B115060LZMR4010508RFQAPart2 PDF

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JOB SPECIFICATION SPECIFICATION NO.
FOR NON DESTRUCTIVE B115-6-44-0016 Rev. A
EXAMINATION REQUIREMENTS
OF PIPING Page 1 of 14
JOB SPECIFICATION FOR

NON DESTRUCTIVE EXAMINATION
REQUIREMENTS OF PIPING
PROJECT- SRU REVAMPING AT ONGC HAZIRA PLANT

ON OBE
JOB NO. - B115
LOCATION - HAZIRA, GUJARAT
CLIENT - ONGC
A 08.11.2017 ISSUED AS JOB SPECIFICATION AN SSP SKG

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
Page 402 of 1296

FOR NON DESTRUCTIVE
EXAMINATION REQUIREMENTS B115-6-44-0016 Rev. A
Abbreviations:
DP/LP : Dye/Liquid Penetrant
MP : Magnetic Particle
CS : Carbon Steel
AS : Alloy Steel
SS : Stainless Steel
ASTM : American Society for Testing & Materials
ASME : American Society of Mechanical Engineers
IBR : Indian Boiler Regulations
PMS: Piping Material Specification
Page 403 of 1296

FOR NON DESTRUCTIVE
CONTENTS
S.NO TITLE PAGE NO.
1. GENERAL 4
2. VISUAL EXAMINATION 4
3. NON DESTRUCTIVE EXAMINATION 6
4. TABLE-1 (With applicable Notes to Table-1) 7
Page 404 of 1296

FOR NON DESTRUCTIVE
1. GENERAL
1.1 SCOPE
This specification covers the general requirements for non destructive examination of
shop & field fabricated piping.
1.2 RELATED CODES & ENGINEERING STANDARDS
Referred codes / standards / job specifications are as follows. Latest editions of the
Codes/Standards / job specifications referred to shall be followed.
a) ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div.1) including addenda.
b) ASME B31.3
c) ASME B16.5
d) ASME B16.34
e) Piping Material Specification, B115-6-44-0005
f) Welding Specification Charts for Piping Classes, 6-77-0005.
g) Standard Specification for Fabrication & Erection of Piping 6-44-0012.
h) ASTM E10
i) Welding specification for fabrication of piping, 6-77-0001.
j) Design Guide for Radiography Requirements, 8-77-0010
k) Indian Boiler Regulations (IBR)
2. VISUAL EXAMINATION
2.1 Weld shall be visually inspected wherever accessible in accordance with the following
requirements:
a) Internal misalignment 1.5 mm or less
b) Cracks or lack of fusion Not permitted
c) Incomplete penetration Depth shall not exceed the lesser of 0.8mm or 0.2
times thickness of thinner component joined by
butt-weld. The total length of such imperfections shall not exceed
38 mm in any 150 mm of weld length.
d) Surface porosity and Not permitted

exposed slag inclusions
(For nom. wall thickness
4.7 mm and less)
Page 405 of 1296

FOR NON DESTRUCTIVE
e) Concave root surface For single sided welded joints, concavity of the
root surface shall not reduce the total thickness
(Suck up) of joint, including reinforcement, to less than the
thickness of the thinner of the components being
joined.
f) Weld ripples irregularities 2.5 mm or less.
g) Lack of uniformity in bead 2.5 mm or less.

width
h) Lack of uniformity of leg 2.5 mm or less.

length
i) Unevenness of bead 2.0 mm or less.
j) Weld undercutting 0.8 mm or 1/4 thickness of thinner components

joined by butt weld, whichever is less. (shall be
smooth finished)
k) Overlap 1.5 mm or less
l) Bead deflection 2.5 mm or less
m) External weld reinforcement and internal weld protrusion (when backing rings are
not used) shall be fused with and shall merge smoothly into the component
surfaces. The height of the lesser projection of external weld reinforcement or
internal weld protrusion from the adjacent base material surface shall not exceed
the following limits:
Wall thickness of thinner Weld reinforcement or internal weld protrusion

component joined by butt (mm) max
weld (mm)
6.4 and under 1.6

Over 6.4 -12.7 3.2
Over 12.7 -25.4 4.0
Over 25.4 4.8
n) Throat thickness of fillet welds:
Nominal thickness of the thinner component x 0.7 or more.
o) Flattening
Flattening of a bend, as measured by difference between the nominal outside

diameter and minimum or maximum diameter at any cross section shall not
exceed 5 % of the nominal outside diameter of pipe.
p) Reduction of wall thickness
Reduction of wall thickness of a bend, as measured by difference between the

nominal thickness and minimum thickness shall not exceed 10 % of the nominal
wall thickness of pipe.
Page 406 of 1296

FOR NON DESTRUCTIVE
2.2 Welds having any of imperfections which exceed the limitations specified in various
clauses of 2.1 shall be repaired by welding, grinding or overlaying etc. Number of times
of repair welding for the same weld, however shall conform to applicable notes to Table
1- Note 6(b) b.5.
3. NON DESTRUCTIVE EXAMINATION
3.1 The type and extent of weld examination shall be in accordance with Table-1. All visual
and supplementary methods of girth weld examination shall be in accordance with ASME
B31.3 & the requirements of this standard specification.
3.2 Welds between dissimilar materials shall be examined by method & to the extent required
for the material having the more stringent examination.
Page 407 of 1296

FOR NON DESTRUCTIVE
4. TABLE-1 (With applicable notes)
TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION
INSPECTION CLASS: I


INSPN. SERVICE MATERIAL P.NO. TEMP. PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) DEG.C CLASS PIPING EXAMINATION
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACH- FAB. FAB.
BUTT WELD MENT BRANCH WELDS
WELD (NOTE 2) WELD WELD OF
(NOTE 1) MITRES /
REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
I CATEGORY 'D' CARBON 1 0 A3A, J2A

FLUID STEEL TO
SERVICE 186
a) 100 %
100% 100% 100% 100%
VISUAL
AUSTENIC 8 - 29 150# A3K
S.S. TO UPTO
186 10.55
KG/CM2 b)
--- --- --- 5% 10 %
LP (NOTE 4, 6,9,)
REMARKS FOR ABOVE TABLE:
(i) MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 408 of 1296

FOR NON DESTRUCTIVE
TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)
INSPECTION CLASS: II

INSPN. SERVICE MATERIAL P. TEMP. PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) NO. DEG.C CLASS PIPING EXAMINATION
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACH FAB. FAB.
BUTT WELD -MENT BRANCH WELDS
WELD (NOTE 2) WELD WELD OF
(NOTE 1) MITRES/
REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
II a)
ALL SERVICES CARBON 1 - 29 A1A, A32A
COVERED STEEL TO 150#
UNDER 371
INSPECTION
CLASS-I, BUT,
EXCEEDING
CATAGORY 'D'
PR./T EMP
LIMITATIONS.
b)
ALL SERVICES
a) 100% 100% 100% 100% 100%
OTHER THAN
THOSE VISUAL
COVERED
UNDER b)
INSPECTION RADIOGRAPHY 5% --- --- --- 20%
CLASS-I BUT (NOTE 5,6)
NON-TOXIC, NOT
SUBJECTED TO c)
SEVERE CYCLIC MP / LP (NOTE --- 5% --- 5% 20%
CONDITIONS. 4,6,10,11)
c) d)
TOXIC, NON- HARDNESS NOTE 7 NOTE 7 NOTE-7 NOTE-7 NOTE-7
LETHAL &
FLAMMABLE.
d) FLAMMABLE /
NON
FLAMMABLE &
TOXIC / NON-
TOXIC; NOT
SUBJECT TO
SEVERE CYCLIC
CONDITIONS
(i) NOTE-7 FOR HARDNESS IS VALID FOR P.NO. 8
(ii) MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 409 of 1296

FOR NON DESTRUCTIVE
INSPECTION CLASS: III
B16.5/ CLASS
WELD (NOTE 2) WELD WELDS OF
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III FIRE WATER CARBON 1 -29 TO 150# A33A

& IBR STEEL (FIRE 300 a) 100% 100%
100% 100% 100%
SERVICES WATER) VISUAL
b) ---
RADIOGRAPHY
10% --- --- 50%
(NOTE 5,6)
CARBON A2A
STEEL (IBR)
c)
--- 10 % --- 10% ---
LP / MP (NOTE
4,6,11)
d)
NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
HARDNESS
(i) FOR IBR SERVICE A2A NOTE- 8 IS ALSO APPLICABLE.
(ii) FOR A33A FIRE WATER SERVIC NOTE-12 IS ALSO APPLICABLE.
(iii) MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 410 of 1296

FOR NON DESTRUCTIVE
INSPECTION CLASS: IV

B16.5/ CLASS
WELD (NOTE 2) WELD WELDS OF
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
AUSTENITIC 8 - 29 150#
IV SULPHUR STAINLESS TO A11K
SLURRY, LO- STEEL 204
CAT SOLUTION,
ACID GAS, KOH
SOLUTION, 100% 100% 100% 100% 100%
a)
VENT GAS VISUAL
b)
20% --- --- --- 100%
RADIOGRAPHY
(NOTE 5,6)
c)
--- 20% --- 20% ---
LP / MP (NOTE
4,6,10,11)
d)
NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
HARDNESS
a. NOTE- 7 FOR HARDNESS IS NOT VALID FOR P. NOS. 8.
b. MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 411 of 1296

FOR NON DESTRUCTIVE
Applicable Notes to Table I
1. Branch welds shall consist of the welds between the pipe & reinforcing element (if any),
nozzles & reinforcing element and the pipe & nozzle under the reinforcing element.
Reinforcing element to be interpreted as pads, saddles, weldolets, sockolets etc.
2. Seal welds of threaded joints shall be given the same examination as socket welds.
3. Unless specifically stated, all materials shall be for "Non-IBR" service.
4. Magnetic Particle & the Liquid Penetrant method of examination shall be in accordance
with Section V of the ASME Boiler and Pressure Vessel Code, Article VII and VI
respectively. The entire area of the accessible finished weld surface shall be examined.
Selected root runs, subject to a maximum of 10%, before finished weld, may also be
examined, at the discretion of the engineer-in-charge.
a) Wherever MP / LP testing is specified, either MP or LP test may be used. But

wherever only MP test is specified, LP method of examination may be used only
if MP examination is impracticable in the field as concurred by EIL site-in-
charge.
b) "Random 5%" of Liquid Penetrant / Magnetic Particle test shall mean testing, by
applicable test, one weld for each twenty welds or less made by the same welding
procedure. "Random 10%" shall mean testing, by applicable test, one weld for
each ten weld or less made by the same welding procedure.Similarly "Random
20%" shall mean testing, by applicable test, one weld for each five welds or less made
by the same welding procedure.
c) When Liquid Penetrant examination is specified, the surface shall be free of

peened discontinuities.
d) Inspection shall be performed in the welds excluding those for which radiography
has been done.
5. RADIOGRAPHY:
a) "Random5% or 10% or 20% radiography" shall mean examining not less than one
from each 20 welds or less in case of "Random 5% radiography" or 10 welds or
less in case of "Random 10% radiography or one from each five welds or less in
case of "Random 20% radiography" made by the same welding procedure.
Irrespective of percentage, no. of welds to be radiographed shall be minimum 1.
However first two welds made by each welder shall also be radiographed in case
of "Random radiography". Welds selected for examination shall not include
flange welds and shall be radiographed for their entire length. However, where it
is impossible or impracticable to examine the entire weld length of field welds for
either random or 100% radiography, and if the same impossibility is agreeable to
EIL site-in-charge, then a single 120 deg. exposure of the weld length may be
given a Magnetic Particle test or Liquid Penetrant test. However in such cases for
ferro-magnetic materials, only MP test shall be acceptable for classes higher than
600#.
Page 412 of 1296

FOR NON DESTRUCTIVE
b) In-process examination shall not be substituted for any required radiographic

examination.
c) Number of radiographs per one circumferential weld shall be as per ASME Sec.V
Articles 2 and 22.
6. When radiography or other non destructive inspection is specified, acceptance criteria for
repairs or defects shall be as follows:
a) In case of 100% examination, any unacceptable weld shall be repaired and re-
inspected.
b) If required random examination reveals a defect requiring repair, then:
b.1 Two additional examinations of same type shall be made of the same kind
of item (if welded joint, then by the same welding procedure or operator
or both).
b.2 If the group of items examined as required by b.1 above is acceptable, the
items requiring repair shall be repaired or replaced and reexamined as
required and all items represented by this additional examination shall be
accepted.
b.3 If any of the items examined as required by b.1 above reveals a defect
requiring repair, two further comparable items shall be examined for each
defective item found by examination.
b.4 If all the items examined as required by b.3 are acceptable, the items
requiring repair shall be repaired or replaced and reexamined as required,
and all items represented by this further examination shall be accepted.
b.5 Number of times repair welding could be done for the same weld before
acceptance shall be as follows:
Material No. of times repair welding is allowed
C.S. up to 300 # 3 or less
C.S. above 300 # 2 or less
b.6 Welds not found acceptable for allowed number of times of repair as per
b.5 above shall be replaced and reexamined.
b.7 If any of the items examined as required by b.4 above reveals a defect
requiring repair, all items represented by these examinations shall be
either :
- repaired or replaced and reexamined as required.
- fully examined and repaired or replaced as necessary, and

reexamined as necessary.
Page 413 of 1296

FOR NON DESTRUCTIVE
7. HARDNESS TEST:
a) Hardness test shall be in accordance with ASTM specification E10.

Hardness tests of the heat affected zone shall be made at a point as near as
practicable to the edge of the weld. One test per weld shall be performed.
b) Hardness test where specifically called out in Table-I of this specification

or in PMS, shall be carried out irrespective of thickness and to the extent
(%age) as mentioned therein.
c) All welds which are given heat treatment shall be hardness tested.
Hardness test shall be performed after final heat treatment.
d) A minimum of 10% of welds, hot bends and hot formed components in

each furnace heat treatment batch and 100% of those which are locally
heat treated shall be hardness tested.
e) Hardness test requirement not covered in this specification shall be as per

ASME B31.3.
f) The hardness limit applies to the weld and heat affected zone. Following
hardness values shall be maintained:
Base Metal Group Maximum

Hardness
(BHN/RC)
CS 238BHN/RC22
CS (NACE) 200BHN
CrUpto 2% 225BHN
Cr 2.25%-10% 241BHN
18/8 SS (NACE) RC22
g) In case hardness values are mentioned in both Welding Specification

Charts for Piping Classes& table given in Note-7(f), the lower of the two
values shall be applicable.
Page 414 of 1296

FOR NON DESTRUCTIVE
8. FABRICATED FITTINGS
LP test shall be done on the final pass of welding only, in addition to visual examination.
9. MITRES AND FABRICATED REDUCERS
LP / MP test shall be done on root pass in addition to radiography applicable to

circumferential joint of respective piping class.
10. BRANCH CONNECTIONS
LP/MP test shall be done on root pass and final pass.
11. 10% of the butt welded joints shall be radio graphed, however 50% of these butt weld joints
shall be field weld joints.
12. For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.
Page 415 of 1296

STANDARD SPECIFICATION STANDARD SPECIFICATION
siitaet5 (Cr) ENGINEERS FOR SURFACE PREPARATION NO. 6-79-0020
Keg INDIAN.LIMITED
RI AQFIV CA , IA GOO Of Undeflangl AND PROTECTIVE COATING Rev. 0
PAGE 1 OF 59
tin a K4
1-49-br
(7q. Wu! tg)
STANDARD SPECIFICATION
FOR
SURFACE PREPARATION
AND PROTECTIVE COATING
(NEW CONSTRUCTION)
6-44-0004 REV. 3 REVISED, RE-

0 30.08.12 NUMBERED 8 ISSUED AS STANDARD A.SRIDHAR R.CHAUDHURY P.P.LAHIRI D.MALHOTRA
SPECIFICATION
Standards Standards
Rev. Prepared Committee Bureau
No Date Purpose by Checked by Convenor Chairman
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 416 of 1296

02-zieLa ENGINEERS NO. 6-79-0020
$1?-eir la Me ear INDIA LIMITED FOR SURFACE PREPARATION
HIM eknillcIAJAA.M IA GNI al India LInderlaIm9/ AND PROTECTIVE COATING Rev. 0
PAGE 2 OF 59
Abbreviations:
AS Alloy Steel
CS Carbon Steel
DFT : Dry Film Thickness
DM De-mineralized
GI Galvanized Iron
ID Internal Diameter
IRN Inspection Release Note
LTCS : Low Temperature Carbon Steel
MS Mild Steel
NB Nominal Bore
OD Outside Diameter
RCC : Reinforced Cement Concrete
SS Stainless Steel
TSAC : Thermally Sprayed Aluminium Coating
WFT : Wet Film Thickness
SMMS Standards Committee
Convener : Mr. P.P. Lahiri
Members : Mr. A. Amin (SMMS)

Mr. R. Chaudhury (SMMS)
Mr. S. Ghosal (SMMS)
Mr. G.S. Hegde (SMMS)
Mr. P. Saha (SMMS)
Mr. R Nanda (Piping)
Mr. Raj Kishore (Pipeline)
Mr. A.K. Gupta (HMTD)
Mr. S. Mukharjee (Construction)
Mr. A.R. Purushottam (POSD)
Mr. R. Muthulingam (Inspection)
Mr. M.P. Jain (Projects)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
Page 417 of 1296

OfteituvaNEERs STANDARD SPECIFICATION STANDARD SPECIFICATION
FOR SURFACE PREPARATION NO. 6-79-0020
laiReedi INDIA LIMITED Rev. 0
PIM FRW ZIRJR140 IA Go.4 ei India unden.lono AND PROTECTIVE COATING PAGE 3 OF 59
CONTENTS
SL. DESCRIPTION PAGE

NO NO.
1.0 General 4
2.0 Scope 4
3.0 Reference Codes & Standards 6
4.0 Equipment 7
5.0 Surface Preparation, Shop Primer,Coating Application & Repair and Documentation 7
6.0 Paint Materials 16
7.0 Coating Systems 21
8.0 Coating System for Gratings, Rolling & Stationery Ladders, Spiral Stairways and
Hand Rails in All Location 23
9.0 Coating System for Offsite Area (Inland Plants) 24
10.0 Coating System For Unit Areas as well as DM, CPP, Cooling Tower of Inland Plants
and for All Areas (Unit, Offsite, DM, CPP, etc.) of Coastal Plants 25
11.0 Coating System for Effluent Treatment Plant (ETP) 27
12.0 External Coating Systems for Uninsulated Carbon Steel and Low Alloy Steel Storage
Tanks (For All Plant Locations, Coastal or Inland) - All Process Units & Off-Sites 28
13.0 Internal Coating Systems for Carbon Steel and Low Alloy Storage Tanks - All
Process Units & Off-Sites 30
14.0 Coating Systems for External Side of Underground Carbon Steel Plant Piping and
Underground Vessels 32
15.0 Coating Under Insulation (Coastal Or Inland Plants) All Units Areas & Off-Sites 33
16.0 Coating System for Carbon Steel Components of Coolers / Condensers (Internal
Protection) for Fresh Water Service 34
17.0 Coating System (Internal Protection) for Galvanized or Non Ferrous or Stainless
Steel/ Duplex Stainless Steel Components of Coolers/ Condensers for Fresh Water
Service 35
18.0 Storage 35
19.0 Colour Code 35
20.0 Identification of Vessels, Piping etc 42
21.0 Painting for Civil Defence Requirements 42
22.0 Quality Control, Inspection and Testing 42
23.0 Guarantee 46
24.0 Qualification Criteria of Painting Contractor/Sub-Contractor 46
25.0 Qualification/Acceptance Criteria for Paint Coating System 46
26.0 Method of Sampling & Dispatch for Laboratory Testing 48
Annexure-I Specification For TSAC 50
Page 418 of 1296

StilMziet- ENONEERS
Oar iiiRtg Ter INDIA LIMITED Rev. 0
own ARAW/INJOSA) /A Govt a htha Unden•ingi AND PROTECTIVE COATING PAGE 4 OF 59
1.0 GENERAL
1.1 This technical specifications shall be applicable for the work covered by the contract, and
without prejudice to the provisions of various international codes of practice, standard
specifications etc. It is understood that contractor shall carry out the work in all respects with
the best quality of materials and workmanship and in accordance with the best engineering
practice and instructions of Engineer-In-Charge.
1.2 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor.
Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
1.3 This specification coven the requirement for protective coating for new construction.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the
following.
2.1.1 This specification defines the requirements for surface preparation, selection and application
of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts,
steel structures, external & internal protection of storage tanks for all services and chimneys
if any. The items listed in the heading of tables of paint systems is indicative only, however,
the contractor is fully responsible for carrying out all the necessary painting, coating and
lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting:
All uninsulated Carbon Steel & Alloy Steel equipments like vessels, Columns, storage
Tanks, Exchangers if any, parts of boilers etc.
All uninsulated carbon steel and low alloy plant and related piping, fittings and valves
(including painting of identification marks), furnace ducts and stacks.
All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping and if
any other insulated items present.
All items contained in a package unit as necessary.
All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms etc.
Flare lines, external surfaces of MS chimney with or without refractory lining and
internal surfaces of MS chimney without refractory lining. (If present)
Page 419 of 1296

0a-zetaENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
51gar fatilegW INDIA WIRD Rev. 0
laiRrIMENVOIMBIll (A GoN ot India undertaiongi AND PROTECTIVE COATING PAGE 5 OF 59
Identification of colour bands on all piping as required including insulated aluminium

clad, galvanized, SS and nonferrous piping.
Identification lettering/ numbering on all painted surfaces of equipment/piping insulated

aluminium clad, galvanized, SS and non-ferrous piping.
Marking / identification signs on painted surfaces of equipment/piping including

hazardous service.
Supply of all primers, paints and all other materials required for painting (other than
Owner supplied materials)
Over insulation surface of equipments and pipes wherever required.
Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
Painting of pre-erection/fabrication and Shop primer.
Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the
field/site before and after erection as required.
All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP
plant.
Quality control, testing and inspection during all stages of work (surface preparation,
application of coating and testing of furnished coating).
2.2.2 The following surfaces and materials shall not require painting in general. However, if there
is any specific requirement by the owner, the same shall be painted as per the relevant
specifications:
Uninsulated austenitic stainless steel.
Plastic and/or plastic coated materials
c. Non-ferrous materials like aluminum, Cu-Ni alloy, galvanized steel.
2.3 Documents
2.3.1 The contractor shall perform the work in accordance with the following documents issued to
him for execution of work.
Bill of quantities for piping, equipment, machinery and structures etc.
Piping Line List.
c. Painting specifications including special civil defence requirements.
2.4 Unless otherwise instructed, final paint coating (i.e., application of field primer,
wherever required, intermediate and top coats) on pre-erection/ shop primed
Page 420 of 1296

151fraeLA ENGINEERS
Itgar 'Matt INDIA umnB) FOR SURFACE PREPARATION NO. 6-79-0020
(NM Fletifie Maga,/ IA Gobi al India uncienaton9/ AND PROTECTIVE COATING Rev. 0
PAGE 6 OF 59
equipments shall be applied at site, only after all welding, testing on systems are
completed as well as after completion of steam purging wherever required .
2.5 Changes and deviations required for any specific job due to clients requirement or otherwise
shall be referred to E1L for deviation permit.
3.0 REFERENCE CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, latest editions of the following codes and standards are applicable for the work
covered by this contract.
IS-5 : Colour coding

RAL DUTCH : International Standard for colour shade (Dutch Standard)
IS-101 : Methods of test for ready mixed paints and enamels
IS-2379 : Indian Standard for Pipe line identification-colour code
ISO-12944 : Corrosion Protection of steel Structures by Protective Paint
System
ASTM-Vol 6.01&6.03 : American standard test methods for Paints and Coatings.
ANSI A 13.1 : Scheme for identification of piping systems: American
National Standards Institution
SSPC : Steel Structures Painting Council
3.2 Surface Preparation Standards
The latest editions of any of the following standards shall be followed for surface
preparation:
3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for Preparation of steel substrates before
application of paints and related products. This standard contains photographs of the various
standards on four different degrees of rusted steel and as such is preferable for inspection
purpose by the Engineer-In-Charge.
3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).
3.2.3 National Association of Corrosion Engineers, U.S.A., (NACE).
3.2.4 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
3.4 The paint manufacturer's instructions shall be followed as far as practicable at all times for
best results. Particular attention shall be paid to the following:
Instructions for storage to avoid exposure as well as extremes of temperature.
Surface preparation prior to painting shall be followed as per Table 8.0 to 16.0 of
this standard shall be followed.
Page 421 of 1296

oga1511teTa
naleuw ENONEERS
INDIA umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
Men KROP7m3R6311 IA GOY/ India Undatalang/ AND PROTECTIVE COATING
PAGE 7 OF 59
Mixing and thinning.
Application of paints and recommended limit on time intervals in between coats.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all
equipments, scaffolding materials, shot & grit blasting equipments & air compressors etc.
required to be used shall be suitable for the work and all in good order and shall be arranged
by the contractor at site and in sufficient quantity. The manufacturer's test certificates / data
sheets for all the above items shall be reviewed by Engineer-in-charge at site before start of
work.
4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack systems
except that the Engineer-In-Charge may allow the hand mixing of small quantities at his
discretion in case of specific requirement for touch up work only.
5.0 SURFACE PREPARATION, SHOP PRIMER COATING APPLICATION & REPAIR

AND DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed, depending on condition of surface to be painted and as
instructed by Engineer-In-Charge. Adhesion of the paint film to surface depends largely on
the degree of cleanliness of the metal surface. Proper surface preparation contributes more to
the success of the paint protective system.
Abrasive blast cleaning
Mechanical or power tool cleaning
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and
dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per
provisions of relevant tables given elsewhere in this specification. The minimum acceptable
standard, in case of thermally sprayed metal coatings, in case of mechanical or power tool
cleaning it shall be St. 3 or equivalent. In case of blast cleaning it shall be Sa 2-1/2 as per
Swedish Standard SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning
shall be Sa 3 as per Swedish Standard in case thermally sprayed metal coatings.
Before surface preparation by blast cleaning, the surface shall be degreased by aromatic
solvent to remove all grease, oil etc.
5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning shall not be
performed where dust can contaminate surfaces undergoing such cleaning or during humid
weather conditions having humidity exceed 85%. In case of internal coating of storage tanks,
dehumidifier shall be used, to control humidity level below 60%. Dehumidifier should
depress the dew point of air in the enclosed space, sufficient enough so as to maintain it 3°C
Page 422 of 1296

Oa ft ENGINEERS STANDARD SPECIFICATION
FOR SURFACE PREPARATION
NO. 6-79-0020
Og a 'Meg INDIA LIMITED
Rev. 0
MON FIXOW COIORFM /A Govt kW Undertaking) AND PROTECTIVE COATING PAGE 8 OF 59
below the metal substrate temperature during centre period of blasting and coating
application. During the interval time between application of primer coat and subsequent
intermediate and top coats or between blast cleaning completion and start of application of
primer coat, dehumidifier unit should be in continuous operation to ensure that no
condensation occurs on substrate.
Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25
grains per pound of air per hour. Dehumidifier should have capacity of at least 2 air changes
per hour of the enclosed space. All necessary psychometric data should be collected by
contractor for the given site conditions before starting operation of dehumidifier to ensure
that desired values of dew point, moisture content in enclosed scope is achieved.
Dehumidification to be maintained round the clock for surface preparation and painting till
the total coating application is over.
Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed
to the satisfaction of the technical representative of the paint manufacturer interested with
quality assurance for the work. In case the dehumidifier breaks down in middle of the job, the
same shall be replaced at the risk and the cost of the contractor and the entire unfinished
work shall be repeated.
5.1.4 The Engineer in-charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances the
contractor shall remove the equipment and replace the same with another equipment to
provide satisfactory results without any additional cost to the owner.
5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray/ air assisted conventional spray if recommended by the paint manufacturer on
dry surface. This should be done immediately and in any case within 4 hours of cleaning of
surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall
have the liberty to control the time period, at his sole discretion and/or to insist on re-
cleaning, as may be required, before primer application is taken up. In general, during
unfavorable weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose
particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush.
Acid etching with 10-15% HCL solution for about 15 minutes shall be carried and surface
must be thoroughly washed with water to remove acid & loose particles and then dried
completely before application of paint.
5.2 Procedure for Surface Preparation
5.2.1 Air Blast Cleaning with abrasives
The surfaces shall be blast cleaned using one of the abrasives like angular chilled cast iron or
steel grit, copper slag or Nickel slag, Al 203 particles at pressure of 7kg/cm 2 at an appropriate
distance and angle depending of nozzle size maintaining constant velocity and pressure.
Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16 — G42
conforming to SSPC AB I and 5250 grade size of steel shots (maximum) to obtain a desired
surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the
Page 423 of 1296

aielMENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Iguemegwir INDIA LIMITED Rev. 0
Men AMR =MOM (A GS of India UndedaIngl AND PROTECTIVE COATING PAGE 9 OF 59
range of G16 — G24. The combination of steel grits and shots shall be normally in the ratio of
3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet
the requirements of SSPC AB I . Compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the
materials for liners. Nozzles orifice may vary from 3/16" to %". On completion of blasting
operation, the blasted surface shall be clean and free from any scale or rust and must show a
grey white metallic luster. Primer/first coat of paint shall be applied within 4 hours of surface
preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible
vacuum collector shall be installed for collecting the abrasives and recycling.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding
wheels or rotating steel wire- brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and /or washed by water or steam and thoroughly dried with
compressed air jet before application of paint.
5.3 Non-Compatible Shop Coat Primer
For equipments on which application of total protective coating (Primer + Intermediate + top
coat) is carried out at shop, compatibility of finish coat with primer should be checked with
paint manufacturer. If the shop coat is in satisfactory condition showing no major defect upon
arrival at site, the shop coat shall not be removed.
5.4 Shop coated equipments (coated with Primer & Finishing coat) should not be repainted unless
paint is damaged. Repair shall be carried out as per Table 7.2 of paint systems depending
upon compatibility of paint.
5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means
of power tool brush cleaning or hand tool cleaning and.then spot primed before applying one
coat of field primer unless otherwise specified. If shop primer is not compatible with field
primer then shop coated primer should be completely removed before application of selected
paint system for particular environment.
5.6 For Package units/equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer's standard can be followed after review.
As mentioned in section 2.4, all coating application at field (field primer, intermediate and
top coat) on equipments, structures, piping, etc, shall be carried out only after its erection and
all welding, testing, steam purging (wherever carried out) have been completed.
5.7 Coating Procedure and Application
All paint coatings shall be applied by airless spray excepting at the following special
cases where application can be carried out by brush subject to suitability of the
application of the paint product by brush.
Spot repair
Stripe coating on edges
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — MI rights reserved
Page 424 of 1296

samzEift. ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
51?eg faitegW: INDIA LIMITED Rev. 0
MUT fIRIVOIMIPM (A Ga.( al Oda undenakm AND PROTECTIVE COATING PAGE 10 OF 59
- Small bore parts not suitable for spray application.

