150 200 219.11 ASTMA 182 Gr. ERW ASTMA 182Gr.F304 SOCKET WELDED / FLAT FACE / Class 150 ASMEB16.90 4.5/ASMEB 18.67 3.00 12.30 1219.21 SOCKET WELDED END Class 3000 ASMEB 16.

Pressure details shall be provided later 3. WPB CNAF (Compressed Non asbestos fibre ASMEB16. B 7 & NUTS A194 Gr. 5. ACW Piping system and Raw Water System .1 / ASME B 18. 4.B /Class 150 Note: 1. Miter Bends shall be used for size 300NB and above. ERW IS 3589 Fabricated from IS 2062 Gr.9 ASTM A 234 Gr.Pressure & Temperature have been indicated preliminary and subject to change.IS 1239 IS 1239 (Part-2) l Mild d Ste ! -IS 1239 ASME B 16.B Flanges End Type / Facing /Class Standard Bolts / Nuts SOCKET WELDED / FLAT FACE / Class 150 ASMEB16. * . Pipe thickness details have been indicated preliminary and subject to change. Epoxy coating shall be provided above 500NB pipe size for CW Piping system.1 Gaskets Material / Class Standard Fittings End type Class /Thick Standard Material SOCKET WELDED END TO MATCH PIPE THICKNESS IS 1239 (Part-2) Mild Stee .IS 1239 (Heavy Grade) .2. * * . 2.2 / ASME B1.B AWWA M11 Fabricated from IS 2062 Gr.5 SLIP ON/FLAT FACE/Class 150 SLIP ON/FLAT FACE / Class B or Class D AWWA C 207 Material / Class Standard BOLTS A193Gr.Material Mild Steel . 2H/Class 150 ASME B 16.21 BUTT WELDED END / BEVELED END TO MATCH PIPE THICKNESS AWWA C 208 / BS 534 Fabricated From Mild Steel IS 2062 Gr.2.5 / ASME B 18.

.....0............................................................ SIMPLEX/DUPLEX FILTERS..............................0...............................................................................0 8.............................................................................................................0......0 5...............................4 EXCLUSIONS...............0............0 INSPECTION........0.................................................................................................0........................................................................6 06 SECTION .......................................10 ERECTION OF VALVES...........9 BURIED PIPING....................................12 12..... ERECTION.....................................................11 10.......................................................................14 17.0 DETAILED TECHNICAL SPECIFICATION SECTION ..0 ERECTION OF SUPPORTS..4 2..................................12 13...ERECTION OF BURIED PIPING TECHNICAL SPECIFICATION ...................0...................................0...........0 LINE MOUNTED FILTERS......................................................5 2........0 7.............................................13 14...............................0...................0 2................................................... CUTTING AND FITTING UP......6 LAYOUT.....0 9......3 SCOPE OF WORK...........................................................................0.............................................................................0..............................................................10 INSTALLATION AND ASSEMBLY........................0 MATERIAL IDENTIFICATION..0.........1 TECHNICAL SPECIFICATION ERECTION OF LP PIPING TABLE OF CONTENTS 1....0............0 INTENT OF SPECIFICATION.......13 15.1 TECHNICAL SPECIFICATION FOR ERECTION OF LP PIPING 14 23 06 05 05 2............................0 4........2 2...........2...................................0 ERECTION OF INSTRUMENTS....................................................HYDRO TEST PROCEDURE TECHNICAL SPECIFICATION ..........................2...........................14 .............................12 11.........0.......1 DETAILED TECHNICAL SPECIFICATION -FABRICATION..................0 INSTRUMENT CONNECTIONS.....................................................................0..........14 16.................................................................................0 HYDROTEST......................................SECTION ..LP PIPING FLUSHING AND CLEANING PROCEDURE TECHNICAL SPECIFICATION-WRAPPING& COATING OF BURIED PIPING 2...... MIXERS & FLEXIBLE HOSES......3 TECHNICAL SPECIFICATION-WELDING PROCEDURE TECHNICAL SPECIFICATION ................................2...............0....................................................3 CODES AND STANDARDS....0 6.............0 RECORDS.......................0 3........... TESTING & COMMISSIONING SECTION CONTENTS SHEET NO 2..................6 ERECTION........................0.......

Fabrication of miter bends (above 300NB / The plate material will be free issued by owner). Handling at site. Laying. site supervision. • • • • • • • • CW Blow down System. DM Feed Water System a) DM Water Transfer Pumps all suction. d) Boiler Feed Pumps suction.1 TECHNICAL SPECIFICATION ERECTION OF LP PIPING 1. Plant Water System . c) Ash Water Tank Fill pumps suction and discharge lines. Wash Water System. • Plant Water System -I a) Raw Water System. Pipes and fittings (free issue by owner). inspection & testing atsite. supports and specialties etc. Colony Potable Water pumps all suction and discharge lines. All tanks external down comer pipe lines. Sludge Water system. cleaning & painting. b) APH Wash pumps all suction and discharge lines. d) Service Water Pumps suction and discharge lines e) DM plant pumps suction lines. discharge and recirculation lines (Condensate Make up line). discharge and recirculation lines. valves. Wrapping and Coating. vent pipe lines and draw of sump lines. Erection. over flow lines.SECTION 2.0 INTENT OF SPECIFICATION This specification covers the minimum requirements and guidelines to be adhered by the Bidder for the Receipt of material from site stores.II a) b) Plant Potable Water pumps all suction and discharge lines. The LP piping Erection comprises the following: • • • • • Instrument Air Distribution System Service Air Distribution System Service Water Distribution System Potable Water Distribution System. supply and Fabrication of Supports. Effluent System. c) DM Cooling Water Make up Pumps suction. DM Cooling Water Supply & Return Line for Main Plant compressor & Ash Handling compressor. . discharge and recirculation lines. f) • AHS Seal Pumps suction lines. Fabrication of Supports (Support material will be free issued by owner). calibration and commissioning at site for LP piping. discharge and recirculation lines. b) Hot Well Make up Pumps all suction. SSF Backwash line. All pipe line headers.0.

0.0 CODES AND STANDARDS The erection and testing of piping. Ring joint gaskets and grooves for steel pipe flanges Butt welding ends Code for design.1. Non destructive Examination Pressure Vessels Welding and Brazing qualifications. Standard for Field Welding of Steel Water Pipe.2. Visual inspection & testing Magnetic particle testing Radiographic testing Steel Pipe . Standard for Steel Water Pipe 6 in.1 ANSI B16. valves. specialities and flash vessels.A guide for Design and Installation.1 ANSI B 2. The following standards shall be followed in particular.25 IS:803 ASME BPVC Sec V ASME BPVC Sec VII ASME BPVC Sec IX MSS-SP-55 MSS-SP-53 MSS-SP-54 AWWA-M11 AWWA-C206 AWWA-C208 AWWA-C200 Power Piping Pipe threads Wrought steel Butt Welding Fittings.9 ANSI B 16. Dimension for fabricated steel water pipe fittings. .20 ANSI B 16. testing and erection of mild steel storage tanks.(150mm) and larger. shall comply with the requirements of latest edition of ASME B31. • • • • • • • • • • • • • • • • ANSIB31.

Fine fittings. Supply and receipt of materials. if there are problems in the operation. Prefabrication including cold bending of pipes. Welding of temporary . All tubes and pipes shall be cleaned and blown with compressed air before erection. fittings & supports. power cylinders. layout of small bore piping shall be done in accordance with site requirement. No temporary supports shall be welded on the pressure parts. Providing all labour. NDT examinations as per ASME sec IX. etc. All the valves. shall be serviced and lubricated before erecting the same and also during precommissioning.0 • • SCOPE OF WORK The scope of work covered in this document include but not limited to the following. and opening or closing the fabricated bends of high-pressure piping to suit the layout shall be considered part of the work and the Contractor is required to carry out such work.3. cleaning including steam blowing as per the specification given hereinafter. valves and specialities. Supply and application of grouting material including non-shrinkable cement and erection of grouting. As such. and other small bore piping have to be routed according to site conditions and hence shall be done only in position. The valves shall be checked. flushing. Certain adjustments in length may be necessary while erecting high-pressure pipelines and the Contractor shall remove the extra lengths / add extra lengths to suit the final layout after preparing edges afresh and adopting specified heat treatment procedures. hydro testing etc. shall be supplied in running lengths which shall be cut to suitably sizes and adjusted as required.. erected. actuators. installed and tested shall be as per the erection drawings. wherever required. etc. PQR). reducers. The Purchaser/Consultant will furnish isometric drawings for all LP lines above 2". The quantity of piping and equipment to be fabricated. drain piping. Erection of all rod hangers and supports including auxiliary structures as required. Welding or jointing of extension spindle for valves to suit the site conditions and operational facility shall be part of erection work. weld neck flanges. etc. etc. heat treatment. Bigger size pipes shall be cleaned with flexible wire brush. which shall include specified heat treatment procedures. Adjustments such as removal of ovailties in pipes. pressure parts... modification during execution. Work shall also include fabrication of small bends at site from straight lengths to suit the site conditions. manufacture and testing at site as required. or overhauled in full or in part before erection. wherever necessary. oil systems. cleaned. after chemical cleaning. identification. • • • • • • • • • Broad Guidelines for Erection and Installation of Low Pressure Piping • All fittings like "T” pieces. There is a possibility of slight change in routing the above pipelines even after completion of erection.. The Tenderer shall prepare the erection drawings for all LP piping lines. Supply and application of cathodic protection for all buried piping. and during commissioning. shall be suitably matched with pipes for welding. handling. erection of complete piping. these shall be attended to by the Contractor. Even after commissioning the equipment. lighting equipment. all field welding of pipes and fabrication of pipes. Hydro testing. prequalification of welding procedures and welders (WPS. Supply and application painting for above ground piping. unloading. consumables and equipment as necessary for fabrication. Supply and application of coating and wrapping for all buried piping. Suspension for piping. The Tenderer shall supply all required piping / supports etc on take back basis after dismantling the same.0. Execution of field engineering. material. Tenderer shall prepare isometrics for lines below 2" based on site routing and get the approval of the Purchaser/ Consultant during the time of erection.

pipe racks/ pipe trenches etc. on the building columns shall also be avoided. Preparation of butt welding joints shall be as per ASME B 31. All drips and drains for piping and equipment whether shown on the drawings or not shall terminate on the ground floor at the station drain unless otherwise noted. All specialties their counter flanges along with fastener and gaskets. All valves their counter flanges along with fastener and gaskets. (b) The piping shall be arranged to provide clearance for the removal of equipment for maintenance and for easy access to valves.. buildings. Civil: • • • All Civil Engineering works such as RCC foundation. Plate for fabricated pipe and fittings.supports. the Contractor shall fabricate and erect all hangers and supports as required with due regard to general arrangement and layout of other pipes. cable trays. Pipe Support materials. (c) Piping shall be generally routed above ground but. (f) For field run piping.0 Cutting and fitting-up • Pipes shall be cut to required length in accordance with piping layout drawings and/or spool drawings. structural members etc. Making opening in the walls for routing of pipes Encasement for the buried piping.0. unless otherwise approved by the Engineer. hangers. • The ends of piping com ponents to be joined shall be aligned as accurately as is practicable within existing tolerance on diameters.0. (d) Overhead piping shall generally have a minimum overhead clearance of 2.0 Branch Connections . and other piping accessories required for operation and maintenance.1.0 LAYOUT. (a) All pipes shall be grouped wherever practicable and shall be routed to present a neat appearance.3 meters above walkways and working areas and 6 metres above roadways. etc. The pipelines shall be sloped towards the drain points.2. where specifically indicated / approved. Supply of pipes and fittings (other than fabricated from the plate material). ducting. Internal radial misalignment exceeding 1.1/as per enclosed figure elsewhere in this tender document. (e) Drains shall be provided at all low points and vents at high points in accordance with actual layout regardless of whether the same have been shown in the respective drawings or not. after getting approval from Engineer. 5.6 mm shall be taper trimmed as per enclosed figure elsewhere in this tender document. Leading such drains to the station drainage is also the responsibility of the Contractor.0 EXCLUSIONS Mechanical: • • • • • • • Erection of Piping beyond battery limits. Preparation of pipe ends shall preferably be done by any combination of turning and grinding. When oxygen or arc cutting is resorted to then the cut shall be reasonably smooth and true and all slag is cleaned from the flame cut surfaces. 5. CUTTING AND FITTING UP 5. roads. 4. wall thickness and out-of-roundness. All instruments with their accessories. cleats. piping may be arranged in trenches or buried. instruments.

Rotation Out of alignment measured across the diameter e. End preparation of branch and runner pipe shall be as per the relevant clause of ASME B31. Cold bending is only permitted and no hot bending is envisaged at site. 5. 5. Face to face/center to face Lateral translation in any direction c. slag free. 5.8. • 5. However. Machine cut bevels to form the welding groove are preferred in carbon steel pipe.1.10. i. • All buried piping shall be as per the specification given in Section 2.• Openings for branch connections shall preferably be made by drilling. 5.0 Threaded Connections Taper pipe threads shall be used in accordance with ANSI B.5 mm (max) ±1 .0 Mitre Bends Mitre bends shall be fabricated in accordance with "Piping Standard Drawing" unless otherwise specified in piping GA drawing.4.0 Layout • • • For laying out headers.0 Minimum Distance between Longitudinal Welds The distance between two longitudinal weld shall be staggered suitably.0 Heat Tracing Wherever applicable pipes should be installed along with heat tracer pipes as per the details given in the piping layout drawings. 5.pressure piping such as drain and vent lines.5.0 Threaded Joints When threaded couplings or nipples are welded to the pipe spools.3. 5.11. Single cut mitre are not allowed.0 Bending Hot bending is not permitted except for non. b. Edge Preparation details for branch connection joints shall be subjected to approval of Consultant/ Purchaser. : ±1 mm : : ± 1.9.5 deg (max) : ± 3 mm (max) Flattening measured as difference between maximum and minimum OD at any Cross Section. Heat tracer pipes shall be of non-cementing type with the main pipe line. clean.2.0 Dimensional Tolerances The dimension tolerances generally acceptable are as follows a.7. Oxygen or arc cutting is acceptable only if the cut is reasonably smooth and true and all slag is cleaned from the flame cut surfaces. flame cut bevels using flame bevel cutting machines. the thread must be checked for fit and roundness after welding. smooth.1 "Pipe Threads" for threaded pipe joints. For pipe with external .4. templates shall be used to ensure accurate cutting and proper fit-up. All cutting shall follow the outline of the template. 5.0 Flanged Connections Flange bolt holes shall straddle the established center-lines (horizontal or vertical) unless otherwise shown. 5.6. d. laterals and other irregular details. tees.