Irregular surfaces such as sharp edges, welds, small brackets, and interstices may stripe
coated to ensure specified DFT is achieved. Paint manufacturer recommendation
should be followed before deciding for brush application.
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
exists, when the steel surface temperature is less than 5°F above dew point when the relative
humidity is greater than 85% or when the temperature is below 40°F and when the
ambient/substrate temp is below the paint manufacturer's recommended temperature of
application and curing. De-humidifier equipment shall be used to control RH and Dew point.
The paint application shall not be done when the wind speed exceeds 20km per hour.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous
film uniform thickness free of probes. Any spots or areas missed in application shall be
recoated and permitted to dry before the next coat is applied. Applied paint should have the
desired wet film thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding
coat. Material shall be considered dry for recoating when an additional coat can be applied
without the development of any detrimental film irregularities, such as lifting or loss of
adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval.
5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage
of the surface. The tinting material shall be compatible with the material and not detrimental
to its service life and shall be recommended by the original paint manufacturer.
5.7.6 Airless spray application shall be in accordance with the following procedure: as per steel
structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An air compressor or
electric motor is sued to operate a pump to produce pressures of 1000 to 6000 psi. paint is
delivered to the spray gun at this pressure through a single hose within the gun, a single paint
stream is divided into separate streams, which are forced through a small orifice resulting in
atomization of paint without the use of air. This results in more rapid coverage with less over
spray. Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks
paint from any container, including drums. The unit shall have in built agitator that keep the
paint uniformly mixed during the spraying. The unit shall consist of in built strainer. Usually
very small quantity of thinning is required before spray. In case of high build epoxy coating
(two pack). 30:1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern.
Ideally fluid hoses should not be less than 3/8" ID and not longer than 50 ft to obtain
optimum results.
In case of gun choking, de-choking steps shall be followed immediately.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —AI rights reserved
Page 425 of 1296

ada INGINEERS
#ar1512-
epeow INDIA umirED
NO. 6-79-0020
OfferleIRPRIM3aqi/ IA Gov1 a/ India UnclettSagl AND PROTECTIVE COATING Rev. 0
PAGE 11 OF 59
5.7.7 Brush application of paint shall be in accordance with the following:
Brushes shall be of a style and quality that will enable proper application of paint.
Round or oval brushes are most suitable for rivets, bolts, irregular surface, and
rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they
shall not have width over five inches.
Paint shall be applied into all corners.
Any runs or sags shall be brushed out.
There shall be a minimum of brush marks left in the applied paint.
Surfaces not accessible to brushes shall be painted by spray, doubers, or sheepkin.
5.7.8 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be
ensured in the qualification trial.
5.8 Drying of Coated Surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered
dry for re-coating when another coat can be applied without the development of any film
irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat
should not exceed maximum specified for it as a first coat; if it exceeds the paint material has
possibly deteriorated or maxing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling,
blistering formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturer's
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry
to the fullest extent practicable.
5.9 Spot Repair of Damaged Primer
5.9.1 Where pre erection shop primer has been damaged at isolated localized spots during handling
and transportation, or after erection / welding, the repair of damaged coating of pre-erection /
pre-fabrication or shop primer shall be done as given below and as per the Table 7.2 of this
specification.
5.9.2 Repair of damaged inorganic zinc silicate pre-erection / pre-fabrication or shop primer
(F9) after erection / welding in the design temperature of -90°C to 400°C and damaged
silicone aluminium (F-12) pre-erection / pre-fabrication or shop primer after erection /
welding for design temperature range of 401 — 550 °C.
Surface Preparation: Quickly remove the primer from damaged area by mechanical scraping
and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the
Page 426 of 1296

0R-4:Aft ENGINEERS
Siga tilaiegel INDIA LIMITED Rev. 0
11412712013Valgarff / IA Gott of Ha undertaking) AND PROTECTIVE COATING PAGE 12 OF 59
surface, if possible. Feather the primed surface over the intact adjacent surface surrounding
the damaged area by emery paper.
Primer coating: One coat of F-9 shall be applied wherever damage was observed on pre-
erection / pre fabrication or shop primer of inorganic zinc silicate coating (F-9). Similarly
one coat of F-12 shall be applied wherever damage observed on pre-erection / pre-
fabrication shop primer of silicone aluminium (F-12).
5.9.3 Wherever if damaged areas are found extensive and spread over large areas, then entire pre-
erection / pre-fabrication or shop primer shall be removed by blasting to achieve SSPC-SP-
10 then entire blasted surface shall be primed again with F-9 or F-12 as applicable for the
intended design temp. (See note under table 7.2).
5.10 Paint Application
5.10.1 Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface
(SSPC-SP-10)
5.10.2 Shop priming / pre-erection priming with F9 or F 12 shall be done only with airless spray.
5.10.3 Assessment of Painting Requirement
The paint system to be applied for a specific job shall be arrived at sequentially as given
below:
- Identify the environment from area classification details and chose the appropriate table.
- Identify the design temperature from the technical documents
- Identify the specific field paint system and surface preparation requirement from the above
identified table and temperature range.
- Identify the shop priming requirement from Table 7.1 based on compatibility of the above
paint system.
- Identify the need of repair of shop primer and execute as per Table 7.2.
5.11 Documentation / Records
5.11.1 A written quality plan with procedure for qualification trials and for the actual work
including test and inspection plan & procedure for approval before start of work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no of
coats and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness,
holiday detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
Page 427 of 1296

02zielt. ENGINEERS
I@Tif WeVITIV INDIA LIMITED Rev. 0
INIPPIFIRINVMMICID (A Gov of Inda Underliong) AND PROTECTIVE COATING PAGE 13 OF 59
5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
The coating applicator must maintain a job record consisting of all the information as per
5.11.2 -5.11.7 above as well as the approved procedure of work (5.11.1 above). The job
record consisting of information as required in accordance to 5.11.2 — 5.11.7 shall be entered
on daily basis and should be daily signed by Engineer-in-charge.
Page 428 of 1296

1515036a ENGINEERS
KiegW WA LIMITED FOR SURFACE PREPARATION NO. 6-79-0020
l aildleRzer7013Rdill Cdd d India Underldm9) AND PROTECTIVE COATING Rev. 0
PAGE 14 OF 59
TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL
SI. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Manual or hand tool
cleaning
Removal of loose rust, loose ST.2 SSPC-SP-2 --

1 mill scale and loose paint,
chipping, scrapping, This method is
standing and wire brushing. applied when the
Surface should have a faint surface is exposed to
metallic sheen normal atmospheric
Mechanical or power tool conditions when
cleaning other methods cannot
be adopted and also
Removal of loose rust loose ST.3 SSPC-SP-3 -- for spot cleaning
mill scale and loose paint to during maintenance
2 degree specified by power painting.
tool chipping, de-scaling,
sanding, wire brushing and
grinding, after removal of
dust, surface should have a
pronounced metallic sheen.
Dry abrasive Blast cleaning
3
There are four common
grades of blast cleaning
White metal
Blast cleaning to white metal Where extremely

cleanliness. Removal of all clean surface can be
3.1 . SA 3 SSPC-SP-5 NACE#1
visible rust. Mill scale, paint expected for prolong
& foreign matter 100% life of paint system.
cleanliness with desired
surface profile.
Near white metal The minimum
requirement for
Blast cleaning to near white chemically resistant
metal cleanliness, until at paint systems such as
least 95% of each element of epoxy, vinyl,
surface area is free of all polyurethane based
visible residues with desired and inorganic zinc
3.2 SA 21/4 SSPC-SP-10 NACE#2 .
surface profile. silicate
licate paints, also
for conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
Page 429 of 1296

Isdozesk -r ENGINEERS
fatalegwv INDIA mem FOR SURFACE PREPARATION NO. 6-79-0020
laiRn FRaW !N W) GoA a/ India Undenaly.91 AND PROTECTIVE COATING Rev. 0
PAGE 15 OF 59
VARIOUS INTERNATIONAL
SI. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Commercial Blast For steel required to
be painted with
Blast cleaning until at least conventional paints
two-third of each element of for exposure to
3.3 SA 2 SSPC-SP-6 NO.3
surface area is free of all mildly corrosive
visible residues with desired atmosphere for longer
surface profile. life of the paint
systems.
Brush-off Blast
Blast cleaning to white metal

3.4 cleanliness, removal of all SA 1 SSPC-SP-7 NO.4
visible rust, mill scale, paint
& foreign matter. Surface
profile is not so important
Page 430 of 1296

15illtea ENGINEERS
Itgai Bakst INDIA map FOR SURFACE PREPARATION NO. 6-79-0020
Men eiMEORMCFM (A Govt of India Undertalung) AND PROTECTIVE COATING Rev. 0
PAGE 16 OF 59
6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on original printed
literature, alongwith the test certificate for all specified characteristics given in this
specification. All the paint materials shall be of first quality and conform to the following
general characteristics as per the tables 6.1, 6.2, 6.3 and 6.4.
PAINT MATERIALS
TABLE No. 6.1 PRIMERS
SI. DESCRIPTION P-2 P-4 P-6 P-7

No.
Chlorinated Etch Epoxy zinc ZINGA,
rubber Zinc primer/wash phosphate primer LOCKTITE or
1 Technical name
Phosphate primer. primer ZRC
cold galvanizing
Single pack, air Two pack Two component One pack
drying chlorinated polyvinyl butyral polyamine cured Synthetic Resin
rubber based resin medium epoxy resin based zinc
medium cured with medium, galvanizing
2 Type and composition plasticised with phosphoric acid pigmented with containing min
unsaponifiable solution zinc phosphate. 92% of electrolytic
plasticizer, pigmented with zinc dust of
pigmented with zinc tetroxy 99.95% purity.
zinc phosphate. chromate.
3 Volume Solids % 40±3 10±1 50±1 37%
DFT (Thy Film
4 thickness) per coat in 40-45 8-10 40-50 40-50p
microns
Theoritical covering
5 8-10 8-10 8-10 4m2/kg
capacity in M2/coat/ litre
Weight per litre in
6 1.3±0.05 1.2±0.05 1.4±0.05 2.67 kg at 15°C
kgs/litre
Touch dry at 30°C
7 30 minutes 2 hrs. After 30 min. 10 minutes
(minimum)
Hard dry at 30°C
8 8 hrs. 24 hrs. 8 hrs 24 hrs.
(maximum.)
9 Overcoating interval Min.: 8 hrs Min: 4-6 hrs. Min.:Shrs. Min.:4 hrs
Pot life at 30°C for two Not
10
component paints Applicable
Not applicable 6 - 8 hrs. Unlimited
Temperature (Resistance 60 °C NA 80°C 50°C
11
(minimum) Dry service Dry service Dry service Dry service
Page 431 of 1296

15ifiziEgftENIONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
star taRegWINDIA LIMITED
011iTIF01112451W1, (A GM al Se Undertab19) AND PROTECTIVE COATING Rev. 0
PAGE 17 OF 59
PAINT MATERIALS
TABLE No. 6.2 FINISH PAINTS
SI. DESCRIPTION F-2 F-3 F-6A/I3 F-6C F-7

No
Acrylic Chlorinated
1 Technical name Polyurethane rubber based Epoxy-High
. Build Solvent less High build coal
finish paint finish paint coati ng epox coating tar
coating.
epoxy
Single pack F-6A Two-pack Two pack, Two

plasticised Aromatic amine cured pack
with polyamide
Two-pack chlorinated cured epoxy resin Amine
aliphatic rubber based medium suitably Adduct; cured epoxy
2 Type and isocynate medium with resin blended
composition pigmented. with
cured acrylic chemical and F-6B: polyamide catalyzed
epoxy resin
coaltar
finish paint. weather cured epoxy resin suitably medium,
resistant .
medium suitably pigmented suitably
pigments. pigmented pigmented
3 Volume Solids % 40 ± 3 38±2 60±3 99+1 65±3
DFT (Dry Film
4 thickness) per coat in 30-40g 30-40 100-125g 200-500 100-125g
microns
5 capacity in 11-15 11-15 5-6 2-3 5.2-6.5
M2/coat/litre
6 Weight per liter in 1.15±0.03 1.150.03 1.41+0.03 1.40+0.03 1.40±0.03
kgs/litre
7 Touch dry at 30°C 30 minutes 30 minutes. 3 hrs. 3 hrs. 4 hrs.
Hard dry at 30°C
(max) 16 hrs
8 hrs 48 hrs
8 Full cure at 30°C (for 8 hrs 16 hrs
immersion/ high 5 days
5 days
temperature service)
9 Over-coating
at 30°C
interval Min.12 hrs. Min.: Min.: Overnight Min.: 8 hrs. Min.: 24 hrs
Overnight Max.: 5 days Max.: 48 hrs. Max.: 5 days.
Pot life (approx.) at
10 30°C for two 6-8 hrs. ot 4-6 hrs 30 minutes
applicable 4-6 hrs.
component paints
Temperature 120°C(Diy
Resistance 80 °C 60 °C service), 125°C
11 (minimum) Dry service Immersion 80°C 50°C Immersion
min service Dry service
(Immersion service
service)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — NI rights reserved
Page 432 of 1296

ogesOwes
kveg
ENGINERS
INDIA Limo) FOR SURFACE PREPARATION NO. 6-79-0020
Wien diereer eagatale deort d India Undertaking) AND PROTECTIVE COATING Rev. 0
PAGE 18 OF 59
PAINT MATERIALS
SI.
DESCRIPTION F-8 F-9 F-11 F-12
No
Self priming type Heat resistant
Heat resistant
surface tolerant synthetic medium
silicone
high build epoxy Inorganic zinc based two pack
1 Technical name Aluminium paint
coating (complete silicate coating Aluminium paint
suitable upto
rust control suitable upto
500 ° C dry temp.
coating). 250°C dry temp.
A two pack air
Two pack epoxy drying self curing
resin based solvent based
Heat resistant
suitable inorganic zinc Single pack
synthetic medium
pigmented and silicate coating with silicone resin
based two pack
2 Type & composition capable of minimum 80% zinc based medium
Aluminium paint
adhering to content on dry film. with Aluminium
suitable upto
manually The final cure of flakes.
250°C.
prepared surface the dry film shall
and old coating. pass the MEK rub
test.
3 Volume Solids % 7813 60±3 3810.03 2012
DFT (Dry Film
4 thickness) per coat in 100-125 65-75p 15-20g 15-20g
microns
5 capacity in M2/coat/ 6.0-7.2 8-9 10-12 8-10
litre
Weight per liter in
6 1.4110.03 2.310.03 0.95±0.03 1.0010.03
kgs/litre
Touch dry at 30°C
7 3 hrs. 30 minutes. 3 hrs. 30 minutes.
(maximum)
Hard dry at 30°C
(maximum) 24 hrs 12 12 hrs 24 hrs
8 Full cure 30°C (for
immersion thigh 5days NA NA NA
temperature service)
Mb. 12 hrs . at 20°C
Mm.:
9 Over-coating interval Min.: 10 hrs 24 lin Mb.: 24 hrs
& 50 % RH
Pot life at 30°C for two
10 90 minutes. 4-6 hrs. Not applicable Not applicable
component paints
Temperature 80 °C 400 °C 250°C 500°C
11
Resistance (minimum) Dry service Dry service Dry service Dry service
Page 433 of 1296

ate ENGINEERS
azir Wear INDIA LIMITED
Rev. 0
NOM MN ?AMMO (A GS of kola tAlerlicing) AND PROTECTIVE COATING PAGE 19 OF 59
PAINT MATERIALS
SI. F-16
DESCRIPTION F-14 F-15 F-17
No
Ambient temperature
curing Poly Siloxane
Two-component Two component
coating/High build
Epoxy phenolic solvent free type
cold applied inorganic
coating cured with high build epoxy
copolymer based
Polyamine cured Polyamine adduct phenolic/novalac
1 Technical name aluminium coating
coal tar epoxy hardner system epoxy phenolic
suitable for under
(primer + . coating cured with
Insulation coating of
intermediate coat Polyamine adduct
CS and SS piping for
+ finish paint) hardner system
high temperature
service.
Two pack ambient Two component
Specially
temperature curing Amercoat 738 from solvent free type
formulated
epoxy phenolic PPG Protective & high build epoxy
polyamine cured
coating system Marine Coatings or phenolic/novalac
2 Type & composition coal tar epoxy
suitable for Intertherm 751 CSA of epoxy phenolic
suitable for
application under International (Akzo coating cured with
application under
insulation of Nobel). Note: 6 Polyamine adduct
insulation
CS/SS piping hardner system
3 Volume Solids % 70±3 70±3 60±2 98-100
DFT (Dry Film
4 thickness) per coat in 100-125 75-100 75-100 125- 150
microns
5 capacity in M2/coat/ 5-8 4-5 7.0- 9.0 6.5 - 8
litre
Weight per liter in
6 1.4540.03 1.650.03 1.3 1.7
kgs/litre (mix paint)
Touch dry at 30°C
7 4 hrs 3 hrs 1 hr 2 hrs
(maximum)
Hard dry at 30°C
(maximum) 24 hrs 24 hrs 16 hrs 24 hrs
8 Full cure 30°C (for
immersion Thigh 168 hrs (7 days) 168 hrs (7 days) - 168 hrs (7 days)
temp. service)
Over-coating interval Min. 6 hrs Min. 36 hrs Min.16 hrs Min. 16 hrs
9
Max.S days Max.21 days Max. Not applicable Max.21 days
Pot life at 30°C for
10 two component 4 hrs 4-6 hrs 1 hr 1 hr
paints
Temperature upto 400 °C for C.
Resistance Steel & S. Steel for
-45°C to 150°C
-45°C to 125°C Intertherm 751 CSA
under insulation & -45°C to 150°C for
11 under insulation upto 480 °C for C.
immersion immersion service
And immersion Steel & upto 600 °C
(Note: 5)
for S. Steel for
Amercoat 738
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell. —All rights reserved
Page 434 of 1296

0151-43-eta ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Igtlf Emegw INDIA LIMIIID Rev. 0
IMWIFIRMFM WD IA Gobi of Incl. Unded*V AND PROTECTIVE COATING PAGE 20 OF 59
NOTES (for tables 6.1 to 6.4):
Covering capacity and DFT depends on method of application. Covering capacity

specified above are theoretical. Allowing the losses during application, min specified
DFT should be maintained.
All primers and finish coats should be cold cured and air drying unless otherwise
specified.
All paints shall be applied in accordance with manufacturer's instructions for surface
preparation, intervals, curing and application. The surface preparation, quality and
workmanship should be ensured. In case of conflict between this specification and
manufacturer's recommendation, the same shall be clarified through EIL SMMS
department.
Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
F-15: Two-component Epoxy phenolic coating cured with Polyamine adduct hardner
system (primer + intermediate coat + finish paint) suitable upto 225°C (Intertherm 228
from M/s Akzo Nobel Coatings India Pvt Ltd. Bangalore). For all other companies, the
temperature resistance shall be a maximum of 150°C.
F-16: Ambient temperature curing epoxy poly siloxane Coating or high build cold
applied inorganic co-polymer based aluminium coating.
Amercoat 738 from PPG Protective & Marine coatings. Mumbai, is suitable up to
480°C for CS surfaces and 600°C for SS surfaces.
Intertherm 751 from Akzo Nobel Coatings India Pvt Ltd. Bangalore, Inorganic co-
polymer cold applied Aluminium spray coating is suitable upto 400°C of CS & SS
surfaces.
Page 435 of 1296

fit ENGINEERS
ligar ta2eg e INDIA LIMITED
i
Rev. 0
1 11101.124112=3WRI■ IA Gen a/ Ind4a Undertalng) AND PROTECTIVE COATING PAGE 21 OF 59
7.0 COATING SYSTEMS
The coating system should be selected based on the Plant location as given below:
Classification based on Plant Location:
a) Plant located in Inland area (more than 50 km from coast);

Environment Classification — Industrial
For offsite areas: Table 9.0 to be followed
For all unit areas including DM,CPP and Cooling Tower: Table 10.0 to be
followed
b) Plant located on sea coast or within 50 km from sea coast;

Environment classification- Industrial marine
- For offsite area, as well as all unit area including DM, CPP, Cooling Tower:
Table 10.0 to be followed
c) For external surface of above ground tanks, table 12.0 to be followed for all
locations (Inland or coastal)
Notes:
Coating systems (Primers, Finish Paints etc.) based on Area

classification/environments/Applications are tabulated in Table 8.0 to Table 17.0
Primers & Finish paints covered in Tables 8.0 to 17.0 are listed in Table 7.1.
3. Repair of Pre-Erection/Pre-Fabrication & Shop priming after erection/ welding shall be

done as per Table 7.2.
Page 436 of 1296

el ENGINEERS NO. 6-79-0020
Raft
litaimeneRanuoim INDIA LIMITED
IA GNI d Undertakng)
AND PROTECTIVE COATING Rev. 0
PAGE 22 OF 59
TABLE 7.1: LIST OF PRIMERS & FINISH COATS COVERED IN TABLE NOS. 8 to 18.0
PRIMERS
P-2 Chlorinated rubber zinc Phosphate Primer
P-4 Etch Primer/Wash Primer
P-6 Two component Epoxy Zinc Phosphate Primer cured with polyamine hardener
Single pack, cold galvanizing compounds containing minimum 92% electrolytic zinc in dry film.
P-7
make ZINGA, LOCKTITE (of HENKEL) or ZRC
FINISH COATS / PAINTS

F-2 Two component Acrylic — Polyurethane finish paint
F-3 Chlorinated Rubber finish paint
F-6A High Build Epoxy finish coating cured with polyamine hardener
F-6B High Build Epoxy finish coating cured with polyamide hardener
F-6C Solvent less Epoxy Coating cured with poly amine hardener
F-7 High. build Coal Tar epoxy coating cured with polyamine hardener
F-8 Self priming surface Tolerant High Build epoxy coating. cured with polyamine hardener
F-9 Two component Inorganic Zinc Silicate coating
F-11 Heat resistant synthetic medium based Aluminium paint
F-12 Two component Heat resistant Silicone Aluminium paint.
F-14 Specially formulated coal tar epoxy coating. cured with polyamine hardener
F-15 Two component Epoxy phenolic coating cured with Polyamine adduct hardener system
Engineered Epoxy poly Siloxane Coating or high build cold applied inorganic co-polymer based
F-16
aluminium coating
Two component solvent free type high build epoxy phenolic/novalac epoxy phenolic coating cured
F-17
with Polyamine adduct hardener system
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — NI rights reserved
Page 437 of 1296

latrazieLre ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
lgaf Efieg NDIA LIMITED
Rev. 0
lageR21201701JMAI (A Govt Lea Undertakin) AND PROTECTIVE COATING PAGE 23 OF 59
TABLE 7.2 REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER

AFTER ERECTION/WELDING
For all un-insulated CS, LTCS & low allow steel items in all Environments
Total DFT
SI. Surface Coating System in Microns Remarks
No.
Design Temp. in °C Preparation
(min.)
7.2.1 -90 to 400 SSPC-SP-3 1 coat of F-9 65-75 See note
below and
7.2.2 401 to 550 SSPC-SP-3 1 coat of F-12 20 clause 5.9.3
NOTES
1 The application and repair of pre-erection/pre-fabrication or Shop Primer given in above tables
shall be done for all the items to be painted. In case the damages of primer are severe and spread
over large area, entire primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces
to be primed again with F-9 or F-12 as applicable.
TABLE 8.0 COATING SYSTEM FOR GRATINGS, ROLLING & STATIONERY

LADDERS, SPIRAL STAIRWAYS AND HAND RAILS IN ALL LOCATION
Design
SI. Total DFT
No.
Temp. in Coating System in Microns (min.)
°C
Hot Dip Galvanizing to 80-85 microns (600-610
80 microns of finish coat
gm/m2)as per IS 4759, 2629, 4736, 2633 +
8.1 Up to 60 (excluding the thickness of
1 coat of P-6 @ 40u DFT/coat + 1 coat of F-2 @ 40
)
microns DFT/coat
NOTES:
1 No galvanized specimen shall have thickness less than 80 microns.
2 Repair of the damaged area of galvanized coatings due to welding during erection shall be
carried out as per recommended practice IS 11759 using cold galvanizing spray process.
Organic Paint systems are not acceptable for repair.
3 After repair of damaged galvanized coating by Cold Galvanized, the repaired area shall be top
coated with paint system as given in Table 8.0 above (i.e., 1 coat of P-6 @ 40g DFT/coat + 1
coat of F-2 @ 40g DFT/coat).
4 Approved Cold Galvanizing manufacturers are ZINGA, LOCKTITE or Z.R.C.
Page 438 of 1296

PlitiegaENONIEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Oga ft W INDIA UMITED Rev. 0
lam mewl:limn.) IA Gal of w. undmanno AND PROTECTIVE COATING PAGE 24 OF 59
TABLE 9.0 COATING SYSTEM FOR OFFSITE AREA (INLAND PLANTS)

For external surfaces of Un-insulated & aboveground (atmospheric exposure)
Structures, Piping, Vessels, Equipments, Pumps, etc. (Note-1); (For Carbon Steel,
LTCS & Low Alloy Steel). See Note Below*
Surface Coating System Total Final

Design
SI. Preparation & (Post-erection / Field) DFT
Temp. in Remarks
No. Pre-erection/Shop in Microns
°C Primer Finish Coat
Primer (min.)
SSPC-SP-10; No over-
9.1 -90 to -15 lcoat of F-9 @ None None 65-75 coating to be
65-75p DFT/coat done on
SSPC-SP-10; F-9 as it will
I coat of F-2 @
9.2 -14 to 60 1 coat of F-9 @ None 105-115 lead to mud
40p DFT/coat cracking.
65-75p DFT/coat
SSPC-SP-10;
1 coat of F-2 @
9.3 61 to 80 lcoat of F-9 @ None 105-115
40g DFT/coat
65-75g OFT/coat
2 coats of F-11
SSPC-SP-10;
20p
9.4 81 to 250 I coat of F-9 @ None 105
DFT
@/coat;
65-75p DFT/coat
(2x20=40)
2 coats of F-12
SSPC-SP-10;
@ 20p
9.5 251 to 400 1 coat of F-9 @ None 105-115
DFT/coat
65-75p DFT/coat F-12 shall be
(2x20=40)
ambient
SSPC-SP-10; 2 coats of F-12 temperature
9.6 401 to 550 lcoat of F-12 @ None @20g DFT/coat 60 curing type
20g DFT/coat (2x20=40)
* Flare line within unit or offsite areas shall be coated as per Clause 10.3 of Table 10.0, but
having finish coat of 2 coats of F-12.
NOTES:
1 The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2 If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
3 In case of Paint systems as per SI. Nos. 9.5 and 9.6, the color bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
4 All coating system including surface preparation, primer, and finish coat for piping shall be done
at field only.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —NI rights reserved
Page 439 of 1296

15Naeg a- ENGNEERS
NO. 6-79-0020
5litaf talateltli INDIA LMTED
Rev. 0
eRternorni IA God al Indo Undenalogl AND PROTECTIVE COATING
PAGE 25 OF 59
TABLE 10.0 COATING SYSTEM FOR UNIT AREAS AS WELL AS DM, CPP,
COOLING TOWER OF INLAND PLANTS AND FOR ALL AREAS (UNIT,
OFFSITE, DM, CPP, etc.) OF COASTAL PLANTS
For external surfaces of un-insulated and above ground (atmospheric exposure)

structures, piping, vessels, equipments, external surface of MS chimney/stacks,
RCC chimney, internal surface of MS chimney without refractory lining, towers,
columns, pumps, compressors, blowers etc. of carbon steel, LTCS & low alloy
steels (note-1)
Surface Preparation & Coating System Total DFT

Design Pre-erection/Shop (Post-erection / Field) in
SI. Remarks
Temp. in °C Primer Microns
No. Primer Finish Coat
(min.)
SSPC-SP-10; No over-
10.1 -90 to -15 lcoat of F-9 @ None None 65-75 coating to be
65-75g DFT/coat done on
F 9 as it will
2 coats of F-6A lead to mud
@ 100 g cracking.
DFT/coat + 1
SSPC-SP-I 0; 1 coat of P-6
coat of F-2 @ 345_355 F-12 shall
10.2 -14 to 80 lcoat of F-9 @ @ 40 p
4 0p DFT/coat; be ambient
65-75p DFT/coat DFT/coat
(2x100 + 40= temperature
240) curing type
c) Finish coat
including
2 coats of F-12 primer
SSPC-SP-10; @ 20p compatible
10.3 81 to 400 lcoat of F-9 @ None DFT/coat 105-115 with finish
65-75p DFT/coat 2x20=40 coat (i.e. field
primer) shall
be applied at
site only.
Finish
2 coats of F-12 coating is not
SSPC-SP-10; permitted at
@ 20p
10.4 401 to 550 lcoat of F-12 @ None 60 equipment
DFT/coat;
20p DFT/coat manufacture
(2x20=40)
shop.
NOTES:
The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
Page 440 of 1296

ail-ileaENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Eififtw INDIA LIMITED
imprriWREM3001411 (A GS of In& Undertalargl
AND PROTECTIVE COATING
NO. 6-79-0020
Rev. 0
PAGE 26 OF 59
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
For external surface of MS chimney with or without refractory lining and for internal surface
without refractory lining, paint system as per 10.3 above shall be followed.
For external surface of RCC Chimney, 2 coats of F-6 @ 10012 DFT/coat to obtain total DFT of
200 p. shall be applied after proper surface preparation as per guidelines in 5.1.6.
In case of paint systems as per SI. Nos. 10.3 and 10.4, the colour bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
All coating system including surface preparation, primer, finish coat for piping shall be done at
site/field only.
Page 441 of 1296

OWIETte. ENONEERS
1ga fa2e3 WV INDIA LIMITED Rev. 0
Olen eiROIMMICR)A GM a/ Incia Undertalong) AND PROTECTIVE COATING PAGE 27 OF 59
TABLE 11.0 COATING SYSTEM FOR EFFLUENT TREATMENT PLANT (ETP)
Coating System Total

SI. Design Temp. DFT in
Surface Preparation Remarks
No. in °C Primer Finish Coat Microns
(min.)
For Extemal Surfaces of C.S./M.S. items: Screens, Walk way bridges, Baffles, Dual media filters,
11.1 Vertical pumps, piping in treated effluent sump, bio sludge pump, Screw pump and pump house, CS
tanks, sumps and vessels.
2 coats of
F-6A @100g
DFT/coat + 1
1 coat of F-9
coat40g
of F-2 @
-14 to 80 SSPS-SP-10 @ 65-75g 305-315 -
DFT/coat
DFT/coat;
(2x100+40=2
40)
For Internal Surfaces of CS/MS Items: Bio-sludge sump, Fil er feed sump, Process sump, Sanitary
11.2
sump, Transfer ump, Sludge, Slop oil tank, scrapping mechanism in Clarifier
3 coats of
1 coat of F-9
F-6A @100g
-14 to 80 SSPS-SP-10 @ 65-75g 365-375 Note:1
DFT/coat
DFT/coat.
(3x100=300)
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc. in
11.3 Process sump, TPI separator (Process and Oil), Aeration Tank and Transfer sump etc.
Epoxy screed
lining shall be
Blast cleaning to SSPC-SP
applied as per
guide lines and Acid
specific
-14 to 80 etching with 10-15% HCI Epoxy Screed lining 3mm
manufacturer
acid followed by thorough
and Engineer-
water washing.
in-Charge
instructions
C.S/M.S Dual media filters (Internal), Chemical dosing tanks(intemal such as Di-Ammonium
11.4
Phosphate (DAP) and Urea
Natural
Rubber lining
shall be
Natural Rubber Lining applied as per
Up to 60 SSPC-SP-10 (As per IS 4682, Part 1) 4.5mm specific
manufacturer
and Engineer-
in-Charge
instructions
NOTES
1. The paint /coating manufacturers shall provide their Quality control test certificate of coating
materials (F-6A) for immersion service of the exposed effluent given in 11.2.
Page 442 of 1296

azdZICS ENGNEERS
Oa' 111e W INDIA LIMITED Rev. 0
(02,121POIRCOMWM (A Sort el In& Undeftm g ) AND PROTECTIVE COATING PAGE 28 OF 59
TABLE 12.0 EXTERNAL COATING SYSTEMS FOR UNINSULATED CARBON STEEL

AND LOW ALLOY STEEL STORAGE TANKS (For all plant locations, coastal
or inland)
All Process Units & Off-sites
Total
Surface Coating system (Field) DFT
SI. Design Temp. Preparation (see note 1 below) in Remarks
No. in °C (Field)
Microns
Primer Finish Coat (min.)
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tank including top
12' 1 . of external and internal floating roof and associated external structural works.
side
F-6 should
2 coats of F-6A @
lcoat of F-9 @ 65-75p be suitable
100p DFT /coat + 1
SSPC-SP-10 DFT/coat + lcoat of P-6 for
12.1.1 -14 to 80 coat of F-2 @ 40p 345-355
@ 40p DFT/ coat ; occasional
DFT/ coat;
water
immersion
1 coat of F-15 primer @ 1 coat of F-15 finish

SSPC-SP-10 80p DFT/ coat + 1 coat coat @80p DFT/ coat +
12.1.2 81 to 150 280 -
of F-15 intermediate lcoat of F-2 @ 40p
coat @ 80p DFT/coat ; DFT/ coat;
2 coats of F-12 @20 p

105
DFT/ coat
lcoat of F-9 @ 65-75p or or
12.1.3 151 to 500 SSPC-SP-10 -
DFT/coat 115
1 coat of F-16 @ 50 p
DFT / coat
12.2 External surfaces of bottom pla e (soil side) for all storage tanks.
F-7 should
be suitable
for
SSPC-SP-10 1 coat of F-9 @ 3 coats of F-7@ 100p 365_375 immersion
12.2.1 -14 to 80
65-75p DFT/ coat DFT/coat (3x100=300) service of
the
products
given
1 coat of F-15 primer @
80p DFT/ coat + 1 coat
SSPC-SP-10 1 coat of F-15 finish
12.2.2 81 to 150 of F-15 intermediate 240 -
coat @ 80p DFT/ coat
coat @ 80p DFT/coat ;
(80+80=160)
1 coat of F-16 @ 125 p 1 coat of F-16 @ 125 p
12.2.3 151 to 550 SSPC-SP-10 250 -
DFT /coat DFT /coat
12.3 For underside of the bottom plate (in case tank is not lifted during PWHT) (see Note 2c)
Page 443 of 1296

5Rizth ft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
1@U Elffleg NDIA LIMITED
Rev. 0
leiarr FIROIMIWII IA Gut d India Undedalung) AND PROTECTIVE COATING PAGE 29 OF 59
For CS Products
SSPC SP-6 from
JOTUN or
Commercial
Blast HI-TEMP
2 coats of inert
-180 to 650 1 coat of inert polymeric coatings or
12.3.1 polymeric matrix 350-400
For SS matrix coating @ 125 u SK
coating @ 125 Ft
SSPC SP-1 FORMULA
with non- TIONS are
chloride
chlo recommend
solvent ed.
NOTES
All paint coating application including primer for tankage shall be carried out at field after
erection and completion of all welding.
For underside of bottom plate :

Painting shall be carried out before laying of bottom plate for tanks with Non-Post Weld
Heat Treatment (PWHT).
For tanks with PWHT, painting shall be carried out after PWHT.
c) In case tank is not lifted during PWHT then painting shall be applied before laying of bottom
plate, clause no. 12.3.1 shall be followed.
Caution: PWHT temperature shall not exceed 650°C.
Page 444 of 1296

151fizieta ENCINEERS
Oga tiRegs INDIA LMTED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
INF 212(INVINMER) (A Gout of kb Undettiong) AND PROTECTIVE COATING
PAGE 30 OF 59
TABLE 13.0 INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY
STORAGE TANKS
All Process Units & Off-sites
Coating system (Field) Total

Surface DFT
SI. Design Preparation (see note 1 below)
in Remarks
No. Temp. in °C (Field) Microns
Primer Finish Coat
(min.)
CRUDE OIL, ATF, TURPENTINE OIL, LUBRICAT NG OIL AND VEGETABLE OIL
Underside of floating roof, internal surface of cone roof, inside of bottom plate, Internal surfaces of Shell
13.1
- including wetted and free board height, oil side surfaces of deck plates, oil side surfaces of pon oons,
roof structures, structural steel, ladders and other CS internals
1 coat of F-15
intermediate coat @
13.1. 1 coat of F-15 primer a -
-14 to 90 SSPC-SP-10 — 800 DFT/coat + 1 coat 240-300
1 800 DFT/ coat
of F-15 finish coat @
80p DFT/ coat,
PETROLEUM PRODUCTS & INTERMEDIATES like LDO, HSD , GAS OIL, FEEDS of
FCC-PC, FCC-LCO, VGO-HDT, ISOM, DHDT, REFORMATE, DCU, NHT & GASOLINE,
NAPHTHA, ISOMERATE AND KEROSENE.
13.2
Underside of Floating roofs, internal surface of cone roof, inside of bottom plate, internal surfaces of
Bare shell for full height, underside of floating roof, oil side surfaces of deck plates, oil side surfaces of
pontoons, support structures and ladders etc.
13.2. I coat of F-9 @
-14 to 45 SSPC-SP-10 - 75 Note 2
I 75 0 DFT/coat
1 coat of F-15
intermediate coat @
13.2. 1 coat of F-15 primer @
46 to 90 SSPC-SP-10 80p DFT/coat + 1 coat 240-300 -
2 80p DFT/ coat
of F-15 finish coat @
800 DFT/ coat;
POTABLE AND FIRE WATER
13.3 All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
2 Coats of F-6A @
13.3. 1 Coats of P-6 @ Note-4
-14 to 60 SSPC-SP-10 1000 DFT/ Coat; 300-350
1 100 0 DFT/coat;
(2x100=200)
DE-MINERALIZED (DM) WATER
2 coats of F-6C @
13.4. 1 Coats of P-6 @
-14 to 60 SSPC-SP-i0 200p DFT/ coat; 400-450 -
1 1000 DFT/coat;
(2x200=400)
1 coat of F-15
intermediate coat @
13.4. 1 coat of F-15 primer @ 800 DFT/coat + 1 coat
61 to150 SSPC-SP-10 240-300
2 800 DFT/ coat of F-15 finish coat @
800 DFT/ coat;
(80+80=160)
HYDROCHLORIC ACID (HCI) 10 %
13.5
All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
13.5. 4.5 mm -
-14 to 60 SSPC-SP-10 None Natural Rubber Lining
1
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
Page 445 of 1296

ofteiftENGINEERS
ogaiEgRegewr INDIA um-rED FOR SURFACE PREPARATION NO. 6-79-0020
114M MK,'"UMR0 IA GS of Undertaiong) AND PROTECTIVE COATING Rev. 0
PAGE 31 OF 59
AGGRESSWE SOLVENTS LIKE HEXANE, HEXENE, BENZENE, XYLENE AND TOLUENE