The Tenderer shall provide adequate number of field welds.0 Piping Alignment The pipes to be jointed by welding shall be aligned correctly with the existing tolerances on diameters.2 Installation a) Location of welding machines and the switch boards to be connected with them shall be decided in consultation with Engineer to prevent them for disturbing other work as well as to prevent overloading of the switchboards. equipment and where required for ease of erection and maintenance as indicated in drawing. wire brush etc.5 mm. The same alignment shall be preserved during welding.W) to be provided to take care of these. c) Portable power cables used with welding machines shall be carefully examined and . wire brush etc. BW joints shall be used for 65 NB and above and SW/Threaded/BW joints shall be used for sizes 50 NB and below as specified in piping drawings.pressure ii. Field welds (F. it shall be the responsibility of the Tenderer to notify the Purchaser prior to fabrication and erection. During erection the pipe end with extra length of each field weld may be cut to obtain proper dimension. Welding machines shall be periodically inspected at least once a month for maintenance. Inspection and Maintenance of Welding Machines.12. cutting chips etc. 5.15. For pipe with internal pressure : 3% (max) : 8% (max) Tenderer shall be responsible for working to the dimensions shown in the drawing. all pipes and fittings shall be cleaned inside and outside by suitable means (Mechanical tools. DC Machines only to be used. For the internal misalignment due to difference in wall thickness of the mating components exceeding 1. sand. In general. However. However. weld spatter particles. This is applicable for non-galvanised piping and piping without lining. 5.15. Wherever omissions/ errors occur in drawings and bill of materials. 5.0 Cleaning of Piping On completion of fabrication. b) Electric cables. All field fabricated piping shall be cleaned at the conclusion of the fabrication. cables and electrical power sources.15. 5. 5. Proper earthing to be provided for welding machine.) before erection to ensure that assembly is free from all loose foreign material such as scale. Flanged joints shall be used at connections to vessels.1 Welding Machines 1. This inspection and maintenance shall be done mainly for quality control purpose and shall be periodically recorded in a list showing the location and conditions of the welding machines being used.0 Quality Control For Welding 5.0 Pipe Joints Pipe joints shall be generally welded or as indicated in Piping drawings. wall thickness and out of roundness. All welding shall be as per the welding procedure specified.14.13. All burrs. there may be slight variations due to minor variation in the location of equipment. switches and connections for welding machines shall be carefully checked and repaired atleast once a month and before operating the welding machines.) Field fabricated piping shall be blown out with compressed air at the termination of cleaning and capped. the component with the higher wall thickness shall be internally machined ground so that the adjoining surfaces are approximately flushed. BW joints may be used after getting prior approval from Purchaser/Consultant in place of SW/Threaded connections in long runs of piping. welding circles and weld spatter shall be removed by any suitable means (mechanical tools. insert etc. An extra pipe length of 100 mm over and above the dimension shown in the drawing may be left on one side of the pipe at each end of field weld.

3. e) Welding at any joint shall be completed uninterrupted. 6.16.6. In case the Tenderer is unable to maintain the indicated slope he shall check the sagging of the pipe with a precision spirit level and maintain a difference in levels higher than that.repaired as necessary every day.7.16. 5. 6.e.3 enclosed along with this section. The Tenderer shall provide vent and drain connections even when these are not shown in the drawings and are found necessary by the Engineer. tested for tightness and kept dry wherever instructed. The details for the type of connections to be adopted shall be as per enclosed drawings. 6. it shall be cleaned.0 ERECTION 6.0. use of davits. filing or grinding. stops and anchors must be made in such a manner that they will not over stress a line while protecting a weaker or more sensitive component e. welding of temporary supports on adjacent equipment / structure. 6. turbine. restraints such as guides.0 Erection and fabrication or supports i. Welding procedure and welder qualification records shall be maintained for reference of Purchaser/Consultant at any time.4. 6. Automatic or semi-automatic welding processes may be done only with the specific approval of Purchaser/ Consultant. 6. b) No welding shall be done if there is impingement of any rain.0 All piping shall be routed and located as shown in piping drawings keeping in view the piping specifications.2 Welding Procedure For detailed welding procedure refer Section -2.0 Location and design of pipe supports shown in support drawings should be strictly adhered to. turbines. Vents and drains are shown in the isometric of each line and these are intended for releasing the trapped air during hydrostatic test and draining out the test fluid after testing. Pipe supports have been designed and located to effectively sustain the piping system for weight and thermal offsets. use of existing foundation or steel structure shall be allowed only after approval of Engineer-incharge. excessive gap etc.g.2. etc. In each case. Valved vents and drains are also shown wherever required.1 General a) All welding and heat treatment shall be performed in accordance with the welding requirements detailed in ASME B31. Temporary protective covers shall be provided at all flanged connections of pumps.0. 5. The final tightening shall be redone when the machines are aligned completely and specifically authorised by the Engineer. pump compressor. compressors and other equipment shall be made in such a way as not to induce any stresses due to misalignment.0 Welding 5.0 Flanged connections at the pump. as described in this specification. c) Before welding. d) Proper earthing of the welding machines shall be ensured by the Tenderer. f) Welding shall be done by manual shielded metal arc process and TIG welding as applicable.1. 7. the weld shall be completely removed and a new joint shall be made. compressors. d) Welding shall be done by certified welders only.0 Slopes specified for various lines in the drawings shall be maintained by the Tenderer. No deviations from the arrangement shown shall be permitted without the approval of the Engineer. Pipes shall not be pulled and connected to equipment as well as during welding. or high winds on the weld area except when suitable protection or shield against the rain or wind is provided.0 BURIED PIPING . the ends shall be cleaned by wire brushing.16.0 For erection of piping.0 After the piping is erected in final position. 6. Each weldrun shall be cleaned of slag before the next run is deposited. If this cannot be followed for some reason. maximum allowable load and erection procedure shall be as directed by the Engineer-in-charge. turbines and other similar equipment until the piping is finally connected. vessel nozzles.1.5.

the direction of those shall conform to the flow direction shown on piping drawings.4. b) Care shall be taken to prevent damage to equipment nozzle caused by the weight and moment of fabricated spools or piping components.4.5.5 Bolting Procedure Anti galling compound shall be applied on all flanges bolts in order to prevent seizing.2.4.4 8.0 Connection to Equipment Nozzles a) Faces of flanges and the bolt holes shall accord reasonably to those of equipment nozzle flanges. Bolt loads shall be in accordance with the manufacturer's recommendation. No load shall be transferred to the connected equipment.1 Threaded Piping Teflon seal tape shall be used for all threaded piping.0 8.4. 8. All flanged joints shall be fitted so that the faces of the flange meet evenly with the gasket. check and needle valve. i) Flange faces which connect piping to the primarily aligned machinery shall be strictly parallel with the clearance between them equal to the thickness of the gasket so that alignment of the machinery after tightening the flanges will be within the allowable tolerances specified.2 8.1. d) Care shall be taken that the faces of companion flanges for flanged cast iron components shall be parallel with the required clearance for gasket thickness and that the flange bolts shall not be off-centre. Steel-to-cast iron flange joints shall be assembled with care to prevent damage of the cast iron flange. b) For installation of angle. if drilled.0 INSTALLATION AND ASSEMBLY General a) Installation and assembly of fabricated spool and piping components shall be made so that the completely installed piping system conforms to the requirements of relevant drawings and specifications. 8.0 along with this section. b) Lines connected to rotating machinery shall be aligned so as to meet the following requirements. ii) Off-center of bolt holes shall be minimised so that the bolt can pass smoothly through the bolt holes. Permanent or suitable temporary pipe supports shall be installed prior to installation of such a piping. 8. the bolt shall be tightened in a proper manner to compress the gasket to build up a compression suitable for the type of gasket used. All bolts shall extend completely and uniformly through their nuts. . c) Direction of the pressure balancing hole for gate valves. shall conform to piping drawings. 8.0 8. 8.0. No lead based component shall be used. In bolting flanged joints.5.0 8. and then the bolts shall be tightened in a sequence to ensure uniform bolt stress.0 Installation of Spools and Piping Components a) Care shall be taken to protect/prevent tack welds at both weld ends from any damage caused by weight and the moment of piping components. blow-down.3 8.Buried piping shall be as per detailed procedure enclosed as Annexure-3. The alignment of the piping shall be checked after completion of piping fabrication with flanges disconnected and witnessed by the Engineer.4.1 8.3.2.4. control valve and pressure relief valve.

protection cover shall be used at control valves. mixers.6.4. if duplex filters. shall be welded by qualified pipe welders. he shall install all the in-line instruments such as orifice flanges including orifice plates. MIXERS & FLEXIBLE HOSES 12. valve stems shall be installed in a vertical direction and shall not be installed with stems below the horizontal. reference may be made to relevant clause of the chapter for pressure testing inspection procedures. Shims and wedges may be employed for levelling and alignment of the supports on the grade.0 Globe valve. He shall.4. 11. however.1.1 The first nipple and valve of small connections including instrument connections to piping.0 All globe valves shall be installed with the pressure on the bottom of the disc. with valves.3.0. nozzle and flange. 10. its cleaning and up-keeping shall be part of the piping erection work and no separate payment shall .0. or any other arrangements.0 Valve spindle positions are shown in the arrangement drawings and the Tenderer shall be required to follow them. flow meter etc.2.1. 9.0 For installation of all in-line instruments.0 ERECTION OF VALVES Erection and testing of the valves shall be in accordance with the applicable standards.0 Fabrication All supports shall be properly levelled and plumbed as per pipe support drawings. "Non mandatory rules for design and safety valve installations" shall apply.0 Welding Pipe supports which are welded to the pressurised pipe directly.0. Rupture discs and other safety devices against excess pressure the directives of the Appendix II of the code ANSI B 31. control valves etc.3.0 Where practicable and except when otherwise shown on the drawings.9.4. Rigid temporary wooden frames or other suitable devices may be used for supporting piping before installation of pipe supports. ejectors including installation of all types of supports will be done the by Tenderer as part of piping erection work. 9.0 Installation of line mounted filters with by-pass arrangements.4.2. 10.0 All in-line instruments shall be installed only after final flushing of the line and when the line is ready for commissioning.2.0.0 LINE MOUNTED FILTERS. 10. vessel or equipment shall be braced if required. 10.0 Installation of temporary strainers as per requirements either during finishing or start-up.any.0 ERECTION OF INSTRUMENTS 11.0 The limits of piping Tenderer are clearly shown in the drawings provided (such as upto first block valve. 12. additional pipe supports may be installed to improve the stability of the piping after approval of the Engineer.0 9. 12.1.3. rotameters.0 Care shall be exercised and adequate precautions to be taken to avoid damage to the instruments while transportation. bring it to the notice of the Engineer in case he encounters some difficulty in installing them.0 ERECTION OF SUPPORTS10. taps etc. to avoid contamination with dust and foreign matter.4. pressure relief/safety valves.0 Supports Permitting Pipe Movement Supports permitting pipe movement shall be assembled to allow the necessary movement pipes of as caused by thermal expansion and contraction in accordance with the piping drawing and stress analysis reports giving details of movements at individual support locations.2 For 2" and smaller piping. venturi control valves. In addition to this.0 For Safety valves. 9.5. 11.2. 9.0 Bracing 10. installation etc. SIMPLEX/DUPLEX FILTERS. 9. positive displacement meters with strainers. 11. Pressure relief valves. check valve. shall be installed in the correct sequence and direction as shown in P&I diagram and piping drawings. rupture/bursting discs etc.1. flow integrators.1.). 11. 10.

with the following functions but not limited to: i.4.5 of this tender document.1.2.0 Flexible hoses shall be installed on the suction of naphtha and distillate unloading pump as indicated in relevant piping layout maintaining necessary slope.1.4. 14. 12. The number.0 INSTRUMENT CONNECTIONS . 15.0.1.1 During erection of the piping.0 General 13. 13. 13. 13. To iii.0 Details of inspection and defect acceptance norms its repair and removal shall be as per this tender document. Nuts 12.3.3 Tenderer shall notify inspection dates sufficiently in advance with all facilities necessary for carrying out his work at no extra cost to the Purchaser. Only bolts of adequate length. Hexagonal bolt heads shall be all at the same side with horizontal flanges at the top.0 Thickness and Pressure Temperature Rating a) Thickness and pressure temperature rating of piping components to be used shall be checked by stencil or other marking and measurement referring to the material shown on piping drawing and piping service classes.1. the Tenderer shall install proper number and size of bolts and nuts as per drawings and specifications. iv To check whether welding is conforming to relevant specification and the procedure followed and is in accordance with good pipeline construction practice.be made on this account.4. Threaded ends with machine bolts shall protrude adequately through the nuts.1.3 All bolts shall extend completely through their nuts.2 Purchaser is entitled to send his own inspector or his representative to field where prefabrication and erection of pipe lines are being done. To check any other activity to ensure quality of work.1 Purchaser's/Consultant's inspector shall have free access to all places where the work is being done or any other place concerned with the work. b) Markings on pipe stencilled by manufacturer shall be left until final use of the pipe and be transferred by painting on to the length to be cut off prior to cutting. 14.2 Grease and Graphite shall be supplied by the Tenderer. To check that the execution of welding and welding equipment used on the job are suitable and conform to relevant standards. 13. 12.0 HYDROTEST Hydrotest shall be as per Section 2. 16.0.4. To supervise welding procedure qualification.1.0 MATERIAL IDENTIFICATION Specification of all materials shall be as per the relevant piping drawings and piping service sections.0 INSPECTION 13.0. v.2.0 Material Check a) All the materials before usage the materials shall be identified by means of stencil and/or colour identification or other marking. 14.0.4 Approval from the Purchaser's inspector shall not relieve the Tenderer partially or fully of his responsibilities and guarantees under this Work order. ii.0 Bolts. 13. Bolts/stud threads and compressed asbestos gaskets shall be treated with graphite oil before assembly or as per the specification. 12. specified material and machining quality shall be used. supervise welder performance qualification. 12. required die. material shall be readable for all the same side.

.....16.............................0 INTENT OF SPECIFICATION....................0...................................0......0 RECORDS Fabrication details and results of inspection of piping shall be recorded on the piping drawings for records.......A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS................. • • Instrument Air Distribution System Service Air Distribution System .......0........................................0 5.......20 ANNEX-E: RADIOGRAPHIC TECHNIQUE LOG..............................................................................................9 14..........21 ANNEX.....................0 3.................................................................................................................D : FORMAT FOR STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION.............4 GENERAL STORAGE OF WELDING CONSUMABLES......0....19 ANNEX .........................0 INSPECTION AND TESTING..............8 11..0 2......0.......................................................................................................................................................0..........2...0.....F: WELDER'S IDENTIFICATION CARD.........................................................................0 7......................0 6......15 ANNEX-B: FORMAT FOR PROCEDURE QUALIFICATION RECORD....0 8............0 Stubs with root valves shall be provided for all pressure connections and half couplings shall be provided forthermowells..............................................5 WELDING PROCESS..................WELDING PROCEDURE 1...............................................0 WELDING PROCEDURE QUALIFICATION...................................................................8 13..5 EDGE PREPARATION.........................................................................0..................................................0............................................... 17................. SECTION ............8 12.............................0 SAFETY REQUIREMENTS............3 APPLICABLE CODES AND STANDARDS......22 ANNEX-G: LIST OF APPROVED ELECTRODE MANUFACTURER.....................0 INTENT OF SPECIFICATION This specification shall be followed for the fabrication of all types of welded joints of carbon steel / mild steel LP piping system within the battery limits of the plant............................................23 SECTION 2.........0 WELD HEAT TREATMENT PROCEDURES.......................................2 TECHNICAL SPECIFICATION WELDING PROCEDURE TABLE OF COTNENTS 1...................0 WELDER'S QUALIFICATION..............0................................................1.............................................0..................0...........................0..................................................0........................................................................................2 TECHHNICAL SPECIFICATION ..........................13 ANNEX.......6 WELDING TECHNIQUE..................................................0 9...............................................5 ALIGNMENT& SPACING....................0 4..............17 ANNEX ......................0..........................................................................................7 10....C : FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR QUALIFICATION TESTS.......................0......................4 EQUIPMENT AND ACCESSORIES........4 BASE METAL..................................................

DM Feed Water System a) DM Water Transfer Pumps all suction. • Plant Water System . All pipe joints of the longitudinal and circumferential butt welded and socket welded types. discharge and recirculation lines. discharge and recirculation lines. DM Cooling Water Supply & Return Line for Main Plant compressor & Ash Handling compressor. vent pipe lines and draw of sump lines. c) Ash Water Tank Fill pumps suction and discharge lines. • Plant Water System -I a) Raw Water System.0 APPLICABLE CODES AND STANDARDS . b) APH Wash pumps all suction and discharge lines. hence it will not come under the purview of this document). All pipe line headers. Welded manifold headers and other sub-assemblies. shall not relieve the Contractor of his responsibilities and guarantee. All tanks external down comer pipe lines. over flow lines. d) Boiler Feed Pumps suction. f. f) AHS Seal Pumps suction lines. e. b. Welded branch connections with or without reinforcing pads. Effluent System. (Instrument Air System / Service Air System / Potable water system pipes (upto 150NB) are of threaded ends. d) Service Water Pumps suction and discharge lines e) DM plant pumps suction lines.0.II a) b) Plant Potable Water pumps all suction and discharge lines. drain drips and other instrument tappings. The welded pipe joints shall include the following:a. discharge and recirculation lines. flanges and other supports to pipes. Any approval granted by the Engineer-in-Charge or Owner's inspector.• • • Service Water Distribution System Potable Water Distribution System. c) DM Cooling Water Make up Pumps suction. Wash Water System. The attachments of smaller connections for vents. b) Hot Well Make up Pumps all suction. d. • • • • • • • CW Blow down System. Colony Potable Water pumps all suction and discharge lines. c. Sludge Water system. discharge and recirculation lines (Condensate Make up line). Attachments of forgings. 2. Joints in welded / fabricated piping components.

the following codes and specifications referred in the relevant code of fabrication shall be followed for the welding qualifications. . giving details of physical and chemical tests carried out has to be submitted by them.V ASME Sec. All statutory regulations shall be adhered to (including qualification of personnel) for radiographic equipments & personnel.IX ASME BPVC Sec. radiographic films.1. 5. automatic temperature recorders with suitable calibration certifications shall be provided duly approved by Engineer. In case of conflicting requirements. ASME BPVC Sec. Drying of welding rods Welding rods shall be baked in a heating cabinet in accordance with the manufacturer's recommendation. Handling of welding rods being used During welding work welding rods shall not be laid down directly on the ground or any other humid place to ensure that rods are not damaged by moisture. The package of the welding rods shall not be opened until immediately buffer use.0 GENERAL STORAGE OF WELDING CONSUMABLES The welding electrodes and filler wires supplied shall confirm to the class specified in the welding specification chart. Electrode qualification test record have to submitted in the enclosed format. welding rods.All welding works.0 The make & type of radiographic equipments. Welding rods not consumed in a day shall be baked by the same method with only two rebakings permitted. Portable ovens shall be utilized to maintain a temperature of 80°C at actual site locations.0. thermo-couples.II Part C IS: 2825 MSS-SP-55 MSS-SP-53 MSS-SP-54 3. Since this section covers welding procedure for LP piping all IBR related procedure may be ignored.0. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. 4.0 BASE METAL Welding and Brazing Qualifications Non destructive examination Material specifications. Batch test certificates has to be submitted from the electrode manufactures.0 All the equipments for performing the heat treatment. 5. the requirements mentioned in welding specification chart/Technical notes shall be applicable. Welding rods shall be stored indoors free from moisture. Code for Unfired Pressure Vessels Visual inspection and testing Magnetic particle testing Radiographic testing Base metal shall be as detailed in Welding Specification chart.0 EQUIPMENT AND ACCESSORIES 5. and all the equipments/materials required for carrying out the dye-penetrant/magnetic particle test shall be subjected to approval of Engineer in charge. including transformers.1 ANSI B16.2. consumable qualifications and non-destructive test procedures. equipments for welding heat treatment other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the following acceptable standards and procedures unless otherwise specified in the welding specification chart. pyrometers. electrodes and filler metals.9 IBR Power piping Wrought steel Butt Welding Fittings Indian Boiler Regulations In addition.0. ANSIB31.

without causing any surface irregularity. shall be removed by grinding and chiseling. but it must be removed after tack welding and before laying the root bead. earth and other foreign matter.2. Since the tack welds become part of the final weldment they shall be executed carefully and shall be free from defects. 7. the ends to be welded shall be secured position in with the aid of couplers. After plasma cutting. Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the Engineer-in-charge. oxides shall be removed by chipping or grinding.1 a) Carbon Steel Gas cutting. 8.3. for maintaining the alignment. welding irregularities.1. 8. machining or grinding methods shall be used.4. Shielded Metal Arc Welding Process (SMAW) Gas Tungsten Arc Welding Process (GTAW) 6. oxides. The welding procedure adopted and consumables used shall be specifically approved. Suitable grinding wheels and wire brushes should be used for carbon steels and stainless steels. craters.2. sand. The ends shall be completely dry before the welding commences. of pipe joints shall be made only by qualified welders.0 EDGE PREPARATION 7.0 Welding of various materials under this specification shall be carried out at site using one or more of the following processes with the approval of the Engineer-in-charge. grease.0.5.0 8. machining or grinding methods shall be used.3. After gas cutting. Special care must be taken to ensure proper fitting and alignment when the welding is performed by GTAW process.6.1. methods shall be used. Defective tack welds must be removed prior to the actual welding of the joints.0 Tack welds.0 A wire spacer of suitable diameter may be used to maintain the weld root opening while tacking.0 For pipes of wall thickness 5 mm and above.0 A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-incharge. Yokes shall be detached after the completion of weld.2. slag etc.0 The welding processes to be employed are given in the Welding Specification Chart. machining or grinding shall be carried out on the cut surface. Edge shall conform to B31.1 Cleaning The ends to be welded shall be properly cleaned to remove paint. Any deviation desired shall be done through the consent of the Engineer-in-charge. b) Low Alloy Steels (containing upto 2/4% Chromium) (Not applicable for LP piping) Gas cutting. rust. ALIGNMENT & SPACING 7. oil. c) High alloy steels. to maintain perfect alignment.2. After gas cutting. 6. On completion of each run. 6.0.0 Components to be welded shall be aligned and spaced as per the requirements laid down in applicable code. Minimum number of tacks shall be . and aluminium alloys: Plasma cutting.0 Automatic and semi-automatic welding processes shall be employed only with the approval of the Engineer-in-charge.0 WELDING PROCESS 6. machining or grinding.2 8. Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and the grinding wheels used for grinding stainless steel shall be of a suitable type.1. 8.0 The edges to be welded shall be prepared to meet the joint design requirements by any of the following methods recommended. cupro-nickel.2. 7.. 8.4. Flame heating for adjustment and correction of ends is not permitted unless specifically approved by the Engineer-in-charge.0.0 7. yokes and 'C clamps.0 Tacks should be equally spaced. nickel alloys. cut surfaces shall be machined or ground smooth.

0 Root Pass a) Root pass shall be made with electrodes/filler wires recommended in the welding specification chart. shocks. Face to Face/Center to Face Lateral translation in any direction Rotation Out or alignment measured across the diameter 9. recommended in the Welding Specification Chart. just adjacent to the weld.7. Joint completion a) Joint shall be completed using the class of electrodes.5 mm (Max) ±1. For welds between two dissimilar Cr-Mo low alloy steels. b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.0 Engineer-in-charge shall check and approve the fit-up and alignment of pipe joint prior to the commencement of welding.2 tacks .2.0 8. .5degMax 9.for 14" and larger dia pipes.3 8. preheat and post weld heat treatment shall be those specified for higher alloy steel and electrodes used shall correspond to those specified for steel of lower alloy content.4 Dimensional tolerances generally acceptable are as follows.1 8.for 2/4" and smaller dia pipes 4 tacks . c) The root pass of butt joints should be executed so as to achieve full penetration with complete fusion of the root edges. 8.6 mm. f) No painting shall be done until the weld joint has been approved.3. Dissimilar Welds Where welds are to be produced between carbon steels and alloy steels.7. Metal stamping shall not be used as a standard. Suitable paint shall be used on thin wall pipes for identification.0 g) Penning shall not be used. d) Any deviation desired from the recommended welding technique and electrodes indicated in the welding specification chart should be adopted only after obtaining approval of the Engineer-in-charge. e) Welding shall be uninterrupted.1. 9. : ± 1 mm : : : ±3mm (Max) ±1.0 WELDING TECHNIQUE 9. For fillet welding shall be done with consumables recommended for filler passes. vibrations and stresses to prevent occurrence of weld cracks. d) Each weld joint should have a workman like finish.5 mm diameter (12 SWG) but in any case not greater than 3.6. preheat and postweld Heat Treatment requirements shall be to those specified for corresponding alloy steels and electrodes shall correspond to AWS E-7016 / 7018 type. c) Butt joints shall be completed with a cover layer that would effect good fusion at the joint edges and a gradual notch free surface.7.0 g) All welded joints are subjected to acceptance by Engineer-in-charge.0. f) While the welding is in progress care should be taken to avoid any kind of movement of the components.25 mm (10 SWG).for 3" to 12" dia pipes 6" tacks . Size of the electrode shall not exceed 4 mm in diameter for stainless steels and alloy steels used for low temperature applications.7.2 8. e) Weld identification work shall be stamped clearly at each joint. The preferable size of the electrodes is 2. b) Two weld beads shall not be started at the same point in different layers.7. Weld projection inside the pipe shall not exceed 1. 8.

12.3. The welding procedure.1. operating conditions and requirements laid down in the detailed drawings and specifications. electrodes/filler wires to be used shall be approved by the Engineer-in-charge. applicable codes standards and the instructions of the Engineer-in-charge. on both sides of the weld. Only those welders who have been approved by the Engineer in charge shall be employed for welding. that is proposed to adopt for each of the materials/assembly/part involved shall be submitted for the approval of the engineer . Temperature indicating crayons or other temperature indicating devices shall be provided to check the temperature.0 The welders shall always have in their possession the identification card as shown in enclosed Annex.0. 11.1.IX latest edition or other applicable codes and the job requirements. 12. use of electrodes E-309/E-310/E NiCr Fe-2 shall be made.B shall be submitted to the Purchaser's inspector for his approval immediately after completing the procedure qualification test.2. 11. iv) Overhead welding should be avoided to the extent possible. 11. 12. wherever required for joints between pipes. dye penetrant examination.2. pipes and fittings. 12. pipe body and supports shall be carried out as per the welding specification chart.2. Standard tests as specified in the code shall be carried out in all cases. he shall be debarred from doing any further work. Purchaser's inspector will review.For carbon steel or alloy steel to stainless welds. Following shall be generally adopted to ensure proper welding: i) Relation of welding rods matches with parent material. The welder qualification test reports shall be submitted in the format enclosed as Annex . . ii) Preheating to the required value of the parent material before welding. 12.C and obtain express approval before commencement of the work.2 The details of the post weld Heat Treatment procedure (as per Annex . A complete set of test results in format as per enclosed Annex .A should be submitted.0 WELDER'S QUALIFICATION 11.charge well before carrying our actual heat treatment. with neutral flame may also be carried when permitted by the Engineer-in-charge.2 Preheating requirements for the various materials shall be as per the welding specification chart attached.0 WELD HEAT TREATMENT PROCEDURES 12. iii) Quality & brand of the welding rods approved by owner. 12.0.0 If a welder is found to perform a type of welding or in a position for which he is not qualified.D attached). charpy V-notch and U-notch impact tests etc.0 Preheating 12. check and approve the welding procedure submitted and shall release the procedure for qualification tests.0 No welder shall be permitted to work without the possession of identity card duly certified by the inspector.1 No welding shall be performed without preheating the joint to 10°C (50°F) when ambient temperature is 10°C and below. The Purchaser's inspector shall witness the test and certify the qualification of each welder separately. hardness tests.1.0 Postweld Heat Treatment 12.1 Post weld Heat Treatment. shall be carried out on specimens depending upon the type of base material. Preheating by gas burners.5 Preheating temperature shall be maintained over the whole length of the joint during welding. The welding procedure specifications in format as per enclosed Annex .IX or other applicable codes.0.0 WELDING PROCEDURE QUALIFICATION Welding procedure qualification shall be carried out in accordance with the relevant requirements of ASME Sec. 10.1. other tests like macro/micro examination. All welds performed by an unqualified welder shall be cut and redone by a qualified welder.4 Preheating shall extend uniformly to atleast three times the thickness of the joint. In addition to these tests. 11. but not less than 50 mm.3 Preheating shall be performed using resistance or induction heating methods.1.2.4.1.0 Welders shall be qualified in accordance with the ASME Section . utilizing oxy-acetylene or oxy-propane gas mixtures. 12.F and shall produce it on demand by the Engineer in charge.1.in .

i.8 Each joint shall bear an identification number which shall be maintained in the piping sketch. 13.12. the portion outside the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at the exposed surface or pipe.2. the post weld Heat Treatment Charts/records alongwith the hardness test results on the weld joints. 12. Adequate number of thermocouples should be attached to the pipe directly at equally spaced location along the periphery of the pipe joint. 13.2.1 Inspection of all welds shall be carried out as per ASME . scale.1 Purchaser's/Consultant's inspector shall have free access to all places where the work is being done or any other place concerned with the work.1. ii. iv. . supervise welder performance qualification. unrepaired burnthrough.2. Finished welds shall be visually inspected for parallel and axial misalignment of the work. wherever required as per the welding specification chart.2.4 Throughout the cycle of Heat Treatment.1.1. To check that the execution of welding and welding equipment used on the job are suitable and conform to relevant standards. weld reinforcement and lack of fusion.B31. 12.2.3 Approval from the Purchaser's inspector shall not relieve the Tenderer partially or fully of his responsibilities and guarantees under this work order. To check any other activity to ensure quality of work. 2 upto 10" dia and 3 for 12" dia and above.1.6 Automatic temperature recorders which have been suitably calibrated should be employed.0 INSPECTION AND TESTING 13.2.2. 13. 12. dimensions.2. cracks. technique of application of heat must ensure uniform temperature attainment at all points of the portion being heat treated.5 The temperature attained by the portion under heat treatment shall be recorded by means of thermocouple pyrometers. The minimum number of thermocouples attached per joint shall be 1 upto 6" dia. 12. c) Surfaces to be welded shall be checked to assure that they are clean and free from foreign material such as grease.2.7 Immediately on completion of the Heat Treatment. shall be submitted to Engineer-in-charge for his approval. 13. To check whether welding is conforming to relevant specification and the procedure followed is in accordance with good pipeline construction practice. or others for a distance of at least 25 mm from the bevel ends. The joint identification number should appear on the corresponding post weld heat Treatment Charts. under cut on surface.3 While carrying out local post weld Heat Treatment. paint.0. Care shall be taken to ensure that width of heated band over which specified post weld Heat Treatment temperature attained complies with relevant applicable standards/codes. and other surface defects. incomplete penetration. 12.2 Inspection before welding a) Dimension and orientation of spool assembly and installed spool and/or piping components shall be checked with the piping drawings.1. 13. However the Engineer-in-charge can increase the required minimum number of thermocouples to be attached if found necessary. The calibration chart of each recorder should be submitted to the Engineer-in-charge prior to starting the Heat Treatment operations and his approval should be obtained. To iii. b) Width of root space. To supervise welding procedure qualification. bevel angle and alignment of components shall also be checked on each joint fitted up.0 General 13.2 Inspection dates shall be notified sufficiently in advance with all facilities necessary for carrying out his work at no extra cost to the Purchaser.0 Visual Inspection 13. The chart containing the identification numbers and piping sketch shall be submitted to the Engineer-in-charge in suitable folders. v. oil.

charge.4 Inspection of Welds Bead appearance under cut. welding slag on inter passes.1 Radiographic Examination Radiographic examination shall be performed in accordance with the following requirements. and finish after back chipping shall be checked. P. Material Combination P. All piping above 51 kg/sq cm (g) shall have 100% Radiography. Run Specn. Gr. 13.3.2 Random Examination a) Radiographic testing and acceptance shall be in accordance with MSS-SP-54.2. 13.3 Identification of Radiographs Identification marks shall be marked on every radiograph and radiographs of repaired welds shall be marked separately. 13.0 Liquid Penetrant or Magnetic Particle Examination a) Socket welds in piping system shall be liquid penetrant or magnetic particle examined in accordance with Table A. Gamma ray with Iridium-192 source is acceptable for carrying out radiography. CIRCULATING WATER. 13. spatter.No . All other IBR piping (steam) shall be tested as per regulation 360 of IBR or Table-A whichever is higher. Root Further Run No. Plate fabricated pipes & specials forCW/ RW/ CLW service shall have 10% radiography. d) All fuel lines shall have for 100% LP/MP tested on welded joints.13. 3. e) Conducting radiographic test outside the Purchaser's premises should be performed only on approval of Engineering . overlap. c) Liquid penetrant or magnetic particle examination shall be performed in accordance with section V ASME code.3. 4. c) The welds to be examined shall be selected to ensure that the work product of each individual welder is included. However. 5.3 Inspection During Welding Crack in tack welds.in .4. d) The extent of radiographic examination shall be as per Table-A. welding current conditions. crater. All alloy steel and SS welding shall have 100% Radiography. RAW WATER. 2.No.3.NON IBR (LP IPING) SERVICES : COOLING WATER.A PIPING WELDING DETAILS FOR ERECTION . CLARIFIED WATER. 13. No.3. All fuel lines shall have minimum 50% radiography.2. SS lines used for services like bearing lubrication oil supply shall be tested as per the instruction of Engineer-in-charge.0 Radiography 1. 13. TABLE . Specn. AWS Specification Gr. b) All completed girth butt and socket welds of carbon steel to Austenitic steel shall be subjected to 100% liquid penetrant examination. b) Random radiographic examination shall be applied to the entire circumference of a specified percentage of the girth butt welds as designated in Table A. EFFLUENT LINES AND EXHAUST PIPING TO ATMOSPHERE Sl. reinforcement of weldment and size fillet of weld shall be checked.