13.6. 1 coat of F-9 @ 75p

-14 to 65 SSPC-SP-10 --- 75
1 DFT/ coat
ETHYLENE GLYCOL (EG) TANKS

13.7 Internal shell-full height, bottom plate, underside of roof and all accessories
3 coats of vinyl
chloride co-polymer
13.7. AMERCOAT 23 @ 225 -
All SSPC-SP-10 None
1
75p /Coat;
(3x75=225)
13.8 Inside pontoon and inside of double deck of all floatingroofs
13.8. 1 coat of F-8 @ 100p 1 coat of F-8 @ 100p
- 14 to 80 SSPC-SP-3 200
1 DFT/coat DFT/coat
WET SLOPS, AMINE soluCons, SOUR WATER , WATER DRAW OFF
13.9
1 coat of F-15
intermediate coat @
13.9. 1 coat of F-15 primer @ 80p DFT/coat + 1 coat
-14 to 90 SSPC-SP-]0 240
1 80p DFT/ coat of F-15 finish coat @
80p DFT/ coat;
(80+80=160)
VACUUM RESIDUE, FUEL OIL , DRY SLOP, BITUMEN AND OTHER HIGH TEMPERATURE
HYDROCARBON LIQUIDS
13.10 Underside of floating roof, internal surface of cone roof, bottom plate, inside of bare shell — including
wetted and non wetted surfaces, oil side surfaces of deck plates, oil side surfaces of pontoons, roof
structures, structural steel and ladders
1 coat of F-17
intermediate coat @
13.10 1 coat of F-17 primer 125p DFT/coat + 1 coat 375 .. N.. _
Up to 150°C SSPC-SP-10 ote:3
.1 @ 125p DFT/ coat of F-17 finish coat
@125p DFT/ coat.
(125+125=250)
ALKALIS UP TO 50 % CONCENTRATION
13.11
2 Coats of F-6 A @
13.11 1 coat of F-15 primer
mer @
Up to 60°C SSPC-SP-10 100p DFT/coat; 280-100 -
1 80p DFT/ coat
(2x100=200)
NOTES
I. All paint coating application including primer shall be carried out after erection and completion
of all welding work at site.
F-6A should be suitable and resistant for immersion service for the respective Hydrocarbons.
This system can be used where maximum operating temperature is below 150°C and design
temperature is upto 200°C. Cases of operating temperature > 150°C are not covered in this spec,
such cases shall be covered in the job specifications.
4 F-6 A shall be suitable for drinking water service and should have competent authority
certification.
Page 446 of 1296

ateaftINGINEERS
Igar fitileuW WA LIMITED Rev. 0
Iiik717421191PONAZIPI) IA GM al Ma Undslasn91 AND PROTECTIVE COATING PAGE 32 OF 59
TABLE 14.0 COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND

CARBON STEEL PLANT PIPING AND UNDERGROUND VESSELS
Surface Coating system (Field) Total Final

Design Preparation
SI. Surface DFT
Temp. in & Remarks
No. Preparation & Finish Coat in Microns
°C Shop Primer
(min.)
min.)
14.1 Underground carbon steel plant piping
I layer of coaltar tape

The primer
coating @ 2mm +1
DFT is not
coat of synthetic fast
SSPC-SP-10; measurable.
drying primer 25 @u
Reconciliation
OFT/ coat + 1 layer of
14.1.1 25 to 65 --- 1 coat of synthetic 4 mm primer shall
coal tar tape coating @
fast drying primer be done by
2mm /layer as per
25 @it DFT/ coat coverage of
EIL Standard
maximum 10
Specification No
sq.m/litre
6-79-0011
SSPC-SP-10; 1 coat of F-17

intermediate coat @
14.2.1 66 to 150 --- 1 coat of F-17 125u DFT/coat + I 375 -
primer @ 125u coat of F-17 finish
DFT/ coat coat @125u DFT/ coat
SSPC-SP-10;
1 coat of F-16 finish
14.2.2 151 to 400 ---
1 coat of F-I6 250 -
coat @125u DFT/ coat
primer @l25µ
DFT/ coat
14.3 External side of un-insulated underground storage vessels
SSPC-SP-10;
I coat of F-9 3 coats of F-7 @ 100u

14.3.1 -40 to 80 -- 365-375 -
@ DFT/coat
65-75u DFT/
coat
SSPC-SP-10;
I coat of F-17
intermediate coat @
1 coat of F-17
14.3.2 81 to 150 --- 125u DFT/coat + 1 375 -
primer @
coat of F-17 finish
125u DFT/
coat @12512 DFT/ coat
coat
SSPC-SP-10;
I coat of F-16 1 coat of F-16 finish

143.3 151 to 400 --- 250 -
primer @ coat @125u DFT/ coat
125u DFT/
coat
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved
Page 447 of 1296

azosfillteifitENONEERS
eies INDIA utsiTED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
IMIPWd3,0111 IA GOA d loan Undeglaan9) AND PROTECTIVE COATING
PAGE 33 OF 59
TABLE 15.0 COATING UNDER INSULATION (COASTAL OR INLAND PLANTS). ALL

UNITS AREAS & OFF-SITES
For insulated Piping, Equipments, Storage vessels, tanks, Columns etc of Carbon
Steel, LTCS, Low Alloy Steel & Stainless Steels

Surface
(Post-erection / Field) Final
Preparation &
SI. Design DFT
Pre- Remarks
No. Temp. in °C Primer/ in
erection/Shop Finish Coat
Intermediate Microns
Primer
(min.)
15.1 Carbon steel, LTCS and low Alloy steel Piping
SSPC-SP-10; 2 coats of F-15 @
1 coat of F-15 @
15.1.1 -45 to 120 'coat of F-15 @ 75p DFT/coat; 225- 250 -
75p DFT/coat
75p DFT/coat (2x75= 150)
SSPC-SP-10; 2coat of F-I2 @
15.1.2 121-540 'coat of F-12 @ None 20p DFT/coat; 60 -
20p DFT/coat (2x20=40)
15.2 Carbon steel, LTCS and low Alloy steel - Storage vessels, Reactors, Columns & Equipments
SSPC-SP-10; 2 coats of F-15 @
1 coat of F-15 @
15.2.1 -45 to 120 'coat of F-15 @ 75p DFT/coat; 225- 250 -
75p DFT/coat
75p DFT/coat (2x75= 150)
Temporary oil
based varnish Thermally Sprayed Aluminium coating
121 to 540 coating to be (TSAC)
15.2.2 - -
provided for Refer ANNEXURE-I
transport and
storage
153 Stainless Stee (SS) including Alloy-20 piping (Note:2)
For CS
SSPC SP-6 Products from
Commercial Blast JOTUN or HI-
1 coat of inert 2 coats of inert
-180 to Zero TEMP coatings or
15.3.1 polymeric matrix polymeric matrix 350-400
For SS SK
coating @ 125 p coating @ 125 p
SSPC SP-1 with FORMULATIONS
non-chloride are recommended.
solvent
If the piping &
equipments are
already erected
then surface shall
SSPC-SP-10
1 coat of F-15 be prepared by
(15-25p surface 1 coat of F-15
cleaning with
15.3.2 0 to 125 profile) intermediate coat finish coat@ 80 240
emery paper and
1 coat of F-15@ @80 p DFT/coat p DFT/coat; wash/flush with
80 p DFT/coat
chloride free DM
water followed by
wiping with
organic solvent
SSPC-SP-10 Not recommended
1 coat of F-16 @
15.3.3 126 to 400 1 coat of F-16 @ None 250 for operating
125 0 DFT/coat
125 g DFT/coat temperature
Page 448 of 1296

laizEtha ENGINEERS FOR SURFACE PREPARATION
NO. 6-79-0020
Glg a tiOtegmv INDIA UNITED Rev. 0
1011PFT 21R077 ttUatf 0 IA Govl of Yea Undetlicingi AND PROTECTIVE COATING PAGE 34 OF 59
SSPC SP-10; between

I coat of
1 coat of 60 - 120 °C
15.3.4 401 to 600
Amercoat 738@
None Amercoat 738@ 250
125 it DFT/coat 125 g DFT/coat
15.4 Coating system for Cyclic Service of Carbon Steel, LTCS, Low Alloy Steel & Stainless Steel
SSPC-SP-10 Apcothem EPN
(15-25g surface 1 coat of F-15 1 coat of F-15 200 of M/s Asian
15.4.1 - 40 to 150 profile) intermediate coat finish coat @ 240 Paints Ltd
1 coat of F-15 @ @ 80g DFT/coat 80m DFT/coat; OR
80 p DFT/coat Equivalent
For CS
Products from
SSPC SP-6
JOTUN or HI-
Commercial Blast 1 coat of inert 2 coats of inert
-180 to 650 TEMP coatings or
15.4.2 For SS polymeric matrix polymeric matrix 350-400
SK
SSPC SP-1 with coating @ 125 g coating @ 125 g FORMULATIONS
non-chloride are recommended.
solvent
15.5 No painting is required for insulated Monel, Incoloy and Nickel lines.
NOTES
"Cyclic Service" is characterized by rapid temperature fluctuation.

The blast cleaning abrasives for SS and Alloy steel surfaces shall be Aluminium oxide
grits/shots or garnet.
3. In case of overlapping of temperature ranges as mentioned in 15.4.1 and 15.4.2, clause 15.4.1
shall be followed.
TABLE 16.0 COATING SYSTEM FOR CARBON STEEL COMPONENTS OF COOLERS /

CONDENSERS (INTERNAL PROTECTION) FOR FRESH WATER SERVICE
Fresh Water boxes, channels, partition plates, end covers and tube sheets etc.

Surface Preparation Final DFT
SI. Design (Post-erection / Field)
& Pre-erection/Shop Remarks
No. Temp. in .C in Microns
Primer Primer Finish paint (min.)
1 coat of F-15 2 coats of F-15 @
16.1 Up to 80 °C SSPC-SP-10 240
@ 80 microns 80p DFT/coat;
1 coat of Glass
Fibre Reinforced
16.2 80 to 140 SSPC-SP-10 1500 -
Novolac epoxy of
1.5 mm DFT
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL - All rights reserved
Page 449 of 1296

laitairiENONEERS
5fgaitameni, INDIA umiTED FOR SURFACE PREPARATION NO. 6-79-0020
MR" eleanSFM (A Gm 0/ India Undertiongi AND PROTECTIVE COATING Rev. 0
PAGE 35 OF 59
TABLE 17.0 COATING SYSTEM (INTERNAL PROTECTION) FOR GALVANIZED OR

NON FERROUS OR STAINLESS STEEL/ DUPLEX STAINLESS STEEL
COMPONENTS OF COOLERS/ CONDENSERS FOR FRESH WATER
SERVICE
Coating System Total Final

Surface Preparation
SI. Design (Post-erection / Field) DFT Remarks
& Pre-erection/Shop in Microns
No. Temp. in °C
Primer Primer Finish paint
(min.)
1 coat of F-15 @ 1 coat of F-15 @
17.1 Up to 80 Sweep Blasting 160 -
80g DFT/coat; 80g DFT/coat;
I coat of Glass
Fibre Reinforced
17.2 80 to 140 Sweep Blasting --- 1500 -
Novolac epoxy of
1.5 mm DFT
18.0 STORAGE
18.1 All paints and painting materials shall be stored only in rooms to be arranged by contractor
and approved by Engineer-in-charge for the purpose. All necessary precautions shall be
taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word "PAINT STORAGE - NO NAKED LIGHT -
HIGHLY INFLAMABLE" shall be clearly displayed outside. Manufacturer's
recommendation shall be followed for storage of paint materials.
19.0 COLOUR CODE
The following colour coding system shall be followed. However alternate colour coding may
also be followed as per Owner's colour coding practice/scheme.
19.1 IDENTIFICATION
The system of colour coding consists of a ground colour and secondary colour bands
superimposed over the ground colour. The ground colour identifies the basic nature of the
service and secondary colour band over the ground colour distinguishes the particular service.
The ground colour shall be applied over the entire length of the un-insulated pipes. For
insulated lines ground colour shall be provided as per specified length and interval to identify
the basic nature of service and secondary colour bands to be painted on these specified length
to identify the particular service. Above colour code is applicable for both unit and offsite
pipelines.
Page 450 of 1296

,S RS STANDARD SPECIFICATION STANDARD SPECIFICATION
0?atitatuvoy INDIA LIMITED
Rev. 0
Sifflirel3qtall IA Govt d Irda Undenkr9) AND PROTECTIVE COATING PAGE 36 OF 59
COLOUR CODING
SR. SERVICE RECOMMNDED COLOUR FOR RAL COLOUR CODE

No. PAINT SYSTEM
BASE BAND
COLOUR COLOUR
HYDROCARBON LINES (UNINSULATED)
1 CRUDE SOUR Dark Admiralty grey with 1 orange band 7012 2011
2 CRUDE SWEET Dark Admiralty grey with I red band 7012 3001
3 LUBE OILS Dark Admiralty grey with 1 green band 7012 6010
4 FLARE LINES Heat Resistant Aluminium 9006
5 LPG Orange with 1 oxide red band 2011 3009
6 PROPYLENE Orange with 2 blue bands 2011 5013
7 NAPTHA Orange with 1 green band 2011 6010
8 M.S. Orange with 1 dark admiralty grey band 2011 7012
9 AV.GASOLINE (96 RON) Orange with 1 band each of green, white 2011 6010 9010 3001
and red bands
10 GASOLINE (regular, leaded) Orange with 1 black band 2011 9005
11 GASOLINE (premium, Orange with 1 blue band 2011 5013
leaded)
12 GASOLINE (white) Orange with 1 white band 2011 9010
13 GASOLINE (Aviation Orange with 1 red band 2011 3001
100/130)
14 GASOLINE (Aviation Orange with 1 purple band 2011 4006
115/145)
15 N-PENTANE Orange with 2 blue bands 2011 5013
16 DIESEL OIL (White) Oxide red with 1 white band 3009 9010
17 DIESEL OIL (Black) Oxide red with 1 yellow band 3009 1023
18 KEROSENE Oxide red with 1 green band 3009 6010
19 HY.KEROSENE Oxide red with 2 green bands 3009 6010
20 DISUFIDE OIL (EX- Oxide red with 1 black band 3009 9005
MEROX)
21 M.T.0 Oxide red with 3 green bands 3009 6010
22 DHPPA Oxide red with 2 white bands 3009 9010
23 FLUSHING OIL Oxide red with 2 black bands 3009 9005
24 LAB FS Oxide red with 2 dark admiralty grey 3009 7012
bands
25 LAB RS Oxide red with 3 dark admiralty grey 3009 7012
bands
26 LAB (Off. Spec) Oxide red with 1 light grey band 3009 7035
27 N-PARAFFIN Oxide red with 1-blue band 3009 5013
28 HEAVY ALKYLATE Oxide red with red band 3009 3001
29 BLOW DOWN, VAPOR Off white / Aluminum with 1-Brown 9006 8004
LINE band
30 SLOWDOWN Off white / Aluminum with 2 brown 9006 8004
bands
31 A.T.F. Leaf brown with 1 white band 8003 9010
32 TOULENE Leaf brown with 1 yellow band 8003 1023
33 BENZENE Leaf brown with 1 green band 8003 6010
34 LAB PRODUCT Leaf brown with 1 blue band 8003 5013
35 FUEL OIL Black with 1 yellow band 9005 1023
Page 451 of 1296

ogegOfrae
liftENGINEERS NO. 6-79-0020
gaituw INDIA umn-ED FOR SURFACE PREPARATION
INIMMER1101MOR0 IA GOA d India Undedakingl AND PROTECTIVE COATING Rev. 0
PAGE 37 OF 59
36 FULE OIL (Aromatic rich) Black with 2 yellow bands 9005 1023
37 ASPHALT Black with 1 white band 9005 9010
38 SLOP AND WASTE OILS Black with 1 orange band 9005 2011
39 SLOP AROMATICS Black with 2 orange bands 9005 2011
CHEMICAL LINES
40 TRI-SODIUM PHOSPHATE Canary yellow with 1 violet band 1012 5000

41 CAUSTIC SODA Canary yellow with 1 black band 1012 9005
42 SODIUM CHLORIDE Canary yellow with 1 white band 1012 9010
43 AMMONIA Canary yellow with 1 blue band 1012 5013
44 CORROSION INHIBITOR Canary yellow with 1 Aluminum band 1012 9006
45 HEXAMETA PHOSPHATE Canary yellow with 2 black bands 1012 9005
46 ACID LINES Golden Yellow with 1 red band 1004 3001
47 RICH AMINE Canary yellow with 2 blue bands 1012 5013
48 LEAN AMINE Canary yellow with 3 blue bands 1012 5013
49 SOLVENT Canary yellow with 1 green band 1012 6010
50 LCS Canary yellow with 1 smoke grey 1012 7031
WATER LINES
51 RAW WATER Sky blue with 1 black band 5015 9005

52 INDUSTRIAL WATER Sky blue with 2 signal red band 5015 3001
53 TREATED WATER Sky blue with 1 oxide red band 5015 3009
54 DRINKING WATER Sky blue with 1 green band 5015 6010
55 COOLING WATER Sky blue with 1 light brown band 5015 1011
56 SERVICE WATER Sky blue with 1 signal red brown 5015 3001
57 TEMPERED WATER Sky blue with 2 green bands 5015 6010
58 DM WATER Sky blue with 1 aluminum band 5015 9006

59 DM WATER ABOVE 150°F Sky blue with 2 black bands 5015 9005
60 SOUR WATER Sky blue with 2 yellow bands 5015 1013

61 STRIPPED WATER Sky blue with 2 blue bands 5015 5013
62 ETP TREATED WATER Sky blue with 2 oxide red bands 5015 3009
FIRE PROTECTION SYSTEM (ABOVE GROUND)
63 FIRE WATER FOAM & Post office red 3002

EXTINGUISHERS
AIR & OTHER GAS LINES (UNINSULATED)
64 SERVICE MR Sea green with 1 signal red band 6018 3001

65 INSTRUMENT AIR Sea green with 1 black band 6018 9005
66 NITROGEN Sea green with 1 orange band 6018 2011
67 FREON Sea green with 1 yellow band 6018 1023
68 CHLORINE Canary yellow with 1 oxide band 1012 3009
69 SO2 Canary yellow with 2 white bands 1012 9010
70 H2S Orange with 2 red oxide bands 2011 3009
71 GAS (Fuel) Orange with 1 aluminum band 2011 9006
72 GAS (Sour) Orange with 2 aluminum bands 2011 9006
Page 452 of 1296

ogatimever
ol
gra14 ENGINEERS
NA UNITED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
1 4*Vi MeRnm agara) (AGutsneauncleilaking) AND PROTECTIVE COATING PAGE 38 OF 59
73 GAS (Sweet) Orange with 2 signal red band 2011 3001

74 HYDROGEN Orange with 1 light green band 2011 6021
STEAM AND CONDENSATE LINES (UNINSULATED)
75 HP STEAM Off white / Aluminum with 1 yellow band 9006 1023

76 MP STEAM Off white / Aluminum with 1 red band 9006 3001
77 MLP STEAM Off white / Aluminum with 1 orange band 9006 2011
78 LP STEAM Off white / Aluminum with 1 light green 9006 6021
band
79 CONDENSATE Sky blue with 1 white band 5015 9010
80 CONDENSATE ABOVE Sky blue with 3 oxide red band 5015 3009
150°F .
81 BFW Sky blue with 2 red bands 5015 3001
Note: For all insulated steam lines, the colour coding shall be follow as given for un insulated lines with the
specified length of color bands.
INSULATED HYDROCARBON PIPING
82 IFO SUPPLY 1Black ground colour with 1 yellow band

9
9005 1023
in centre
83 IFO RETURN Black ground colour with 1 green band in 9005 6010
centre
84 HPS Black ground colour with 1 red band in 9005 3001
centre
85 BITUMEN Black ground colour with 2 red bands in 9005 3001
centre
86 CLO Black ground colour with 1 brown band 9005 8004
in centre
87 VB TAR Black ground colour with 2 brown bands 9005 8004
in centre
88 VR AM (BITUMEN / VBU 1 Black ground colour with 1 blue band 9005 5013
FEED) in centre
89 VR BH 1 Black ground colour with 2 blue bands 9005 5013
in centre
90 VAC. SLOP 1 Black ground colour with 1 white band 9005 9010
in centre
91 SLOP 1 Black ground colour with 1 orange band 9005 2011
in centre
92 CRUDE SWEET 1 Dark admiralty grey ground colour with 7012 3001
1 red band in centre
93 CRUDE OUR 1 Dark admiralty grey ground colour with 7012 2011
1 orange band in centre
94 VGO / HCU 1 Oxide red ground colour with 2 steel 3009 7011
grey bands in centre
95 OHCU BOTOM / FCCU 1 Oxide red ground colour with 2 steel 3009 7011
FEED grey bands in centre
UNINSULATED EQUIPMENTS, TANKS AND STRUCTURES
96 HEATER STRUCTURE Steel grey 7011

97 HEATER CASING Heat resistant aluminium 9006
98 VESSELS & COLUMNS Aluminium 9006
Page 453 of 1296

15ilfraq t ENGINEERS
igeg Eveglief INDIA um iTED FOR SURFACE PREPARATION NO. 6-79-0020
INA/ 2ROWMACNI) IA Cal el India Undertaking) AND PROTECTIVE COATING Rev. 0
PAGE 39 OF 59
99 HYDROGEN BULLETS Pink 3014

100 LPG VESSELS Oxide red 3009
101 SO2 VESSEL Canary yellow 1012
102 HEAT EXCHANGER Heat resistant aluminium 9006
103 FO TANK AND HOT Black 9005
TANKS
104 ALL OTHER TANKS Aluminum / Off white 9006
105 CAUSTIC / AMINE / ACID Golden yellow 1004
TANKS
106 SOUR WATER Sky Blue 5015
107 OUTER SURFACE IN Heat resistant aluminum 9006
BOILER HOUSE
108 COMPRESSORS AND Dark admiralty grey 7012
BLOWERS
109 PUMPS Navy blue 5014
110 MOTORS & SWITCH GEAR Bluish green 5024
111 HAND RAILING Signal red 3001
112 STAIRCASE, LADDER Black 9005
AND WALKWAYS
113 LOAD LIFTING Leaf brown 8003
EQUIPMENT AND
MONORAILS ETC
114 GENERAL STRUCTURE Black 9005
PIPES AND FITTINGS OF ALLOY STEEL AND SS MATERIAL IN STORE
115 IBR Signal red 3001

116 9Cr-lMo Verdigris green 6021
117 5Cr-0.5Mo Satin blue 5012
118 2 1,4 Cr-1 Mo Aircraft yellow 1026
119 1,,4Cr- 1/2 Mo Traffic Yellow 1023
120 SS-304 Dark blue grey 5008
121 SS-316 Dark violet 4005
122 SS-321 Navy blue 5014
SAFETY COLOUR SCHEMES
123 DANGEROUS Black and alert orange band 9005 2008

OBSTRUCTION
124 DANGEROUS OR Alert orange 2008
EXPOSED PARTS OF
MACHINERY
Note: All LPG service PSVs shall be painted Deep Blue.
All drains & Vents shall be painted in Main line colour.

The colour code scheme is for identification of piping service group, It consists of a ground
colour and 1 / 2 colour bands.
19.2 Ground Colour

On uninsulated pipes, the entire pipe has to be painted in ground colour., and on metal cladded
insulated lines, minimum 2M long portion should be painted.
Page 454 of 1296

el ENGNERS NO. 6-79-0020
lazir faiatowNDIAumn-ED FOR SURFACE PREPARATION
O
7R W ,a MOM g
IA God d Ada Undertakin / AND PROTECTIVE COATING Rev. 0
PAGE 40 OF 59
19.3 Colour Bands

Location of colour bands:
At Battery Limits
Intersection points & change of direction points in piping
Midway of piping section, near valves, across culverts
At 50 M interval on long stretch pipes
At starting and termination points.
Minimum width:
NB Width
3" and below 75 mm
Above 3" to 6" NB X 25 MM II! Note:
Above 6" to 12" NB X 18 MM For insulated pipes, NB indicates
Above 12" NB X 15 MM OD of the insulation
Sequence :
Colour bands shall be arranged in sequence showing Table above and the sequence follows the
direction of flow. The width of the l st Band to 2nd band is 4:1,
!!! Note : Wherever deemed required by Process Department or Safety, pipes handling hazardous
substances will be given hazard marking of 30 mm wide diagonal stripes of Black and Golden Yellow
as per IS : 2379.
19.4 Special Camouflage Painting for Uninsulated Crude and Product Storage Tanks.
Paint specification shall be as per standards.
Camouflage painting scheme for Defense requirement in irregular patches will be applied with
3 colours
Dark Green Light green Medium Brown

5 3 2
The patches shall be irregular and asymmetrical and inclined at 30 to 60 Degrees.
Patches should be continuous at surface meeting lines / points.
Slits / holes shall be painted in dark green shade.
Width of patches shall be 1 to 2 meters.
19.5 Identification Markings on Equipment / Piping
Equipment tag Numbers shall be Stenciled / neatly painted using normal 'Arial' Lettering
Style on all equipment and piping (Both insulated & uninsulated) after completion of all paint
works. Lettering colour shall be either BLACK or WHITE, depending upon the background,
so as to obtain good contrast.
Page 455 of 1296

02zieLft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
NO. 6-79-0020
-
IgZIT gate* WA LIMITED FOR SURFACE PREPARATION

IMEAMIIInM 3AIFAI IA GoN d India Undeoliongl AND PROTECTIVE COATING Rev. 0
PAGE 41 OF 59
Operations Group shall specify location.
Sizes shall be:

Columns, Vessels, Heaters: 150 mm
Pumps and other M/c 50 mm
Piping OD / 2 with Maximum 100 MM.
Storage Tanks (As per Drawings)
19.6. Colour Coding for Control Valve
Carbon steel body - Light grey
Alloy steel body - Canary yellow
Stainless steel body - Natural
The actuator of the Control valve shall be painted as :
Direct action (open on air failure) valves - Green
Reverse acting (close on air failure 1 valves - Red
The painting Status shall be comprehensively updated every 6 months for compliance
19.7 Colour Coding for Structural & Others
SI Item Color Indicative

No
1 Pipe rack structurals Dark Admiraltry Grey
2 Chequered Plate ( Both faces) Black
3 Grating Black
4 Ladder Rungs & Railing Vertical Posts Black
5 Hand Rail, Middle rail, Toe Plate Signal Red
6 Ladder Verital Posts Signal Red
7 Building Structurals, Steel Columns; brackets,
beams, bracings, roof trusses, purlings, side Dark Admiratry Grey
girts, louvers, stringers
8 OverHead Monorail Signal Red
9 Gantry Girder & Monorail Dark Green
10 Monorail Stopper Plates Signal Red.
11 Coke Cutting System Signal red
12 EOT / HOT Cranes Canary Yellow
13 Transformers, & Battery room structurals Dark Admiraltry Grey
14 Electrical Motors Dark Blue
Page 456 of 1296

OWES ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
Sga €10e3W INDIA LIMITED
a
Rev. 0
PRA panne an) IA Govt Crl hda Undertakng ) AND PROTECTIVE COATING PAGE 42 OF 59
20.0 IDENTIFICATION OF VESSELS, PIPING ETC
20.1 Equipment number shall be stencilled in black or white on each vessel, column, equipment &
machinery (insulated or uninsulated) after painting. Line number in black or white shall be
stencilled on all the pipe lines of more than one location as directed by Engineer-In-Charge;
Size of letter printed shall be as below:
Column & Vessels 150mm (high)

Pump, compressor & other machinery 50mm (high)
Piping 40-150 mm
20.2 Identification of Storage Tanks
The storage tanks shall be marked as detailed in the drawing.
21.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
21.1 Following items shall be painted for camouflaging if required by the client.
All Columns
All tanks in Offsites
Large Vessels
Spheres
21.2 Two coats of selected finishing paint as per defense requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
21.3 Method of Camouflaging
21.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all
matte finish).
Dark Green Light Green Dark Medium Brown

5 3 2
21.3.2 The patches should be asymmetrical and irregular.
21.3.3 The patches should be inclined at 30° to 60° to the horizontal.
21.3.4 The patches should be continuous where two surfaces meet at an angle.
21.3.5 The patches should not coincide with corners.
21.3.6 Slits and holes shall be painted in dark shades.
21.3.7 Width of patches should be 1 to 2 meters.
22.0 QUALITY CONTROL, INSPECTION AND TESTING
22.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and shall be
Page 457 of 1296

OPzEtt, ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
NO. 6-79-0020
laatuilir INDIA UMITED
1142710IROW WWI/ IA Gait pi India Uadettiong)
AND PROTECTIVE COATING Rev. 0
PAGE 43 OF 59
accompanied by manufacturer's test certificates. Paint formulations without certificates are

not acceptable (see section 24.0).
22.2 The contractor must produce Test Certificate from Pre Qualified Paint Manufacturer for
various tests as detailed out in section 25.1 of this document, for each batch & for each
category of product. The Engineer-in-Charge shall have the right to test wet samples of paint
from each batch at random for verifying quality of paint supplied. Contractor shall arrange to
have such tests, when called for by Engineer-in-Charge, performed at his cost any one of the
independent laboratories listed in the 25.1 of this document.
Samples for the test will be drawn at random in presence Engineer-in-Charge or his
representations. Following tests to be carried out if called for by Engineer-in-Charge:
Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
Drying time (touch dry & full curing)
- Adhesion
Flexibility
- Hardness
Storage stability (pot life)
Test methods for above tests shall be as per relevant ASTM or ISO Standard.
22.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as follows:
Surface preparation
Primer application
(c) Each coat of paint
During surface preparation, following tests are to be carried out:
Test for absence oil & grease after degreasing before blasting as per procedure given in
sec 6.7 of Annexure-I of this specification (specification for thermally sprayed
Aluminium Coating).
Tests for surface finish of blasted surface shall be done by visual inspection using SSPC-
VISI. Clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of
dust on blasted surface. Checks shall be done on each component atleast once per 200 m2
of blasted surface and minimum of 3 checks per shift.
Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt
content shall be considered 20 mg/m 2 (2 mg/cm 2). Checks shall be done on each
component atleast once per 200 m2 of blasted surface and minimum of 3 checks per shift.
In case salt exceeds specified limit, the contaminated surface shall be cleaned by method
as per Annexure-C of IS 12944-4 (water cleaning). After cleaning surface shall be
retested for salt after drying.
Blast profile measurement — This shall be done as described in sec 6.2 of Annexure-I of
this specification (Specification for thermally sprayed Aluminium).
Test for blasting Media and Blasting air- this shall be done as described in sec 6.6 of
Annexure-I of this specification (Specification for thermally sprayed Aluminium).
Page 458 of 1296

w ENGINEERS
161daelela,
Ogzir tapeg NDR FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
Mien FIRM WWI) LID
IA Gad of Nu Uncle/01V AND PROTECTIVE COATING PAGE 44 OF 59
In addition to above, record should include type of shop primer already applied on equipment
e.g. zinc silicate, or zinc rich epoxy, or zinc phosphate.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be responsible
for making good any defects found during final inspection/guarantee period/defect liability
period as defined in general condition of contract. Dry film thickness (DFT) shall be checked
and recorded after application of each coat and extra coat of paint should be applied to make-
up the DFT specified without any extra cost to owner, the extra coat should have prior
approval of Engineer-in-charge.
22.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
22.5 The shades of successive coats should be slightly different in colour in order to ensure
application of individual coats, the thickness of each coat and complete coverage should be
checked as per provision of this specification. This should be approved by Engineer-In-
Charge before application of successive coats.
22.6 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required for
checking in case of immersion conditions.
22.7 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The thickness of
paint on test panels shall be determined by using gauge such as 'Elkometer'. The thickness of
each coat shall be checked as per provision of this specification. This shall be approved by
Engineer-In-Charge before application of paints on surface of chimney.
22.8 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and without
any obligation to the owner, as it would be in the interest of the manufacturer to ensure that
both surface preparation and application are carried out as per their recommendations. The
contractor is responsible to arrange the same.
22.9 Final inspection of finished coating shall consist of measurement of:

Paint dry film thickness (DFT),
Adhesion, and,
3) Holiday detection check as well as for finish and workmanship.
1) Coating DFT measurement shall be as per ISO 2808. Type II electromagnetic gauges
should be used for ferrous substrates. DFT gauge calibration, number of measurement
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — M rights reserved
Page 459 of 1296

agraes STANDARD SPECIFICATION STANDARD SPECIFICATION
ENGINEERS NO. 6-79-0020
azit ta5tegWV INDIA LIMITED FOR SURFACE PREPARATION
ilMweg awo (A GM of Inda Undertalcmg) AND PROTECTIVE COATING Rev. 0
PAGE 45 OF 59
shall be as per SSPC-DA 2. Measured DFT shall be within + 10% of the dry film
thickness, specified in the specifications.
Adhesion of the primer to the steel substrate and intercoat adhesion of the subsequent
coat(s) after curing for at least a week after application of the topcoat shall be examined by
a knife test in accordance with ASTM D 6677. For the knife test, if the rating is better than
8, the adhesion is considered acceptable. The adhesion is destructive and tested areas shall
be repaired afterward using the spot repair procedure. Alternatively, the applicator may
perform the adhesion test on a steel coupon coated using the same surface preparation and
coating application procedure as the work piece. Adhesion testing shall be carried out for
each component at least once per 200 m2 (2000 ft2) of coated surface.
Holiday testing shall be conducted in accordance with NACE SP 0188. For immersion
services, 100% of coated area shall be inspected for holidays. For atmospheric exposure,
10% of coated area which must include weld seams, corners and edges to be holiday
tested. Voltage at which test is to be carried out will depend upon DFT of coating being
tested and shall be as per NACE SP 0188. Any holiday is unacceptable and should be
marked and repaired immediately.
22.10 The contractor shall arrange for spot checking of paint materials for Specific gravity, glow
time (ford cup) and spreading rate.
22.11 Final Inspection of coating system
A final inspection shall be conducted prior to the acceptance of the work. The coating
contractor and the facility owner shall both be present and they shall sign an agreed inspection
report. Such reports shall include:
General
Names of the coating contractor and the responsible personnel
Dates when work was performed
Coating Materials
- Information on coating materials being applied
- Condition of coating materials received
Environmental Conditions
- Weather and ambient conditions
- Coating periods
Surface Preparation
Condition of surface before preparation
Tools and methods used to prepare surface
Condition of surface after preparation
Coating Application
- Equipment used
- Mixing procedure prior to application
- Coating application techniques used
Page 460 of 1296

15i1frita ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
V_IF INDIA UNITED Rev. 0
le FROWCPWO (A Gpi of Irda usertakm9) AND PROTECTIVE COATING
PAGE 46 OF 59
Testing
Type and calibration of inspection instruments used
Type of quality control tests performed, and results
23.0 GUARANTEE
23.1 The contractor shall guarantee that the chemical and physical properties of paint materials used
are in accordance with the specifications contained herein/to be provided during execution of
work.
24.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR
Painting contractor who is awarded any job for EL, Projects under this standard must have
necessary equipments, machinery, tools and tackles for surface preparation, paint application
and inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor supervisor, inspector,
surface preparator and paint applicator must be conversant with the standards referred in this
specification.
25.0 QUALIFICATION/ACCEPTANCE CRITERIA FOR PAINT COATING SYSTEM
25.1 Pre-Qualification of Paint Coating Manufacturer and his Products
Paint Coating manufacture meeting the following requirements shall be considered for supply
of their products. Contractor is advised to select coating manufacturer. Only after obtaining
prequalification from EL for the manufacturer based on following requirements. Even those
manufacturers, whose names are appearing elsewhere in the tender document, under the list of
"EIL's Recommended or Approved Vendors", will also be required to meet the following
prequalification requirements.
Manufacturer should have been in continuous business of paint coating formulation and
manufacturer for at least past 5 years.
Manufacturer should posses past experience of supplying his products to hydrocarbon

processing industry or offshore platforms in the past 5 years.
- Coating manufacturer should have supplied at least 10000 litre of an individual product
to hydrocarbon processing industry or offshore platform.
The manufacturer's manufacturing procedure & QA/QC system shall meet ISO 9001
requirements and preferably should posses ISO 14000 certificate.
The Quality control set up should be manned by qualified paint technologists whose bio
data should be sent along with quality control organization chart.
Pre-Qualification Testing:
Manufacturer should have got his products tested at least one time in last 3 years at a
reputed independent laboratory for the following test items. Test certificates which are
more than 3 years old will not be considered.
Page 461 of 1296

OFEET STANDARD SPECIFICATION STANDARD SPECIFICATION
ENONEERS NO. 6-79-0020
Iariaffleg41, INDIA UNITED FOR SURFACE PREPARATION
iwnewa.mgarm IA Gart Inda Undertaar0 AND PROTECTIVE COATING Rev. 0
PAGE 47 OF 59
Test Test Method