1 IS 3589/ IS 1239/ IS 2062 Note: P1 1 Any combination P1 1 E6013* E6013* WPS shall be qualified (PQR) by the respective quality department of erection groups (FQA) prior to welding. .

section V.0 Acceptance Standards The following acceptance standards shall be used unless otherwise specified. 13. for Tup to 3/4 in. where T is the thickness of weld. include. The through thickness of slag inclusions shall not exceed 1/4 of the thickness of the thinner member being joined.2 Magnetic Particle and Liquid penetrant Acceptance standards Linear MP and LP indications up to 1/2 T where T is the weld thickness or 1/4 inch in length.030 0. The cumulative length of linear magnetic particle or liquid penetrant indications shall not exceed T in any 12T length of weld. for Tup to 3/4 in. 13. to 2-1/4 in.None for component thickness up to 1/8 in. 2/3 T for T from 3/4 in . and the lengths exceed the following: 1/2 in.4 Visual Acceptance Standards The visual acceptance standards shall be as follows: Cracks-None Linear Indications .5. Elongated slag or tungsten inclusions with lengths greater than the following are not permitted: 1/2 in.5. are acceptable. MAXIMUM PERMISSIBLE POROSITY IN 6 INCH LENGTH OF WELD 3 13. fort over2-1/4 in.(Including Burnback).5. 13. to 2-1/4 in.088 0. Groups of slag inclusions in line that have an aggregate length greater than T in length of 6T are not permitted. Porosity in excess of that specified in the following table shall not be permitted.None Undercuts . Where indications are interpreted as cracks or lack of penetration. 2/3T for T from 3/4 in.3 Ultrasonic Acceptance Standards Indications are unacceptable if the amplitude exceeds the reference level established by the basic calibration block for ultrasonic examination of welds as stipulated in ASME Boiler and Pressure Vessel Code. 1/32 in max. whichever is smaller. for component thickness over 1/8 in.360 .120 0. for T over 2-1/4 in. where T is the thickness of the weld.13.1 X-Ray Acceptance Standard No cracks or lack of penetration are permitted.5.090 0. they are unacceptable regardless of length. 1-1/2 in.060 0. and which are not visible cracks.240 0. IV) (inches) Less than 1/8 1/8 1/4 1/2 3/4 1 Pore t/4 1/32 1/16 1/8 3/16 ¼ ¼ ¼ Area 8(t/4) 0. 1-1/2 in. Article 5.5.

The welding sets shall be earthed properly and properly insulated cables shall be used for welding purposes. 14. for component thickness up to 3/16 in include. etc. Appearance . ANNEX -A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200. such as handgloves. etc. welding glass.charge and after ensuring from him that the environment is quite safe for welding purpose the work shall be commenced. No tools.6.6.0 Repair and removal of visual defects 13. Wherever necessary ladder and scaffolding shall be used to carry out work at elevated positions. 13. 13.1. care should be taken to ensure that tools and materials are not left in position from where they can fall on the persons below.6. Section IX.1/16 in max.in . Gas cutting torches shall be lighted by means of friction lighter and not with matches.Reinforcement .6. Spatter and slag shall be removed by a hammer or a brush. All arc strikes in the base metal are unacceptable. The wearing of safety by the gas cutters. Scaffolding and ladders should be maintained in good conditions. While working on elevated position use of safety belt shall be ensured which has to be periodically checked for its suitability to provide safety. craters and beads shall be ground and weld metal deposited. regulators.6 Repairs of weld reinforcement and overlap shall be ground smooth._ Revision No ________________________________ _By:_ Date _Supporting PQR No (s)_ .4 Traces of jigs removed.6. A crack found visually shall be removed and examined by a magnetic particle or liquid penetrant test until assured no defect remains. Oxygen & Acetylene gas cylinders shall be stored and maintained properly including its valves. helmet. the weld and the ends of the joints shall be restored.2 When the whole joint is found unacceptable.1 Defects which are not within the acceptable limits shall be removed from the joint completely by chipping or grinding. 13. 13.5 Repairs of weld reinforcement and overlap shall be ground and weld metal deposited.0 SAFETY REQUIREMENTS Utmost care shall be taken during welding and gas cutting process to avoid fire hazard. grinders and welders.6. 13. should be observed strictly.0. for component thickness over 1/2 in. Spatter and projections from welding and any remaining tack welds shall be removed. For carrying out welding work in plant area necessary work permit shall be obtained from the Engineer . Any blending in the base metal shall not exceed the undercut allowance. safety goggles. for component of 3/16 in. 13.3 No repair shall be carried out without prior approval of the Engineer. Overhead work While carrying out the work in elevated positions. tackles and materials shall be dropped from any height which may endanger anybody. max. undercutting. ASME Boiler and pressure Vessel Code) Company Name ________________________________ Welding Procedure Specification No.Welds shall have a workmanship appearance with minimum variations in width and size of weld. and absence of sharp notches at undercuts and surface ripples. 1/8 in max.6.

the root spacing and the details of weld groove may be specified (At the option of the Mfgr. weld layers and bead sequence. Machine.filler metal combination should be recorded individually . to P. (Refer to both backing and retainers. Weld Symbols or Written Description Should show the general arrangement or the parts to be welded. for multiple process procedures. etc. Manual. or semi-Auto) JOINTS (QW-402) Joint Desiqn Details. Where applicable.g.) * Base Metals (QW-403) P Nn Group No OR Grmip No.Welding Process (es)_ _Type(s)_ (Automatic.) | Metal I | Nonmetallic | | Metal | Other | | Nonfusing Sketches. sketches may be attached to illustrate joint design. for notch toughness procedures. Production Drawings.No OR Hhpm Analysis and Mpnh Prnp Thickness Range: Paso M°tar Fillet Other • FILLER METALS 9QW-404 nrnnvo Weld Metal Thickness Range : Groove Fillet Electrode-Flux (class) Flux Trade Name Consumable Insert Other " Each base metal. e.

Grinding. POSTWELD HEAT TREATMENT (QW-407) Temperature Range Time Range ___________________ __________________ PREHEAT (QW-406) Preheat Temp. Class Type Polar Current Amp. etc. Automatic. Remarks. Semi-Auto) . This information maybe listed in a tabular form similar to that shown below. position.B : FORMAT FOR PROCEDURE QUALIFICATION RECORD QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-200. Company Name Procedure Qualification Record No WPS No. short circuiting arc. and thickness. Comments. Rev.g.) Method of Back Gouging Oscillation Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Other Weld Layer (s) _______________ Process Filler Metal Dia. etc. Range Volt Range Travel Speed Range Other (e. etc. etc. Torch angle. Technique. 2% Thoriated. Section IX.) Tungsten Electrode Size and Type ________________________________________________________ (Pure Tungsten. GAS (QW-408) Shielding Trailing Percent Composition Gas (es) (Mixture) Flow Rate (Continuous or special heating where applicable should be recorded) Backing ELECTRICAL CHARACTERISTICS (QWCurrent AC or DC_______________Polarity Amps (Range) Volts (Range) (Amps and volts range should be recorded for each electrode size.2.) Mode of Metal Transfer for GMAW (Spray arc. ANNEX .) Electrode Wire feed speed range TECHNIQUE (QW-410) String or Weave Bead Orifice or Gas Cup Size ___________________ ___________________ Initial and Interpass Cleaning (Brushing. Min. Max.. Hot Wire Addition. ASME Boiler and Pressure Vessel Code) Record Actual Conditions used to Weld Test Coupon.POSITIONS (QW-405) Position (s) of Groove Welding Progression: Up Position (s) of Fillet Down QW-482 (Back) WPS No. _______________ Date Welding Process (es) Types (Manual. Etc. Interpass Temp.

Notch Location Area Test Temp Impact Values Result________Satisfactory: Yes Macro —. and tested in accordance with the requirements of Section IX of the ASME Code.No Thickness of Test Coupon to P.JOINTS (QW-402) Groove Design of Test Coupon (For combination qualifications. POSTWELD HEAT TREATMENT (QW-407) Temperature GAS (QW-408) Percent Composition Gas (es) Flow Rate (Mixture) FILLER METALS (QW-404) SFA specification ELECTRICAL CHARACTERISTICS (QW-409) Current Amps. Width Thickness Area Ultimate Total Load Ib Ultimate Unit Load Psi Type of Failure & Location Guided-Band Tests (QW-160) Toughness Tests (QW-170) Specimen No. Tungsten Electrode Size Volts POSITION (QW-405) Position of Groove TECHNIQUE (QW-410) Travel Speed PREHEAT (QW-406) Preheat Temp QW-483 (Back) Tensile Test (QW-150| Specimen No.Results No Fillet-Weld Test (QW-180) Penetration into Parent Metal: Yes Other Tests No Type of Test Deposit analysis Other Welder's Name Tests conducted by : ______________________________________________ Clock No. Manufacturer . _________________________________________________________ ______Stamp No. the deposited weld metal thickness shall be recorded for each filter metal or process used) BASE METALS 9QW-403) Material Spec P. We certify that the statements in this record are correct and that the test welds were prepared.No. welded.

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

etc) Guided Bend Test Results Guided Bend Test Type () QW-462. R&F) Result Actual Values ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ Actual Values ______________________ ______________________ ______________________ ______________________ ______________________ ______________________ Range Qualified _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________ Range Qualified _________________ _________________ _________________ _________________ _________________ _________________ Radiographic test results (QW-304 and QW-305) _________________________________________________________________________________________ (For alternative qualification of groove welds by radiography) Fillet Weld Macro test fusion _____________Fracture test ________________________________Length and percent of defects ______________________________ ii __________________________Fillet leg size _________________in. R&F) Type () QW-462.3(b) (Long. ________________________ We certify that the statements in this record are correct and that the test coupons were prepared. Consumable insert for GTAW or PAW Weld deposit thickness for each welding process Welding position (1G. etc. welded from both sides. X ____________in. ______ Welding process(es) used ___________________________________________Type____________________________ ________________________________ Identification of WPS followed by welder during welding of test coupon Base material(s) welded____________________________________________________________________Thickness Manual or Semiautomatic Variables for Each process (QW-350) Backing (metal. STRESS RELIEF/HEAT TREATMENT Name of the project PROCEDURE SPECIFICATION Specification Name of the HeatTreater .) Consumable insert Backing (metal. weld metal.no.ANNEX .) (QW-405) progression (uphill/downhill) Backing gas for GTAW. if pipe) Filler metal specification (SFA):____________Classification (QW-404) Filler metal F-no.2 (Side) Results () QW-462. 5G. Section IX. etc. PAW. fuel gas for OFW (QW-408) GMAW transfer mode (QW-409) GTAW welding current type/polarity Machine Welding Variables for the process Used (QW-360) Direct/remote visual control Automatic voltage control (GTAW) Automatic joint tracking Welding position (1G. Organization Date ______________________________________ By __________________________________________________________ ANNEX . flux. Concavity/convexity_____________________ ii Welding test conducted by Mechanical tests conducted by __________________________________________________________ __________________________________________________________Laboratory test no.No.D : FORMAT FOR STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION. ASME Boiler and Pressure Vessel Code Welder's name _________________________Clock number ________________________________Stamp no. _____________toASMEP.weld metal. and tested in accordance with the requirements of Section IX of the ASME Code. welded. (QW-403) () Plate () Pipe (enter diameter.) (QW-402) ASMEP. flux.3 (a) (Trans. etc.C : FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR QUALIFICATION TESTS QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW301. %G. or GMAW. welded from both sides.

S .Res:/ Equipment: Name of the Assembly/Part Assembly/Part Drawinq No. if any 5 Hardness test A. Thickness Atmosphere Control 3 Heat Treatment Cycle Details Charqinq Temp °C Rate of heatinq °C/Hr Soakinq Temperature °C Soakinq time. Hrs Rate of Coolinq 7Hr Mode of Coolinq 4 Other details.S C. Material (Tick mark) Capacity (size) Maximum Temp.1 General Details Name of the Other Details Type of Heatinq : Induction Elec.CC) Method of Temp.

ANNEX . : : : : : : : : .No.E : RADIOGRAPHIC TECHNIQUE LOG RADIOGRAPHIC TECHNIQUE LOG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 18 Location Date of Testing Name of the Contractor and welder Material: Carbon steel/Alloy Steel/Stainless Steel Diameter & Thickness Type of Weld Joint Radiation Source Source strength Screen Screen thickness Focus film distance Limit of Film coverage Film type and make Exposure Time Processing Density Sensitivity Penetrameter thickness (Source Side) Penetrameter thickness (Film slide) Shim thickness Signature of Contractor with seal Approval of Inspector ANNEX .F : WELDER'S IDENTIFICATION CARD WELDER'S IDENTIFICATION CARD 1 Name : Photograph 2 3 4 5 6 7 8 9 Identification Date of Testing Valid until Process Material Thickness Diameter F.

10 11 Approval of welding Position : : Approved by: Employee's Signature with seal .

Ferro Weld 2 .Philips 36 H .D & H .Vordian Esab/IOL ANNEX-A QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200. Oerlikon .ANNEX .Overcord S.G : LIST OF APPROVED ELECTRODE MANUFACTURER LIST OF APPROVED ELECTRODES AND MANUFACTURERS Accepted manufacturers of 6010. 7018 and 6013 electrodes are given below:Root .run . ASME Boiler and pressure Vessel Code) Company Name ______________________________ Welding Procedure Specification No.Advani ._ Revision No _By:_ Date _ Date Supporting PQR No (s)_ Welding Process (es)_ _Type(s)_ .Advani Oerlikon .Supertherm .Supercito .1.ESAB -Modi 7018-MODI 6013 .Tenacito . Section IX.ESAB .Philips (ESAB) 31 CS E6010 7016/7018 .