Specific gravity ASTM D 1475
Dipping properties ASTM D 823
Film characteristics -
Solids content by weight ASTM D 2369
Drying time ASTM D 1640
Flexibility ASTM D 1737/ D 522
Hardness ASTM D 3363
Adhesion ASTM D 2197
Abrasion resistance ASTM D 968/ D 1044
DFT/coat As per SSPC guidelines
Storage Stability ASTM D 1849
Resistance to moisture vapour permeability for 2000 hrs ASTM D 2247
Cyclic Test for the duration of 4200 h (25 cycles a 168 ISO 7253, ASTM G53
hours)
% Zn in Dry film for Inorganic Zinc -
Silicate primer
Chemical Resistance test ASTM D 543
- 10% & 40% NaOH (applicable only for F-6 & F-15)
- 10% H2SO4 (applicable only for F-6 & F-15)
- 10 % Nitric Acid test (applicable only for F-6 & F-15)
- Benzene / Toluene (applicable only for F-6 & F-15)
- Kerosene (applicable only for F-6 & F-15)
- Sea water (applicable only for F-6 & F-15)
- MIBK test (applicable only for F-6 & F-15)
Resistance to water using water immersion (applicable ASTM D 870
only for F6-, F-7, F-8, F-14 & F-15)
Dry Heat Resistance test
(applicable only for F-9, F-6A/B, F-2, F-15, F-16,
polysiloxane, heat resistance Al silicone)
Thermal shock resistance test ASTM D2485 - 91
(only for F-9, F-6, polysiloxane)
Each coating product to be qualified shall be identified by the following
An infrared scan (fingerprint), for Part A and B, each component as per ASTM
D 2621
Specific gravity of Base and curing agent (Ref. ISO 2811)
3) Ash content (ASTM D1650), volatile and non-volatile matters (ISO 3251) of each
component
The identification shall be carried out on the batch, which is used for the Pre-
qualification testing. Pre-qualification of the products shall be carried out at an
independent laboratory.
Test shall be carried out at any one of the following laboratories and tests to be witnessed &
certified by third party inspection agency (TUV, BV, DNV).
Page 462 of 1296

000:eftENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
siges eg W: WA LIMITED
Rev. 0
men eeteRtel3AARI (A God d( Undell/A1A) AND PROTECTIVE COATING PAGE 48 OF 59
IICT, Hyderabad
HBTI, Kanpur
DMSRDE, Kanpur
BIS Laboratories
UICT, Matunga, Mumbai
RITES, Kolkata
PDIL, Sindri
NTH, Kolkata
Contractor shall furnish to EIL for approval/ acceptance of all necessary

documents/information including test certificates to prove that the paint manufacturers, from
whom he intends to procure paint products, meet the various requirements for fulfilling the
pre-qualification criteria as given under section 25.1 above. The paint manufacturer shall be
qualified and approved for supply after review/assessment of the submission made by the
contractor.
25.2 Information to be furnished during delivery of coating system:
Contractor along with delivery of paint material has to furnish following information from
paint manufacturer to EIL for acceptance/approval of products.
Batch test certificates (Batch Testing)
Along with delivery to site of the paint products from pre-qualified coating manufacturer.
Contractor has to produce test certificate from paint manufacturer for each batch and for
each category of product for the following test items. Test to be witnessed & certified
by third party inspection agency. All test results must mention clearly the batch no. and
category of product tested. Tests to be conducted for following properties:
Infrared scan for Part A and B, each component

- Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
Product information sheet/ technical data sheet for each category of product.
26.0 METHOD OF SAMPLING & DISPATCH FOR LABORATORY TESTING

(Pre-Qualification tests (sec. 25.1), Batch testing (sec. 25.2) and Inspection testing (sec.
22.0))
26.1 Samples of coating materials should be submitted to the Govt. laboratory in sealed containers
with batch no. and test certificate on regular format of manufacturer's testing laboratory. The
sampling shall be certified and sealed by a certifying agency.
26.2 All test panels should be prepared by Govt. testing agency coloured photographs of test
panels should be taken before and after the test and should be enclosed along with test report.
Sample batch no. and manufacturer's test certificate should be enclosed along with the
report. Test report must contain details of observation and rusting if any, as per the testing
code.
Page 463 of 1296

Oftieta ENGINEERS
Tif Ell5leg4TV WA LIMITED Rev. 0
Mien a21017 ./L7RIM IA GM of India Undeddimal AND PROTECTIVE COATING PAGE 49 OF 59
26.3 Manufacturers should intimate the company, details of sample submitted for testing, name of
Govt. testing agency, date, contact personnel of the govt. testing agency. At the end of the
test the manufacturer should submit the test reports to the company for approval.
26.4 Coating systems for panel test shall be decided after discussion with EIL
Page 464 of 1296

151Rat ENGINEERS
71E1071ft%, INDIA LIMITED
NO. 6-79-0020
11;4 Rev. 0
MM.'MOWS° g
IA GM India Underlim ) AND PROTECTIVE COATING PAGE 50 OF 59
ANNEXURE-I
SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM (TSA) COATING
1.0 SCOPE
The following sections outlines the requirement of supply, application and testing of thermally
sprayed aluminum coatings (TSAC) for corrosion protection of insulated carbon steel piping
and equipments with design temperature not exceeding 540 ° C.
2.0 ITEMS TO BE THERMALLY SPRAYED
Steel Structures/equipments to be protected by TSAC shall be as per Tables 15.0 of this

standard specification. Structures, components thermally sprayed shall not have any uncoated
area or shall not be in mechanically connected by flanges etc to any uncoated bare steel work.
Such adjacent areas to TSA coated areas, if not coated by TSA shall have suitable paint
coating system as per the standard specification.
3.0 TSAC REQUIREMENTS
3.1 Surface Preparation
All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and
grease after degreasing shall be tested by method given elsewhere in the specification (Refer
Sec. 6.7). Thereafter the surface to be abrasive blasted to white metal finish as per NACE
1/SSPC-SP 5 for marine and immersion service. Using SSPC VIS 1, it is to be visually
assessed that the blast cleaned surface meets requirement of SSPC-SP 5. Thereafter clear
cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust on the blasted
surface Finally blasted surface shall be tested for presence of soluble salts as per method ISO
8502-9. Maximum allowable salt content shall be considered 50mg/m 2 . (5 micrograms/cm2)
.In case salt content exceeds specified limit. The contaminated surface shall be cleaned by
method as per Annex C of IS 12944-4 (Water Cleaning). After cleaning the surface shall be
retested for salt content after drying. Testing shall be carried out at least on each component,
once per 200 m2 and a min of 3 times per shift during progress of work.
The blasting media shall be either chilled iron or angular steel grit as per SSPC-AB-3 of mesh
size G-16 to G-40. Copper, Nickel slag, Garnet or Aluminum Oxide as abrasives will also be
suitable having mesh size in the range of G16 to G24 (10-30 mesh), conforming to SSPC-AB-
1. Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and
blasting equipment used. The blasted surface should be having angular profile depth not less
than 65 microns with sharp angular shape but shall not exceed 85 microns. The profile depth
shall be measured according to NACE standard RP 0287 (Replica Tape) or ASTM D 4417
method B (Profile depth gauge).
For manual blasting one profile depth measurement shall be taken every 10-20 m 2 of blasted
surface.
Surface preparation shall be completed in one abrasive blast cleaning operation wherever
possible.
Page 465 of 1296

agraift ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
$1g a fifReall INDIA UNITED Rev. 0
(NMI MIRMIARI/ (A Gout al lita Underlakin3) AND PROTECTIVE COATING PAGE 51 OF 59
If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal
spraying, the affected area shall be reblasted to achieve specified degree of cleanliness after
which only thermal spraying shall commence.
Air blasting pressure at nozzle shall be normally maintained at 100 psi. Air pressure and
media size should be reduced and adjusted to preclude damage/distortion to thin gauge
materials. Blasting time on work piece should be adjusted to only clean the surface and cut
required anchor tooth with minimum loss of metal. Blast angle should be as close to
perpendicular as possible but in no case greater than ± 30 ° from perpendicular to work
surface. Blasting media must be free of debris, excessive fines, and contaminants such as
NaCI and sulfur salts (Ref. SEC 6.0 of this Spec). Blast cleaning shall not be performed when
the surfaces to be blasted are wet or less than 5°C above dew point temperature or when the
relative humidity in the vicnicity of the work is greater than 90%.
3.1.1 Blasting Equipment
The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning
equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall be
used to validate clean and dry air.
3.1.2 Feed Stock
The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminum of
commercial purity grade, its composition shall be in accordance with requirement of BS 1475
or ASTM B833 or ISO 209-1 type Al (wrought aluminum and aluminum alloys, wire). Wire
shall be supplied in protective wrapping indicating batch number and other details.
3.1.3 Thickness Requirement
The nominal thickness of finished TSAC shall be 250 microns having minimum value of 225
microns at low thickness areas (valleys) and not more than 275 microns at peak areas.
The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge
(Magnetic Gauge).
3.1.4 Coating Bond Strength Requirement
The TSAC coating shall have a minimum individual tensile-bond strength value of 1000 psi
for flame sprayed and 1500 psi for arc sprayed coating with an average of 2000 psi for arc
sprayed coatings. Minimum tensile bond strength should be achieved by proper anchor tooth
profile of blasted surface, laying down the TSA thickness in multiple passes and carrying out
TSA application under controlled environment
3.1.5 Porosity
All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum
coatings porosity shall not exceed 15% of total surface area for flame sprayed coating and 8%
for arc spray coating.
Page 466 of 1296

lafteleENIONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
es iiptew INDI A umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
(MRPI FRaRVINJWMil IA GO. Dna Wean) AND PROTECTIVE COATING Rev. 0
PAGE 52 OF 59
4.0 THERMAL SPRAY APPLICATION PROCEDURE
Items in the atmospheric zone to be coated by TSA shall be applied by either Flame
spray or Arc spray method only. For coating under insulation, application shall be by
arc wire method.
4.1 Equipment Set Up
4.1.1 Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer
instructions/technical manuals and also TSAC applicators refinement thereto and (2) as
validated by Procedure Qualification (Sec 7.0 of this specification).
4.1.2 Spray Parameters
Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall
be validated with bend test (See 6.5 of this Spec).
4.1.3 Spray Parameters
Spray Parameters Method of Application

Arc wire Spray Flame Wire Spray
Arc voltage 27 V -
Air pressure 80 psi 80 psi
NACE-1 white metal /
Steel surface cleanliness NACE-1 white metal
or Near white metal
Steel surface profile 75 microns (minimum) 75 microns (min.)
Arc current 250-280A -
Coating thickness 225 microns (nominal) 225 microns(Nominal)
Coating adhesion > 1500 psi (Total coating),see 3.1.4 >1000 psi
Coating porosity Less than 8% Less than 15%.
Spray distance (spray Gun 5-7"
6-8"
work piece)
Spray Pass width 40mm 20 mm
The above parameters to be validated with a bend test by the contractor before start of work
(for details of bend test see Sec 6.5 of this Spec).
4.2 Post Blasting Substrate Condition and Thermal Spraying Period.
4.2.1 The steel surface temperature shall be at least 5°C above dew point of ambient air temperature.
Steel substrate surface temperature shall be recorded by with a contact pyrometer.

Thermal spraying should commence within 15 minutes from the time of completion of blasting
4.2.2 Holding Period
Time between the completion of final anchor tooth blasting and completion of thermal
spraying of blasted surface should be no more than four hours. If within this period rust bloom
appears Sec 4.4.1of this specification will apply.
Format No. 8-00.0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 467 of 1296

az
dzieft ENGINEERS NO. 6-79-0020
1&11€151erilV INDIA LIMITED FOR SURFACE PREPARATION
imerreRaRtitM11711 IA Gat al InCia UNIeltaking) AND PROTECTIVE COATING Rev. 0
PAGE 53 OF 59
4.3 Pre-Heating
For flame spraying, the initial starting area of 1-2 square feet to be preheated to approx.120°C
to prevent condensation of moisture in the flame on the substrate. For arc spraying the
preheating is not required.
4.4 Thermal Spraying
Spraying should commence only after validation of equipment set up by procedure

qualification test and spray parameter validation tests described in Sec 7.0 and 6.5
respectively. Thermal spraying must commence within 15 minutes from the time of
completion of blast cleaning
The specified coating thickness shall be applied in several crossing passes. The coating bond
strength is greater when the spray passes are kept thin. Laying down an excessively thick spray
pass increases the internal stresses in TSAC and decreases the bond strength of total TSAC.
The suitable thickness for crossing passes shall be determined by procedure qualification test
described in Sec 7.0 of this specification.
For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin
spots in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.
The surface geometry of the item or area to be sprayed should be inspected before application.
The spraying pass and sequence shall be planned according to following.
Maintain Gun as close to perpendicular as possible and within ± 30° from perpendicular to
the substrate.
Maintain nominal standoff distance and spray pass width as given below:
Spray pass width

Spray method Standoff (Inches)
(Inches)
Arc Wire 6-8 1 'A( 40mm )
Flame wire 5-7 %( 20mm )
4.4.1 Rust Bloom (Visual appearance of rust or Discoloration)
If Rust bloom appears on the blasted surface before thermal spraying, the affected area shall be
reblasted to achieve the specified level of cleanliness.
If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at any
time during application of TSAC, then spraying shall be stopped and acceptable sprayed area
shall be marked off. The unsatisfactory areas shall be repaired to the required degree of surface
cleanliness and profile.
Blast the edges of the TSAC to provide for 2-3" feathered area overlap of the new work into
existing TSAC.
Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the extent
of feathered edge so that overlap is a consistent thickness.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell. —AI rights reserved
Page 468 of 1296

latazidie ENGINEERS FOR SURFACE PREPARATION
NO. 6-79-0020
sigtaReW INDIA LIMITED Rev. 0
2174WZAJWIRD .
(A Go .4 Inda Undedalungl AND PROTECTIVE COATING PAGE 54 OF 59
4.4.2 Masking
Masking all those parts and surfaces which are not required to be thermally sprayed as
instructed by purchaser should be inspected by applicator to ensure that they are properly
marked and covered by purchaser.
Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator to

minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to substrate
distance and spray angle).
4.4.3 TSAC Finish
The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed steel
as examined with 10 X magnification.
5.0 SEALER
Sealant shall be applied after satisfactory application of TSAC and completion of all testing
and measurements of the finished TSAC as per Sec 6.0 of this specification.
For shop workSealer shall be applied immediately after thermal spraying and for field work
sealer shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the
body of TSAC.
The sealant shall be Silicone Alkyd Aluminium paint having DFT not more than 35-40 micron.
Typically seal coat shall be applied at a spreading rate resulting in theoretical 38 microns DFT.
The seal coat shall be applied in accordance with SSPC-PA 1 and the paint manufacturer
instruction for sealing.
6.0 TESTING AND MEASUREMENT SCHEDULE
6.1 Surface Finish
That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5) shall be
visually inspected using SSPC-VIS 1. The clear cellophane-tape test as per ISO 8502-3 shall
be used to confirm absence of dust or foreign debris on the cleaned surface. Checks shall be
done on each component at least once per 200 m2 of blasted surface and minimum of 3 checks
per shift.
6.2 Blast Profile Measurement: (In-Process testing during actual production before application
of TSA coating)
The angular profile depth measurement shall be done by profile tape as per method NACE
Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot
measurement shall be carried out every 15m 2 of blasted surface. At each spot three
measurements shall be taken over an area of 10 cm 2 and average of measurements to be
recorded and reported.
If profile is <65 microns blasting shall continue till grater than 65 microns depth profile is
achieved.
Page 469 of 1296

Oftela ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
felliteCe INDIA LIMITED Rev. 0
awn maw nem) (A Gem al inda Underlikog AND PROTECTIVE COATING PAGE 55 OF 59
6.3 TSAC Thickness (In-Process Testing For finished coating during regular production)
6.3.1 TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.
6.3.2 For flat surfaces, measurements shall be taken along a straight measurement line, one
measurement line for every 15 m2 of applied TSAC shall be selected along which 5
measurements to be taken at 25 mm internal and average to be reported.
6.3.3 For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring
10 cm2 in area. One spot to be taken for every 15 m2 of applied TSAC area.
6.3.4 The TSAC thickness in surface changes or contour changes, welds and attachments shall be
also measured and reported.
6.3.5 If TSAC is less than specified minimum thickness, apply additional TSAC until specified
thickness range is achieved.
6.3.6 All locations and values of TSAC thickness measurements shall be recorded in Job Record
(JR).
6.4 Tensile Bond Testing (In-Process testing for finished coating during regular production)
Tensile Bond strength of the TSAC finish coat shall be determined according to
ASTM D 4541 using a self-aligning adhesion tester.
One measurement shall be made every 50 m2. If tensile bond at any individual spot
is less than 1000 psi for flame sprayed coating and 1500 psi for arc sprayed coating
the degraded TSAC shall completely removed and reapplied.
The tensile bond portable test instrument to be calibrated according to ASTM C 633
6.5 Bend Tests
Bend test shall be carried out at beginning of each work shift. Bend tests shall also be
conducted on sample coupons before start of thermal spraying work to qualify the following as
mentioned earlier in this specification.
To qualify spray parameters and thickness of each crossing pass.
6.5.1 Test Procedure
Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm

thk. to be prepared.
Surface shall be prepared by dry abrasive blast cleaning as per this specification.
TSAC shall be applied as per specified thickness range. TSAC should be sprayed in
crossing passes laying down approx. 75-100 microns in each pass.
TSAC applied coupons shall be bent 180 ° around a 13 mm diameter mandrel.
Page 470 of 1296

g,, STANDARD SPECIFICATION STANDARD SPECIFICATION
(gal etiregw ENGINEERS
INDIA LMTED FOR SURFACE PREPARATION NO. 6-79-0020
1411MeRePWW) IA Govt al India Undertiong) AND PROTECTIVE COATING Rev. 0
PAGE 56 OF 59
e) Bend test shall be considered passed if on bend radius there is
- No cracking or spalling or lifting by a knife blade from the substrate

- Only minor cracking that cannot be lifted from substrate with a knife blade.
Bend test fails if coating cracks with lifting from substrate.
6.6 Tests for blasting media, blasting air
6.6.1 Blasting Media (For every fresh batch of media and one random test during blasting)
Blasting Media shall be visually inspected for absence of contamination and debris using 10 X
magnification.
Inspection for the absence of oil contamination shall be conducted using following
procedure :
Fill a small clean 200 ml bottle half full of abrasive.
Fill the bottle with potable water, cap and shake the bottle.
Inspect water for oil film/slick. If present, the blasting media is not to be used.
Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If

present, media to be replaced.
c) Clean blasting equipment, especially pot and hoses, and then replace blasting media
and retest.
6.6.2 Test for Blasting Air (Once Daily before start of blasting and once at random during blasting)
The air for blasting shall be free from moisture and oil. The compressor air shall be checked
for oil and water contamination per ASTM D 4285.
6.7 Test for presence of oil/grease and contamination
The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following
procedure to validate absence of oil and grease contamination.
Visual inspection - Continue degreasing until all visible signs of contamination are removed.
Conduct a solvent evaporation test by applying several drops or a small splash of residue-free
trichloromethane on the suspect area especially pitting, crevice corrosion areas or depressed
areas. An evaporation ring formation is indicative of oil and grease contamination.
Continue degreasing and inspection till test is passed.
7.0 TSAC APPLICATOR QUALIFICATION
Following tests to be carried out as part of procedure qualification test for the applicator.
Thickness measurement
Coating bond strength
Porosity test
Page 471 of 1296

loi
rif&JelitENIGINERS
gtIf WegNEW INDIA LIMITED Rev. 0
MDR [111,3M11/ IA Gael d hdia Underlain)) AND PROTECTIVE COATING PAGE 57 OF 59
Bend strength
TSAC applicator's surface finishing and application process and equipment set up, calibration
and operation shall be qualified by application of TSA on a reference sample which shall be
used as a comparator to evaluate the suitability of application process. Only that applicator will
be permitted to carry out the work when test specimens coated by the applicator meets the
desired requirements as cited below.
The sample shall be made of a steel plate measuring approx. 18"x 18" x Vo" thick. If the actual
work is less than 1/4" thick then the sample to be made from material of representative
thickness.
The surface preparation, TSAC application shall be made with actual field equipments and
process/spray parameters and procedures as per the specification. The depth profile of blasted
surface, TSAC coating thickness for each cross pass and total thickness range shall be as per
specification.
The surface preparation and thermal spraying shall be carried out in representative
environmental conditions spraying with makeshift enclosure.
7.1 After application of coating, thickness and tensile bond measurements shall be made in
following manner.
Divide the sample piece into four quadrants.
Measure thickness along the diagonal line of each quadrant.
Four each quadrant five in-line thickness measurements at 1" interval shall be done
using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four "five in line"
thickness measurements to be done for the whole sample.
One tensile bond measurement using ASTM D 4541 type III or IV portable self
aligning test instrument to be done at centre of each quadrant. Total of 4 measurements
for the sample.
One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be
prepared for Metallographic examination as per ASTM E — 3.
The procedure shall be considered qualified if thickness and tensile-bond strength and
porosity values meet the specification requirement.
7.2 Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification.
Applicators thermal spray equipment set-up, operation and procedure of application including
in-process QC checkpoints adopted during procedure qualification as described above should
be always subsequently followed during entire duration of work.
8.0 DOCUMENTATION
The following information shall be provided by TSAC applicator before award of work.
Page 472 of 1296

S ilOzeift ENONEERS
f
NO. 6-79-0020
gaf 215leg e INDIA WAITED
li ir
Rev. 0
1411PMFIRFROMPI) IA &vet Incha Undertaang/
AND PROTECTIVE COATING PAGE 58 OF 59
TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.
Detailed application procedure and in-process quality control check points for (a)
surface preparation (b) thermal spraying (c) seal coats.
Type and specification of instruments to be deployed for measurement of blast profile

depth, TSAC thickness and tensile bond.
Paint manufacturer data sheet for the selected sealing coat to be applied.
9.0 RECORDS
The TSAC applicator shall maintain job record to record production and QC
information. All the results of the tests and quality control checks shall be entered in
the record for each component/part thermally sprayed. All the result of tests
(thickness, tensile bond, bend tests) and other validation tests (e.g. procedure
qualification test, test for surface cleanliness after abrasive blasting, test for
cleanliness of abrasives and air) shall also be recorded and duly signed by owner.
All the information mentioned in Sec 8.0 above should also form part of the Job
record.
Any modification affected after procedure qualification in the procedure, QC, spray
parameter, equipment spec to the original information (submitted before award of the
work) must also form part of Job record.
10.0 WARRANTY
The TSAC applicator shall warrant the quality of material used by providing the purchaser
with a certificate of materials used to include
Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical
analysis, name of supplier, manufacturer.
Sealant: Name of manufacturer, application data sheet.
11.0 SAFETY
The TSAC applicator shall follow all safety procedures required by the purchaser/owner.
Owner shall also give compliance requirement to be followed by applicator. The applicator
shall follow all appropriate regulatory requirements.
12.0 CODES AND STANDARDS
This specification shall apply in case of conflict between specification and following
applicable standards:
Page 473 of 1296

(3i1tael4t ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
5gaia2egwiNDIA umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
t
Wen FRaW ',AMER) IA Govi al India Undeltalang l AND PROTECTIVE COATING Rev. 0
PAGE 59 OF 59
AWS C. 2.17 Recommended Practice for Electric arc Spray.

ASTM C 633 Test Method for Adhesive/Cohesive Strength of Flame Sprayed Coatings.
ASTM D 4285 Method for indicating Oil or Water in Compressed Air.
ASTM D 4417 Test Method for Field Measurement of Surface Profile of Blasted Steel.
BS 2569 Specification for Sprayed Metal Coating.
NACE Standard RP Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel
0287 Surfaces Using a Replica Tape.
Test method for Pull-Off Strength of Coating Using Portable Adhesion
ASTM D 4541
Testers.
Guide for the Protection of Steel with Thermal Spray Coatings of
ANSI/AWS C2.18
Aluminum, Zinc and Their Alloys and Composites.
NACE No. 12/AWS Specification for the application of thermal spray coatings (Metallizing) of
C2.23M/SSPC-CS aluminum, zinc, and their alloys and composites for the corrosion
23.00 protection of steel.
The inspection of coatings and linings: A Handbook of Basic practice for
SSPC Publication
Inspectors, Owners, and Specifiers.
SSPC-AB 1 Mineral and Slag Abrasives.
SSPC-AB 3 Ferrous Metallic Abrasives.
SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel.
SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages.
NACE No. 1/SSPC- White Metal Blast Cleaning.
SP 5
NACE No. 2/SSPC- Near —White Metal Blast Cleaning.
SP 10
Guide and Reference Photographs for Steel Surfaces Prepared by Dry
SSPC-VIS 1
Abrasive Blast Cleaning.
Page 474 of 1296

JOB SPECIFICATION DOCUMENT No.
(ELECTRICAL)
B115-60-16-50-SP-4010
SRU REVAMPING OF ONGC
Rev. B
HAZIRA PLANT ON OBE,
M/S ONGC Page 1 of 6
JOB SPECIFICATION
(ELECTRICAL)
PRESSURE FILTRATION SYSTEM
PROJECT : SRU REVAMPING AT ONGC HAZIRA ON OBE MODE
OWNER : ONGC HAZIRA
JOB NO. : B115
B 06.07.2018 Revised & Issued with MR SH ANPS ANPS
A 13.04.2018 ISSUED WITH MR DK/SH ANPS ANPS
Rev. Prepared Approved

Date Purpose Checked by
No by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 475 of 1296

(ELECTRICAL)
B115-60-16-50-SP-4010
Rev. B
1.0 General
1.1 The purpose of this specification is to cover the basic requirements of the electrical works in
Bidder scope for the subject Material requisition for Pressure filtration system at ONGC Hazira
SRU revamping Project of M/S ONGC. This Job specification shall be read in conjunction with
the EIL specifications, data sheets and documents attached with the Material requisition. This
specification covers major aspects of design, manufacture, installation, testing and
commissioning of electrics for pressure filtration system.
1.2 The equipment shall conform to this specification, enclosed data sheets and standard
specifications.
1.3 In case of conflict between requirements specified in various documents, the more stringent
one shall be followed. Owner / EIL decision shall be binding. The same shall be complied
without any time / cost implication to Owner.
2.0 Scope
2.1 Bidder’s scope, shall include sizing, design, engineering, manufacturing, supply, testing at
manufacturer’s works, packing, delivery at site, supervision of installation testing and
commissioning of all the electrical equipment viz. Power distribution board, motors, local
control panels etc. including supply of all mandatory spares, two year recommended spares
for normal operation and maintenance, commissioning spares, special tools & tackles as per
the specifications and data sheets enclosed with the requisition. The major electrical
equipment for package includes
 All MV Motors.
 Power distribution board for all motors & other loads of the package
 Local control station(LCS) for motors away from LCP
 All interconnecting cabling (including supply of power and control cables) between the
equipment within the package battery limits.
 Earthing of electrical equipments within the package battery limit and connections for
bonding with main plant earth grid.
 Any other equipment not specifically mentioned above but required for safe operation of
the system.
3.0 Exclusions
3.1 415V TPN feeder for Power distribution board for the package.
3.2 All power, control, space heater, signal cables from field to Substation / Control room and from
substation to MCC room in SRR (incoming cable to PDB).
3.3 Earthing grid outside battery limit.
4.0 Site Conditions
The Electrical equipments offered in the pressure filtration system shall be suitable for
continuous operation under the following site conditions:
Design ambient temperature : 45 °C

Minimum ambient temperature : 5 °C
Maximum ambient temperature : 45°C
Altitude above MSL : 1000 M
Page 476 of 1296

(ELECTRICAL)
B115-60-16-50-SP-4010
Rev. B
5.0 Power Supply system from Owner
Medium voltage (motors) : 415V ± 6 %

System frequency : 50Hz ± 3 %
6.0 Utilization Voltage
Motors rated below 0.18 KW : 240V, 1 Phase AC

Motors rated 0.18 KW to 160 KW : 415V, 3 Phase AC
Anti-condensation heaters : 240V, 1 Phase AC
7.0 Area Classification & Equipment selection
7.1 Area classification for the field equipment shall be considered as per following:
a) Area classification for the field equipment shall be suitable for Zone-21, dust group IIIB
applicable for inflammable sulphur dust.
b) Power distribution board shall be located in MCC room of owner’s SRR that is in safe area.
c) The minimum enclosure protection for equipment shall be as follows:
Equipment Type of enclosure protection

Motors/LCS/Field equipment Dust ignition proof Ex-‘tb’, Temp.
Class-T4 suitable for zone-21,
dust group IIIB as per
IEC 61241-10/61241-14
d) Cable glands as per IS/IEC-60079-0 for termination of power and control cables at vendor
supplied hazardous area equipment.
7 Equipment specification:
7.2 MV motors
7.2.1 MV motors shall conform to the EIL spec 6-51-0064.Vendor shall strictly supply as per EIL’S
MOU with approved vendors. Variation / Clarifications against the standard specification of MV
Motor 6-51-0064, shall be as per the MOU agreed with EIL by respective motor manufacturer.
No further deviations to MR requirements shall be entertained.
7.2.2 All motors shall be high efficiency type, i.e. IE3 as per IS-12615.
7.2.3 Canopy for all outdoor electrical equipment shall be FRP type.
7.3 All cable glands/adapters / blocking plugs for hazardous area equipment shall meet the
requirements of IS/IEC- 60079-0.
7.4 Design requirements for Power distribution board
7.4.1 Rating : 415V, TPN, 50Hz

7.4.2 No of incomers : Two
7.4.3 Ammeter & Voltmeters in Incomers : Required
7.4.4 Control supply for motor starter feeders : 240V, A.C.
7.4.5 Contactor & switch fuse with overload relay : Upto 22 kW
7.4.6 Contactor, switch fuse & overload
relay with CBCT for earth fault protection : Above 22kW upto 55Kw
7.4.7 ACB feeder : Above 55kW upto 160kW
7.4.8 Field ammeters : Reqd. for motors > 5.5KW
7.4.9 Applicable specification : 6-51-0093; 6-51-0099
Page 477 of 1296

(ELECTRICAL)
B115-60-16-50-SP-4010
Rev. B
7.5 Local Control Panel/LCS
7.5.1 In case Local Control Panel is provided the same shall be used for starting/stopping of motors.
Following facilities shall be provided as a minimum on Control panel
a) Start/Stop push buttons for motor

b) Ammeters for driver motor rated above 5.5kW
c) Selector switches
For all other control and indication requirements refer elsewhere in MR.
7.5.2 Separate local control stations with start/stop P.B shall be provided for motor located away
from LCP, In case LCP is not provided local control station shall be provided for all motors.
The flameproof Local control stations shall conform to EIL spec. 6-51-0006 and the same shall
be provided with following facilities as minimum:
a) Start/Stop push buttons for motor

b) Ammeters for driver motor rated above 5.5kW
c) Selector switches (As required)
7.5.3 Local push button control station shall be wired directly from the switchboard installed in the
substation/SRR. Overall shielded paired cable shall be utilised for wiring the LCS with
Package MCC.
7.5.4 Emergency push buttons as required for plant operation and safety etc. shall be provided.
8 Any special tools required for maintenance of motor and its auxiliary systems shall be included
in the scope of vendor.
9 All power and control cable sizes shall be finalised during detailed engineering. Provisions as
required in Vendor’s equipment for termination of the same including incoming cable in
Purchaser’s scope shall be made accordingly without any cost & time implications to Owner.
10 Cables shall be sized in accordance to cl.no.4.6 of Electrical specification, Design philosophy

for Electrical facilities document number 6-51-0099 attached elsewhere.
11 Bidder shall consider approx. 300 m distance between MCC room in SRR and field for
considering interconnecting cables (power and control cables). However Bidder to supply
cable as required which shall be finalised during detailed engineering.
12 Bidder shall supply Cable glands and tinned crimping type copper lugs for equipment supplied
by them. Double compression nickel plated brass cable gland shall be provided for the cable
to be terminated at motor and local control panel/LCS. Single compression nickel plated brass
cable glands for electrical equipment mounted in indoor shall be provided. Cable details of
these cables shall be finalised during detail engineering.
13 MAKES OF EQUIPMENTS/COMPONENTS
Makes of equipments and components shall be as follows;

ITEM MAKES
Switchboard fixed for Accusonic Controls Pvt Ltd ,Dharia Switchgear & Control,
package equipments M.K. Engineers & Controls Pvt. Ltd. ,Popular Switchgears
Pvt Ltd ,Positronics Pvt Ltd ,Tricolite Electrical Industries Pvt
Ltd ,Vidhyut Control (India) Pvt Ltd,Zenith Engineering Corp.
,Maktel System, Electro-Allied Products , Larsen and toubro
ltd (ahmednagar), Nitya electro controls,
Control station- Flame Baliga lighting equipments. Flameproof equipment Pvt. Ltd.,
proof Flexpro electrical pvt. Ltd. FCG power industries,FCG
flameproof control gear Ltd, ,Sudhir switchgear, Kaysons
Page 478 of 1296

(ELECTRICAL)
B115-60-16-50-SP-4010
Rev. B
ITEM MAKES
techno equipment pvt. Ltd., pepperl & fuchs manufacturing
india pvt. Ltd.
Control station- Safe Baliga lighting equipments, Electrical equipment corporation,
area Ex- protecta, FCG flameproof control gear Ltd, FCG power
industries, Flameproof equipment Pvt. Ltd., Flexpro electrical
pvt. Ltd, pepperl & fuchs manufacturing india pvt. Ltd,
Sudhir switchgear,
Motor-induction-MV ABB Ltd. (Faridabad), Marathon electric motor ltd.,Bharat
(Zone-2-Type n) Bijlee ltd.,ABB(Bangalore), Cg power & industrial solutions
ltd, Kirloskar electric ltd., laxmi hydraulics pvt ltd,
Motor-induction-MV Bharat Bijlee ltd, Cg power & industrial solutions ltd,
(flameproof) Kirloskar electric ltd., laxmi hydraulics pvt ltd, Marathon
electric motor ltd.,
Motor-induction-MV ABB(Bangalore), ABB Ltd. (Faridabad), Bharat Bijlee ltd, Cg
(Industrial type safe power & industrial solutions ltd, Kirloskar electric ltd, laxmi
area) hydraulics pvt ltd, Marathon electric motor ltd., Siemens Ltd.,
Motors – Imported Asea Brown Boveri Limited Hitachi ltd (Japan), Loher
GMBH,WEG Exportadora,Cemp SRL, Ge energy power
conversion france SAS, General electric Canada, Geumont
SA/Framatone ANP.
MV power Cables Associated flexibles & wires pvt. Ltd, Cord cables industries
ltd, Finolex cables ltd, Gemscab industries ltd, Havells india
ltd, Kec international ltd, Kei industries ltd, Polycab wires ltd,
Sriram cables ltd, Special cables pvt ltd, Torrent power ltd,
Universal cables ltd.
Control cables Associated flexibles pvt. Ltd, Associated flexibles & wires
pvt. Ltd, CMI ltd, Cord cables industries ltd, Delton cables
ltd, Elkay telelinks ltd, Finolex cables ltd, Gemscab industries
ltd, Havells india ltd, Icon cables ltd, Kec international ltd, Kei
industries ltd, North eastern cables pvt. Ltd, Polycab wires
ltd, Scot innovation wires & cables pvt. Ltd, Sriram cables
ltd, Suyog electricals ltd, Special cables pvt ltd, Thermo
cables ltd. Torrent power ltd, Universal cables ltd.
Meters Automatic Electric, MECO Instruments, Rishabh
Instruments, Nippen Electrical Instruments, Secure meters
ltd.
Contactors ABB india ltd, G.E. india industries ltd, L&T, Schneider
Electric, Siemens,
Fuses G.E. india industries ltd, L&T, Siemens, Novateur electrical
and digital system , Cooper Bussman India,
Fuse Switch Havell’s India, L&T, , Siemens, G.E. india industries ltd,
Combination Unit Standard Electricals, Novateur electrical and digital system
Control Switches / GE T&D india ltd, Hotline Switchgear, Kaycee Industries,
Selector Switches L&T, Reliable Electronic Components, Siemens ,Switron
Devices,
Heavy Duty Switches L&T,Siemens, Novateur electrical and digital system
Instrument Transformer Kalpa Electrical, Pragati Electricals, Precise Electricals,
(CT/PT)-MV Silkaans Electricals, Narayan Powertech, Gilbert & Maxwell,
Push Buttons & Hotline switchgear, L&T, Schneider Electricals, Siemens,
Page 479 of 1296