Manual. Machine. GAS (QW-408) Shielding Trailing Backing Percent Composition Gas (es) (Mixture) Flow Rate InterpassTemp. or semi-Auto) JOINTS (QW-402) Joint Design Details. Analysis and Mech.(Automatic. Anaysis and Mech. Where applicable. weld layers and bead sequence. e. OR Chem. Range: Groove Other * FILLER METALS 9QW-404 Groove Fillet Weld Metal Thickness Range : Groove Other * Each base metal.) |______| Metal |____| Nonfusing Metal |______| Nonmetallic | | Other Sketches. etc.) * Base Metals (QW-403) P Nn Nn firnur OR Grnup Nn tn P No. POSTWELD HEAT TREATMENT (QW-407) Temperature Range Time Range _________________ _________________ PREHEAT (QW-406) Preheat Temp. Weld Symbols or Written Description Should show the general arrangement or the parts to be welded. Max. for notch toughness procedures. Prop. Prop to Chem. for multiple process procedures. Rev.g.filler metal combination should be recorded individually POSITIONS (QW-405) Position (s) of Groove Welding Progression: Up Position (s) of Fillet Down QW-482 (Back) WPS No.. (Refer to both backing and retainers. the root spacing and the details of weld groove may be specified (At the option of the Mfgr. Min. (Continuous or special heating where applicable should be recorded) ELECTRICAL CHARACTERISTICS (QW-409) . sketches may be attached to illustrate joint design. Production Drawings. Thickness Range: Base Metal: Fillet Pipe Dia.

2% Thoriated. etc. etc.Current AC or DC______________Polarity Amps (Range) _________ _______________Volts (Range)__________ (Amps and volts range should be recorded for each electrode size. Class Type Polar Current Amp. and thickness. Comments. Torch angle. etc. etc.) Method of Back Gouging Oscillation Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Other Weld Layer (s) Process Filler Metal Dia. Technique. This information may be listed in a tabular form similar to that shown below. Remarks.) Initial and Interpass Cleaning (Brushing. Etc.) Tungsten Electrode Size and Type Mode of Metal Transfer for GMAW Electrode Wire feed speed range TECHNIQUE (QW-410) String or Weave Bead Orifice or Gas Cup Size __________________ __________________ (Pure Tungsten. Range Volt Range Travel Speed Range Other (e.) (Spray arc.g. Grinding.. short circuiting arc. ______________ . position. Hot Wire Addition.

\\ ANNEXURE B QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-200. Section IX. \ Welding Process (es) Types (Manual. ASME Boiler and Pressure Vessel Code) Record Actual Conditions used to Weld Test Coupon. Company Name Date Procedure Qualification Record No WPS No. Automatic.2. Semi-Auto) .

JOINTS (QW-402) Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filter metal or process used)

BASE METALS 9QW-403) Material Spec P.No Thickness of Test Coupon to P.No.

POSTWELD HEAT TREATMENT (QW-407) Temperature

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

(Mixture)

FILLER METALS (QW-404) SFA specification ELECTRICAL CHARACTERISTICS (QW-409) Current Amps. Tungsten Electrode Size Volts

POSITION (QW-405) Position of Groove

TECHNIQUE (QW-410) Travel Speed

PREHEAT (QW-406) Preheat Temp

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

Specimen No.

Width

Thickness

Area

Ultimate Total Load Ib

Ultimate Unit Load Psi

Type of Failure & Location

Guided-Band Tests (QW-160)

Toughness Tests (QW-170)

Specimen

Notch

Area

Test

Impact

Result_______Satisfactory: Yes Macro — Results

No

Fillet-Weld Test (QW-180) Penetration into Parent Metal : Yes

No

Other Tests Type of Test Deposit analysis Other Clock No. Welder's Name Tests conducted by : _______________________________________ ________________________________________

______Stamp No.

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

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

ANNEX -C
QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW-301, Section IX, ASME Boiler and Pressure Vessel Code Welder's name ________________________Clock number _______________________________Stamp no. ______

Welding process(es) used

_________________________________________Type__________________________ ______________________________

Identification of WPS followed by welder during welding of test coupon

Base material(s) welded_________________________________________________________________Thickness Manual or Semiautomatic Variables for Each process (QW-350) Backing (metal,weld metal, welded from both sides, flux, etc.) (QW-402) ASME P.No. ____________to ASME P.no. (QW-403) () Plate () Pipe (enter diameter, if pipe) Filler metal specification (SFA):___________Classification (QW-404) Filler metal F-no. Consumable insert for GTAW or PAW Weld deposit thickness for each welding process Welding position (1G, %G, etc.) (QW-405) progression (uphill/downhill) Backing gas for GTAW, PAW, or GMAW; fuel gas for OFW (QW-408) GMAW transfer mode (QW-409) GTAW welding current type/polarity Machine Welding Variables for the process Used (QW-360) Direct/remote visual control Automatic voltage control (GTAW) Automatic joint tracking Welding position (1G, 5G, etc.) Consumable insert Backing (metal, weld metal, welded from both sides, flux, etc) Guided Bend Test Results Guided Bend Test Type () QW-462.2 (Side) Results () QW-462.3 (a) (Trans. R&F) Type () QW-462.3(b) (Long, R&F) Result Actual Values _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ Actual Values _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ Range Qualified ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ Range Qualified ________________ ________________ ________________ ________________ ________________ ________________

Radiographic test results (QW-304 and QW-305) ____________________________________________________________________________________________________________________________ (For alternative qualification of groove welds by radiography) Fillet Weld in. Macro test fusion in. ____________Fracture test ______________________________Length and percent of defects _____________________________

________________________Fillet leg size

________________in.X ___________in. Concavity/convexity____________________

Welding test conducted by Mechanical tests conducted by

________________________________________________________ ________________________________________________________Laboratory test no.

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

(°C) Method of Temp.S ____ ____ ____ .Date ____________________________________ ANNEX-D By STRESS RELIEF/HEAT TREATMENT PROCEDURE SPECIFICATION Name of the project Name of the Heat Treater General Details Name of the Equipment: Name of the Assembly/Part Assembly/Part Drawing No.S C. Measurement Atmosphere Control Elec. if any 5 Hardness test A. Other Details Type of Heating : Capacity (size) Maximum Temp. Hrs Rate of Cooling °/Hr Mode of Cooling 4 Other details. Material Thickness 3 Heat Treatment Cycle Details Charging Temp °C Rate of heating °C/Hr ____ ____ Specification Reference No.Res:/ Induction (Tick mark) 1 Soaking Temperature °C_____ Soaking time.

ANNEX-E RADIOGRAPHIC TECHNIQUE LOG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 18 Location Date of Testing Name of the Contractor and welder Material: Carbon steel/Alloy Steel/Stainless Steel Diameter & Thickness Type of Weld Joint Radiation Source Source strength Screen Screen thickness Focus film distance Limit of Film coverage Film type and make Exposure Time Processing Density Sensitivity Penetrameter thickness (Source Side) Penetrameter thickness (Film slide) Shim thickness Signature of Contractor with seal Approval of Inspector .

D& H .No.Philips 36 H .Supercito .Tenacito .WELDER'S IDENTIFICATION CARD 1 Name Photograph 2 3 4 5 6 7 8 9 10 11 Identification Date of Testing Valid until Process Material Thickness Diameter F.Philips (ESAB) 31 CS E6010 7016/7018 .ESAB -Supertherm . 7018 and 6013 electrodes are given below:Root .run . Approval of welding Position Approved by: Employee's Signature with seal ANNEX -G LIST OF APPROVED ELECTRODES AND MANUFACTURERS Accepted manufacturers of 6010. Oerlikon -Vordian Esab/IOL .Overcord S.Advani Oerlikon .Advani .Ferro Weld 2 .ESAB -Modi 7018-MODI 6013 .

....................................... facing................0.................................................... 6 SECTION-2................................................. 4 5.................................................................0 EXCAVATION FOR PIPE TRENCHES ...0 INTENT OF SPECIFICATION This specification covers the minimum requirements and guidelines to be adhered by the bidder for the erection of complete underground piping of LP piping which includes excavation................................0 RECORDS ............................................ High Voltage Electrical Inspection of pipeline coating prior to Installation.............0 CODES & STANDARDS ..............................0........ (SP-I solvent cleaning and SP-10 near white blast cleaning).... 3 4..................................................................................... Recommended Practice................ 6 7......................0 BACKFILLING ...................................0..............................0....................... facing......... 5 6.0......... and fabrication Flanges: rating................ 2........................................................................0 VENT AND DRAINING .................................................................................................................0......................................................0 LAYING OF UNDERGROUND PIPING .TECHNICAL SPECIFICATION -ERECTION OF BURIED PIPING TABLE OF CONTENTS 1...............0 INTENT OF SPECIFICATION ................................0............. reinforcement of branch connection..3 TECHNICAL SPECIFICATION ERECTION OF BURIED PIPING 1..............................0 CODES & STANDARDS Piping design........... and drilling for larger than 24 inches (609 mm) Pipe specification Field applied external coatings for underground piping Repair of damaged field applied coatings for underground piping Dimensional checks Steel structure painting council............................................................... 3 2.......... 3 3.....0...0.................................................................0 CLEAN UP OF SURROUNDINGS ......................... 6 8..................................................... materials........................................................................... laying and backfilling of buried pipe. .............................. and drilling for 24 inches (609 mm) and smaller Flanges: rating..................................0..............

the extra depth shall be filled with concrete or approved equivalent material as directed by the owner's project manager at no extra cost to Owner. gradient and at any suitable distance as directed by the owner's project manager.0 If the trench is excavated below the required level indicated in the drawing.0 The trench shall be excavated so as to provide an average cover of 1000 mm or equal to the diameter of the largest pipe to be laid in the trench unless otherwise shown in drawings. Generally it shall not be less than 150 mm on either side or 1/3 of dia of pipe whichever is greater. or E as indicated in the specification AWWA C207. 3.AWWA C200 and AWWA M11 ANSI B16. to the finished grade. shall be sufficient to give free working space on each side of the pipe. Class 150 or AWWA C207 Class B.3. . C208 and other applicable AWWA standards SPC-SPI&SP10 NACE RP-02-74 3.2. The free working space shall conform to IS: 783.0.1. Section 3.0 EXCAVATION FOR PIPE TRENCHES AWWA C203/IS 10221 AWWA C209. Class B. The minimum average cover will be reckoned from top of the pipe of the largest diameter to be laid in the trench.4 AWWA C200. D or E as indicated in the specification AWWA C200 / IS 3589 / IS 1239 /ANSI B31. 3. D.1 3. at change of direction.5. The width of the trench.0 The trench shall be cut true to the line leveled with the help of sight rails provided at every 30M.

10. until the pipe is laid and tested.0 During excavation if some obstacle is met with.7. All materials to shore the trench in order to prevent caving are to be furnished and removed by the Bidder at no extra cost to the Owner. shall be redone conforming to the original specifications by the Bidder at his own cost. same shall be reported to the owner's project manager and dealt with as instructed by him. 3.e. The Tenderer shall be responsible for correct layout and gradient of the line.0 In case pipe is lowered in caved trench and back-filled before being inspected by the owner's project manager. if any. metal.0 No excavated material shall be deposited within 1. He shall also provide reasonable by pass at his own cost when a road is cut for laying pipeline.3.9. 3.0 4. coating and wrapping and trenching the Tenderer shall lay the underground piping in accordance with the following clauses and as per the approved piping arrangement drawings.6.2. Dewatering shall be done in advance of the laying of the pipe to allow adequate inspection of padding of the bottom if required and dewatering shall be continued throughout during laying of the pipe and backfilling of the trench.2. The Bidder shall keep the trench in good condition. already transported to the pipe laying site/convenient length of pipe assembly coated and wrapped near the trench after hydrostatic testing shall be placed on clean square cut skids suitably spaced so as to keep the pipe away from touching the ground. prime. At tie in welds and other places.1 By machine The shop coated pipe. However if in the opinion of the Engineer-incharge that the temperature condition do not allow direct lowering.3. chains hooks etc. conditions and using methods which will not damage coating the pipe may be lowered into the trench.1 Method & Time of lowering pipe Under favorable temperature. shore or do whatever might be required to excavate the trench. shall be taken out carefully and kept separately for reuse and road work shall be redone upto the original level prior to cutting the road with the excavated road materials after laying & testing of the pipeline within 10 days from the date of starting the work at the cost of the Bidder.0 LAYING OF UNDERGROUND PIPING General After prefabrication.1.2 By Hand The pipe may be lowered with the help of tripods and chain pulleys blocks into the trench immediately after the coating and wrapping. Bare cables. install the pipe in it and backfill the trench.0. Also short sections of pipelines which are impracticable to shop treat may be hand treated but only on the prior written approval of the Engineer-in-charge. 4.0 The Bidder shall dewater.8. . in accordance with the specifications at no extra cost to the Owner. The pipe may be lowered down in the trench by the launcher cranes. 4. 3. 3.0 In case of road cutting.0 Lowering & Laying The pipes shall be lowered either by mechanical methods or by hand when the trench is ready and bottom of the trench is graded as per required pipe laying conditions and specifications. 3. with sufficient care to protect the coating and wrapping of the pipeline. affected due to laying of the pipes.5 meters from the excavated trench. then the pipe shall be set down on clean square cut skids. 4. The skids shall be so spaced as to keep the pipe away from touching the ground. No extra claim shall be entertained due to its caving or setting down either before or after the pipe is laid.4. bricks. shall be rectified by the Tenderer at his own cost. etc.0 4. Errors.5.0 The trench shall follow the gradient of pipeline as specified in the drawing. all material i. shall not be permitted to come in contact with the coating. The Bidder shall provide suitable signs and barricades to prevent accidents.0 In muddy/slushy ground.3. the Tenderer shall clean. 4. the Bidder shall re-excavate the trench for inspection and backfill it at his own cost. 4. the bed shall be provided with a layer of a sand or lean concrete as directed by the owner's project manager. coat and wrap manually.2. The dykes etc. 3.

0. because of unfavorable temperature conditions shall be lowered into the trench normally in the cool of the morning and only when the temperature of the pipe is below the softening point of the coating materials. some portion of the pipeline is backfilled without approval of the Engineer-in-charge.5. 5.3.0 All lines and equipment shall be completely drained after the hydrostatic test of a system has been completed.5. hard clods.1. 7. the Engineer-in-charge shall have the right to order uncovering of the pipe for examination and the cost of such uncovering shall be borne by the Tenderer. identification of the piping system. well watered and rammed to avoid any settling afterwards.0 4.3. 6.0 5.0 If it becomes necessary to leave a system filled with the testing medium from any abnormal length of time.4. Lining up & Welding The ends of the pipe line shall be kept securely closed to prevent entry of any foreign material/ moisture after lowering into the trench. Before making joints the pipe shall be carefully laid so as to be perfectly aligned in both plan and profile and the end closures provided shall be removed. Tie-in shall be made in the coolness of the morning or when the ambient temperature is not exceeding 29°C or softening temperature of the coating material whichever is less.5. layouts giving actual elevations of pipeline as laid. aligning and welding shall be in accordance with the welding specifications.4. Coated pipe shall not be handled or moved by means of cable or chains or by prying with skids or bars. No trench shall be backfilled without the approval of Engineer-in-charge.0 BACKFILLING 7.4. 7. Coated pipe shall not be dragged along the ground or otherwise handled in a manner that will be detrimental to the coating. suitable arrangement such as venting shall be made to provide for possible liquid expansion with change in ambient temperature. Free access shall be provided for the welding of the circumferential joints by increasing the width and depth of the trench at these points.2. date of flushing & approval by Purchaser's Inspector.3.2.0 RECORDS 6.0 Records in triplicate shall be made by the Tenderer for each piping system as follows: 6.2. welding rods etc.0 Backfilling with the excavated material shall be done in layers of 100 mm. It shall be tied and lowered by using lowering in belts of a standard width and designs for the size of pipe being handled. All skid marks and other places of damages shall be thoroughly examined to ensure proper patching where necessary.0 The Tenderer shall place soil over the trench to such a height as to provide adequately for future settlement of the trench backfill. There should be no obstruction to the welder from any side so that a good welded joint is obtained.4. If due to exigencies of the work. VENT AND DRAINING 4.5. All beveling.0 Aftertesting and inspection of the pipeline to the entire satisfaction of the Engineer-in-charge.0.0 Test certificates containing date of test.1 4.5. Handling of Coated Pipes Coated pipes shall not be placed in trench until cave in plugs.3 4.1 4.2. the trench shall be backfilled with the same material as the pipe bed above the top of the pipe.4 5. High point vents shall be open to prevent excessive vacuum and permit complete draining.0 4. have been removed there from.0 In case of underground piping.0 Pipe previously set on skids. Where the trench has a hard or jagged bottom sufficient fine dirt or sand shall be placed therein. . before the pipe is lowered.1. 7.0.4.2 4. stones.1.2 4. 6.0 4.3 4. before the pipe is finally lowered into the trench. skids.