(ELECTRICAL)
B115-60-16-50-SP-4010
Rev. B
ITEM MAKES
Indicating Lamps Teknic electric (I) pvt. ltd, Precifine Products, Shri Tulsi
Switchgear, Essen deinki
ELCB Legrand, Havell’s , Schneider, ABB india ltd,, G.E. india
industries ltd, Novateur electrical and digital system,
Siemens,
Bimetal relays ABB, L& T, Schneider, Siemens, G.E. india industries ltd
Timer Electronic automation, L&T, Siemens
MCB Havell’s, Indiana current control ltd, Legrand india pvt ltd,
Standard electrical, Schneider, ABB, Novateur electrical and
digital system, Siemens
Note:-
6.1 Bidder may procure materials from any of Owner/ EIL approved vendors. However,
current validity and range of approval as per EIL enlistment letter, workload, stability
and solvency need to be verified by the contractor before placement of order.
6.2 Bidder can offer components of makes other than specified in the Tender during
order execution. The alternate make of components will be evaluated post order,
based on the satisfactory track record and test certificates to be furnished by the
contractor. In case the alternate makes are not found acceptable, components shall
be supplied strictly as per above vendor list.
14 ATTACHMENTS
Load data : B115-60-16-50-DS-4010

Motor data Sheet : B115-60-16-50-DS-4011
MV Switchboard hardware datasheet : B115-60-16-50-DS-4023
MV Switchboard component : B115-60-16-50-DS-4024
MV cable datasheet : B115-60-16-50-DS-4025
Vendor Data Requirement : B115-60-16-50-VR-4010
Standard Electrical Spec. for package units : 6-51-0093

Standard specification for Flameproof Control Stations : 6-51-0006
Standard spec for energy efficient medium voltage : 6-51-0064
Induction Motor
Specification for medium and high voltage cables : 6-51-0051
Specification for cable installation : 6-51-0082
Specification for earthing installation : 6-51-0084
Specification for field inspection, testing and : 6-51-0087
commissioning of electrical installations
Design philosophy for Electrical facilities : 6-51-0099
Equipment earthing schedule : 7-51-0116
Inspection and test plan for FLP control station ` : 6-81-1006

Inspection and test plan for MV motors : 6-81-1032
Inspection & test plan for MV & HV cables : 6-81-1051
& accessories
Page 480 of 1296

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or
used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1650-1281, Rev 1 A4-210x297.
ELECTRICAL LOAD DATA

REV DATE PURPOSE BY CHECKED APPROVED
Project: SRU REVAMPING AT DRAWING NO Date REV

ONGC HAZIRA ON OBE MODE
Location: HAZIRA
Electrical Load Data B115-60-16-50-DS-4010 A
ENGINEERS INDIA LIMITED 13.4.18
NEW DELHI Client: M/s ONGC Sheet 1 of 2
Page 481 of 1296

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or
used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1650-1281, Rev1 A4-210 X 297
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
S.no Tag no. Service Nor- Type of Manufacturer Eqpt. Mounting Drive Rated GD of Desi- End Min Dri Mot. Motor
mal / eqpt.:Pump/Cent of equipment Status arrgmt. speed Rot. gn of Rec. ver dir.
Std.by .comp./Recip.co r.p.m. Part kg- abs. curve kW of incl of Rated Speed
mp./blower etc. m Shaft /max motor Yes rot. kW rpm
kW KW /No (from
nde)
Legend for Equipment status: # : Based on offer @ : Based on formal data * : Estimated Sheet X of X
Plant: SRU REVAMPING AT DRAWING NO Date REV
ONGC HAZIRA ON OBE MODE
ENGINEERS INDIA LIMITED Location: HAZIRA B115-60-15-50-DS- 13.04.18 A
NEW DELHI Electrical Load Data
Client: M/s ONGC 4010
Sheet 2 of 2
Page 482 of 1296

Document No.
Medium Voltage Squirrel Cage
B115-060-16-50-DS-4011
Induction Motor
Rev. No. B
Datasheet
Page Page 1 of 3
Project SRU Revamp at ONGC Hazira on OBE mode Client ONGC - HAZIRA PLANT
Unit Pressure Filtration System & Location Job No. B115 Unit No. 060
Common Unit
PURCHASER'S DATA
A. Site Conditions
1. Maximum Ambient Temperature °C45
2. Minimum Ambient Temperature °C5
3. Design Ambient Temperature °C 45
4. Relative Humidity % 87
5. Altitude mm <1000
6. Environment:
B. Technical particulars
1. Motor Tag no.: TO BE FILLED BY VENDOR
2. Driven Equipment name:
3. Voltage: V 415 +/- 6 %
4. Phase: Three
5. Frequency: Hz 50 +/- 3 %
6. Fault level: kA 50
7. Method of starting: D.O.L
8. Winding Connection: Delta
9. No of Terminals: 6
10. Cable size: mm²
11. Cable type:
12. Temperature rise: °C 75
13. Cooling: IC411
14. Insulation class: F
15. Temperature rise Limited to insulation class B
16. Hazardous area classification:
17. Dust classification Zone-21
18. Gas group:
19. IIIB
Dust Group
20. Type of explosion protection: refer Electrical job spec-B115-60-16-50-SP-4010
21. Prestart purging for Ex(n) motor Not Required
22. Type of ingress protection: IP-65
23. Color shade: 632 as per IS 5
24. Thermisters: Not Required
25. RTD: Not Required
26. BTD: Not Required
27. RTD/BTD monitoring device: Not Required
28. Applicable specification: EIL SPEC. 6-51-0064

29. Efficiency: IE 3
DRIVEN EQUIPMENT MANUFACTURER's DATA
1. Suggested motor rating: kW
2. Manufacturer:
3. BkW at Full load: kW
4. kW:at end of Curve kW
B 06-JUL-2018 ISSUED WITH MR KINDO DEEPAK KARTIC SRIHARI S SINGH ARVIND N P (MS)
A 13-APR-2018 ISSUED WITH MR KINDO DEEPAK KARTIC SINGH ARVIND N P (MS) SINGH ARVIND N P (MS)
Rev. No. Date Purpose Prepared By Reviewed By Approved By
Format No: EIL 1650-3054 Rev.2 Generated through Electrical Datasheet system (Copyrights EIL - All rights reserved)
Page 483 of 1296

Document No.
B115-060-16-50-DS-4011
Induction Motor
Rev. No. B
Datasheet
Page Page 2 of 3
Common Unit
5. Speed: RPM
6. Rotation of eqpt. from coupling end:
7. Driven equipment:
8. Coupling type:
9. Torque required starting mkg
Torque required Maximum mkg
10. GD2 of eqpt including flywheel kgm²
excluding flywheel: kgm²

11. thrust Up: kg
thrust Down: kg
12. Starting condition:
MOTOR MANUFACTURER's DATA

1. Rating: kW
2. Manufacturer:
3. No. of poles:
4. Frame designation:
5. Full load speed: RPM
6. Mounting:
7. Full load torque (FLT): mkg
8. Starting torque: % of FLT
9. Break down or pull out torque: % of FLT
10. Full load current (FLC): A
11. Starting current at 100% voltage: % of FLC
12. Rotation viewed from coupling end:
13. Starting time at 75% voltage: sec.
100% voltage: sec.
14. Locked rotor withstand time (cold/hot) at,
75% voltage sec.
100% voltage: sec.
15. Time (Te) for Increased Safety Motor at 100% Voltag sec.
16. Heating/Cooling Time Const. (min.) min
17. Space heater - voltage & power:
18. Efficiency at 75% Load: %
100% Load: voltage: %
19. Power factor at 75%/ Load:
100% Load:
starting
20. Moment of inertia, GD2: kgm²
21. NDE bearing type & no
22. DE bearing type & no.:
23. Type of lubrication:

24. Weight of motor: kg
Page 484 of 1296

Document No.
B115-060-16-50-DS-4011
Induction Motor
Rev. No. B
Datasheet
Page Page 3 of 3
Common Unit
25. Thermisters, quantity no.

make: type:
26. RTD, quantity: no.
make: type:
27. BTD, quantity no.

make: type:
28. Shaft voltage: V

29. Critical speed, 1st/2nd stage: RPM
30. Canopy:
Notes
1 For Approved makes of motors refer else where in the MR.

2 Starting time calculations shall be based on operating conditions specified on Material Requisition eg. open valve condition/closed valve condition, at no
load/full load, as applicable.
3 Recommended list of maintenance spares for two years operation shall include the following as minimum: (a) Bearing DE/NDE one set, (b) Terminal box
coverwith screws, (c) Fan, (d) Terminal block
4 Cable glands to be supplied with motors shall meet all requirements as per IS/IEC-60079.
5 Temperature class shall be T4.
6 All unfilled data shall be filled by contractor/ vendor.
7 Starting power factor of motor shall be limited to 0.2-0.3.
Page 485 of 1296

Page 486 of 1296
Page 487 of 1296
Page 488 of 1296
Page 489 of 1296
Datasheet No.
DATA SHEET
B115-60-16-50-DS-4024
FOR
Rev.No. A
MV SWITCHBOARD COMPONENTS
Page 1 of 1
COMPONENT RATING (A)

FEEDER MOTOR MAX. CABLE
TYPE RATING KW SIZE
HEAVY DUTY CONTACTOR
FUSE/BMR FUSE/BMR CT RATIO
SWITCH (AC3)
FVNR-15 6/0.8-1.2 10/2-3.3

FVR - 15 10/2.5-4 16/4.5-7.5
≤5.5 4*16 15/1 32 15
FVNR - 15HD 16/5.5-8 6/20/2010
32/11-16 32/9-15
FVNR-30
FVR - 30 32/11-16 32/9-15
5.5 < KW≤11 3.5*35 30/1 63 30
FVNR - 30HD 63/30-45 63/14-23
FVNR-60
FVR - 60 63/25-40 63/20-33 60/1
11< KW ≤22 3.5*70 125 60
FVNR - 60HD 80/30-45 100/30-50 (See note-1)
FVNR-100 125/38-63 125/45-75

FVR - 100 160/50-90 150/45-75 100/1
22< KW≤45 3.5*150 250 100
FVNR - 100HD 200/70-110 200/66-110 (See note-1)
FVNR-150
FVR - 150 150/1
45< KW≤55 3.5*185 200/70-110 200/66-110 400 150
FVNR - 150HD (See note-1)
MOTOR PROTECTION RELAY

ACB Feeder 55< KW £160 2*3.5*185 ACB
(46,50,49,50N & 51LR)
SWF-32 _ 3.5*50 32 32 _ 32 _
SWF-63 _ 3.5*50 63 63 _ 63 _
SWF-100 _ 3.5*120 100 100 _ 100 _
SWF-125 _ 2*3.5*120 125 125 _ 125 _
SWFC-63 _ 3.5*50 63 63 _ 63 _
SWFC-125 _ 2*3.5*120 125 125 _ 125 _
SWFC-250 _ 2*3.5*300 250 250 250/1 250 _
MCCB-160 MCCB 2*3.5*185 160 160 _ 160 _
250A MCCB WITH O/C, S/C & E/F

MCCB-250 MCCB 2*3.5*300 250/1 _ _
RELEASES
400A MCCB WITH O/C, S/C & E/F
MCCB-400 MCCB 3*3.5*300 400/1 _ _
RELEASES
NOTES:
1. CBCT and earth leakage relay shall be provided for motors rated above 22 kW & up to 55 kW.
2. Major components are shown above, all other items as specified in equipment data sheet and specification: 6-51-0018 shall
also be in vendor’s scope.
3. Typical fuse rating and bimetal relay ranges are specified above. Final fuse rating and bimetal range shall be selected by the
manufacturer meeting type-2 co-ordination as per IS-13947.
4. Number of cores for motor feeders shall be 4.
5. Cable sizes indicated are tentative only, actual cable size for feeder having CBCT shal be informed during detail engg.

Rev. Date Purpose Prepared Checked Approved
Format No. EIL-MVSWCDS REV 0 Copyrights EIL - All rights reserved
Page 490 of 1296

Atmospheric condition Altitude Location
Humid & highly corrosive < 1000 m Outdoor
> 1000 m Indoor
Voltage Voltage Duty Fault level Starting method Earthing No.of terminals
3.3 kV ±6% Continuous 20 kA D.O.L. Direct 3
6.6. kV ±10% 25 kA V.S.D. Resistance 4
11 kV 40 kA Star-delta 6
N.A. Auto transformer
Insulation Class Area Class Gas group Area Classification IP

B Zone 1 IIA Ex(n) IP 23
F Zone 2 IIB Ex(e) IP 44
H Divn. 1 IIC Ex(d) IP 55
C Divn. 2 IIB/IIC
A
B
C
D
Std. Spec. color C&D RTD/BTD
EIL spec. 6-51-0031 631 as per IS 5 Not applicable
Frequency Frequency2 Cooling Cable Type

±3% 50 Hz IC401 Al. cond. XLPE insulated
±5% 60 Hz IC511 Cu. cond. XLPE insulated
IC611
Format No. EIL-1650-687H Rev.3 Copyrights EIL - All rights reserved
Page 491 of 1296

Document No.
HV / MV Cable B115-060-16-50-DS-4025
DATA SHEET Rev. No. A
Page 1 of 2
Common Unit
PURCHASER'S DATA
A. Site Conditions
1. Maximum Ambient Temperature °C 45
2. Minimum Ambient Temperature °C 5
3. Design Ambient Temperature °C 45
4. Relative Humidity % 87
5. Altitude Above MSL mm <1000
6. Environment
B. Technical particulars
1. System Voltage
Nominal 415 V
Highest 500 V
Voltage grade 650/1100V
2. Frequency Hz 50 +/- 3 %
3. Conductor material
HV Power cable NA
MV Power cable Copper & Aluminium
MV control cable Copper

4. Installation under DGMS jurisdiction (See Note) No
5. Applicable spec. 6-51-0051
6. Insulation PVC
7. PVC compound type ST-2
8. Type of conductor as per spec.
9. Conductor class Class-1/2 for fixed installation
10. Types of cable Flame retardant low smoke
11. Armour
Type As per spec.
Size of armour as per spec.
12. Type of drum Steel
MANUFACTURER'S DATA
A. Technical particulars
1. Name of manufacturer
2. MR/PR item no.
3. Cable type/ code
4. Conductor material
5 Conductor semiconducting screen (HV cables)
Material
Thickness mm
6. Insulation
Type of compound
Thickness mm
7. Insulation semiconducting screen (HV cables)

Material
A KINDO DEEPAK KARTIC
Page 492 of 1296

Document No.
HV / MV Cable B115-060-16-50-DS-4025
DATA SHEET Rev. No. A
Page 2 of 2
Common Unit
Thickness mm
8. Copper tape
Thickness mm
9. Inner sheath
Type of compound
Thickness mm
10. Nominal dia under armour mm
11. Calculated dia under armour mm
12. Armour
Material
Type
Size
13. Nominal dia under outersheath mm
14. Calculated dia under outersheath mm
15. Outersheath
Type of compound
Thickness mm
16. Nominal outer dia of cable mm
17. Tolerance on outer dia %

18. Weight of cable per km kg
19. Maximum drum length mtr.
20. Maximum DC resistance of conductor at 20 °C
21. AC resistance at 90 °C
22. Reactance of cable at 50 Hz
23. Capacitance of cable
24. Zero sequence impedance of cable
25. Capacitive charging current per km
Notes
1
A KINDO DEEPAK KARTIC
Page 493 of 1296

JOB SPECIFICATIONS DOCUMENT NO.
(INSTRUMENTATION) B115-060-16-51-SP-4010
FOR REV D
PRESSURE FILTRATION
SYSTEM Page 1 of 25
JOB SPECIFICATIONS
(INSTRUMENTATION)
FOR
(MR No.: B115-060-LZ-MR-4010)
PROJECT : SRU REVAMPING AT ONGC HAZIRA PLANT
OWNER : OIL & NATURAL GAS CORPORATION LTD.(ONGC)
CONSULTANT : ENGINEERS INDIA LTD.
JOB No. : B115
UNIT No. : 060
D 06.07.18 Revised and Re-issued for Bids SKA RK SD
C 31.05.18 Issued for Bids BB RK SD
B 30.05.18 Issued for Bids BB RK SD
A 23.03.18 Issued for Bids BB RK SD
Rev. Prepared
Date Purpose Checked by Approved by
No by
Page 494 of 1296

FOR REV D
Page 2 of 25
JOB SPECIFICATIONS
Sr. Description Properties Requirement

No.
1.0 General
1.1 Location Safe Area

Hazardous area 
1.2 Area Classification Zone 1 – Gas Group IIA/IIB
Zone 1 – Gas Group IIA/IIB/IIC
Zone 2 Gas Group II A,B, Temp Class T3
Zone 2 Gas Group II A, B, C, Temp Class
T3
Zone 1 Temp Class T3
Zone 21 Dust Group IIIB Ignition 
Temperature 232 Deg C as per European
IEC 79
1.3 Type of Electronic 
Instrumentation Pneumatic
1.4 Type of Conventional (Note-3)
Instruments Smart (Note-3)
Field-bus
1.5 Type of Control Valve Actuators
Pneumatic 
Electrical
Electro – Hydraulic.
Any other
1.6 Type of hazardous area protection
Field Instruments Intrinsically safe  (If intrinsically safe
including flow, suitable for Zone 21 Dust
Group IIIB Ignition
pressure, Temperature 232 deg C
temperature, level are classification can be
etc. offered instead of dust
flameproof, Barriers shall
be supplied/ installed by
Vendor)
Dust Flame proof certified as per 
European IEC 79
FF with field barrier concept
Any Other
Analyzers Dust Flame Proof certified as per 
European IEC 79
Purged
Any other
Solenoid Valves Intrinsically safe
Dust Flame proof certified as per (Note-10)
European IEC 79
Any Other
Process Switches Intrinsically Safe
-NA (Note-3) Flame Proof
Any other
1.7 Operational Requirements
Main operational Local panel
Interface Location Local control Room
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Control room(SRR) 
Any Other( Refer Note)
1.7. Control and Monitoring
1 a) Type Skid Mounted System
Panel Mounted Instruments
Dedicated PLC based Control System 
Purchaser's Control System 
b) Location of Local Panel (If applicable)

Panel mounted Local Control Panel
Instruments Main Control Panel
Any other
c) Location of Local Control Room
Dedicated Satellite Rack Room 
Control System. Main Control Room
Any other
d) Interlock & Dedicated PLC system 
Shutdown Purchaser's Control System
System
e) Location (if Skid mounted
dedicated) Local Control Panel
Local Control Room
Satellite Rack Room 
Main Control Room
Purchase control system
Location (if Control room
Purchaser's Satellite Rack Room
Control System)
1.8 Cable Distances
Package battery limit and local BY VENDOR
control panel
Local control panel / package and
Control room.
Local control panel / package 500 meters
And Satellite Rack Room
Rack Room and Console Room within
Control room
1.9 Signal Routing Philosophy

Through Junction boxes 
Local Control Panel (if applicable)
Any Other
1.1 Logic ISA 
0 Representation Any Other
2.0 Control and Monitoring System
2.1 Type of System Distributed Control System
Programmable Logic Controller (Note-2)
Any Other
Location Local Control Room
Control Room
2.2 Functional Control algorithm
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Page 4 of 25
Requirements Date Acquisition

Interlock logics
Alarm Management
Historisation
Dynamic Graphics
Logging & Report Generation
Any other
Configuration - Single
- Dual redundant
- Quadruplicate or TMR
- Any other
Configuration Type
Controller response time
- 250 m.sec
- 500 m.sec
- Any other
Control processor loading
– Less than 60%
– Any other
Power supply - Single
- Dual
- Each for each processor
for Quadruplicate or
TMR
Console requirements
Type of Consoles
- Desk Console type
- Table Top
- Any other
No. of Operator Console
No. of TFT operating screens / Console
- 2 Nos.
- 3 Nos.
- Any other
No. of Engineering Console
No. of Engineering Screens
- 1 No.
- 2 Nos.
- Any other
Type of video Flat CRT
screen TFT
Any other
Screen Size - 21"
- Any other
Hardwired console
- Required
- Not required
Printers
Hard copier
3.0 Interlock and Common with control and monitoring 
Shutdown system
System Separate from control and monitoring
system
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Page 5 of 25
Type of System Electromechanical relays

Programmable Logic Controller 
Location Local Control Room
Control Room
Local Panel
PLC Response 100msec
Time
250msec 
500msec
Processor Loading 50% 
Screen type Flat CRT
TFT 
Sequence of event 1msec (same as PLC scan
resolution 100msec time)
250msec
Functional Logic execution 
requirements Dynamic Graphics 
Alarm management 
Sequence of event 
Historisation 
Any other 
Configuration Simplex
Dual Processor Single I/o 
Dual Processor dual I/o  (As
Dual processor dual tested I/o  per
TUV
Triple Modular Redundant (TMR) or 
Quadruplicate certific
ation)
Power Supply Redundant 
Separate for each processor
Safety level as per SIL – 2 
IEC 61508 SIL – 3
TUV AK 6
TUV AK 5
Any other
Interface with Serial 
Purchaser's Mod Bus (RTU) 
control system Hardwired
Any other
4.0 Local Control Panel / Hardwire Instrument Panel Requirement

4.1 Panel Type Purged
- Type X (If Zone 1)
- Type Z (If Zone 2)
Page 498 of 1296

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Page 6 of 25
Dust Flame proof type certified as per  (However certified

European IEC 79. dust flame proof
items on panels
instead of dust
flame proof panel
are also
acceptable.)
Weather Proof (Note-5)
4.2 Constructional Details
a) Type Free Standing 
Wall mounted
b) Enclosure Type Dust Flameproof as per European IEC 79, 
IP 65
Purged type
Weatherproof IP65 
c) Door Front
Rear 
d) Cable Entry Bottom 
Side
4.3 Power supply distribution (Note 1)
a) Incoming switch Required 
& Fuse / MCB Not required
b)Switch & fuse Required 
/MCB for each Not required
consumer
c) Power Required 
indication on panel Not Required
front
4.4 Controllers
a) Type P based
Single Loop
b) Scan Time 250msec
Any other
4.5 Indication
a) Type P based
Single Loop
Loop Indicators(HMI)  (Note-5)
4.6 Alarm Annunciator
a) Type Solid State
P based 
Vendor standard
b) Hazardous Intrinsically safe
Protection Safe area
Flame proof type
Any other
c) Indicators Flame proof Lamps
WP Lamp assembly
High intensity LED (Note-5)
LED Cluster (Note-5)
Any other
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Page 7 of 25
d) Switches and Dust Flame proof certified as per (Note-5)

Push Button European IEC 79
Any other
e) Emergency Push type with Mush room head 
Button Pull type with Mush room head
Any other
Current / Voltage indication
Current Transducer
Voltage transducers
4.7 Panel Cooling Required (As per Vendor
Standard)
Not Required
a) Type Dedicated AC (Ex-proof)
Vortex Cooler
5.0 Field Instrumentation
a) Type of Conventional
Transmitters Smart (Note-3)
Field Bus
b) Type of Pneumatic
Positioners Smart (Note-3)
Field Bus
c) Flow instrument Orifice
type Flow nozzle –steam
Orifice – other services
Venturi
Suction /Discharge
Mass flow meter (Coriolis)
Others – as per approved P&ID 
Sizing ISO 5167 for Orifice 
d)Level
Instruments
Type – Other than Displacer Type

Tanks Guided Wave radar up to 2000 mm 
Differential pressure transmitter above (Note-3)
2000 mm
Others 
(as per P&ID)
Guided Wave radar transmitter chamber 
or cage shall be provided with ¾ “ vent &
drain connections. All vent/drain of level
transmitters (GWR, DP Type) shall be
provided with gate type isolation valve and
plugged.
Tanks Radar Type 

Servo Type
Others
Level Gauges Transparent
Reflex
Magnetic 
Others
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Page 8 of 25
Magnetic Level Gauge shall provided with 

¾ “vent & drain connections. All vent/drain
of level gauges shall be provided with
gate type isolation valve and plugged.
e)Temp.
Instruments
Element Type Thermocouple (above 400 degC) (ungrounded)
RTD (upto 400 degC) 
f) Transmitter Field mounted 
Control Room mounted
g)Sensor's for Process switches -
Shutdown Transmitters - For all (Note-3)
- For low DP /
Low pressure
- Flow
- Temperature elements
6.0 Anti Surge Controller
a) Type Dedicated
With Control System
µP based
Conventional
b) Scan time ≤ 40msec.
Any other
c) Configuration Single loop / Dedicated multi-loop
controller
Dedicated HMI
Duplex redundancy
d) Programming / Front facia
Program
Laptop
modification
e) Serial Serial
interface with Main Mod Bus (RTU) with RS 485 port
Control System Any other
7.0 Machine Monitoring System
Type of Sensors Proximity Probes
(Except. Any other
Temperature)
Temperature RTD Pt. 100
Sensors Thermocouple
Vendor Standard
Control Module Local Control Panel
Location Satellite Rack Room
Control Room
Indicators Local Control Panel
Satellite Rack Room
Main Control Room
Serial Interface Required -Modbus TCP/IP
with Purchaser’s Not required
control system
Connectivity with Required
Vibration & Serial
Page 501 of 1296

FOR REV D
Page 9 of 25
Temperature Hardwired
monitoring system
Vendor
and Vendor PLC
Outputs Serial Mod-Bus TCP/IP
4-20 mA for each
Parameter
Contact for shutdown/ pre-alarm
8.0 Installation and Installation material (Note-8)
Hook Ups Prefabricated and pretested with
manifolds -
- For PT and FT
Remote (Piping - For PT and FT 

with tubing at end) - For Level instrument, 
for rating up to DPT
600#, - For PT and FT which are in High
temperature service (>325°C
Operating temp) and in steam
service.
Remote (Piping - For PT and FT 

Impulse Lines for - For Level instrument, 
ratings 900# and DPT
above, other - For PT and FT which are in High
applications temperature service (>325°C
where threaded Operating temp) and in steam
fittings are not service.
allowed as per
PMS)
Diaphragm seal For congealing services as per P&ID. 
type installation
Installation Pipe 
Impulse Line
Tube 
Type of Instrument Ball (Inst. Air line)
Isolation Valves Globe 
for non prefab Gate
hookups
Vent/ Drain Valves Globe
for non prefab
hookups Gate 
Ball
Instrument For DPT and DP type LT - 3 Valves 
integral valve For DPT type FT - 3 Valves
manifolds (for - 5 Valves 
pressure rating
less than 900# & For PG - 2 Valves 
non-steam)
For PT Type - 2 Valves 
- 5 Valves
Page 502 of 1296

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Page 10 of 25
Instrument Site Fabricated with Pipes and valves _ 

manifolds- For ratings 900# and above, other
Fabricated applications where threaded fittings are
not allowed as per PMS.
Cable Routing
Main Duct (Galvanised) 
Tray 
Branch Tray 
Type of trays Galvanized Mild steel Perforated

FRP Trays 
Canopy Pre-fabricated FRP 
For all field instruments 
For Local Control Panels 
9.0 Spares Philosophy
9.1 Mandatory spares Required Note-6
9.2 Consumable Required Note-6

Spares
9.3
Commissioning Required Note-6
spares
9.4 Note-6
Installed Spares Required
9.2 Two Years spares Required(only quote is required) Note-6
for operation and
maintenance
10. Special Requirements
0
Limit Switches Proximity type IS Limit switches 
Signal cables Armoured Note-7
Control Cables Armoured Note-7
Special Cables / Armoured 
Serial Link Cables
Fibre Optic Cable Armoured Orange in HDPE conduit 
Junction Boxes Material:
LM6 alloy, copper free epoxy coated(for 
Dust Flame proof JBs)
SS316( for weather proof JBs) 
As a standard suitable for 6/12 pair, 8 
Triadcables
As a standard weatherproof and Ex-proof ( Note-9)
Ferruling JB Heat shrinkable printed sleeve type. Cross 
ferruling is required.
Cable Glands Material:
Ni plated Brass(for Dust Flame proof JBs) 
SS316 ( for weather proof JBs) 
10. Special Instruments

0
10. Speed Governor/ -
Page 503 of 1296

FOR REV D
Page 11 of 25
1 Over speed
protection
10. Performance -
2 Controller
10. Surge detection -
3 System
Notes:
1) Utility Supply
1.1 Power supply for operation shall be as follows:
a) Control System, PLC, LCP etc.:
110 V AC (UPS) ± 10%, 50Hz ± 3Hz
b) Solenoid valve:
110 V DC + 10%
c) Illuminators for panel:
240V AC 50Hz ± 3 Hz
d) Interrogation Voltage for interlocks & Supply for transmitters
24 V DC + 1 V DC
Vendor shall indicate the power consumption for 110 V AC (UPS), and 240 V AC(Non-
UPS) for package, along with the bid proposal. However Power supply of 110V AC UPS
& 240 V AC Non-UPS shall be given at one place in the package battery limit as well as in
SRR by purchaser; further distribution & conversion shall be in vendor’s scope.
1.2 Instrument air at 6.0 kg/cm2 g normal pressure (Mechanical design pressure: 9 kg/cm2 G,
maximum pressure: 6.5kg/cm2 G & minimum pressure: 5.5 kg/cm2 G) shall be available in
the unit. Actuator sizing shall be done considering the max. instrument air pressure of 4.5
kg/cm2 G and valves shall be suitable for design condition. Vendor shall select the
instruments accordingly and shall indicate the instrument air consumption for the package.
Instrument air shall be given at one place in the field by purchaser and further distribution
shall be by Vendor.
2) Vendor shall provide PLC at SRR for signals of Pressure filtration as well as Membrane
Section. All cables i.e. Single/Triad/power cables from instrument to Junction Box/LCP,
branch cables within the battery limit and Multi-pair/Multi-Triad Cables from Junction
Box/LCP to PLC at SRR for Instruments supplied under Pressure filtration System
Package shall be supplied by bidder. Cables from Instrument to skid mounted JB/LCP
shall be laid and terminated by bidder. Cables from Junction Box/ LCP to SRR shall be laid
by Purchaser.
3) SMART type instruments with 4-20 mA HART signal shall be considered in general. In
case some special instruments are not available as SMART type, conventional shall be
acceptable.
4) Process switches shall not be provided for any application. i.e. Flow, Pressure, Diff
Pressure, Level, Temperature. Only transmitters shall be provided. This shall override any
requirement specified elsewhere including process package.
5) Local control panel shall be provided by vendor for classified area. LCP shall be on
working platform at an elevation of 1.5m from grade level with staircase with sufficient
Page 504 of 1296

FOR REV D
Page 12 of 25
space for carrying out maintenance work. If Weather proof panels are used push button,
lamps; selector switches shall be Dust flame-proof type mounted on LCP. Certified
Intrinsically Safe HMI for display (IS display) with barriers as required shall be used in local
panels.
6) Refer List of Mandatory spares (B115-060-16-51-SL-4010).Installed spares as mentioned

in the Mandatory Spares list shall also be supplied by vendor. Vendor shall separately
quote for 2 Years Operational & Maintenance spares.
7) Control cables, Signal cable shall be flame retardant and low smoke type with outer sheath
colour blue for IS and black for non – IS cables. Instrument electronic signal & alarm
cables, single pair shall be 1.5 mm2 twisted in pair individually shielded with aluminium
Mylar tape with drain wire and armoured. Control wiring for actuating devices and solenoid
valves of the interlock and shutdown system shall generally be 0.5/1.5/2.5 mm² (depending
upon distance) armoured and shielded cable for single pair. Flame retardant and Fire
resistant cables shall be used for fire safe valves and gas and fire detectors.
Weatherproof cable gland used for IP 65 junction boxes shall also be “WP” to IP 65 as per
IS/IEC 60529 and certification shall be as per IS/IEC 60079. Weatherproof and dust
flameproof cable gland shall be used in dust flameproof junction boxes.
8) The following points may be noted regarding Instrument Installation :
(a) 2 valve integral manifolds shall be considered for Local Pressure gauges and
Pressure transmitters. 5 valve integral manifolds shall be considered for pressure
ratings less than 900# and non-steam applications. For High pressure ratings,
steam applications, integral manifolds shall be site fabricated.
(b) Separate Vent/Drain valves shall be considered along with 3 valve integral
manifolds for DP type flow transmitters.
(c) Remote Instrument Installation shall be used for Flow, Pressure, Level and
Differential Pressure Transmitters (DPTs) with hybrid standard (i.e. complete piping
with tubing at the end). Vent / drain valves shall be gate valve and isolation valve
shall be globe valve. Each instrument shall be provided with isolation valve.
(d) The first isolation valves of piping shall be selected in line with piping requirement
defined somewhere else.
(e) The material of construction shall be as per process conditions and PMS.
(f) Installation standards are provided for reference. Final installation standards shall
be provided during detailed engineering. Package vendor to consider material for
the same.
(g) All diaphragm seal installations shall be provided with spacer ring and shall have
Vent/Drain connection with valves and plugs. For purging, spacer ring with suitable
isolation valves shall be used along with rotameter, RO etc. Pipe material shall be
as per piping material specification and the size shall be as per tapping size.
(h) Based on installation standards for each type of instruments, Package vendor shall
prepare Bill of Material (BOM), which shall indicate the requirement of various
installation materials required for installation of each instrument.
(i) Impulse piping for air / water service shall also be as per respective piping class
and piping material specification.
(j) Instruments in gas service are to be installed only above or at least parallel to the
tapping with the slope in the impulse piping towards the tapping to achieve self-
draining
(k) For instruments mounted on Pressure filtration package Skid, OEM’s standard and
proven installation is acceptable.
(l) For instruments in slurry service, purchaser approval shall be taken for finalizing
the type of flow instruments to be considered.
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Page 13 of 25
9) Dust Flame proof (Exd) Junction box shall be provided for Non-IS signals, and for IS-
signal weather proof JB to IP-65 shall be provided. All junction boxes shall be located by
Vendor in the battery limit of Pressure filtration system Package. Following shall be taken
care for the junction boxes:
For Junction Boxes, sizing shall be done with due consideration for accessibility and
maintenance in accordance with the following guidelines:
(a) 50 to 60 mm gap between terminals and sides of box parallel to terminal strip for up
to 50 terminals and additional 25 mm for each additional 25 terminals.
(b) 100 to 120 mm between two terminal strips for upto 50 terminals and additional 25
mm for each additional 25 terminals.
(c) Bottom/top of terminal shall not be less than 100 mm from bottom / top of the
junction box.
(d) All Cable glands are to be provided with Slipper type PVC sleeves (cable shrouds).
The tag no. of JBs shall be an alpha numeric no. as follows:
JB No. Format: - UUU-XXXX-JBY-ZZZZ
Where,
UUU: Unit no.
XXXX: Pressure Filtration package Equipment Number
Y: = N for Junction boxes pertaining to signals(AI/AO-4-20mA )
= A for Junction boxes pertaining to alarms/ contact inputs
= T for Junction boxes pertaining to Thermocouple inputs
= R for Junction boxes pertaining to RTD inputs
= S for Junction boxes pertaining to SOVs
= E for Junction boxes pertaining to shutdown switches
= G for Junction boxes pertaining to gas detectors
= P for Junction boxes pertaining to Power cables
= X for Junction boxes -miscellaneous
=V for Junction boxes pertaining to Vibration probes
ZZZZ- The 4 digit number Range from. JB no. range shall be alloted during detail engineering.
10) Solenoid valves

Solenoid valve voltage shall be 110 V DC.
11) All instruments to be supplied by vendor shall be SIL-2 certified.
TAG NUMBERING
Instrumentation symbol shall follow latest edition of ISA standard S 5.1.

3.2 All Vendor-supplied instruments shall have Tag No. as per the format indicated below.
Numerical no. for all the instruments shall be unique i.e. without any repetition of tag
no. for same type of instrument.
Unit No. Instrument Type Numerical No.

AAA BBBB CCDD
AAA = Unit Number

BBBB = Refer ISA S 5.1
CCDD = Last four digit (To be allotted during detail engineering.)
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Page 14 of 25
a) Vendor to supply Program loader (laptop) along with necessary maintenance

softwares (licensed softwares) for uploading/ unloading of application program
in the Purchaser’s PLC system during system recovery.
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Page 15 of 25
ANNEXURE- I
SPECIFIC JOB REQUIREMENT FOR PRESSURE FILTARTION SYSTEM PACKAGE
1.0 GENERAL
1.1 The purpose of this specification is to define the job requirements & philosophy of
Instrumentation & control for Pressure filtration system package as per P&ID’s, as
given elsewhere in this requisition.
1.2 This specific job requirement shall be read in conjunction with Job specification
“B115-060-16-51-SP-4020”, Standard specification for Package Unit “6-52-0052”,
other instrument standard specifications, standards, datasheet etc. with the MR for
applicable instruments items/systems.
1.3 In case of any conflict between the specification and related standards and codes
and another attachment to this package, the vendor should follow the following
document in the order of their priority for instrumentation.
a) Instrument Job specification/Specific Job Requirement/ Scope of work & Supply

b) Standard Specification and installation standard.
However Vendor shall refer such discrepancies to purchaser / consultant for further
clarification and only after obtaining the same should proceed further.
1.4 Vendor shall note that “Zero Deviation Bidding” shall be followed for this project. A
pre bid meeting shall be arranged with the bidder and any deviations/ queries
brought therein shall be discussed and resolved vide minutes of meeting. The bid
shall comply to the agreed MOM during pre bid meeting. No Deviation shall be
indicated in the offer; else this may lead to the rejection of offer.
1.5 Pressure rating of control valves body and flanges shall be minimum 300# or as per
respective piping specification.
1.6 Instrument connection on vessels, standpipes and tanks shall be as per 7-52-0001
and Instrument connection on pipes shall be as per 7-52-0002.
The minimum rating of all instrument nozzles on the vessels shall be 300#.
Equipment/Standpipe connection and first Block Valve for D.P Instrument on vessel,
Pressure/ Level / Thermowell for temperature Instrument on vessel and equipment
are to be considered as 2” Flanged.
1.7 The rating of all instrument nozzles on the vessel shall be as per the piping class.
1.8 Local Panels, junction boxes terminals shall be screw less clamp–on type. Ferrules
used shall be single sleeve with source destination type. Cross ferruling philosophy
shall be followed for wiring.
1.9 All cables including spare pair / core shall be terminated inside local control panel
and no loose cables shall be allowed. All cables shall be glanded in local control
panel.
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2.0 Control system philosophy:
2.1 The PLC based control systems for Pressure filtration system package under
bidder’s scope of supply shall be supplied by the bidder based on indicative system
configuration diagrams attached with the bid document. Standard Specification for
PLC (6-52-0040) with other drawings/ documents shall also be followed while
selecting the control system.
Apart from the Pressure filtration system, PLC supplied by the vendor shall also be
used for the Control and monitoring and shutdown of the Membrane section of the
SRU unit. Hence vendor shall provide the necessary hardware and software for
Membrane section also as per the requirements of this bid package.
The Configuration diagram is only indicative. The actual number of hardware /
software required shall be based on sizing criteria and the functional requirements
of the bid document. Vendor shall furnish detailed configuration diagram of the
offered system along with the bid proposal for purchaser’s review.
The no. of I/Os for the Membrane section shall be considered as per the I/O list (for
Membrane section) provided in the MR. No. of I/Os for the Pressure filtration system
shall be decided by vendor as per the MR requirements.
Interaction between Filtration package and membrane section signals shall be done
by Filtration vendor.
2.2 The PLC shall be located at Satellite Rack Room.
2.3 The control system shall also meet the total functional requirements, specifications
and plant operational requirements as per process scheme, process description
and any other requirements as defined in this bid package.
If at any point of time of execution of the job, the PLC system supplied is found
inadequate to meet the above requirements, any addition, modification required in
software/ hardware shall be carried out by the vendor without any time/ cost
implication. Logic verification and program changes for membrane section shall
also be done by PLC vendor.
2.4 Input/output from field shall be provided with isolation/ relays for all instruments.
Inputs/ outputs from field and MCC shall be provided with relay for interposing and
contact multiplication as required.
2.5 PLC shall be complete with all pre-loaded basic and application software. Vendor
shall provide the configuration application software, operating system etc. in soft
format. It shall be possible to do all configurations, modifications in the programs, set
point changes, I/O assignments etc and debug/analyse any malfunction in the
software/program.
2.6 Consoles for operation, engineering & programming with 21” TFT-LCD Monitor
shall be supplied with keyboard, hard disk, floppy drive, CD R/W, USB port etc
.Quantity & location of consoles shall be as per system configuration diagram
.Dynamic Graphic displays, Group displays, alarm summary, Trend etc. shall be
provided for operator interface. All the engineering/ modification/ software
download/ updation must be possible on line through menu driven function.
Antivirus software shall be provided to avoid software corruption. The configuration
data shall be protected against power failure. All necessary Licenses for carrying
out Engineering, operation, configuration/ programming, trouble shooting etc shall
be provided by vendor.
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2.7 Laser printers for alarm and event printing, log reports, graphics and Group
displays, programming printouts, SOE reports etc. for the PLC shall be considered
by vendor. Quantity of printers shall be as per the system configuration diagram.
2.8 System diagnostics shall be provided which shall include sensor out of range, open
or shorted loops, checking the compatibility and availability of I/O hardware and
software, memory diagnostics, availability and fault of power supplies etc.
2.9 Fuse to be provided in both lines (ie +ve & -ve or SGNL & GND) of all terminal blocks
in the marshalling rack
2.10 All power supply modules shall have reverse current protection and short circuit
protection.
2.11 The drawing and documentation which are required for complete engineering of
PLC shall be prepared by the vendor, not limited to the documents indicated in
vendor data requirement, enclosed elsewhere in this bid document. The
correctness and completeness of these documents shall be the responsibility of the
vendor. The formats for these documents shall be supplied after order.
2.12 For the signal interconnection the following philosophy shall be followed.
All electrical interfaces (MCC Signals) for interlock / shutdown to programmable logic
controller shall be hardwired through potential free contact. Interposing relays shall be
provided for all electrical contact signals to PLC.
Start / Stop and Local / Remote commands for all electrical drives from Local Control
Station in field (A/M switch shall be in the control room wherever control room auto
start as well as manual start is involved shall be directly wired to DCS/PLC) shall
be directly wired to MCC.
Start / Stop, Local / Remote commands for all electrical drives shall be located in
Local Control Station in field (A/M switch shall be in the control room/ Local control
panel) and shall be directly wired to MCC. Status signals of drives from MCC shall be
wired to PLC marshalling cabinet in SRR Room from MCC and shall be repeated to
desired destinations (as applicable).
2.13 For smart remote output meters located at field, looping shall be either through 3
ways JB or via transmitter test terminals for open loops. In case of closed loops and
interlocks, remote output meter at field signal shall be provided from AO card of the
control system.
2.14 Temperature transmitters shall be provided for all temperature elements in both
simple closed as well as open loops and shall be remote field mounted type.
Temperature transmitter shall be provided with dual compartment type. Duplex
element connected to Temperature Transmitter with auto switch over shall be
considered.
2.15 All SMART (HART) inputs shall be integrated with Instrument Asset Management
system in DCS / PLC. Vendor shall provide necessary hardware and software for
HART communication transmitters / positioners with purchaser’s system.
3.0 Displacer type level instruments shall not be considered for any application.
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4.0 Level gauge shall generally be Magnetic level gauges. Body/ chamber and cover
and flanges material shall be SS316 as a minimum and Body rating of gauge shall
be considered suitably to meet the process design condition.
5.0 Thermowell and flanges shall be of minimum SS 316 or better material to suit the
service condition. Minimum 300# rating shall be considered for all thermowells.
6.0 Multi-pair cable entry to junction boxes shall be from bottom while single pair
cable entries shall be from side.
7.0 Process switches shall not be provided for any application including seal oil system
for flow, pressure, temperature and level. This shall override any specification, API
mentioned in the MR specification elsewhere. Only transmitters shall be provided.
8.0 Pressure gauges shall have over range protection up to 1.3 times maximum
pressure scale without any calibration drift.
9.0 Cable entry size for all instruments in the field shall be ½” NPT (F) only. All
Instruments, Junction boxes in field, local gauge board etc. shall be provided with
SS tag plates.
10.0 Prefabricated FRP canopy shall be used for field electronic instruments, JBs and
analysers as applicable. Canopy for transmitters shall protect the instrument from
direct heat or sunlight from all directions.
FRP canopy shall have Acrylic window & mounting bracket plate material shall be
SS304. Color of the canopy shall be Light grey.
Typical characteristics of FRP canopy shall be following:
i) High mechanical strength

ii) Weather resistant (Resistant to most of the acids, alkalies, vapours &
fumes).
iii) UV resistant
iv) Anti Static
v) Special rubber grommets for Cable/ Tube entry.
If Aluminum material is used for instrument housing, purchaser consent shall be
obtained. Aluminum shall be copper free(<0.25%) and epoxy coated
11.0 Type of flange shall be RTJ type for ANSI rating more than 600# (including
thermowell flanges) and shall be of 63 AARH finish.
12.0 Solenoid valve shall be universal type, low powered and continuous rated type with
class H insulation as per IEC 85/IS 1271 and shall be suitable for 110V DC power
supply. Body enclosure/valve assembly shall be SS316. Surge suppression diodes
shall be integral part of solenoid valves.
13.0 All the positioners shall be SMART type with HART protocol and shall have metallic
enclosure.
14.0 On-Off valve shall be full bore type ball valve.
15.0 All SMART transmitters supplied by vendor shall be capable of configuration using
Purchaser’s Universal Hand Held Configurator. Electronic housing material for the
transmitters shall be SS316.
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16.0 The square root extraction for the differential pressure type flow measurement shall
be carried out in the transmitter if the accuracy of the transmitter as specified could
be maintained throughout the range even after square root extraction. The flow
transmitters integral display unit shall be configured for the engineering unit.
17.0 Local panel shall be used only for start up and normal critical operations. Unless
otherwise indicated in the package, following points shall be kept in mind while
engineering the local panels:
17.1 Local Panel shall house switches/pushbuttons, status lamps, important alarms
and critical indications only. No electronics/electronic devices or Instruments
except intrinsically safe indicators / IS display unit shall be located on the local
panel. Material of construction for the Local panel shall be SS316.
17.2 The pushbutton/switches and lamps on the local panel, which are connected to
DCS or PLC, shall be dust flameproof. The pushbuttons / switches connected to
MCC/PCC/substations shall also be certified dust flameproof as per European
IEC 79.
17.3 All the electronic component / system located at local control panel (LCP) shall
be suitable for combined effect of outdoor ambient/climatic conditions and current
carrying for installation in LCP. Vendor shall confirm with catalogue / document
mentioning ambient temperature rating of vendor supplied located electronic
component / system suitable for installation at local panel or else vendor shall
supply necessary cooling arrangement
17.4 In case any current and voltage transducer is located in local panel same shall be
mounted in Ex. proof enclosure.
18.0 In case of special instrument items, the installation shall be done under the
supervision of that system/ instrument vendor’s personnel. It is the responsibility of
Vendor to co-ordinate and to make available the specialist’s services with qualified
engineers and technicians from the original suppliers of all control system at the
time of installation, testing and commissioning.
19.0 Any Instrument loose supplied items are to be packed separately instead of
packing the same with other mechanical items while shipping to site. Markings shall
be provided for such packings as “Instrument Items – Loose Supply”.
20.0 Auxiliary panels shall be provided by the vendor for machine monitoring system
which shall be installed in the SRR. Cabinets provided by contractor shall be of
same height and depth as the other cabinets in the control room, and shall be of
depth 800 mm and height of 2100 mm (including 100 mm channel base). Cabinets
shall be of Rittal or equivalent make. Colour for the cabinets in control room shall
be RAL 7035 in uniformity with other cabinets to maintain aesthetic look. Exact
colour, height and depth shall be confirmed during detail engineering.
21.0 For all serial communication of vendor’s supplied equipments to purchaser’s DCS,
Vendor shall co-ordinate with DCS vendor to implement the communication
interface and unless the communication with purchaser’s DCS is completed, the
vendor’s system shall not be considered as commissioned.
22.0 For signals in membrane package, Filtration vendor shall coordinate with
membrane vendor as required during engineering stage.
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23.0 Small nut/bolts, used for fixing of instrument items in addition to cable trays, shall
also be stainless steel.
24.0 Intrinsically Safe (IS) type Display (Remote interactive HMI terminal) unit certified
suitable for the hazardous area shall be mounted on the panel front of local control
panel of the package. All local control panel mounted field remote output
indicators, wherever required as per approved P&IDs pertaining to this package,
shall be displayed in this remote HMI .Purchaser shall provide single serial interface
(RS 485 with Modbus RTU protocol) at satellite rack room corresponding to the
signals from DCS and vendor’s scope shall include all necessary converters at both
ends, power supply module in the auxiliary panels at satellite rack room,
connectors at both ends along with serial communication cables for connecting with
purchaser’s DCS serial interface cards.
The RS-485 cables required between auxiliary panel mounted components and
local mounted IS display unit shall be supplied by vendor.
The IS Display unit shall have touch screen facility. Electronic Components /
system located at local panel shall be suitable for combined effect of outdoor
ambient/climatic conditions and current carrying for installation. Vendor shall
confirm with catalogue / document mentioning ambient temperature rating of
bidders supplied Electronic Components / system suitable for installation in local
panel or else bidder shall supply necessary cooling arrangement
25.0 COMPREHENSIVE POST WARRANTY ANNUAL MAINTENANCE AND

SPARES MANAGEMENT CONTRACT FOR PLC SYSTEM:
25.1 The bidder shall include proposal at the time of bid for providing
Comprehensive Post Warranty Maintenance for 6 years after completion of
warranty/guarantee period and provide the total comprehensive maintenance of the
PLC system along with its sub-systems.
25.2 The proposal shall include supply of maintenance spares, tools and tackle as
required, travel, boarding & lodging of service engineer. The bid shall be made year
wise up to 6 years and the price validity shall be available for the entire period of
contract.
25.3 Bidder must quote for 6 years Comprehensive Post Warranty Maintenance
Contract. Bidder shall note that Price of Comprehensive Post Warranty
Maintenance Contract shall be part of evaluation.
25.4 In the event of any malfunction of the system hardware/system software,

experienced service engineer shall be made available at site within 24 hours
on the receipt of such information from owner.
25.5 Owner personnel will work on system day-to-day basis and wherever
possible, owner shall inform the type of failure of hardware/ software to bidder
based on diagnostic available with the system. However Bidder shall be fully
responsible to attend and rectify the root cause and the failure at the shortest
possible time.
25.6 Bidder may utilize the spare modules available with owner if necessary and
available with owner at site, which are part of mandatory spares supplied
with system as per this MR.
However if Bidder desires, additional spares other than what is available as
mandatory spares may be stored at client premises to meet the schedule of
rectification of fault during emergency/ maintenance.
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25.7 In case any hardware/ software used from owner stock, it shall be replaced by
Bidder within 7 days with no cost to owner. Bidder shall maintain a record of all
faults during post warranty period.
25.8 The services under Post Warranty Maintenance Agreement, including supply of
spare parts and services shall broadly comprise of:
a) Preventive Maintenance.
Once in a year during planned shutdown, client will inform the Bidder one
month in advance for shutdown dates. Preventive maintenance shall involve
complete overhaul of the system, inspection of hardware and software, fault
prediction, inspection of power supply quality, environmental operating
condition checks, calibration checks, major repairs/ replacements, replacement
of cards and accessories because of expected ageing failure and detailed
reporting, manual cleaning of each card and cabinet filters.
This visit is in addition to visit required for periodic maintenance.
b) Periodic Maintenance.
Site visits, minimum four (4) times in a year (total days expected 18 in a year),
schedule of visits to be discussed and finalized jointly between Bidder and client
after placement of order/ delivery. It shall include inspection of general healthiness
of the system, study and advice on daily maintenance, inspection of Hardware &
Software, if any problem is reported, running of test programs, on-line servicing
and solving reported problems.
Checks shall be conducted on running system i.e. (i) On-line sub- system (ii)
Power supply checks (iii) TFT (iv) Printer etc.
Cleaning of cabinet filters, minor modification/ addition related to system
configuration/ data base. Bidder shall take back-up in 2 copies of last updated
software also.
c) Software Maintenance/ Support:

Bidder shall maintain the existing operating & application software to improve
upon performance of the system. Software modification and up gradation, as
& when required, shall also be covered under this scope at no extra cost.
d) Emergency Service.
In the event of any malfunction of the Control System hardware/system software
during this period, Service Engineer must report at site within 24 hrs. of report of
failure, with necessary spares. The system must be brought back within 24 hours
after reporting at site.
NOTES
i) Bidder shall note that while carrying out the Comprehensive Post
Warranty Maintenance Contract activities, ONGC engineers shall associate with the
bidder. Site training of these associated engineers shall be covered under this
scope.
ii) This shall include all items being supplied by Bidder, including any bought out
items but not limited to the following:
• Labour and materials, at no additional cost, to repair any system
devices including, controllers, communication devices, computers and
related equipment, network controllers, printers etc.
• Labour and materials, at no additional cost, to provide tests, and adjustment
to system devices including printers,
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• Regular checkups to ensure that a correct procedure is established for data

base backup and archiving.
26.0 Bidder shall arrange training for Owner’s personnel for PLC system at site.
Different type of courses shall be offered for operation/ process engineers and
operators, instrument maintenance engineers and technician. Bidder shall
indicate a detailed proposal for training in the offer.
The training shall include detail operation, configuration, modification, calibration,

troubleshooting, preventive / breakdown maintenance etc. as minimum. Apart
from that, bidder shall also offer operation training basically meant for operating
personnel. The various facilities available in the system for operation, actions
required during emergencies and identifying the various diagnostic messages
shall be the main contents of the operation training. The duration of this training
shall be as follows:
For PLC (Hands on training on simulator)
No. of persons: Three (3)

Course duration: Four (4) days
Location: At site
No. of batches Three (3)
27.0 Cable Philosophy
27.1 Single pair cables from instruments to Junction Boxes and branch cables within
the battery limit shall be in vendor’s scope and shall be through cable tray
supplied by vendor. Cable glands (along with hood for field installation) shall be
provided at instrument end, junction box end, local panel end and PLC/control
room end by vendor.
27.2 Each individual cable routed through trays must be clamped or tied using SS
wires. The overall clamping shall be with aluminium clamp instead of tying with
cable armour. Nuts/Bolts for cable tray fixing shall be SS.
27.3 From field JB to main cable tray within battery limit, the multi-cables (By
purchaser) shall be routed through tray / angles which shall be supplied by
vendor.
27.4 Perforation in the cable trays shall be provided at regular intervals for clamping of
cables from cable trays.
28.0 Tubing and Tube fittings
28.1 Impulse tubing size shall be 12mm OD (SS 316L) with 1.2 mm wall thickness
and fitting (SS 316) shall be used. For air supply 8 mm OD SS 316 tubing and
SS 316 fitting shall be considered as a minimum. 10mm or 12 mm tube shall be
used, in case, actuator requirements are not met by 8mm tube. For steam
tracing, 10 mm OD SS tube (Wall thickness 1.2mm) with SS fittings shall be
used.
29.0 Drawings and Documents
29.1 The package vendor shall thoroughly review and approve vendor drawings for all
instruments and accessories before forwarding to EIL/Owner. Only the approved
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drawings duly stamped and signed by a competent engineer of the package vendor
shall be sent to EIL/Owner.
29.2 Softcopy of all instrumentation documentation shall be submitted in editable format.

Vendor to ensure that all’ final as-built instrumentation documentation are
submitted as separate volume / section.
29.3 The package vendor shall submit all instrument specifications and data sheets as
per ISA format.
30.0 Inspection and testing
30.1 All instruments and system oriented items shall undergo factory testing and
inspection by Third Party Inspection Agency (TPIA), Owner and EIL, unless
specified otherwise.
30.2 The inspection and testing shall be carried out as per related specifications,
international codes and practices/ standards, approved documents and/ or any
other document attached elsewhere in this document.
30.3 Factory Acceptance Testing of any critical System shall be witnessed by TPIA,
Client/ EIL at their discretion.
30.4 Acceptable criteria for Radiography and other NDT requirements for all the
instruments/ instrument castings shall be in line with those specified in ‘valve /
piping specifications’ for the similar service. Valve specifications/ piping
specifications have been attached elsewhere in this package.
30.5 NACE certification (as applicable) shall be provided/met by vendor.
30.6 IBR Certifications (as applicable) shall be provided by Vendor in the appropriate
format duly signed by IBR authority or their authorized agency.
31.0 Vendor List
31.1 Vendor List for Instrumentation items is provided elsewhere in the Bid package.
Vendor shall consider the instrument supplier as identified in the Vendor List.
Vendor list provided in the package is for the Make only, and not for any specific
Model. For any instrumentation item, the offered model for the same must meet the
specification and proven track record (PTR) requirement, as explained above.
Instrument Sub-vendor shall meet the enlistment conditions of EIL approval for the
Project Approved Vendor List. The EIL approval conditions are available with the
Sub-Vendors. Vendor shall follow the approval requirement.
For Instruments / items not covered in the vendor list, Vendor shall get approval
from purchaser/ owner for the vendors proposed, prior to the placement of order.
32.0 Site conditions & climate:

All instruments covered in this package shall be suitable for unprotected installation
in Hot, humid and corrosive coastal environment having following ambient
conditions:
 Ambient temperature (Max/Design.): 45 deg C / (Min) 5 deg C
 Maximum Relative Humidity: 87%
 Maximum recorded rainfall: 495.2 mm in 24 hour
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33.0 Logistic support
a. Vendor shall ensure and provide the following information / details during detail
engineering as part of purchase requisition for the PLC system.
i. Local service facilities in India is available or not from the manufacturer?

ii. If not available, where in the manufacturer’s approved service facility
presently located nearest to India?
iii. Instruments/ System shall be user serviceable.
iv. User reference list.
v. When was quoted model introduced in the market?
b. Logistic support certificate shall be provided from the supplier of special

instruments and system oriented items i.e. PLC, Vibration & temperature
monitoring system, Surge detection system (as applicable).
c. As part of each purchase specification. The logistic support certificate shall be

signed by a corporate level person of the Vendor/ Vendor principal.
d. Certificate For Logistics Support (by Principal)

(To be signed by Principal's corporate level signatory on company's letterhead)
I, on behalf of M/s confirm that the * quoted

by M/s for Pressure Filtration
System Package of SRU Revamp Project of ONGC HAZIRA shall continue to be
supported by us. The quoted item shall not be withdrawn from Indian market in next
three (3) years from the date of placement of order as a matter of our corporate policy.
I further confirm that in case of placement of order by M/s on

M/s we shall continue to support
M/s in providing back-up engineering, maintenance support and
spare part to ONGC for a period of 10 years from the date of expiry of warranty.
SIGNATURE WITH SEAL
AUTHORIZED, SENIOR MANAGEMENT LEVEL
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e. Certificate for Logistics Support (by vendor)

(To be signed by Vendor's corporate level signatory on company's letterhead)
I, on behalf of M/s confirm that the * quoted

by M/s for Pressure Filtration System
package of SRU Revamp Project of ONGC HAZIRA shall continue to be supported by
us and our principal(s). The quoted item shall not be withdrawn from Indian market in
next three (3) years from the date of placement of order as a matter of our corporate
policy as supported by attached certificate from our principal(s) M/s
I further confirm that in case of placement of order by

M/s on us, we shall continue to support
ONGC in providing back-up engineering, maintenance support and spare part to
ONGC for a period of 10 years from the date of expiry of warranty.
SIGNATURE WITH SEAL
AUTHORIZED, SENIOR MANAGEMENT LEVEL SIGNATORY
Page 518 of 1296

Rotameters
UNITS: Flow -> Liquid - Kg/hr Gas - Kg/hr Steam - Kg/hr Pressure -> Kg/cm²G Temperature-> °C Level /length -> mm
1 Tag No. *
2 Line No. *
3 Service *
4
General 5 Type
6 Function
7 Conn.:-Size:Size & Rating *
8 -Facing & Finish *
9 Direction : Inlet ¦ Outlet
10
11 Tube Size ¦ Float Guide *
12 Tube Matl. ¦ Float Matl.
13 Scale length & Type *
14 Scale Gratuation *
15 Range *
Meter 16 Meter Factor *
17 End Fitting Matl. (Flg) *
18 Packing or O-ring Matl.
19 Accuracy
20
21
Extension 22 Extension Well Matl.
23 Gasket Matl. *
24 Type (2 wire)
25 Power supply or Air supply
26 Output
Transmitter 27 Electrical Area Classification
28 Scale Range *
29 Enclosure
30 Cable Entry
31 Prot. Shiels with Safety Glass
32 Jacketting - Medium ¦ Conn.
33 - Temp. °C ¦ Pressure
34 Constant - Diff. Relay
Options 35 Needle Valve
36 Filter Regulator With Gauge
37
38
39
40 Fluid & State *
41 Maximum Flow *
42 Minimum Flow *
43 Normal Flow *
Service 44 Pressure - Oper. ¦ Max. *
Cond- 45 Temp. °C - Min ¦ Oper. ¦ Max *
itions 46 Oper. S.G. ¦ Mol. Wt. *
47 Max. Oper. Viscosity mPa.s(cP) *
48 Max. Allowable Pr.Drop *
49
50
51 Make and Model No. *
52 Tube No. ¦ Float No.
53 IBR Certification
54 Specification Remarks
NOTES:This data sheet is indicative only indicating minimum requirement, vendor to develop the detail data sheet during detail engg
`*' VENDOR TO FURNISH/CONFIRM.
DEVIATION NO DEVIATION VENDORS' SIGNATURES WITH SEAL

VENDOR DRAWING NO- ORDER NO:-
FILE- REQUISITION NO :
CLIENT : M/s ONGC DATE BY CHKD APPD

ENGINEERS INDIA LIMITED DATA SHEET NO. REV
PLANT: Unit -
NEW DELHI
A307-0ID-16-51-DS-0206.xls VENDOR- B115-060-16-51-DS-0206 A
This drawing and the design it covers are the properties of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will
not be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower
Pressure Gauges
1. Type- 13. Connection-
Connection Location-
2. Mounting-
14. Movement-
3. Dial Size-
15. Diaphragm Seal-* (For congealy, corrosive service and heighly viscous
Color: service.)
Type-
4. Case Material- Wetted Parts Material-
Others Material-
Process Connections : Size & Rating:
5. Bezel Ring- Facing & Finish-
Capillary Material-
6. Window Material- Armour-Flexible-Material
Capillary Length-
Flushing/ Filling Connection with
7. Enclosure-
8. Pressure Element- 16. Over Range Protection-
9. Element Material- 17. Blow Out Protection-
10. Socket material- 18. Options

a. Snubber-
11. Accuracy- b. Syphon-
c. Guage Saver-
12. Zero Adjustment d. Liquid Filled casing-
e. Vaccum Protection-
f.
RANGE OPERATI- MAX. MAX.
TAG NO. NG SERVICE SERVI FLUID SERVICE OPTIONS
PRESSURE PRESSU CETEM
* (To be advised * * * * * * *
later)
NOTES:- This data sheet is indicative only indicating minimum requirement, vendor to develop the detail data sheet during detail engg.
* Vendor to specify / confirm.
1. Indicate the make & model number offered.
DEVIATION NO DEVIATION VENDORS' SIGNATURE WITH SEAL
VENDOR DRAWING NO:- ORDER NO:-
FILE: REQUISITION NO :
CLIENT : M/s ONGC HAZIRA DATE BY CHKD APPD

PLANT: Unit -
NEW DELHI
A307-0ID-16-51-DS-1001.xls,sheet1
VENDOR: B115-060-16-51-DS-1001 A
Pressure Instruments
UNITS: Flow->Liq- Gas- Steam- Pressure-> Temperature->°C Level / Length-> mm
GENERAL MEASURING UNIT
1. Function:- 23. Service:-
2. Type:- 24. Element:-
3. Case:- 25. Body Material:-
4. Mounting:- 26. Element Material:-
5. Electrical Area Classification 27. Process Connection.
6. Enclosure:- 28. Process Connection Location
Enclosure Class:-
7. Intrinsically Safe:- 29. Diaphragm Seal: * (For congealy, corrosive service and highly viscous service.)
8. Air Supply:- Wetted Parts Material
9. Power Supply:- Other Material:-
10. Cable Entry:- Process Conn.:
11. Accuracy:- Size & Rating:-
12. Repeatability:- Facing & Finish:-
TRANSMITTER Capillary Material:-
13. Output Armour Flexible:-
14. Trans.Power Supply:- Armour Flexible Material:-
CONTROLLER Capillary Length:-
15. Output:- Flush./Fill. Conn. With Plug:-
16. A/M Switch:- MISCELLANEOUS
No. of Positions:- 30. Over Range Protection:-
17. Set Point Adjusment:-
18. Manual Regulator:- 31. Options:-
19. Mode:- a) IS Output meter:-
RECORDER b) Test jack
20. Chart & Chart Drive:- (for calibration)
21. Moving Parts Material 32. Load driving capability:-
22. Chart Speed:-
Operating Maximum Maximum Range Control
Tag Number Service Options
Pressure Pressure Temp. Span Set Action
* * * * * * * *
NOTES:- This data sheet is indicative only indicating minimum requirement,

vendor to develop the detail data sheet during detail engg.
* BY VENDOR
1. MAKE AND MODEL NO. SHALL BE INDICATED.
CLIENT : M/s ONGC HAZIRA DATE BY APPD

ENGINEERS INDIA LIMITED
NEW DELHI PLANT: Unit - DATA SHEET NO. REV
VENDOR : B115-060-16-51-DS-1102 A
Flow Transmitter
UNITS: Flow->Liq- Gas- Steam- Pressure-> Temperature->°C Level / Length-> mm
GENERAL MEASURING UNIT
1. Function:- 23. Service:-
2. Type:- 24. Element:-
3. Case:- 25. Body Material:-
4. Mounting:- 26. Element Material:-
5. Electrical Area Classification 27. Process Connection.
6. Enclosure:- 28. Process Connection Location
Enclosure Class:-
29. Diaphragm Seal: * (For congealy, corrosive service and heighly
7. Intrinsically Safe:- viscous service.)
8. Air Supply:- Wetted Parts Material
9. Power Supply:- Other Material:-
10. Cable Entry:- Process Conn.:
11. Accuracy:- Size & Rating:-
12. Repeatability:- Facing & Finish:-
TRANSMITTER Capillary Material:-
13. Output Armour Flexible:-
14. Trans.Power Supply:- Armour Flexible Material:-
CONTROLLER Capillary Length:-
15. Output:- Flush./Fill. Conn. With Plug:-
16. A/M Switch:- MISCELLANEOUS
No. of Positions:- 30. Over Range Protection:-
17. Set Point Adjusment:-
18. Manual Regulator:- 31. Options:-
19. Mode:- a) IS Output meter:-
RECORDER b) CCOE Certificate
20. Chart & Chart Drive:-
21. Moving Parts Material 32. Load driving capability:-
22. Chart Speed:-
Operating Maximum Maximum Range Control
Tag Number Service Options
Pressure Pressure Temp. Span Set Action
* * * * * * * *
1. '*' - To be furnished by Vendor.

2. Make and Model number shall be indicated.

NEW DELHI PLANT: Unit DATA SHEET NO. REV
A307-0ID-16-51-DS-1103.xls VENDOR : B115-060-16-51-DS-1103 A
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower’s express Radar Level Instruments (Guided Wave Radar)
agreement that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the 1 Wave Guide Type UNITS **
2 Response Time
3 Linearity
4 Repeatability mm
5 Operating Temp. effect
Sensor 6 Connection Orientation
7 Accuracy mm
8 Chamber material
10 Function – Indicating/ Trans.

11 Output
12 Electrical Cable Entry -Signal Power
13 Power Supply
Transmitter 14 Enclosure
15 Electrical Area Classification
16 Intrinsic Safety
17 Gauge Head Material
18
19 Type
Local 20 Location
Indicator 21 Graduations
22 Enclosure
23
24 Vent Connections
25 Drain Connections
26 Interface Devices:
27 - Temperature Element
28 - Water Cut Probe
29 Type
30 Element Type | No. of Elements
Temperature
31 Connection Size & Rating
Element
32 Element Anchoring
33 Sheath Material
34 Type
Water cut 35 Dedicated | With Temp. Probe
Probe 36
37 Calibration Pin
38 Still Well
39 Power Switch
40 Mounting Brackets
41 Built-in Alarm contacts
Options
42 Inter connecting cables between
43 - Tank side Indicator & Gauge head
44 - Gauge and temperature element
45 - Tank Gauge & Water Probe
46 - Power cable between gauge head & Indicator
47 Fluid
48 Pressure –Oper. Max Kg/cm2g
Service
Conditions
49 Temp. –Oper. Max °C
50 Operating Specific Gravity
51 Viscosity | Corrosive Constituent Cst
52 Statutory
Certification
intended use.EIL-1641-507. A4-210 x 297.
53 Others
54 Manufacturer
Others 55 Model Number
Note: This data sheet is indicative only indicating the minimum requirement, package vendor to develop detail data sheet for
the required instrument.
98 [ ] Deviation [ ] No Deviation Vendor’s Signature

Requisition No.
Legend:
0 Order No.
* By Vendor
Rev Date By Chkd Appd Vendor
ENGINEERS INDIA SPECIFICATION REV
PLANT :
LIMITED
NEW DELHI CLIENT : M/s ONGC HAZIRA B115-060-16-51-DS-2501 0
Page 523 of 1296

Restriction Orifice Plates
1 Tag Number * (To be advised later)
2 Line Number *
General 3 Line Size & Schedule *
4 Service *
5 Plate Only ¦ Assembly ¦ Assembly
6 Required Pressure Drop *
7 Type Concentric Square Edge
8 Single Stage pressure reduction
9 Multi Stage pressure reduction -
10
11 Material *
Plate 12 Thickness 'W' *
13 Beta = d/D *
14 Bore Diameter 'd' *
15 Vent / Drain ¦ Diameter (mm) *
16 Centre Distance 'R' (mm)
17
18
19
20 Type *
21 Material *
22 Size & Rating *
23 Facing & Finish *
Suitable 24 Line I.D. ¦ O.D. *
for 25 Gasket Thickness (mm) *
Flanges 26 Gasket Material *
27 Plate Holder
28 Plate Holder Material
29 Stud Bold Material *
30 Nut Material *
31 Welded Construction *
32 Spool Piece Length
Options 33 Connection
34 Material
35 Fluid ¦ State *
36 Flow - Minimum ¦ Maximum *
37 Flow - Normal *
Service 38 Inlet Pressure *
Cond- 39 Temp. °C - Operating ¦ Maximum *
itions 40 Sp. Gr. at operating temp.¦ at 15°C *
41 Steam specific volume m3/kg
42 Molecular Weight ¦ Cp / Cv *
43 Operating Viscosity m Pa.s (cP) *
44 Compressibility Factor
45 Pipe Reynolds Number
46 Make
47 IBR Certification -
* - Vendor to specify / confirm.