......2.....0 The backfill material shall be free from stone pieces.. to the complete satisfaction of the Engineer-in-charge......... LINE CHECKS BEFORE PRESSURE TEST General After completion of the fabrication and installation works and prior to pressure test....2........0 2....3 TESTING......................7..0 Check Points ................. 3............................ In the event.................. line checks shall be carried out for all works to ensure that the works have been performed properly and that the quality of work is adequate.....4 TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE TABLE OF CONTENTS 1.......2 .... if they are trenched or otherwise disturbed by the Tenderer during laying of the pipelines. 3.. 7........50 m beyond the outside banks of the ditch on either side........ The banks of the ditch shall also be compacted in 150 mm layers at no extra cost to the Purchaser.6.......8... or other special material it shall be borne by him without any extra cost to the Purchaser....0.........0 GENERAL.0 Surplus excavated soil or rubbish material shall be removed by the Tenderer at his own cost to a place designated by the Engineer-in-charge... gravel...........4 S E CT I O N .......0 2. This shall be done by the Tenderer at no extra cost to the Purchaser....3 LINE CHECKS BEFORE PRESSURE TEST.......................5..0.7.. SECTION .0 When the trench has been dug through roads all backfill shall be thoroughly compacted............0 4....0...0 CLEAN UP OF SURROUNDINGS As soon as the backfill is completed.............. 7.1....... 7.............0 GENERAL This specification covers the general requirements related to the hydrotesting of LP piping system.... The Tenderer shall restore the road to its original level and condition.....1... 8..0........0 3.. special compaction methods may be required by the Engineer-in-charge......3 CODES AND STANDARDS.. 7..0 3......0 CODES AND STANDARDS The Hydrotest of piping................4 TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE 1. Valve and drain pits. PCC..... the Tenderer shall immediately clean up the adjoining area by removing all surplus and defective material and dispose of all refuse such as spurs..0........0 3..........0................. broken skids etc.....0.....0........... Excavation and backfilling. sheet iron... valves and specialties comply with the requirements of latest edition the ANSI / Indian Standard or relevant standards..0 When the trench has been dug through unlined ditches the backfill shall be thoroughly compacted in 150 mm layers for a distance of 1......... supports for buried pipes............ RCC.....0 After the roads have been already graded........ Exclusions: CIVIL: 1..... 2.....4. In certain cases.. the Tenderer is required to place extra fill...... 2......

No anchors on piping shall be used except at locations shown in the drawings. are in accordance with applicable drawings and flange connection is properly made with correct use of bolts and gaskets.0. whether indicated in drawing or not to prevent vibrations.1 4. tee. xii) Piping (including all components and attachments) is sufficiently cleaned. vent. Size. xi) Applicable examination or inspection and the heat treatment (if applicable) has been satisfactorily completed and accepted. The testing shall be carried out in convenient sections as approved by Owner/Owner's Engineer. The pipe shall be secured firmly at anchor supports. guides and anchors for piping shall be fabricated and provided as shown in the drawings. slag etc.1. Orientation and direction of piping components are in compliance with piping drawings. hangers. welding jigs and temporary support attachments are removed. but not be limited to these items: a) Lines and components i) ii) iii) iv) v) vi) vii) viii) ix) x) Piping layout is in accordance with the applicable drawings including P&I diagrams. the series of hangers nearby shall be adjusted using the turn buckle to activate the cold set load in all hangers. etc. Drain. flange. 4. ii) Spring supports are to be properly set in cold position with setting pins.1. When the hanger are released they shall be checked for cold set values and if there is any disturbance. b) Pipe Supports i) All pipe supports such as anchors. guided restraints. v) Fabrication and erection of supporting elements and structural fixtures wherever required and pointed out by the Engineer-in-charge. Welding quality and other workmanship complies with the applicable specifications. xiii) Slope is maintained as indicated in relevant drawings. dimension. blind. iii) Enough and adequate temporary supports are to be provided wherever necessary to keep the piping stable.0 4. iv) Supports. header and other components are in accordance with applicable drawings. Thread connections are not damaged and free from weld spatter. rating and material specification are in accordance with the applicable drawings. Valve. reducer and other fittings are in accordance with the applicable drawings. vi) Spring hangers shall be erected with springs locked in cold set position.0 4. etc. The tie rods shall be selected that the pipe center line with slope can be maintained in cold position.This shall include the following confirmation of overall and individual workmanship. shall be carried out by the Contractor. Bend. bands. Tightness and projection of flange bolts are adequate. are to permit free expansion and contraction of piping in the specified direction and are assembled as indicated on support drawings.1. thermal expansion.5 times the design pressure. . The springs shall be released after hydrotesting and before passing steam. All shipping and erection stoppers. excess sag etc.2 TESTING General All pipes shall be tested for leakage to a hydrostatic test pressure of 1.

b) Care shall be taken during flushing that no foreign material can enter into equipment which is connected to the test section.2.2.5 .1. Pressurizing Pressure shall be applied by means of a suitable test pump which shall not be connected to the system until it is ready to test.3 If some defect is noticed during the hydrostatic testing.1 4. Calibration of test gauges shall be the responsibility of the Contractor. SECTION . Any extra work / modification on this account shall be done by the Contractor at his own cost. The hydrostatic testing / flushing of all piping shall be carried out by the Contractor at his own cost.1. Air testing shall be carried as per ASME B31. A pressure gauge shall be provided at the pump discharge for guidance in bringing the system upto pressure.4.7.0 4. Test shall be considered complete only when approval is given by Owner / Owner's Engineer.2. The pump shall be attended to constantly during the test by authorized operator.0 4.1 Temporary Blinds Open ends of piping systems such as at pumps or wherever equipment has been removed or disconnected prior to hydrostatic testing or at termination point of piping branch connections shall be blinded off by temporary blind flange made our of M.6. Venting All piping system and equipment shall be properly vented to remove air from the system during filling. debris and loose foreign material after testing Flushing and Pressure Test a) The piping system shall be sufficiently flushed with the pressure test medium in the presence of Owner/Owner's Engineer.1 4. The Owner /Owner's Engineer shall be notified in advance by Contractor of all testing. c) After flushing and testing.1 4. The test pressure is to be maintained for sufficient time to permit complete inspection of the system under test. plate of suitable thickness.4.1.1 or relevant Indian standard.5 4.0 4.2.3. In situation where water cannot be used air is used as a testing medium.0 4.S. the same shall be brought to the notice of Owner/Owner's Engineer.3. Contractor shall make his own arrangements for flushing at suitable points as per the instructions of the Owner /Owner's Engineer. water shall be drawn off by opening all drain valves and vents.3. The piping system shall be dried internally to the satisfaction of the Owner /Owner's Engineer. If leakage is on the threaded joints.4 4.1 Test Gauges Contractor's own gauge shall be installed as close as possible to the lowest point in the system being tested.0 4.1 4. The pump shall be disconnected immediately after the test pressure is reached. Cleaning All systems shall be cleaned and flushed free of all dirt.2 4.4. Test Medium Soft water shall generally be used as the testing medium for the hydrostatic testing of piping system. 4. if leaking shall be rectified as per welding specifications and instructions of Owner/Owner's Engineer at no extra cost. 4.0 4.6.5.5.7. Joints.2 4. necessary inert chemical bonding material shall be applied to arrest the leak.

...I) .......... • • Cleaning in workshop Cleaning before painting and/or corrosion protection (application of prime coat) ..0.... to keep a set of latest edition of the above standards and codes at site......1 .........TECHNICAL SPECIFICATION -LP PIPING FLUSHING AND CLEANING PROCEDURE TABLE OF CONTENTS 1..................... ASME B31........0.................................5 SECTION .................0.........................0 4...3 INSPECTION..0..A...........0 CODES AND STANDARDS The following codes and standards shall be followed for the work covered by this contract in addition to the detailed specifications of the contract.... All supports have been installed correctly.............................0.. Various international standards equivalent to Swedish standard for surface preparation are given in Table-1...................................... CLEANING METHODS General The Piping components shall be mechanically and /or chemically cleaned during the following stages of the Contract......0 2...........code of practice for painting of Ferrous metals in buildings (Part 1............. (Surface Preparation Specifications British Standards Institution (Surface Finish of Blast cleaned steel for painting) BS-4232...... 3.....3 CLEANING METHODS.0 INTENT OF SPECIFICATIONS This specification covers the general requirements for inspection..0..................power piping The Contractor shall arrange.....SIS-05 5900-1967 (Surface preparation standards for painting steel surfaces). National Association of Corrosion Engineers..0 4............... valves and specialties for LP piping system.......3 FLUSHING.......0 INSPECTION During various stages and after completion of fabrication and erection...... (NACE)......0 Proper piping material has been used....3 CODES AND STANDARDS..0................5 TECHNICAL SPECIFICATION -LP PIPING FLUSHING AND CLEANING PROCEDURE 1..0 INTENT OF SPECIFICATIONS.................. U....... at his own cost.........1...... • ■ ■ ■ ■ ■ ■ Swedish standard Institution ...........0.... 2..... Steel structures (SSPC-SP)............ pre-treatment)..A.............. IS:1477-1971 (Part ............... U................. painting council....2............S.....S..... Test preparations mentioned in this specification have been carried out.............0 3........ Piping has been erected as per drawings and instructions of Engineer-in-charge.0 5.......... cleaning & flushing of piping..........................0................... the piping system shall be inspected by the Engineer-in-charge to ensure that :• • • • 4..............

4. cast iron. spray guns.0 Mechanical Cleaning Mechanical cleaning shall preferably be carried out by abrasive blasting. Al2 O3.0 Removal of abrasive and debris After cleaning.6. Where metal surfaces are to be painted the surface profiles shall conform with the painting specification requirements. The Purchaser is prepared to consider alternative methods provided they achieve the necessary surface condition. and components fabricated by spot welding or riveting shall not be chemically cleaned. Machined surfaces shall be protected during the cleaning operations. shall be used. hand cleaning by wire brushing by puffing method may be permitted. 4. the taking up of surface preparation or painting work in any specific location. For recleaning small areas. For cleaning in workshop and before painting mechanical cleaning as opposed to alternative chemical cleaning is the preferred method for works cleaning except where this is precluded by design or access considerations. rollers. All tools. as appropriate.5.3.0 FLUSHING Flushing of all lines shall be done before pressure testing. wherever water flushing is not desirable.hand power tools for cleaning and all equipment shall be arranged by the Contractor at the site in sufficient quantity at his own cost. abrasive and debris shall be thoroughly removed from components.0. rust. brushes. All weld areas shall be suitably stress relieved before chemical cleaning. debris or loose foreign material. 4. grease and any other deleterious matter. 5. Austenitic stainless steels. to clean the pipe of all dirt. such parts of the cleaning procedures or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the contractor sole expense. Wire brushes of austenitic steel bristles shall only be used. In the event of the surfaces not being cleaned to the purchaser's satisfaction. tarpaulin sheets for covering the areas to be sandblasted . 1Any cleaning work on piping shall be commenced only when erection activities are completed in all aspects and after the system tests have been completed and clearance for taking up painting work is given by the Engineer.0 Abrasives Abrasives containing silica. blast material.0 Alternative Chemical Cleaning The procedure shall comprise both pretreatment and acidic treatment and preservation of the system applicable only for fuel oil system.• Cleaning before erection and after installation. silicates or slag residues shall not be used for water/steam side surfaces of plant except for cleaning sand castings. 4. 4. copper and aluminium alloys.2. Flushing shall be done by fresh potable water or dry compressed air. at his discretion authorise in writing. even prior to completion of system test. bimetallic and metallic/plastic items. For austenitic materials only.0 Surface condition The Metal surfaces shall be clean and free of mill scale. however. 4. who may. Cleaning of fabricated component items shall be carried out after fabrication and final heat treatment or welding at manufacturer's works or at site. where hydro blasting with sand may be used. abrasives containing 98% or more of aluminia. dirt. Where this does not apply surfaces shall have a surface texture not coarser than Grade 80 abrasive paper. .

................ These flanges shall be provided with temporary gaskets at the time of flushing. after flushing is completed........ However..............0................. vessel......5 INSPECTION... Care shall be taken during flushing so as not to damage / spoil work of other agencies...................................6 TECHNICAL SPECIFICATION -WRAPPING & COATING OF BURIED PIPING TABLE OF CONTENTS 1...............0 3......0............. These shall be removed........3 TECHNICAL REQUIREMENT. The pressure shall then be released by quick opening of a valve......0. already in line or installed temporarily for this purpose.. electric motors..................0.0 2..3 COATING THICKNESS......................... Contractor shall submit procedure for flushing and cleaning in detail based on the above for Engineer's approval.... proper temporary drainage shall be provided by the contractor........... such as but not limited to the following: Dropping of valves..................................... this shall be done with the approval of Engineer-in-charge............................. forms part of a piping circuit during flushing....0 6.............. exchanger etc.....Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure for air flushing the line / system will be pressurised by compressed air at the required pressure which shall be 50 psi maximum. instruments electrical installations etc................... In case on equipment such as column.................0.......4 EXTENT OF APPLICATION.0......... In line instruments like control valves........................ From oil permanent strainers the screens / meshes shall be removed before flushing......... in the vicinity of lines being flushed........................ safety valves and other instruments like thermowells which may interfere with flushing instrument shall not be included in flushing circuit....... shall be completely drained and dried with compressed air.6 ......................0.....6 SECTION-2........... inline instruments and any other piping part before flushing.....0 8...0 7......5 REFERENCE DOCUMENT....... This procedure shall be repeated as many times as required till inside of the pipe is fully cleaned............... arising because of flushing requirements........... However equipments thus included in the circuit... piping specials etc............... flanges at equipment nozzles and other places where isolation is required during testing only temporary gaskets shall be provided..................... After flushing is completed and approved the valve distance pieces............. If necessary....... during and after the flushing operation....... cleaned and reinstalled after flushing but before testing....................... Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing done in standard format...... Screen / meshes shall be reinstalled after flushing but before testing.......... rotometers..0 5.. Precautions shall also be taken to prevent entry of water / foreign matter into equipments.............. orifice plates........ The contractor shall carry out all the activities required before.......... specials distance pieces.........6 BOQ FOR COATING AND WRAPPING OF BURIED PIPELINES..................0 9.............3 CODES AND STANDARDS..........3 PROCEDURE FOR COATING AND WRAPPING....... During flushing discharge of water / air shall be drained to the place directed by the Engineerin-charge....0........ The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-in-charge....0.0 4....0 INTENT OF SPECIFICATIONS............. During flushing temporary strainers shall be retained.................... shall be reinstalled by the contractor with permanent gaskets.......... SECTION-2...............

The pipe surface after cleaning by wire brush shall be cleaned with dry cloth thoured.0 Materials The materials required for application of anticorrosive polymeric tape are as below.0. 5.0 PROCEDURE FOR COATING AND WRAPPING 5.92 gms/cm3 and viscosity of 1000-2000 cps. coal tar and solvent based primer of density 0. 2.0 General The coating and wrapping of pipes shall be from a polymeric corrosion protective tape with mix of coaltar. grease and dirt that might fall on the pipe before it has received its final coat. 5. (SP-I solvent cleaning and SP-10 near white blast cleaning).1. 3. c.0. NACE RP-02-74 Recommended Practice. inspection and testing. Wire Brush to remove all foreign debris b.1. Preferably priming shall be done within four hours of completion of wire brushing.2.0.Anticorrosive multilayered polymeric tape of 4 mm or 2 mm thick. a.0 TECHNICAL SPECIFICATION .2.0 TECHNICAL REQUIREMENT 4.1.0 Surface Preparation If the pipe surface is free from oil and grease then wire brush shall used to remove all foreign debris otherwise.0 Application of First Layer of Primer .0. The material shall confirm to ASTM / DIN codes. 4. The solvent cleaning shall be as per SSPC-SP-1. 4.Coat of fibre. 2 mm thick tape is used and two layers of 2mm thick are to be applied one over the above on the pipes. @ 150 gms/sqm (Primer) recommended by tape manufacturer. SSPC-SPI & SP 10 Steel structure painting council.0 CODES AND STANDARDS a) b) c) d) AWWA C-203-91 AWWA standard for coal tar protective coatings and linings for steel water pipe lines enamels and Tape-Hot applied. all oil and grease on the pipe metal surface shall be thoroughly removed by flushing with a suitable solvent (such as xylene or 1. IS 10221 Code of practice for coating and wrapping of underground mild steel pipelines. Application should be with recommended over laps and in accordance with manufacturer's specification.0 COATING THICKNESS The polymeric tape thickness is 2 mm and two layers shall be provided over the buried pipe. coating and wrapping and testing shall be approved by the Engineer-in-charge.0. The sequence of coating and wrapping of pipes shall consist of following operations. rubber & other polymers.WRAPPING & COATING OF BURIED PIPING INTENT OF SPECIFICATIONS This specification covers the procedure for coating and wrapping of corrosion protection coating for buried pipes and fittings using polymeric protection prefabricated tape including. High Voltage Electrical Inspection of pipeline coating prior to Installation. priming. The degreased pipe metal surface shall be wire brushed / power brushed.2 trichlorethane) and wiped with clean rags. i) Surface Preparation ii) Application of First Layer of Primer iii) Application of first Layer of Membrane tape iv) Application of Second Layer of Primer v) Application of Second Layer of Membrane tape vi) Tape Coating of Field Joints All appurtenances and equipment to be used for cleaning. After being cleaned the pipe shall be protected from and be maintained free of oil.2. d.

which does not involve thermofusing.0 EXTENT OF APPLICATION All buried piping of water and utility service shall be applied with above type of coating & wrapping method.0 Tape Coating of Field Joints (common for all thickness of tape) Incase of site coated pipes the welded joints shall be coated. Over the primed surface tape shall be applied in accordance with above section. dust or other foreign matter until tape is applied.0 Application of Second Layer of Primer The second layer of primer is applied over the first layer of tape by brushing or spraying @ minimum 150 gms/sqm. 7. Once again overlaps are maintained at minimum 15 mm. The minimum and maximum drying times of the primer or the period of between application of primer and application of membrane tape shall be in accordance with instructions issued by the manufacturer. 5.0. or bare spots. drips.5. 5. it is allowed to dry until the surface becomes tacky. Primer shall be applied with brushes after cleaning the pipe thoroughly. The welded field joints and uncoated areas shall be cleaned and dried in accordance with the procedure indicated above. The entire pipe length shall be cleaned but the ends of the pipes shall be left without coating and wrapping for a distance of 150 to 200 mm for joints. After application. The primer is allowed to dry for 15 minutes before commencement of application of second layer of tape. sags. overlaps are double sealed by thermofusion as for the first layer.6. 6. 5. field welding and testing the pipes. Whenever buried pipe extents above the ground the coating of tape shall be applied as a minimum length of 500 mm above ground level.0 Application of first Layer of Membrane tape (used for 2 mm thick tape application) After the surface is primed. runs.0 INSPECTION 7. Any bare spots shall be recoated with an additional application of primer. which shall be coated and wrapped manually on site after laying. Overlaps on each side of the weld joints shall be 50 mm. spray. fog. After application the primer coat shall be uniform and free from floods. Primer shall be applied on adjacent tape coating also. The primer and tape coating materials shall be the same as used for yard coating the pipe.1. or drips shall be removed by scraping and cleaning. Tapes shall overlap the coating on each side of the field joint to form a continuous external coating free of defects.0 General . However. Care is taken that the overlap of the second layer does not coincide with the overlap of the first layer. Overlaps are maintained as per specifications with a minimum of 15 to 20 mm.Primer is to be applied on pipes immediately after cleaning. Primer shall be applied on the clean area. This is a cold process. sags.4. primer shall be stirred in drums so that it is mixed properly.0.3. mist. Suitable measures shall be taken to protect the wet primed pipe from contact with rain.0 Application of Second Layer of Membrane Tape (used for 2 mm thick tape application) Second layer of membrane tape is wound over the wet second layer of primer. No wrinkling in the wrapper shall be allowed. The cleaning and priming operation may be carried out in the Bidder's workshop or on site. The membrane tape is then adhered to the primed coated surface. The overlaps are doubly sealed by thermofusion on the exterior for additional security. A LPG torch or other heat source is applied onto the inner face of the membrane tape till the polymeric mix attains a shiny appearance and tape compound is softened. and the cleaned area shall be retouched or remedied by reblasting and repriming. This primer is applied so as to produce effective bond between metal and pipe coating membrane tape prior to application. All runs. Primer is a cold applied primer and is applied by brush @ minimum 150 gms/sqm. 5. If coating and wrapping is found unsatisfactory to the Engineer-in-charge the same area shall be recoated and wrapped with above procedures. membrane tape is applied over the pipe in spiral fashion under slight tension by thermofusion process.

Similarly any pipe having any one holiday bigger than 0. iii) The operating voltage of the detector shall be determined by NACE RP-02-74. handling and storage of coated pipes.3. Any defective places shall be plainly marked with chalk immediately after they are detected visually or by the holiday detector. ii) The thickness shall be measured by pushing the point of an approved pit depth gauge or microtester through the coating and wrappers.2.0 Testing and adhesion of the coating i) Atleast two tests a day shall be carried out on finished coating after 12 hours from completion of coating. Any delay caused by the incorrect functioning of the holiday detector will not be entertained. . ii) The areas where the coating has been removed for testing by the inspector shall be repaired by the CONTRACTOR at his own expense.3.Contractor shall test the coating and any repair subsequently made to it.1 square metre shall be rejected. The test shall be carried out as per AWWA-C-203-91 Sec.0 REFERENCE DOCUMENT For material of construction.3 Technical specifications .2. lowering of pipes. The testing shall be carried out prior to laying of pipes in the trench.3.0 BOQ FOR COATING AND WRAPPING OF BURIED PIPELINES Material: Anticorrosive 2 layered polymeric tape with primer required for the following length of pipe to be coated & wrapped. iii) The specified minimum thickness shall be present both at the pipe or any other point.3. correctly operated and always maintained in good working condition along with adequate supply of spare parts.7.3/3. 7. 7. v) For pipe with pre-fabricated tape. 7.8 / IS 10221 Section B-3. ii) The holiday detector shall be supplied. 8. the test voltage which the pipe should pass with holiday detector kit at voltage 15 kV for 4 mm thickness coating.0 Holiday Detection i) All coated and wrapped pipes shall be subjected to a test with an electric holiday detector as specified in AWWA-C-203-91.Erection of Buried piping. trenching & backfilling refer Section .4.0 Measuring coating thickness i) All pipes shall be tested for thickness as per AWWA-C-203-91.0.1 / 3.0. 9. iv) Any pipe having three (3) or more holidays shall be rejected. Pipe Size( NB) Buried Pipe Length (m) Note: Pipe Size and Buried pipe length details will be provided during details engineering.3.

Raw Water Pump House Area Piping Layout .CW makeup system (Will be submitted later) Isometric .Pipe rack Isometric .Service & Instrument air system( Will be submitted later) Piping Layout .3 LIST OF TENDER DRAWINGS SECTION .Service water system ( Will be submitted later) Isometric .No.Service & Potable Water System (Will be submitted later) Piping Layout .Potable water system ( Will be Title 20 21 22 23 24 25 26 DP-00BQ-35-179 DP-00GH-31-190 DP-00GC-31-191 DP-00PA-31-192 DP-00PA-31-193 DP-00GH-31-194 DP-00GK-31-195 .3 LIST OF TENDER DRAWINGS Sl.CW Make up Water System Piping Layout .DM water system (Will be submitted later) Isometric .CW blow down system Piping Layout . DP-00CE-01-003 DP-00SC-22-074 DP-00SC-22-074 DP-00GC-22-075 DP-00GH-22-072 DP-00PA-22-071 DP-00GH-22-073 DP-00GH-22-077 DP-00UE-01-002 DP-00GH-35-166 DP-00GB-35-167 DP-00GC-35-168 DP-00PA-35-169 DP-00GH-35-170 DP-00MM-35-171 DP-00GC-35-172 DP-00PA-35-173 DP-00GB-35-174 DP-00SC-35-176 Symbols& Legends P&ID for Instrument Air Distribution System P&ID for Service Air Distribution System P&ID for DM Feed Water System P&ID for Plant Water System P&ID for CW and ACW System P&ID for Potable Water Distribution System P&ID for Service Water Distribution System Plot Plan Piping Layout .DM Make up & Condensate System (Will be submitted later) Piping Layout .CW blowdown system (Will be submitted later) Isometric .Raw water system (Will be submitted later) Isometric .Main Plant Air Compressor & Closed Cycle Cooling Water System (Will be submitted later) Piping Layout .SECTION .DM Water System (Will be submitted later) Piping Layout .Clarified Water Pump House Area (Will be submitted later) Piping Layout .Effluent collection to ETP (Will be submitted later) Piping Layout. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Drawing No.

Typical pipe supports (Will be submitted later) The above list of drawings is tentative and indicative only. submitted later) DP-00MM-31-196 DP-00MM-31-197 DP-00GH-31-198 DP-00GB-31-199 DP-197-39-210 Title Isometric .Effluent collection system ( Will be submitted later) Piping support . 27 28 29 30 31 NOTE: Drawing No.Service Air system ( Will be submitted later) Isometric .Instrument air system ( Will be submitted later) Isometric .No. .Plant Water System submitted later) ( Will be Isometric . Final drawings will be furnished progressively to the bidder after the award of the contract.Sl.

specialties and supports etc.....11 UTILITY CONSUMPTION LIST.....4 SCHEDULE 4...........No 1....................... SCHEDULE 4.......9 SCHEDULE 4.. Laying....................................SECTION ......... Receipt of material from site stores.........5 SCHEDULE 4.......... Fabrication of Supports (structural material only by owner)...... Inspection & Testing at site...............................6 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS............... Fabrication of piping & fittings (above 300NB / the plate will be free issued by owner)........................ 3....................... 5...................0 2......7 CONCURRENT COMMITMENTS OF THE BIDDER.... Calibration and Commissioning at site for LP piping........1 SCHEDULE 4..............10 QUALITY ASSURANCE PLAN.....................................12 SECTION 4 TECHNICAL DATA SHEETS & SCHEDULES [Duly filled in by the Bidder] SCHEDULE 4.4 DEVIATION SCHEDULE . Handling at site......10 TECHNICAL DATA SHEET FOR LP PIPING ......3 ERECTION/COMMISSIONING.... Erection....0 Description Establishment of site office Mobilisation of site staff Delivery of Material at site from store (Completion) Completion schedule from date of LOI in (months) ... 4.. valves..5 DEVIATION SCHEDULE-COMMERCIAL... ERECTION& COMMISSIONING.8 SCHEDULE 4........... 1..FABRICATION..... Wrapping and Coating for Buried piping. 6....9 PROPOSED SITE MANPOWER DEPLOYMENT.8 SCHEDULE OF SUB-CONTRACTOR...... ERECTION & COMMISSIONING Bidder shall submit a detailed Technical data sheet for the following...................6 SCHEDULE 4...7 SCHEDULE 4............... Hume pipes / Encasement for Buried line......... 2...2 ERECTION/COMMISSIONING We hereby confirm the completion schedule for the various milestone activities indicated below: Sl............................ Cleaning & Painting....................2 SCHEDULE 4........TECHNICAL...3 SCHEDULE 4.........................4 TECHNICAL DATA SHEETS & SCHEDULES TABLE OF CONTENTS SCHEDULE 4.... Site Supervision...0 3.1 TECHNICAL DATA SHEET FOR LP PIPING FABRICATION.......

Tender References Cl. if any./ Description as Section No.No. Deviations to tender documents. Notes: 1. / specified Volume No. Piping erection (Completion) Testing Trial operation Commissioning / Performance Test and handing over 5. SIGNATURE OF BIDDER NAME ______ COMPANY SEAL DESIGNATION_ DATE SCHEDULE 4. Fittings and Flange etc.0 7. shall be indicated only in this schedule.0 8.3 DEVIATION SCHEDULE -TECHNICAL Sl.0 Fabrication of Pipes.4.0 Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. Deviation Taken Reasons for deviation taken We confirm that above are the only deviations from the bid document. Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. ./Page No. 2.0 6.No.

SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION_ DATE . SIGNATURE OF BIDDER NAME ______ COMPANY SEAL DESIGNATION_ DATE SCHEDULE 4.4 DEVIATION SCHEDULE COMMERCIAL Sl./ Description as specified Section No.No. 3. shall be indicated only in this schedule.No. Deviations listed elsewhere will be summarily rejected and shall be ignored. Notes: 1./Page No.3. 2. Tender References Cl. Deviations to tender documents. Deviation Taken We confirm that above are the only deviations from the bid document. Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. Deviations listed elsewhere will be summarily rejected and shall be ignored. / Volume No. if any.

/ Fax No. SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION_ DATE SCHEDULE 4. No Full postal address of client & name of Officer-in-charge with Telex/Tel.No.6 CONCURRENT COMMITMENTS OF THE BIDDER Sl. No Full postal address Description of Value of of client & name of the work (shall contract Officer-in-charge indicate with Telex/Tel.completion date of cement of as on date completion work 1 5 6 7 8 .5 DETAILS OF SIMILAR WORKS DONE DURING PAST FIVE YEARS Sl.No. major scope) 2 3 4 Completion Time as stated in order Date of % Expected commen. Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule.SCHEDULE 4./ parameters & Fax No. if any Operating Hours Logged 1 3 4 5 6 7 8 9 Certified that documentary proof for above information is enclosed. 2 Description of the work (shall indicate parameters & major scope) Value of contract Date of commen Cement of work Schedule Completion Period Actual completion period Reasons for delay.

Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. SIGNATURE OF BIDDER NAME COMPANY SEAL ______ DESIGNATION_ DATE SCHEDULE 4.Certified that documentary proof for above information is enclosed.7 SCHEDULE OF SUB-CONTRACTOR Sl. SIGNATURE OF BIDDER . No Equipment/ Item Sub-Vendor/SubContractor Place Experience Details Note: This statement shall be furnished section wise separately for each volume of the bid specification.

of Personnel Remarks Note: Additional sheets of similar size and format may be used as per Bidder's requirement and shall be annexed to this schedule. SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION_ DATE _______ . It is understood that this will be augmented from time to time depending on the requirements for timely completion of work.NAME COMPANY SEAL DESIGNATION_ DATE SCHEDULE 4. Sl.8 PROPOSED SITE MANPOWER DEPLOYMENT The Bidder shall also indicate here in proposed site organisation for timely execution of work. as directed by the Engineer. No Designation of Personnel Qualification & Experience of Personnel No.