1. - Vendor to indicate the manufacturer's name


PLANT: Unit -
NEW DELHI
Orifice Plates and Flanges
UNITS: Flow -> Liquid- Gas- Steam- Kg/hr Pressure -> Temperature-> °C Level /length -> mm
1 Tag No.
2 Line No.
General 3 Line Size & Sch.
4 Service
5 Plate Only ¦ Assembly
6 Diff. Range mmH2O
Meter 7 Meter Maximum
8
9 Type
10 Sizing as per
11 Material
12 Thickness 'W' mm
13 Beta = d/D
Plate 14 Bore Dia. 'd' mm
15 Vent / Drain ¦ Dia. Mm
16 Centre Distance 'R' mm
17
18 Type
19 Tap type ¦ Size
20 Number of taps per flange
21 Material
22 Size & Rating
23 Facing & Finish
24 Line I.D. ¦ O.D. mm
Flanges 25 Gasket Thickness mm
26 Gasket Material
27 Plate Holder
28 Plate Holder Material
29 Stut Bold Material
30 Nut Material
31
32 Straight Vanes ¦ Type
Options 33 Connection
34 Material
35 Fluid ¦ State
36 Flow - Min. ¦ Max.
37 Flow - Normal
Service 38 Inlet Pressure - Oper.
Cond- 39 Temp. °C - Oper. ¦ Max
itions 40 s.g at oper. Tempearture ¦ at 15°C
41 Steam sp. Vol. m3/kg
42 Mol. Wt. ¦ Cp / Cv
43 Operating Viscosity mPa.s(cP)
44 Compressibility Factor
45 Pipe Reynolds No.
46
NOTES:

FILE- REQUISITION NO:
CLIENT: M/s ONGC HAZIRA DATE BY CHKD APPD

ENGINEERS INDIA LIMITED UNIT- DATA SHEET NO REV
PLANT:
R.O CHENNAI
Self Actuated Pressure Control Valves
UNITS: Flow -> Liquid- Gas- Steam- Kg/hr Pressure -> Temperature-> °C Level /length -> mm
1 Tag No. *
2 Line No. *
General 3 Line Size & Sch. *
4 Service *
5
6 Type : Standard ¦ Pilot-operated *
7 Size : Body ¦ Port
8 End Conn.: - Size & Rating
9 - Facing & Finish
10 Body Material *
11 Trim Material *
12 Set Point *
13 Impulse Conn.: Int. ¦ Ext. *
14 Conn. Size & Type if External *
Valve 15 Material of Diaphragm *
16 Bonnet type *
17 Cv : Min. ¦ Max. *
18 Cv : Normal *
19 Selected Valve Cv *
20 Pridicted sound Level dBA *
21 Inlet Velocity *
22 Packing or seals *
23 Lubricator ¦ Iso-Valve *
24 Guiding ¦ No. of Ports *
25 Regulation Upsteream¦Downstream *
26 Pressure Indicator
Accessories 27 Relief Valve
28 Line Stainer
29 Fluid ¦ State *
30 Flow - Min. ¦ Max. *
31 Flow - Normal *
32 Inlet Pressure - Max. ¦ Min. *
33 Inlet Pressure - Normal *
34 Del. Pr. Max. ¦ Nor. ¦ Min. *
35 Del. Pr. Shut Off *
36 Temp. °C - Oper. ¦ Max *
37 Oper. S.G ¦ Mol. Wt. *
Service 38 Cp / Cv ¦ Compress. Factor *
Cond- 39 Flash% ¦ Oper. Visc. mPa.s(cP) *
itions 40 Deg. Of Superheat ¦ % Solids *
41 Vapour Pr. ¦ Critical Pr. *
42 Model No. Valve ¦ Actuator *
43 Make and Model No.
45 Specification Remarks
* - Vendor to Specify / Confirm.

1. - Indicate the make & model number offered. Vendor shall submit the model decoding details of the offered model
with tech catalogue.


ENGINEERS INDIA LIMITED PLANT: Unit - DATA SHEET NO. REV
NEW DELHI
VENDOR- B115-060-16-51-DS-3401 A
A307-0ID-16-51-DS-3401.xls
Thermal Relief Valve
1 Tag Number * (To be advised later)
2 Line Number
General 3 Vessel Protected
4 Safety / Relief
5 Type :
6 Full Nozzle Full Lift ¦ Mod. Nozzle
7 Bonnet Type
8 Conv. / Bellows / Pilot Operated
9 Inlet Connection: Size & Rating
10 : Facing & Finish
Valve 11 Outlet Connection: Size &Rating
12 : Facing & Finish
13 Cap Over Adjusting Bolt:
14 Screwed ¦ Bolted
15 Lifting Gear- Type
16 Test Gag
17
18 Body and Bonnet
19 Nozzle and Disc
Material 20 Spring
21 Bellows
22
23
24 Resilient Seat Seal
Options 25 Radiography
26
27 Code
Basis 28 Basis of Selection
29
30 Fluid and State
31 Corrosive Costituent
32 Required Flow Capacity
33 Mol. Wt.¦Sp.Gr. at Relieving Temp.
34 Operating Pressure
35 Operating Temp.¦Relieving Temp.
Service 36 Valve discharges to
Cond- 37 Back Press. ¦ Constant / Variable
itions 38 Set Pressure
39 Cold Bench Test Pressure
40 % Over Pressure ¦ % Blowdown
41 Cp/Cv ¦ Compressibility Factor
42 Viscosity at Rel. Temp. mPas(cP)
43 Vessel:Wall temp°C¦Surf.Area-m2
44
45 Calculated Area - cm2
46 Sel. Area - cm2 ¦ Orifice Design
Orifice 47 No. of valve required for capacity
48 Total area - cm2
49 Actual Flow Capacity
50
51 Make and Model No. *
Model 52
Nos. 53 IBR Certification -
NOTES:- This data sheet is indicative only indicating minimum requirement, vendor to develop the detail data sheet during detail engg
*. Vendor to specify / confirm.
1. Indicate the make and model number of the offered instrument.


PLANT: Unit -
A307-0ID-16-51-DS-3706.xls,Sheet1
NEW DELHI
VENDOR- B115-060-16-51-DS-3706 A
Temperature Gauges
1. Type- FILLED SYSTEM
2. Well- 15. SAMA Class-
Compensation-
3. Mounting-
16. Bulb Type-
4. Dial Size- Bulb Material-
5. Color- 17. Bulb Union Threaded to-
6. Case Material- 18. Extension Type-
7. Window Material- 19. Bulb Dia.-
8. Connection Location- 20. Capillaery Material-
Armour Flexible-
9. Accuracy- Armour Material-
Capillary Length-
10. Enclosure
Enclosure Class- 21. Over Range Protection-
11. Zero Adjustment Screw- THERMOWELL

22. Material-
BIMETAL- 23. Construction-
24. Process Connection-
12. Stem- 25. Guage Connection-
Type- 26. Thermowell as per drawing-
Material-
Size- 27. Options:
a) Liquid Filled
13. Stem Diameter- b)
14. Make and Model No. c)
RANGE Temperature Well Dim. Flange

TAG NO. Service Options
Nor. Max. U T Material Rating, Face, Finish
* (To be advised * * * * * * * * *
later)
* Vendor to specify / confirm.

PLANT: Unit -
NEW DELHI
A307-0ID-16-51-DS-4006.xls,sheet1
VENDOR : B115-060-16-51-DS-4006 A
Magnetic Level Instruments
1. Tag Number 060-LI-0000 Rev. : 0
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,
2. Equipment No.
GENERAL 3. Service
HAZ.LOC 4. Electrical Area Classification
5. Function Indication
6. Mounting Side-Side(External)
7. Measuring Range mm
8. Centre to Centre Distance mm
9. Length of Float Guide Pipe mm
10. Local Indication Required
11. Type of Indication Rolling Magnet
12. Dial Size
13. Measuring Scale Required
14. Minimum Scale Resolution
GAUGE 15. Gauge Accuracy
16. Gauge Connection
(i) Size | (ii) Rating | (iii) Finish inch
17. Drain Connection
(i) Size | (ii) Rating | (iii) Finish inch .75 300# RF 125AARH
18. Material of Construction
- Float Chamber SS316
-Float SS316
-Float Guide Tube SS316
copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use.
-Spring Assembly SS 316

-Indicating Tube SS or Aluminium
-Gauge Head Housing *
-Measuring Scale SS
19. Type
20. Mounting
21. Output
22. Interconneccting Cable Between
Gauge Head and Transmitter
TRANSMITTER
23. Length of Cable
24. Power Supply
25. Enclosure Type
26. Conduit Connection
(i) Signal | (ii) Power
27. Fluid - (i)Upper | (ii) Lower
28. Pressure (i) Operating | (ii) Maximum kg/cm²(g)
SERVICE 29. Temp (i) Operating | (ii) Maximum °C
30. Oper.Sp. Gravity (i)Upper | (ii) Lower
31. Operating Viscosity cP
32. Measuring Levels
(i) Low | (ii) Normal | (iii) Maximum mm
OPTIONS 33. Cable Glands
CERTIFI- 34. Statutory
CATION 35. Others
OTHERS 36. Manufacturer
37. Model No.
Notes:
Sheet 1 Of 1
0 13/03/2018 DC REQUISITION NO :
ORDER NO : LEGEND : ¤ Hold
* By Vendor
REV DATE BY CHKD APPVD VENDOR : ^ Data Revised
PLANT : SRU SPECIFICATION REV

UNIT : 060
NEW DELHI B115-060-YL-DS-2000 0
CLIENT: M/s ONGC
Page 529 of 1296

SIGNAL CABLES
Type (Note1): 12 Pair x 1.5 mm2,Type-IV, Flame retardant Data to be filled in by vendor:
and low smoke, Blue Under Armour Dia: * mm
Core Dia: 1.5 mm2 Over Armour Dia: * mm
No. Of pairs / triads: 12 Overall Dia: * mm
Shielding Req: OVERALL & INDIVIDUAL SHIELDED Bending radius: * mm
Outer Jacket Net wt / meter: * lbs
Color: BLUE Note1: As per Std. Spec 6-52-0046
Mtrl: PVC OUTER JACKET
Inner Jacket
Color: BLACK
Mtrl: PVC INNER JACKET
Primary Insulation Material: PE INSULATION
Code:-
No. of Drums and

Total Cable length
UNIT NO. DRUM NO. Length(m) in each Drum
Required(m)
Total Drum Length
VENDOR :
NEW DELHI PLANT -ONGC-HAZIRA REV DATE BY CHK APP
UNIT : 060 SPECIFICATION Sheet 1 of 1
CLIENT : ONGC Data Sheet No. B115-000-YS-DS-4031
This drawing and the design it covers are the properties of ENGINEERS INDIA LIMITED. They are merely loaned and on the
borrower's express agreement that they will not be reproduced, copied, loaned, exhibited, nor used except in the limited way and
private use permitted by any written consent given by lender to the borrower
Page 530 of 1296

SIGNAL CABLES
Type (Note1): 12 Pair x 2.5 mm2,Type-IV, Flame retardant Data to be filled in by vendor:
and low smoke, Black Under Armour Dia: * mm
Shielding Req: OVERALL & INDIVIDUAL SHIELDED Bending radius: * mm
Color: BLACK Note1: As per Std. Spec 6-52-0046
Inner Jacket
Color: BLACK
No. of Drums and Length(m) Total Cable length

UNIT NO. DRUM NO. in each Drum
Required(m)
Total Drum Length
VENDOR :
Page 531 of 1296

SIGNAL CABLES
Type (Note1): 1 Pair x 0.5 mm2,Type-II, Flame Data to be filled in by vendor:
retardant and low smoke ,Blue Under Armour Dia: * mm
Shielding Req: SHIELDED Bending radius: * mm
Color: BLUE Note1: As per Std. Spec 6-52-0046
Inner Jacket
Color: BLACK
No. of Drums and Total Cable length

Required(m)
Total Drum Length
VENDOR :
Page 532 of 1296

SIGNAL CABLES
Type (Note1): 1 Triad x 2.5 mm2 ,Type-I,Flame Data to be filled in by vendor:
retardant and Fire resistant, Orange Under Armour Dia: * mm
Shielding Req: SHIELDED Bending radius: * mm
Color: ORANGE Note1: As per Std. Spec 6-52-0046
Inner Jacket
Color: BLACK
Primary Insulation Material: As per cl. no. 2.1.13 of Std.
Specification 6-52-0046
No. of Drums and Total Cable length

Required(m)
Total Drum Length
VENDOR :
NEW DELHI
PLANT -ONGC-HAZIRA REV DATE BY CHK APP
Page 533 of 1296

VENDOR LIST DOCUMENT No.
FOR B115-060-80-43-VL-4010
PRESSURE FILTRATION SYSTEM Page 1 of 8
VENDOR LIST
FOR
PROJECT : SRU REVAMPING AT ONGC HAZIRA PLANT
OWNER : M/s ONGC
CONSULTANT : ENGINEERS INDIA LIMITED
EIL JOB No. : B115
Page 534 of 1296

FOR B115-060-80-43-VL-4010
Notes:
a) Bidder shall procure following Equipment from any of EIL approved vendors as mentioned
below. However current validity and range of approval as per EIL enlistment letter,
workload, stability and solvency need to be verified by the bidder before placement of order.
b) In case of inability, the bidder’s proposed sub-vendor other than those specified below with
adequate proven track record (PTR) for similar application / process conditions may be
submitted for OWNER/EIL approval before placement of order, which will be evaluated
further based on the satisfactory track record and inspection release notes (IRN) to be
furnished by the Bidder. In such cases, if the bidder’s proposal is found not acceptable by
OWNER/EIL, bidder shall supply from any one of the sub-vendor listed below, for which
additional time & cost implication will not be entertained.
ITEM VENDOR
1. PUMP_CENT. HOR (GPP) ARAI PUMP MANUFACTURING COMPANY LTD
BHARAT PUMPS & COMPRESSORS LTD [ALLAHABAD]
CLYDE UNION LIMITED (FRMLY T722 & W518)
DMW CORPORATION [Mishima]
EBARA CORPORATION (JAPAN)
FLOWSERVE CORPORATION (FORMERLY I571)
FLOWSERVE INDIA CONTROLS PVT LTD [COIMBATORE]
FLOWSERVE(THOMPSONS KELLY&LEWIS PTY LTD) [VICTORIA]
GOULDS PUMPS INC
HYOSUNG GOODSPRINGS INC. [South Korea]
ITT CORPORATION INDIA PVT LTD [VADODARA]
KIRLOSKAR BROTHERS LTD [SANGLI (PUNE)]
KIRLOSKAR EBARA PUMPS LTD [SANGLI]
KSB AKTIENGESSELSCHAFT
KSB PUMPS LTD (POONA) [PUNE]
RUHRPUMPEN GMBH(FORMERLY THYSSENT509) [GERMANY]
RUHRPUMPEN INDIA PRIVATE LIMITED [KANCHIPURAM-T.N.]
SAM TURBO INDUSTRYPVT. LTD(ENQ-ACE MKTG) [COIMBATORE]
SHIN NIPPON MACHINERY CO LTD
SU MOTORS PVT LTD
SULZER PUMPS (US) INC
SULZER PUMPEN DEUTSCHLAND GMBH
SULZER PUMPS INDIA LIMITED [Navi Mumbai]
TMP S.P.A TERMOMECCANICA POMPE [LA SPEZIA]
WEIR GABBIONETA
WILO MATHER AND PLATT PUMPS PVT. LTD. [PUNE]
2. PUMP_CENT. HOR (GWS) BEACON WEIR LIMITED [CHENNAI]

BHARAT PUMPS & COMPRESSORS LTD [ALLAHABAD]
CLYDE UNION LIMITED (FRMLY T722 & W518)
DMW CORPORATION [Mishima]
EBARA CORPORATION (JAPAN)
FLOWMORE LIMITED [GHAZIABAD]
FLOWSERVE CORPORATION (FORMERLY I571)
FLOWSERVE INDIA CONTROLS PVT LTD [COIMBATORE]
FLOWSERVE(THOMPSONS KELLY&LEWIS PTY LTD) [VICTORIA]
GOULDS PUMPS INC
HYOSUNG GOODSPRINGS INC. [South Korea]
ITT CORPORATION INDIA PVT LTD [VADODARA]
KIRLOSKAR BROTHERS LTD [SANGLI (PUNE)]
KSB AKTIENGESSELSCHAFT
KSB PUMPS LTD (POONA) [PUNE]
RUHRPUMPEN GMBH(FORMERLY THYSSENT509) [GERMANY]
SAM TURBO INDUSTRYPVT. LTD(ENQ-ACE MKTG) [COIMBATORE]
SHIN NIPPON MACHINERY CO LTD
SU MOTORS PVT LTD
SULZER PUMPS (US) INC
SULZER PUMPEN DEUTSCHLAND GMBH
Page 535 of 1296

FOR B115-060-80-43-VL-4010
SULZER PUMPS INDIA LIMITED [Navi Mumbai]

TMP S.P.A TERMOMECCANICA POMPE [LA SPEZIA]
WEIR GABBIONETA
WILO MATHER AND PLATT PUMPS PVT. LTD. [PUNE]
WPIL LTD
3. MECH.SEAL FOR PUMPS/ AESSEAL PLC [ROTHERHAM]

AGITATORS CHETRA DICHTUNGSTECHNIK AG
EAGLEBURGMANN INDIA PRIVATE LIMITED
FLOWSERVE SANMAR LTD [CHENNAI]
JOHN CRANE SEALING SYSTEMS INDIA PVT. LTD.
LEAK PROOF ENGG (I) PVT. LTD [BANASKANTHA-GUJARAT]
4. AGITATOR A J SERVICES
CEECONS INDIA [CHENNAI]
CHEMINEER INC.
DORR-OLIVER
GMM PFAUDLER LTD [KARAMSAD]
JANSEN MIXER INTERNATIONAL
LIGHTNIN MIXERS LTD
LUMPP S.A.
METSO MINERALS CANADA INC.
MILTON ROY MIXING (FORMLY ROBIN R559)
MISSENARD-QUINT INDUSTRIES
MITSUBISHI KAKOKI KAISHA LTD
MIXRITE MIXING SYSTEMS [Mumbai]
PHILADELPHIA MIXING SOLUTIONS LTD
RATHI MIXERS PVT LTD(FRM RLMPL) [PUNE]
REMI PROCESS PLANT & MACHINERY LTD [THANE]
SPX PROCESS EQUIPMENTS [ North Carolina]
STANDARD ENGINEERS [MUMBAI]
Instrumentation
Item: FIELD INSTRUMENTS (P,DP,F,L,T,TD)
1) ENDRESS + HAUSER WETZER INDIA PVT LTD

2) ABB INDIA LTD (BANGALORE)
3) ABB AUTOMATION PRODUCTS GMBH
4) EMERSON PROCESS MANAGEMENT INDIA PVT LTD
5) EMERSON PROCES MGMT ASIA PACIFIC PTE LTD
6) ENDRESS+HAUSER WETZER GMBH+ CO.KG
7) ENDRESS+HAUSER GMBH+CO. KG
8) FUJI ELECTRIC SYSTEMS CO. LTD
9) HONEYWELL AUTOMATION INDIA LTD.
10) HONEYWELL INC.
11) YOKOGAWA INDIA LIMITED
12) YOKOGAWA ELECTRIC CORPORATION
13) ENDRESS + HAUSER (I) AUTO INSTR. PVT LTD
Item: ORIFICE PLATES & FLANGES
1) CAMERON CANADA CORPORATION

2) HYDROPNEUMATICS PVT. LTD
3) BALIGA LIGHTING EQUIPMENTS (P) LIMITED
4) COMFIT & VALVES PVT. LTD.
5) EMERSON PROCESS MANAGEMENT ASIA PACIFIC PTE LTD
6) EUREKA INDUSTRIAL EQUIPMENTS (P) LTD.
7) GURU NANAK ENGG WORKS
8) MICRO PRECISION PRODUCTS PVT LTD
9) MINCO (INDIA) PVT LTD (GEN. INST.)
Page 536 of 1296

FOR B115-060-80-43-VL-4010
10) MINCO (I) FLOW ELEMENT P. LTD. (GIC CO.)

11) PETROL VALVES SRL
12) PIETRO FIORENTINI SPA
13) STAR-MECH CONTROLS (INDIA) PVT LTD
14) TM TECNOMATIC SPA
Item: PRESSURE GAUGES
(1) AN INSTRUMENTS PVT LTD

(2) PRECISION MASS PRODUCTS PVT. LTD.
(3) BAUMER TECHNOLOGIES INDIA PVT.LTD(W058)
(4) BUDENBERG GAUGE CO. LTD
(5) BADOTHERM PROCESS INSTRUMENTS B.V.
(6) GAUGES BOURDON (I) PVT. LTD. (GEN.INST)
(7) GOA INSTRUMENTS INDUSTRIES PVT. LTD.
(8) H GURU INSTRUMENTS(SOUTH INDIA)PVT. LTD
(9) H.GURU INDUSTRIES
(10)MANOMETER (INDIA) PVT. LTD.
(11)WIKA INSTRUMENTS INDIA PVT LTD
(12)WALCHANDNAGAR INDUSTRIES LTD(TIWAC DIVN)
(13)WIKA ALEXANDER WIEGAND & CO GMBH
Item: INSTRUMENT TUBES
1) HEAVY METALS & TUBES PVT. LTD.

2) RATNAMANI METALS AND TUBES LTD.
3) TK FUJIKIN CORPORATION
4) JINDAL SAW LTD.
5) REMI EDELSTAHL TUBULARS LTD
6) SHUBHLAXMI METALS AND TUBES PVT. LTD
Item: TUBE FITTINGS
1. ASTEC VALVES & FITTINGS PVT. LTD.

2. ARYA CRAFTS & ENGINEERING PVT LTD
3. AUTOCLAVE ENGINEERS FLUID COMPONENTS
4. COMFIT & VALVES PVT. LTD.
5. CIRCOR INSTR. TECHNOLOGIES INC.
6. EXCEL HYDRO PNEUMATICS PVT. LTD.
7. EXCELSIOR ENGG. WORKS
8. FLUID CONTROLS PVT. LTD.
9. MULTIMETALS INDUSTRIES
10. PANAM ENGINEERS
11. PARKER HANNIFIN CORP.
12. PRECISION ENGINEERING INDUSTRIES
13. PRIME ENGINEERS
14. RELIANCE ENGINEERING & ELECTRICAL CORP
15. SEALEXCEL (INDIA) PVT. LTD.
16. SWAGELOK CO.
17. SWASTIK ENGG. WORKS
18. SSP FITTINGS CORPORATION
19. TK FUJIKIN CORPORATION
20. FITOK INCORPORATED
21. WESMEC ENGINEERING PRIVATE LIMITED
22. HAM LET (ISRAEL-CANADA ) LTD
Item: AIR FILTER REGULATOR

Page 537 of 1296

FOR B115-060-80-43-VL-4010
1) DIVYA CONTROL ELEMENTS PVT LTD

2) JANATICS INDIA PVT LTD
3) MARSH BELLOFRAM
4) PLACKA INSTRUMENTS INDIA P LTD
5) SCHRADER DUNCAN LIMITED
6) SHAH PNEUMATICS
7) SHAVO NORGREN (I) PVT LTD
8) THOMPSON VALVES LTD
9) VELJAN HYDRAIR PVT LTD
Item: SOLENOID VALVE
1) ALCON ALEXANDER CONTROLS LIMITED

2) ASCO JOUCOMATIC LTD
3) ASCO JOUCOMATIC SA
4) ASCO NUMATICS (INDIA) P. LIMITED
5) AVCON CONTROLS PVT. LTD.
6) HERION WERKE
7) PRECISION INSTRUMENT COMPANY
8) ROTEX AUTOMATION LTD.
9) SCHRADER DUNCAN LIMITED
10) THOMPSON VALVES LTD
11) VERSA BV
Item: SIGNAL CABLE

1) ASSOCIATED CABLES PVT LTD.
2) ASSOCIATED FLEXIBLES & WIRES [P] LTD.
3) CMI LIMITED
4) CORDS CABLE INDUSTRIES LTD.
5) DELTON CABLES LTD.
6) ELKAY TELELINKS LTD.
7) KEI INDUSTRIES LTD.
8) KEC INETRNATIONAL
9) LEONI KERPEN GMBH
10) POLYCAB WIRES PVT LTD.
11) SUYOG ELECTRICALS LTD
12) THERMO CABLES LTD
13) T C COMMUNICATION PVT. LTD.
14) UDEY PYROCABLES PVT. LTD.
15) LEONI CABLE SOLUTIONS(INDIA ) PVT LTD
Item: CONTROL PANEL & ACCESSORIES
1) CONTROL SYSTEMS ENGINEERS

2) ACCUSONIC CONTROLS PVT LTD
3) ELECTRONIC CORPORATION OF INDIA LTD.
4) ELECTRONIC INSTRMNTATION & CONTROL P LTD
5) INDUSTRIAL CONTROLS & APPLIANCES PVT LTD
6) IRIS AUTOMATION PVT LTD
7) POSITRONICS PVT LTD
8) PRIMA AUTOMATION INDIA PVT LTD
9) PYROTECH ELECTRONICS PVT LTD
10) RADHA KRISHNA CONTROLS
Item: PRESSRUE RELIEF VALVES
Page 538 of 1296

FOR B115-060-80-43-VL-4010
1) ANDERSON GREENWOOD CROSBY

2) AST APPARECCHHI DI SICUREZZA E TENUTA SPA
3) ANDERSON GREENWOOD CROSBY SANMAR LTD.
4) BHEL TRICHY
5) BLISS ANAND PVT LTD.
6) CURTISS WRIGHT FLOW CONTROL CORP
7) DRESSER INC.
8) FAINGER LESER VALVES (P) LTD.
9) INSTRUMENTATION LTD(PALGHAT)
10) LESER GMBH & CO. KG
11) NAKAKITA SEISAKUSHO CO LTD.
12) WEIR BDK VALVES
Item: CONTROL VALVES
1) ARCA REGLER GMBH

2) AST APPARECCHHI DI SICUREZZA E TENUTA SPA
3) BELLINO SRL
4) CCI VALVE TECHNOLOGY GMBH
5) DRESER PRODUITS INDUSTRIELS
6) EMERSON PROCESS MANAGEMNT, CHENNAI
7) FLOWSERVE INDIA CONTROL PVT. LTD.
8) FLOWSERVE PTE LTD
9) FORBES MARSHALL ARCA
10) GE OIL AND GAS INDIA PVT LTD
11) ITALVALV SNC
12) KENT INTROL UK LTD.
13) KOSO INDIA PVT LTD
14) KSB MIL CONTROLS LTD
15) METSO FLOW CONTROL OY
16) MOTOYAMA ENGG WORKS LTD.
17) SAMSON AG MESS-UND REGELTECHNIK , FRANKFURT
18) SAMSON CONTROL PVT LTD, PUNE
19) SEVERN GLOCON LTD, GLOUCESTER
20) SEVERN GLOCON INDIA PVT LTD
21) SPX VALVES AND CONTROLS
22) WEIR VALVES & CONTROLS UK LTD
Item: MAGNETIC LEVEL GAUGES
1) ABB INC, LOUISIANA

2) BLISS ANAND PVT LTD
3) CESARE BONNETTI SAP, MILANESE
4) CHEMTROL INDUSTRIES PVT LTD
5) GAUGES BOURDON (I) PVT LTD
6) KLINGER SPA
7) KROHNE S.A.S(CEDEX)
8) MAGNETROL INTERNATIONAL N.V
9) NIHON KLINGAGE CO. LTD.
10) PRATOLINA INSTRUMENTS PVT LTD, MUMBAI
11) PUNE TECHTROL PVT LTD.
12) SHRIDHAN AUTOMATION PVT LTD
13) SIGMA INSTRUMENTS CO.,MUMBAI
14) V AUTOMAT & INSTRUMENTS PVT LTD, DELHI
Item: TEMPERATURE ELEMENT/THERMOWELL
1) ABB AUTOMATION LTD

Page 539 of 1296

FOR B115-060-80-43-VL-4010
2) ALTOP INDUSTRIES LTD

3) DAILY THERMETRICS corporation
4) DETRIV INSTRUMENTATION AND ELECTRONICS LTD, THANE
5) GAUGES BOURDON (I) PVT LTD.
6) GAYESCO –WIKA USA, LP
7) GOA INSTRUMENTS INDUSTRIES PVT. LTD.
8) PYRO-ELECTRIC INSTRUMENTS GOA PVT LTD
9) TECHNO INSTRUMENTS , GANDHINAGAR.
10) TEMP –TECH, GUJARAT
11) TEMPSENS INSTRUMENTS INDIA PVT LTD , UDAIPUR
12) THERMAL INSTRUMENT (I) P LTD. (GEN. INST.)
13) THERMO ELECTRIC CO. INC., NEW JERSEY
14) THERMOCOUPLE PRODUCTS CO.(NEWWELL-WV)
15) TECHNO ELECTRA BV
16) TM TECNOMATIC SPA
17) WIKA ALEXANDER WIEGAND & CO GMBH
Item: GUIDED WAVE RADAR LEVEL TRANSMITTER
1) ABB INC, LOUISIANA

2) EMERSON PROCESS MANAGEMENT INDIA PVT LTD, NAVI MUMBAI
3) ENDRESS+HAUSER (I) AUTO INSTR PVT LTD, AURANGABAD
4) ENDRESS+HAUSER GMBH+CO.KG
5) KROHNE SAS (CEDEX)
6) L & J TECHNOLOGIES
7) MAGNETROL INTERNATIONAL N.V
8) VEGA GRIESHABER KG
Item: TEMPERATURE GAUGE
1) AN INSTRUMENTS PVT LTD

2) BADOTHERM PROCESS INSTRUMENTS B.V (UAE)
3) BAUMER TECHNOLOGIES INDIA PVT. LTD
4) GAUGES BOURDON(I) PVT. LTD.
5) GOA INSTRUMENTS INDUSTRIES PVT. LTD
6) H GURU INSTRUMENTS (SOUTH INDIA) PVT. LTD.
7) H. GURU INDUSTRIES
8) PRECISION MASS PRODUCTS
9) WALCHANDNAGAR INDUSTRIES LTD(DHARWAD)
10) WIKA ALEXANDER WIEGAND & CO GMBH
11) WIKA INSTRUMENTS INDIA PVT LTD, PUNE
Item: PROGRAMMABLE LOGIC CONTROLLER
1) ABB INDIA LTD.

2) ASEA BROWN BOVERY LTD.
3) EMERSON PROCESS MANAGEMENT INDIA PVT. LTD.
4) GE INTELLIGENT PLATFORMS PVT. LTD.
5) HIMA PAUL HILDEBRANDT GMBH + CO KG.
6) HONEYWELL AUTOMATION INDIA PVT LTD.
7) HONEYWELL INC.
8) ICS TRIPLEX PLC
9) INVENSYS SOFTWARE SYSTEMS (S) PTE LTD.
10) LARSEN & TUBRO LTD.
11) ROCKWELL AUTOMATION INDIA PVT LTD.
12) ROCKWELL AUTOMATION INC.
13) SIEMENS LTD
14) SIEMENS AG
15) YOKOGAWA INDIA LTD.
Page 540 of 1296

FOR B115-060-80-43-VL-4010
Item: GAS DETECTOR
1) CROWCON DETECTION INSTRUMENTS LTD.