No. NO. COMPONENT CHARACTERISTIC CHECKED CLASSIFICATION TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENTS ACCEPTANCE NORM FORMAT OF RECORD P 1 2 3 4 5 6 7 8 9 INSPECTION BY REMARKS W 10 V 11 LEGENDS : P-PERFORMANCE. V-VERIFY.SCHEDULE 4.10 UTILITY CONSUMPTION LIST ITEM NO.9 QUALITY ASSURANCE PLAN SL. Equipme Mode (KW) (NM 3/HR) (M3/HR) kg/cm2 (g) C I C I C I C kg/cm2 (g) I . SIGNATURE OF BIDDER COMPANY SEAL NAME DESIGNATION_ DATE SCHEDULE 4. W-WITNESS.

Bidder shall include and give their details.Any items are not covered in the above table.Continuous I Intermittent SIGNATURE OF BIDDER COMPANY SEAL NAME DESIGNATION_ DATE . C .

.3 PRICE BREAK-UP FOR SPECIAL TOOLS & TACKLES.. Site Supervision. 3......... 2... specialties and supports etc.. 6.....5. Rs.2 inclusive of all taxes and duties)......... ERECTION......... Inspection & Testing at site........1 SUMMARY OF PRICE PROPOSAL FABRICATION........5 PRICE SCHEDULES (TO BE FILLED AND SUBMITTED BY THE BIDDER WITH OFFER) TABLE OF CONTENTS SCHEDULE-5... Erection. ERECTION.SECTION ............ 5. valves.... TESTING & COMMISSIONING Details 1. Handling at site.. in lakhs TOTAL PRICE COMPANY SEAL SIGNATURE OF BIDDER NAME DESIGNATION _ DATE ................ Fabrication of Supports (structural material only by owner).. Hume pipe for buried line.. Laying...1 SUMMARY OF PRICE PROPOSAL ........ 4..........0 Erection & Commissioning: Total lumpsum price towards 1.....4 SCHEDULE . Receipt of material from site stores.......FABRICATION... Calibration and Commissioning at site for LP piping..5..3 SCHEDULE..... as detailed in the scope of work (as per Schedule 5... Wrapping and Coating for Buried piping... Fabrication of piping & fittings (above 300NB / The plate material will be free issued by owner).....5 SECTION-5 PRICE SCHEDULES SCHEDULE-5... TESTING & COMMISSIONING..2 SCHEDULE OF PRICE FOR FABRICATION.... Cleaning & Painting............. ERECTION AND COMMISSIONING..

4. as detailed in the scope of work. ERECTION AND COMMISSIONING SL. Erection & Commissioning: Total lumpsum price towards 1. Calibration and Commissioning at site for LP piping. valves. Inspection & Testing at site. Fabrication of piping & fittings (above 300NB / The plate material will be free issued by owner). 2. Handling at site. Bidder shall include and give their details. COMPANY SEAL SIGNATURE OF BIDDER NAME DESIGNATION DATE PRICE BREAK-UP FOR SPECIAL TOOLS & TACKLES . 1. Cleaning & Painting. Site Supervision. 6. 5. Laying.SCHEDULE-5. Fabrication of Supports (Structural material will be free issued by owner). Erection. Wrapping and Coating for Buried piping.2 SCHEDULE OF PRICE FOR FABRICATION. Receipt of material from site stores. BASIC PRICE TAXES & DUTIES INSURANCE TOTAL PRICE REMARKS Note: Any items are not covered in the above table. Hume pipe for buried line. 3.0 DESCRIPTION Fabrication. specialties and supports etc.

SIGNATURE OF BIDDER NAME COMPANY SEAL DESIGNATION DATE . DESCRIPTION OF THE EQUIPMENT/ ITEM QTY.Sl. No. Bidder shall include and give their details. UNIT PRICE EXWORKS (DULY PACKED) (4) TOTAL PRICE EXWORKS (DULY PACKED) (5)=(3)x(4) EXCISE DUTY (%) SALES TAX % OTHER CHARGES INSURANCE CHARGES TRANSPORT ATION CHARGES TOTAL PRICE (1) (2) (3) (6) (7) (8) (9) (10) (11) GROSS TOTAL Note: Any items are not covered in the above table.

The Bidder shall review the life expectancy and exposure requirements and propose complete painting/coating systems for the Owner's considerations. Trolley / crab runway rails shall be standard rail section as per IS:3443 or equivalent. . The tables included at the end of this section provide recommendations for painttng/coating systems at various locations and substrates found in the power station. Coating material and application shall conform to the regulations of the air quality management agency having jurisdiction.25. shall be trolley suspended type. Field. The trolley frame shall be built up from heavy steel sections welded together to form a rigid piece frame adequately braced to resist vertical. Each painting/coating system shall provide an optimum life expectancy of 10 years from the time of original painting. Bridge girder for the crane shall be of plate welded box type construction fabricated from tested steel plates. and Maintenance Painting. Manually operated hoisis shall be of spur gear chain pulley block type. General The requirements for shop and field application of protective painting/coatings and linings are described in this clause. testing of electric hoist shall conform to IS:3938 {Specification for electric wire rope hoist. The hoist hook shall be provided with safety locking arrangement to provide accidental unhooking. unless stated otherwise. End stops and curved wheel stoppers on crab/ trolley runway rails on both end of each bridge girder shall be provided in approved construction. It shall be suspended from the trolley by a hook. Diaphragms shall be provided to transmit the trolley wheel loads to the web piates.25. The load hook shall be swivelling type fitted with a locking device.06 percent lead or chromium in the dried film. AN manually operated hoists. The rail section shall be sufficient to cover the whole runway length and shall be adequate for maximum permissible trolley travel. Electric hoist shall be electric wire rope trolley suspended type. Ferrous metal surfaces shall be cleaned. levelled and properly fixed to bridge girder. operation. prepared. Trolley frame shall be provided with equaliser sheaves and spring bumper at each side for safe operation of the crane assembly. The optimum life of a painting/coating system shall be considered the time until first maintenance painting/touch up should occur before active rusting begins. The design. Provision shall be made for lubrication of all moving parts and bearings while the hoist is in service except where life lubricated bearings are used.2. and painted/coated in accordance with the painting/coating manufacturer's instructions and Steel Structures Painting Council Paint Application Specification No.25. The design of the hoist shall conform to IS:3832. Shop Coating Equipment manufacturers' standard painting/coating systems shall be applied in lieu of those specified provided the system complies with the life expectancy requirements. Box section shall be adequately reinforced by internal diaphragms and ribs. All primers shall contain rust inhibitors. lateral and torsional strain and support all loads without undue deflection. The rails shall be accurately aligned. considering the corrosive saline atmosphere at project site. 3.2x300 MW Chandrapur Thermal Power Project Technical Specification load. The trolley of hoists shall be manually operated. Box girder shall be provided with end plates for sealing. PAINTING PROTECTION 3. Surfaces which are inaccessible after assembly shall be protected for the life of the equipment.1." 3. All exposed bearings shall be suitably sealed or shielded. Materials shall contain not greater than 0. 1 "Shop.

3. 3.0 mm average and for external shall be 0. painting/coating system shall be applied that has been designed for application below thermal insulation. shall be abrasive blast cleaned in accordance with SSPC-SP10. equipment and pipe supports. handrails. 3. The touch-up paint shall be the same type and colour as the shop applied material. Coating thickness for the internal of the pipeline shall be 1. These surfaces shall be painted/coated wfth a consumable preservative and masked. valve operators. and other similar equipment etc. For those surfaces that shall be insulated.5.2x300 MW Chandrapur Thermal Power Project Surfaces to be painted shalt be filled to provide a uniform substrate and shall be prepared for painting in accordance with the appropriate surface preparation specifications. compressors. Mechanical Equipment Mechanical equipment includes pumps. Touch-up Paint Touch-up paint shall be provided for repair painting of at least 25 percent of shop finish painted equipment surfaces. Metal Wall Panels Wall paneis shall be finished with a three coat system consisting of a urethane primer and two fluoropoiymer topcoats. and similar fabrications. ducts.5 mm average. The vertical water pumpsets surfaces particularly in respect of volute casing.25. At the Bidder's option. The coating thickness shall be 1. Near White Metal Blast Cleaning.5 mm thickness for providing corrosion protection. Structural Steel and Miscellaneous Metals Structural steel and miscellaneous metals including steel fabricated items such as plates and shapes. If equipment shall operate at temperatures above 60° C and shall not be insulated.0 mm average. valves. The fabricated steel structures in contact with water shall be coated with a two pack cold cured Isopthalic Polyester acrylic co-polymer with flake glass.4. a high temperature painting/coating system designed for the operating temperatures shad be applied. The external surfaces of the valves shall be applied with a base coat of two pack epoxy compound incorporating a rust converter. No paint shall be applied to surfaces within 75 mm of field welded connections. external piping surfaces. ladders. inhibitor and passivator with leafing platelets + top coat of polyamine cured high solids.25. the primer shall be applied in the shop and the finish coats shall be applied in the field. The internals of the large sized butterfly valves handling water shall be coated with a two pack cold cured Isopthalic polyester acrylic co-polymer with flake glass coating at thickness of 1. The primer shall be inorganic zinc with a total of 85 percent zinc in the dried film applied to a minimum dry film thickness of 75 microns. Profile depth shall be 40 to 50 microns. Surface preparation and application instructions shad be provided. .0 mm average.3. pipe hangers. Steel plate pipes shall be lined with a two pack cold cured Isophthalic Polyester acrylic co-polymer glass flake filled coatings. two pack glass fiake filled epoxy with good gloss and chemical resistance .25. suction elbow etc shall be lined with a two pack cold cured Isophthalic polyester acrylic copolymer with glass flake filled coating at 1. both internally and externally to provide long term corrosion protection. The first topcoat shall be coloured and the second topcoat shali be clear. stair stringers. The surface preparation shall be by light sand blasting.

RustPrevent ive Compo unds Ma chi ne d sur fac es an d oth er fer ro us sur fac es wh ich sh oul d not be co ate d. Additional .25.3.6. but ar e su bje ct to cor ros ion . i sh all be pr ote cte d wit h rus tpr ev ent ive co mp ounds.

Rust-preventive compounds shall be checked every two months while in transit and in site storage and renewed as required to maintain adequate protection. . Rust-preventive compounds which are used to protect surfaces of equipment and piping that are exposed to feedwater or steam shall be completely water soluble. structures and building components shall be finish painted. and other impurities. Field Paintings/Coatings and Linings All surfaces of erected equipment. and primed before application of the finish system. piping. tanks. 3.protection shall be provided for equipment and materials which shall be exposed to the atmosphere for extended periods. Architectural Components Interior non-metallic architectural components. where either member to be boltsd is galvanized. field weids. including concrete block/ cement plastered brick walls. Machined surfaces of weld-end preparations shall be coated with consumable rustpreventive compounds which shall not affect the quality of the weld. Steel shall be hot-dip galvanized in accordance with ASTM A123 or equivalent.7. 3. and durable surface.9. grease. Immersion Service Interior surfaces of shop fabricated and field erected tanks shall be cleaned and lined with materials designed for the specific application. 3. in neutral environments shall be painted with low gloss water-borne materials.25. including doors and frames. For bolted connections. Cleaning shall be in accordance with SSPC-SP5. rust. Pickling shall remove scale. Finishes for metallic architectural components. semi-gioss.25. White Metal Blast Cleaning. prepared. shall provide a smooth. The final topcoat for interior metai surfaces shall be a high solid polyamide epoxy applied to a minimum dry film thickness of 125 microns. Surfaces of connections. Galvanizing Structural steel members and steel assemblies particularly outdoor switchyard structures and metallic surfaces in the open atmosphere to be galvanized shad be pickled after completion of fabrication process. Shop primers shall be touched up and barrier/universal coats shali be applied to a minimum dry film thickness of 50 microns to provide a suitable base for topcoat application.8. and damaged areas shall be cleaned.10.25. The final topcoat for exterior metal surfaces shall be a high soiids aliphatic polyureihane applied to a minimum dry film thickness of 50 microns. 3. erection and structural bolts shall be galvanized in accordance with ASTM A153.25.

the . ve ntil ati on du cts . Documentation Engineering submittals shall identify the painting/coating and lining systems to be applied _______in the shop and the field.11. Pipelines shall be identified with the name of the fluid or gas and the direction of flow. ele ctri cal co nd uit s. Finish colour of mechanical equipment shall match the colour of the system of which it is a part. Finish colour of high temperature surfaces shall be deep grey.25.12. 3. an d rel at ed se rvi ce s sh all be in ac co rd an ce wit h th e re qui re m en ts of BS 1710 and its appendices. Interior surfaces shall be gloss white. D^ta to be provided shall include the surfaces to be painted. Colours Co lou rs for th e ide ntif ica tio n of pip eli ne s.3.25. Finish colour of exterior surfaces of electrical cabinets and panels shall be light grey.

and equipment generated noise and vibration level. such as the turbine foundation. installation and maintenance access requirements. Passenger-cumgoods-elevators shall be provided for each unit as indicated in the ground Moor plan drawing (LII-GEOE09043-203-W-103) The turbine generator floor levels shall be same for both the units and have the same EOT crane serving the TG of two units. General The power plant shall make optimum use of land and facilities to minimize total life cycle costs but not at the cost of flexibility of maintenance and future expansion.3. ease of operation and maintenance. dry film thickness of each coating. The main power plant building shall be functionally subdivided into the turbine-generator area. and major obstructions. with minimum disassembly of surrounding equipment and minimum usage of temporary scaffolding . access-ways and hatches. steam generator area including Mill bay area.26. shall be shown to determine that such items satisfy equipment installation.26. Maintainability The primary objective shall be to maximize the generation of kilowatt-hours. Similarly. and maintenance requirements even when other units are under construction/ operation and are inline with the layout enclosed with this specification. finish colour. Equipment location shall be determined keeping in mind the overhead Travelling Crane clearance & approach required. economy of piping and electrical cables. 3. Major external functional systems shall be so oriented that any maintenance work as well as subsequent construction work can be carried out without any interference and/or hindrance to the adjacent unit.26.104) and Cross-section drawings (LII-GEOE09043-203-W-101. and Material Safety and Data Sheets (MSDS).26. Plot Plan drawing (LII-GEOE09043-G-00010-00). unit control rooms shall be so located that turbine and steam generator areas of the units shall be easily accessible. Genera! Arrangement drawings for different floors (LII-GEOE09043-203-W-102.) are attached with this specification as a guideline for the bidders. Special alloys shali be used which can withstand highly erosive coal S ash. Bidders shall develop their recommended drawings based on the guidelines provided ensuring cost effectiveness. The overall building configuration including internal and external walls and column rows. floor outlines. 3. To achieve this goal.painting/coating system manufacturer's name and product designation. b) Equipment shall be designed to be maintained in place. The following general criteria shall be followed to achieve this objective:a) Equipment shall be of a low maintenance design and shall be easily maintainable. Equipment Arrangement The layout of the major equipment shall be shown on the bidder's general arrangement drawings to be enclosed with the bid indicating the overall internal arrangement of the plant building as well as the setting dimensions and orientation of all significant equipment. PLANT LAYOUT This section describes the philosophy which shall be used in the development of the general arrangement drawings. economy of equipment supports. access. 3.1. the degree of surface preparation. a secondary objective shall be to minimise the complexity and time required for maintenance. 3. and the electrical equipment area. ventilation requirements. operation.2. stairways. the auxiliary bay area. The optimum arrangement of equipment shall be determined by considering functional requirements.103. if possible.

Sign up to vote on this title
UsefulNot useful