2) DETECTOR ELECTRONICS CORP.(KIDDE CO.)
3) DRAGER SAFETY AG. & CO. KGAA
4) EMERSON PROCESS MANAGEMENT INDIA PVT LTD.
5) HONEYWELL ANALYTICS
6) INDUSTRIAL SCIENTIFIC OLDHAM
7) MINES SAFETY APPLIANCES COMPANY
8) NET SAFETY MONITORING INC.
9) RIKEN KEIKI CO. LTD.
Note:
1. For Items not covered in the vendor list, the sub-vendor list proposed by the package vendor shall
have Proven Track Record of 1 year in similar application in Gas Processing Plant, Offshore,
Refinery.
2. Package Vendor may procure materials from the EIL approved vendors as mentioned above.
However, current validity of vendor approval & their approved product range and the qualifying
conditions imposed while according vendor approval as per EIL enlistment letter, workload,
stability and solvency shall be verified by the package vendor before placement of order.
Page 541 of 1296

HART MODULE INTERFACE Document no.
PRESSURE FILTERATION SYSTEM B115-060-16-51-3002
SRU REVAMPING AT ONGC HAZIRA PLANT Rev. 0
Page 1 of 1

TO PURCHASER INSTRUMENT ASSET

MANAGAEMENT SYSTEM
PURCHASER (AT SATELLITE RACK ROOM)
VENDOR Cable by bidder along

with convertors at both
ends
TO / FROM PLC SYSTEMS
HCM
Note1 e.g. MTL 4841 or equivalent
A
NOTE1

HIM
e.g. MTL 4842 or equivalent

PLC SYSTEM ANALOG SIGNAL

MARSHALLING CABINET FOR SIGNAL INTERFACE
Legends :
HCM : HART COMMUNICATION MODULE
HIM : HART INTERFACE MODULE
Notes:
1) Typical arrangement of PLC Systems Analog signal Hook up on Purchaser’s IAMS

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Page 542 of 1296

I/O COUNT FOR PLC
MEMBRANE SECTION B115-060-YE-IOS-4010 Rev 1
Page 1 of 2
(I/O SUMMARY AND SIZING CONSIDERATION)

(MEMBRANE SECTION)
1 06.07.2018 ISSUED with MR BB RK PKS
0 21.03.2018 ISSUED with MR BB RK PKS

Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 543 of 1296

I/O COUNT FOR PLC
MEMBRANE SECTION B115-060-YE-IOS-4010 Rev 1
Page 2 of 2
TABLE - I: I/O SUMMARY (PLC for Plant controls and Interlocks)
INPUT OUTPUT
PBs, HS
RELAY STATUS EMER.
CONTACTS CONTACTS AND
4-20mA 4-20mA AO S LAMP ANN. WIN SW
Unit PROXIMITY SELECT.
SWITCHES MCC SOV MCC OTHER (4-20 mA) (NOTE- (NOTE - (NOTE -3) (NOTE -3)
SWITCHES SW (NOTE-
1) 3)
3)
WB WOB WOB WOB WB WOB WOB WOB WB
10 10 16 12 24 12 12 12 8 - - - - -
NOTES:
Note-1: The no. of I/Os indicated is tentative and shall be finalized before award of contract.
Note-2: Interposing relays shall be provided as per MR requirements.
Note-3: Quantity shall be decided as per the package MR requirements.
Note-4: In case Dust flame proof instruments are supplied by Membrane package vendor instead of intrinsically safe instrument, barriers will
not be required.
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 544 of 1296

Page 545 of 1296
Document No.
SITE SPECIFIC SEISMIC SPECTRA B115-000-16-54-DB-0001
SRU REVAMPING Rev. No.0
ONGC, HAZIRA Page 1 of 6
SITE SPECIFIC SEISMIC SPECTRA
PROJECT : SRU REVAMPING

OWNER : ONGC
CONSULTANT : Engineers India Ltd.
JOB NO. : B115
0 16/11/2017 ISSUED FOR IMPLEMENTATION

MBA GGSA SVRS
Prepared
Rev. No Date Purpose Reviewed by Approved by
by
Template No. 5-0000-0001-T1 Rev. 1 Copyrights EIL – All rights reserved
Page 546 of 1296

Document No.
1.0 SITE SPECIFIC SEISMIC SPECTRA
Site specific seismic spectrum is generated separately for Design Basis Earthquake
(DBE) & Maximum Considered Earthquake (MCE) for different damping values in
accordance with Clause no. 3.5 and Clause no 3.18 of IS 1893 (Part 4) : 2015
respectively. The spectral accelerations presented here shall be used along with Clause
no. 7.3.1 of IS 1893 (Part 4): 2015.
1.1 Spectral Acceleration Coefficients (Sa/g) for Design Basis Earthquake (DBE):
Spectral Acceleration Coefficients (Sa/g) for Design Basis Earthquake (DBE) is given in
Table 1 and shown in Figure 1.
Sa/g (damping: 5%) = 0.122+1.83T for 0.00<T<0.10 sec

= 0.305 for 0.10<T<0.55 sec
0.168
= for 0.55<T<8.00 sec
T
1.342
= for T> 8.00 sec
T2
0.6
Damping (%)
(0.5%)
(1%)
(2%)
Spectral accln. "Sa/g"
0.4
(2.5%)
(3%)
(4%)
(5%)
(7%)
0.2
0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0
Time Period in seconds
Figure 1: Site specific seismic spectra for DBE
Page 547 of 1296

Document No.
Table 1: Spectral Acceleration Coefficients (Sa/g) for Design Basis Earthquake (DBE)
Time Percentage of critical damping

Period
0.5 1.0 2.0 2.5 3.0 4.0 5.0 7.0
(sec)
0.000 0.122 0.122 0.122 0.122 0.122 0.122 0.122 0.122
0.050 0.406 0.342 0.299 0.278 0.256 0.235 0.214 0.192
0.100 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.130 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.200 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.270 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.300 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.400 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.500 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.550 0.580 0.488 0.427 0.397 0.366 0.336 0.305 0.275
0.600 0.531 0.447 0.391 0.363 0.336 0.308 0.280 0.252
0.670 0.476 0.401 0.351 0.325 0.300 0.275 0.250 0.225
0.800 0.398 0.336 0.294 0.273 0.252 0.231 0.210 0.189
1.000 0.319 0.268 0.235 0.218 0.201 0.185 0.168 0.151
1.200 0.266 0.224 0.196 0.182 0.168 0.154 0.140 0.126
1.400 0.228 0.192 0.168 0.156 0.144 0.132 0.120 0.108
1.600 0.199 0.168 0.147 0.136 0.126 0.115 0.105 0.094
1.800 0.177 0.149 0.130 0.121 0.112 0.103 0.093 0.084
2.000 0.159 0.134 0.117 0.109 0.101 0.092 0.084 0.075
2.400 0.133 0.112 0.098 0.091 0.084 0.077 0.070 0.063
2.800 0.114 0.096 0.084 0.078 0.072 0.066 0.060 0.054
3.000 0.106 0.089 0.078 0.073 0.067 0.062 0.056 0.050
3.500 0.091 0.077 0.067 0.062 0.058 0.053 0.048 0.043
4.000 0.080 0.067 0.059 0.055 0.050 0.046 0.042 0.038
4.500 0.071 0.060 0.052 0.048 0.045 0.041 0.037 0.034
5.000 0.064 0.054 0.047 0.044 0.040 0.037 0.034 0.030
5.500 0.058 0.049 0.043 0.040 0.037 0.034 0.031 0.027
6.000 0.053 0.045 0.039 0.036 0.034 0.031 0.028 0.025
6.500 0.049 0.041 0.036 0.034 0.031 0.028 0.026 0.023
7.000 0.046 0.038 0.034 0.031 0.029 0.026 0.024 0.022
7.500 0.042 0.036 0.031 0.029 0.027 0.025 0.022 0.020
8.000 0.040 0.034 0.029 0.027 0.025 0.023 0.021 0.019
8.500 0.035 0.030 0.026 0.024 0.022 0.020 0.019 0.017
9.000 0.031 0.027 0.023 0.022 0.020 0.018 0.017 0.015
Page 548 of 1296

Document No.
1.2 Spectral Acceleration Coefficients (Sa/g) for Maximum Considered Earthquake

(MCE):
Spectral Acceleration Coefficients (Sa/g) for Maximum Considered Earthquake (MCE)

is given in Table 2 and shown in Figure 2.
Sa/g (damping: 5%) = 0.183+2.745T for 0.00<T<0.10 sec

= 0.458 for 0.10<T<0.55 sec
0.252
= for 0.55<T<8.00 sec
T
2.013
= for T>8.00 sec
T2
1.0
Damping (%)
(0.5%)
0.8
Spectral accln. "Sa/g"
(1%)
(2%)
(2.5%)
0.6
(3%)
(4%)
0.4 (5%)
(7%)
0.2
0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0
Time Period in seconds
Figure 2: Site specific seismic spectra for MCE
Page 549 of 1296

Document No.
Table 2: Spectral Acceleration Coefficients (Sa/g) for Maximum Considered Earthquake

(MCE)
Time Percentage of critical damping

Period
0.5 1.0 2.0 2.5 3.0 4.0 5.0 7.0
(sec)
0.000 0.183 0.183 0.183 0.183 0.183 0.183 0.183 0.183
0.050 0.608 0.512 0.448 0.416 0.384 0.352 0.320 0.288
0.100 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.130 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.200 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.270 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.300 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.400 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.500 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.550 0.869 0.732 0.641 0.595 0.549 0.503 0.458 0.412
0.600 0.797 0.671 0.587 0.545 0.503 0.461 0.419 0.377
0.670 0.714 0.601 0.526 0.488 0.451 0.413 0.376 0.338
0.800 0.598 0.503 0.440 0.409 0.377 0.346 0.315 0.283
1.000 0.478 0.403 0.352 0.327 0.302 0.277 0.252 0.226
1.200 0.398 0.336 0.294 0.273 0.252 0.231 0.210 0.189
1.400 0.341 0.288 0.252 0.234 0.216 0.198 0.180 0.162
1.600 0.299 0.252 0.220 0.204 0.189 0.173 0.157 0.142
1.800 0.266 0.224 0.196 0.182 0.168 0.154 0.140 0.126
2.000 0.239 0.201 0.176 0.164 0.151 0.138 0.126 0.113
2.400 0.199 0.168 0.147 0.136 0.126 0.115 0.105 0.094
2.800 0.171 0.144 0.126 0.117 0.108 0.099 0.090 0.081
3.000 0.159 0.134 0.117 0.109 0.101 0.092 0.084 0.075
3.500 0.137 0.115 0.101 0.093 0.086 0.079 0.072 0.065
4.000 0.120 0.101 0.088 0.082 0.075 0.069 0.063 0.057
4.500 0.106 0.089 0.078 0.073 0.067 0.062 0.056 0.050
5.000 0.096 0.081 0.070 0.065 0.060 0.055 0.050 0.045
5.500 0.087 0.073 0.064 0.059 0.055 0.050 0.046 0.041
6.000 0.080 0.067 0.059 0.055 0.050 0.046 0.042 0.038
6.500 0.074 0.062 0.054 0.050 0.046 0.043 0.039 0.035
7.000 0.068 0.058 0.050 0.047 0.043 0.040 0.036 0.032
7.500 0.064 0.054 0.047 0.044 0.040 0.037 0.034 0.030
8.000 0.060 0.050 0.044 0.041 0.038 0.035 0.031 0.028
8.500 0.053 0.045 0.039 0.036 0.033 0.031 0.028 0.025
9.000 0.047 0.040 0.035 0.032 0.030 0.027 0.025 0.022
Page 550 of 1296

Document No.
NOTES :
1. For methodology of calculation of seismic forces and other seismic design criteria, refer
latest revisions of the following codes:
IS 1893 (Part 1):2016 : General provisions and buildings
IS 1893 (Part 4):2015 : Industrial structures including stack-like structures
2. All parameters shall be in accordance with the above mentioned codes. However, in
Table 3, the response reduction factors of some of the structures/equipment specific to
the project are included for guidance. In case of ambiguity between the values
mentioned here and those mentioned in the code, lower value shall be considered in
the analysis/design.
3. Structures/equipment categorized as Category 1 shall also be checked for MCE.
4. For design purpose, spectra shall be considered as per the section 1.1 and 1.2. For any
other purpose such as ductile detailing requirement, the site location shall be
considered as Zone III.
5. When cylindrical storage tanks are designed as per API 650/620 using site-specific
design methods, the percentage of critical damping and response reduction shall be
taken in accordance with the respective design codes.
Table 3. Response reduction factors of some of the structures/equipments
Response
S.
Structure/Equipment Reduction
No.
Factor (R)
Piperacks: Designed as RC Special Moment Resisting 5.0

1
Frame (SMRF).

2
Frame (SMRF) upto 10 m and steel frame beyond 10 m.

Frame (SMRF) upto 10 m and Special moment resisting
3
steel frame beyond 10 m designed as per IS 800 without
ductile detailing.
Technological structures: In the direction of concentric 4.0

4
braces.
Technological structures: In the direction of Steel moment 5.0

5
resisting frame designed as per SP 6(6)
Staircase structure: Steel frame with concentric braces in 4.0

6
both directions
7 Steel Reactors, Columns and Vessels 2.0
Page 551 of 1296

STANDARD SPECIFICATION STANDARD SPECIFICATION No.
~zit4 ENGINEERS FOR FABRICATION AND
$1g-ar 0154- g w INDIA LIMITED ERECTION OF PIPING
6-44-0012 Rev. 4
1.~ cYrTK M13,4.1 Ift Govt of Incha Unclertaking)
Page 1 of 15
STANDARD SPECIFICATION FOR

FABRICATION AND ERECTION OF
PIPING
REVISED AND ISSUED AS STANDARD

4 30.07.14
SPECIFICATION AK ATD SC
3 31.03.09
SPECIFICATION RN VKB SC ND
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03
STANDARD SPECIFICATION RN DM BN SKG
REAFFIRMED AND ISSUED AS STD.
1 15.09.98 SH BRB NS AS
SPECIFICATION
0 14.04.93 ISSUED AS STANDARD SPECIFICATION AKG BPV GRR AS
Standards Standards
Rev. Committee Bureau
Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Page 552 of 1296

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEEFZS
RLJI £;Mes o INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1~1 C-1,9,1, 051 3W1,) (A Govt ol Indo Undertakngt
Abbreviations:
A.S. : Alloy Steel

C.I. : Cast Iron
C.S. : Carbon Steel
HMTD : Heat & Mass Transfer Division
IBR Indian Boiler Regulations
LTCS : Low Temperature Carbon Steel
NACE : National Association of Corrosion Engineers
NB Nominal Bore
NDT : Non Destructive Testing
P&ID : Piping and Instrumentation Diagram
PMI Positive Material Identification
S.S. Stainless Steel
SMMS : Specialist Material & Maintenance Services
Piping Standards Committee
Convenor : Mr. R. Nanda
Members : Mr. M. Ismaeel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.J. Harinarayanan (HMTD)
Mr. P P Lahiri / Mr. S. Ghoshal (SMMS)
Mr. S. Mukherjee (Construction)
Mr. K.V.K. Naidu (Projects)
Page 553 of 1296

zig ENGINEERS
OgLar INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1>ffeR IA Tool ol Ind2 Undertakin)
CONTENTS
1.0 SCOPE 4
2.0 SCOPE OF WORK OF CONTRACTOR .4
3.0 BASIS OF WORK 7
4.0 FABRICATION 8
5.0 ERECTION 11
Page 554 of 1296

ENGNEERS
fffl it—
eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
.1"2-, 21,1,1,
151,41,411 IA Govt of India Undertalong)
1.0 SCOPE
This specification covers general requirements of fabrication and erection of above ground
and trench piping systems at site. The specification covers the scope of work of Contractor,
basis of work to be carried out by Contractor and standards, specifications and normal
practice to be followed during fabrication and erection by the Contractor.
2.0 SCOPE OF WORK OF CONTRACTOR
Generally the scope of work of Contractor shall include the following:
2.1 Transportation of required piping materials (as described in C1.2.1.1), pipe support (material
as described in Cl. 2.3) and all other necessary piping materials from Owner's storage point
or Contractor's storage point (in case of Contractor's scope of supply) to work site/shop
including raising store requisitions for issue of materials in the prescribed format &
maintaining an account of the materials received from Owner's stores.
2.1.1 Piping materials include the following but not limited to the same.
a. Pipes (A11 sizes and schedule)
b. Flanges (A11 sizes, types & Pressure ratings).
c. Fittings (All sizes, types and schedule)
d. Valves (A11 sizes, types and Ratings)
e. Gaskets (All sizes, types & Ratings)
f. Bolts, Nuts or M/C Bolts (All types)
g. Expansion Joint/Bellows (All types)
h. Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air
traps, springs, silencers, snubbers, steam and condensate manifolds, injection nozzles,
MOVs, sight glass, spray nozzles, integrated steam traps, hoses, hose couplings, etc.
i. Online instruments like control valve, orifice flange, rotameter, safety valves,
restriction orifice, rupture disc, de-super heaters, corrosion probes, annubar, magnetic
flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi PG/PT/ Flow
transmitter, ejectors, static mixers, flame arrestors, thermal flow switches, pre-
fabricated hook-ups etc.
j. Shut Down Valves with and without fire box.
2.2 Shop & field fabrication and erection of piping in accordance with documents listed under
C1.3.0 i.e. 'BASIS OF WORK' including erection of all piping materials enumerated above.
2.3 Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips,
cradles, hangers, turn-buckles, supporting fixtures, bracket cantilevers, struts, tee-posts
including erection of spring supports, sway braces, dummy pipes, corrosion pads/protection
shields, low friction pads, clamps, special support, expansion bellows, steam and condensate
manifolds supports etc. Corrosion Pads/Protection shields, stiffeners and stiffening rings, if
not covered in the specifications/standards, shall be of the same material as of parent pipes.
Page 555 of 1296

ENGINEEFZS
dg INDIA LIMITED
Odi FABRICATION AND ERECTION 6-44-0012 Rev. 4
.R27T 0,
1 J~1,
A
GoN of Ind,a Underta«.9) OF PIPING Page 5 of 15
2.4 Site fabrication of Piping items
Site fabrication of Piping items shall include but not be limited to the following
2.4.1 Fabrication of piping specials like special radius bends, reducers, mitres etc.
2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3 Fabrication of swage nipples as and when required.
2.4.4 Fabrication of odd angle elbow like 60°, 30° or any other angle from 90°/45° elbows as and
when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
2.4.6 Fabrication of stub-in connection with or without reinforcement.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/different
thickness wherever required.
2.4.8 Fabrication of circular pipe for steam rings, fire water lines, utility lines.
2.4.9 Threading of all small bore piping as per piping material specifications.
2.4.10 Drilling on blind flange for inserting / joining small bore lines.
2.4.11 Fabrication and welding of reinforcement pads at branch pipe locations wherever required.
2.4.12 Equipment nozzle reinforcement with pads, jacket & stiffeners wherever required.
2.4.13 Fabrication of injection nozzles as per details provided wherever required.
2.4.14 Fabrication of chain operation arrangement for valves, wherever required. A11 material
required for this modification shall be supplied by Contractor.
2.4.15 Fabrication and erection in position of funnels required for OWS/ SS/ Condensate blow
down system as per direction of Engineer-in-charge.
2.4.16 Grinding/ finishing of uneven surfaces/ joints after welding. Internal grinding of welds of
orifice flanges to render smooth surface.
2.4.17 Tapping and drilling of holes in flanges, blind flanges, piping connections for jack screw, if
required.
2.4.18 Providing bird screens at the outlet of lines open to atmosphere.
2.5 Modifications like providing additional cleats, extension of stem of valve, locking
arrangement of valves etc. as and when required.
2.6 Piping isometrics for main process/utility lines shall be provided to the Contractor.
Preparation of miscellaneous small bore isometrics with bill of materials for process and
utility lines (up to 11/2" size) like instruments & pump flushing / cooling, sample connection,
purging, pump casing vents & drains, pump Base plate drains, control valve drains / vent to
flare, instrument drains & vents, steam tracing (non-IBR) from steam supply stations up to
condensate recovery station, and lines specified as field routed within the Unit battery limit
Page 556 of 1296

ry s ENGINEERS
Ogz-drr 2fal-egI INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1.1r7R Crt-LISTC 2/513,721,) IA Govl o■ Indu UnclettakIng)
as and when required are in Contractor's scope of work. Approval for these isometrics
prepared by the Contractor shall be taken from Engineer-in-charge before erection.
Small bore piping isometrics given by Owner shall be rechecked by Contractor before
erection and installation.
2.7 Obtaining approval for drawings prepared by Contractor from statutory authority, if
required.
2.8 Spun concrete lining of the inside of pipes 3" NB & above including fittings and flanges as
required in accordance with specification.
2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specification.
2.11 Performing PMI using alloy analyzers as per `Standard Specification for Positive Material
Identification at Construction Sites, 6-82-0002'.
2.12 Casting of concrete pedestals and Fabrication and erection of small structures/ platforms for
pipe supports and valve operation / attending some instruments, spectacle blinds etc.,
providing brackets, modification / extension of platforms, providing additional platforms /
ladders for improving / providing accessibility.
2.13 Providing insert plates with anchor fasteners in concrete structures / paved floors and repair
of platform gratings around pipe openings and providing suitable members for support
under the platform grating.
2.14 Making material reconciliation statement and return of Owner's supply left over materials to
Owner's storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection,
flushing and testing of piping systems (Specification No. 6-44-0013). The accessories
required for blinding the line like flange, blind flange, gasket (all sizes, type and rating),
stud-bolts, flexible hoses etc. are to be arranged by the Contractor. During flushing the
discharged water / air shall be drained / routed as directed by the Engineer — In Charge.
2.16 Contractor shall prepare welding specifications for all weld joints where dissimilar welding
will be performed, and obtain approval from EIL.
2.17 Contractor to ensure meeting all requirements for carrying out work in shutdown/running
plant.
2.18 Pickling (as and when applicable) as per Job specification(s) for chemical cleaning of CS
suction piping of compressors, SS Piping, Weldments etc, as applicable.
2.19 Chemical Cleaning/ Hydro jet cleaning as per marked-up P&IDs with supply of chemicals,
consumables, DM water, equipments, boilers, coupons, tools & tackles and other testing
equipments required for the same.
Page 557 of 1296

■31 ENGINEERS
FABRICATION AND ERECTION
ar 1.1W1 <9,741 451 ,1,1~)
INDIA LIMITED 6-44-0012 Rev. 4
in Govt ot India Undertaloow
3.0 BASIS FOR WORK
3.1 The complete piping work shall be carried out in accordance with the following:
3.1.1 "Approved for Construction" drawings and sketches issued by EIL to the Contractor - Plans
and/or Isometrics.
3.1.2 "Approved for Construction" drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
3.1.3 Approved Process Licensor's standards and specifications.
3.1.4 Drawings, sketches and documents prepared by Contractor duly approved by Engineer-in-
Charge (such as isometrics of small bore piping and offsite piping etc.).
3.1.6 EIL specifications/documents as below:
a. Process and Instrument Diagram.
b. Job Piping Materials Specification (****-6-44-0005). **** denotes job number.
c. Piping support, engineering standards.
d. Line list
e. Piping support indices (only in offsite), if supports are not shown in plan.
f. Job specification of Non-destructive Requirement of Piping (****-6-44-0016)
g. Job Welding Specification Charts for Piping Classes (****-6-77-0005)
h. Job Welding specification for fabrication of piping (****-6-77-0001).
i. Any other EIL or OTHER specifications attached with Piping Material Specification
or special condition of contract (such as standard for cement lining of pipe, standard
ofjacketed piping, standard for steam tracing, Dimensional Tolerances etc.)
j. Standard specification for positive material identification (PMI) at construction sites,

6-82-0002
k. Standard Spec for application of torque & hydraulic bolt tension for flange joints (6-
76-0002) and its addendum, if any.
3.1.7 Following codes, standards and regulations
a. ASME B 31.3 Process Piping
b. ASME Sec. VIII Code for unfired pressure vessel.
c. IBR Regulations
d. ASME Sec. IX Qualification standard for welding and brazing

procedures, welders, brazers and welding and
brazing operators.
Page 558 of 1296

ENGINEERS
Og-ar fa2es
I è-117R C4c,7>r, ,Lq .~11
INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
IA Govt 01 India UndetaMing)
e. NACE Std. Code for Sour Services material requirements

MR-0175/MR0103/Job spec(NACE), as applicable
Note : A11 codes referred shall be latest edition, at the time of award of contract.
3.2 Deviations
Where a deviation from the "Basic of Work" and approved job procedure described above is
required or where the basis of work does not cover a particular situation, the matter shall be
brought to the notice of Engineer-in-Charge and the work carried out only after obtaining
written approval from him in each case.
4.0 FABRICATION
4.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system
shall be strictly as per the "Piping Material Specification" for the "Pipe Class" specified for
that system. To ensure the above requirement, all piping material supplied by the Owner /
Contractor shall have proper identification marks as per relevant standards / EIL
specifications / Licensors specification. Contractor shall provide identification marks on left
over pipe lengths wherever marked up pipe lengths have been fabricated/erected. Material-
traceability is to be maintained for A.S., S.S., NACE, LTCS, material for Hydrogen service
and other exotic materials by way of transferring heat number, etc. (hard punching) as per
approved procedure. This shall be in addition to colour coding for all piping materials to
avoid mix-up.
For the purpose of common understanding the construction job procedure, to be submitted
by the Contractor, shall include proposal for
- Maximizing prefabrication, inspection and testing at fabrication shop with minimum

field joints.
- Positive material identification, handling, storage & preservation.
4.2 Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per EIL Standard No. 7-44-0486.
The Contractor shall be responsible for working to the dimensions shown on the drawings.
However, the Contractor shall bear in mind that there may be variations between the
dimensions shown in the drawing and those actually existing at site due to minor variations
in the location of equipments, inserts, structures etc. To take care of there variations "Field
Welds" shall be provided during piping fabrication. An extra pipe length of 100 mm over
and above the dimensions indicated in the drawing may be left on one nide of the pipe at
each of the field welds. During erection, the pipe end with extra length at each field weld,
shall be cut to obtain the actual dimension occurring at site. Isometrics, if supplied may have
the field welds marked on them. However, it is the responsibility of the Contractor to
provide adequate number of field welds. In any case no extra claims will be entertained
from the Contractor on this account. Wherever errors / omissions occur in drawings and
Bills of Materials it shall be the Contractor's responsibility to notify the Engineer-in-Charge
prior to fabrication or erection.
4.3 IBR Piping
4.3.1 Contractor shall obtain approval for the piping systems falling under purview of IBR from
the statutory Indian Boiler Regulations (IBR) authority of the state where the plant is
Page 559 of 1296

ENGINEERS
5gU Offl— g
1.1WR Govt of UnOettaking)
situated. The Owner shall provide documentation for the IBR System. The Contractor shall
carry out the fabrications, erection and testing of this piping as per requirements of Indian
Boiler Regulations and to the entire satisfaction of the Local Boiler Inspector. The
Contractor shall also get the approval of IBR inspector for all fabrication and testing done
by him at his own cost. All certificates of approval shall be in proper IBR forms.
4.3.2 IBR Package for residual, field routed and site modified steam lines shall be prepared by the
Contractor. IBR approval for the same shall be in Contractor's scope, at his own cost.
4.4 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general,
joining of lines 2" and above in process and utility piping shall be accomplished by butt-
welds. Joining of lines 1-1/2" and below shall be by socket welding/butt welding/threaded
joints as specified in "Piping Material Specifications". However, in piping 1-1/2" and below
where socket welding/ threaded joints are specified butt - welds may be used with the
approval of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only
applicable for non-galvanized piping without lining.
Flange joints shall be used at connections to Vessels, Equipment's, Valves and where
required for ease of erection and maintenance as indicated in drawings.
4.5 Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating,
post-heating and heat treatment shall be as described in the Job welding specification
(****-6-77-0005) and NDT specification (****-6-44-0016).
4.6 Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.1 NPT as
required to match threads on fittings, valves etc. All other piping shall have threads as per
ANSI B2.1, tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed.
Threading of pipes shall be done preferably after bending, forging or heat treating
operations. If this is not possible, threads shall be gauge checked and chased after welding
heat treatment etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly
cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated
with thread sealant and the joint tightened sufficiently for the threads to seize and give a
leakproof joint. Threaded joints to be seal-welded shall be cleaned of all foreign matter,
including sealant and made up to full thread engagement before seal welding.
4.7 Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation
is shown in the drawing.
Wherever jack screws are to be provided, drilling and tapping for the jack screws in the I
flange, shall be done as per EIL Standard before welding it to the pipe.
4.8 Branch Connections
Page 560 of 1296

■
31 ENGINEERS
fg-r;Ir fa2e5 INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
14.2R ar a,
W,7,1~1) IA GoN of Indo Underfaon9)
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using
forged tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
4.9 Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be
used.
Cold bends for lines 1-1/2" and below, with a bend radius of 5 times the nominal diameter
shall be used as required in place of elbows wherever allowed by piping specifications.
Bending of pipes 2" and above may be required in some cases like that for headers around
heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles,
bulges, flat spots and other serious defects. They shall be true to dimensions. The flattening
of a bend, as measured by the difference between the maximum and minimum diameters at
any cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal
and external pressure respectively.
4.10 Forging and Forming
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2" and
below, shall be as per ASME B 31.3.
4.11 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabricated reducers shall be governed by
the Piping Material Specifications. Reducers shall be fabricated as per directions of
Engineer-in-Charge. The radiographic requirements shall be as per Material Specifications
for process and utility systems and NDT Specification for steam piping under IBR,
radiographic requirements of IBR shall be complied with.
4.12 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per drawings
and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight
length piping.
4.13 Galvanized Piping
Galvanized carbon steel piping shall be completely cold worked, so as not to damage
galvanized surfaces. This piping involves only threaded joints and additional external
threading on pipes may be required to be done as per requirement.
Page 561 of 1296

ENGINEERS
r Êtral
fg--a,- -g
e INDIA LJMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
oloo,r1.,om, IA Go, ol lnO. Undellaking)
4.14 Jacketed Piping
The Jacketing shall be done in accordance with EIL Specification or Licensors specification
as suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at

shop by Contractor. Position of jump-over and nozzles on the jacket pipes, fittings etc. shall
be marked according to pipe disposition and those shall be prefabricated to avoid damaging
of inner pipe and obstruction of jacket space. However, valves, flow glasses, in line
instruments or even fittings shall be supplied as jacketed.
4.15 Shop Fabrication / Prefabrication
The purpose of shop fabrication or pre-fabrication is to minimize work during erection to

the extent possible. Piping spool, after fabrication, shall be stacked with proper
identification marks, so as facilitate their withdrawal at any time during erection. During this
period all flange (gasket contact faces) and threads shall be adequately fabricated by coating
with removable rust preventive. Care shall also be taken to avoid any physical damage to
flange faces and threads.
4.16 Miscellaneous
4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler,
supporting elements like turn-buckles, extension of spindles and interlocking arrangement of
valves, operating platforms as required by Engineer-in-Charge.
4.16.2 Spun Concrete Lining
The work of inside spun concrete lining of pipes and specials of diameter 3" and above shall
be done as per material specifications and special condition contract.
4.16.3 Fabrication of pipes from plate
Pipes shall be fabricated at site as and when required as per the specifications and the actual
Piping Material Specification.
5.0 ERECTION
5.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing
with compressed air/or flushing out with water. Special cleaning requirements for some
services, if any, shall be as specified in the piping material specification or isometric or line
list. S.S jacketed piping requiring pickling shall be pickled to remove oxidation and
discolouring due to welding.
5.2 Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without the
consent of Engineer-in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings
shall be strictly followed as these clearances may be required for the free expansion of
Page 562 of 1296

ENGINEERS
$1gul8M--eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1.117R +1,13,70,) (A Govt ol roma Undertalong)
piping / equipment. No deviations from these clearances shall be permissible without the
approval of Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall be
brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his
instructions.
5.3 Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as
indicated in the drawing. Confirmation in writing shall be obtained by the Contractor from
the Engineer-in-Charge, certifying that the gap between the pipes is as indicated in the
drawing, before drawing the cold pull. Stress relieving shall be performed before removing
the gadgets for cold pulling.
5.4 Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the
Contractor. Corrective action shall be taken by the Contractor in consultation with Engineer-
in-Charge wherever the Contractor is not able to maintain the specified slope.
5.5 Expansion Joints / Bellows
Installation of Expansion Joints/Bellows shall be as follows:
5.5.1 Al1 Expansion joints / Bellows shall be installed in accordance with the specification and
installation drawings, supplied to the Contractor.
5.5.2 a. Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the
case(s) and check for any damage occurred during transit.
b. The Contractor shall bring to the notice of the Engineer-in- Charge any damage done
to the bellows / corrugations, hinges, tie-rods, flanges/ weld ends etc.
c. Each Expansion Joint / Bellow shall be blown free of dust / foreign matter with
compressed air or cleaned with a piece of cloth.
5.5.3 a. For handling and installation of Expansion Joints, great care shall be taken while
aligning. An Expansion Joints shall never be slinged from bellows corrugations/
external shrouds, tie / rods, angles.
b. An Expansion Joints / Bellow shall preferably be slinged from the end pipes / flanges
or on the middle pipe.
5.5.4 a. All Expansion Joints shall be delivered to the Contractor at "Installation length",
maintained by means of shipping rods, angles welded to the flanges or weld ends or
by wooden or metallic stops.
b. Expansion Joints stop blocks shall be carefully removed after hydrostatic testing.
Angles welded to the flanges or weld ends shall be trimmed by saw as per
manufacturer's instructions and the flanges or weld ends shall be ground smooth.
5.5.5 a. The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned
or shall have specified lateral deflection as noted on the relevant drawings.
b. The pipe ends / flanges shall be spaced at a distance specified in the drawings.
Page 563 of 1296

■31 ENGINEERS
r 02-
$1g-a,ffum eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
IA Go, ol Underlaking)
5.5.6 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall be
tack welded/bolted. The mating pipes shall again be checked for correct alignment.
5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged Expansion
Joint, the mating flanges shall be bolted.
5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes and
Expansion Joints are in correct alignment and that the pipes are well supported and guided.
5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain
parallelism of restraining rings or bellows convolutions.
5.5.10 Precautions
a. For carrying out welding, earthing lead shall not be attached with the Expansion Joint.
b. The Expansion bellow shall be protected from arc weld spot and welding spatter.
c. Hydrostatic Testing of the system having Expansion Joint shall be performed with
shipping lugs in position. These lugs shall be removed after testing and certification
is over.
While fitting up mating flanges, care shall be exercised to properly align the pipes and to
check the flanges for trueness, so that faces of the flanges can be pulled together, without
inducing any stresses in the pipes and the equipment nozzles. Extra care shall be taken for
flange connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange
connections to these equipments shall be checked for misalignment, excessive gap etc. after
the final alignment of the equipment is over. The joint shall be made up after obtaining
approval of Engineer-in-Charge.
Hydraulic bolt tensioning & torque tensioning shall be performed on flange joints as per the
requirements specified in "Standard Specification for application of Torque & Hydraulic
Bolt Tension for flange joints," 6-76-0002 and its addendum, if any.
Temporary protective covers shall be retained on all flange connections of pumps, turbines,
compressors and other similar equipments, until the piping is finally connected, so as to
avoid any foreign material from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between these
flange faces is uniformly compressed. To achieve this, the bolts shall be tightened in a
proper sequence. A11 bolts shall extend completely through their nuts but not more than 1/4".
Steel to C.I. flange joints, if any, shall be made up with extreme care, tightening the bolts
uniformly after bringing flange flush with gaskets with accurate pattern and lateral
alignment.
5.7 Vents and Drains
High point vents and low point drains shall be provided as per the instructions of Engineer-
in-Charge, even if these are not shown in the drawings. The details of vents and drains shall
be as per piping material specifications / job standards.
Page 564 of 1296

ENGINEERS
Og'-ar Ofd i gw
2,22F1? 461 34.--,1
IA Govt of Ind‘a Undenak,n9)
5.8 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. In case of any difficulty in doing this or if the spindle orientation / position is not
shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his
instructions. Care shall be exercised to ensure that globe valves, check valves, and other uni-
directional valves are installed with the "Flow direction arrow "on the valve body pointing
in the correct direction. If the direction of the arrow is not marked on such valves, this shall
be done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking arrangements of

valves (if called for), shall be carried out as per drawings/ instructions of Engineer-in-
Charge.
5.9 Instruments
Installation of in-line instruments such as control valve, orifice flange, rotameter, safety
valves, restriction orifice, rupture disc, de-super heaters, corrosion probes, annubar,
magnetic flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi PG/PT/
Flow transmitter, ejectors, etc. and Shut Down Valves with fireboxes shall form a part of
piping erection work.
Fabrication and erection of piping upto first block valve / nozzle / flange for installation of
offline Instruments for measurement of level, pressure, temperature, flow etc. shall also
form part of piping construction work. The limits of piping and instrumentation work will be
shown in drawings / standards / specifications. Orientations / locations of take-offs for
temperature, pressure, flow, level connections etc. shown in drawings shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above and the
precautions to be taken are covered in flushing, testing and inspection of piping (EIL Spec.
6-44-0013). Care shall be exercised and adequate precautions taken to avoid damage and
entry foreign matter into instruments during transportation, installation, testing etc.
5.10 Line Mounted Equipments / Items
Installation of line mounted items like filters, strainers, steam traps, air traps,
desuperheaters, ejectors, samples coolers, mixers, flame arrestors, light glasses etc
including their supporting arrangements shall form part of piping erection work.
5.11 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise
specified in piping classes) all bolts and nuts during storage, after erection and wherever
flange connections are broken and made-up for any purpose whatsoever. The grease and
graphite powder shall be supplied by the Contractor within the rates for piping work.
5.12 Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal effects
of the piping system and to prevent its vibrations. Location and design of pipe supports will
be shown in drawings for lines 2" NB & above. For lines 11/2"NB & below Contractor
shall locate and design pipe supports in line with EIL Stds. In case of IBR Lines 1 1/2"NB &
below only indicative supporting shall be provided & detailing of such supports is in
Contractor's scope. Contractor shall obtain approval of Engineer - in - Charge on drawings
prepared by Contractor, before erection. However, any extra supports desired by Engineer-
in-Charge shall also be installed.
Page 565 of 1296

ENGINEERS
1~1 ,i,cmtJ9-0,-.1) IA Govt of InOla Undertaxng)
No pipe shoe / cradle shall be offset unless specifically shown in the drawings.
Hanger rods shall be installed inclined in a direction opposite to the direction in which the
pipe move during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and
insulation is over. Springs shall be checked for the range of movement and adjusted if
necessary to obtain the correct positioning in cold condition. These shall be subsequently
adjusted to hot setting in operating condition. The following points shall be checked after
installation, with the Engineer-in-Charge and necessary confirmation in writing obtained
certifying that:
- A11 restraints have been installed correctly.

- Clearances have been maintained as per support drawings.
- Insulation does not restrict thermal expansion.
- A11 temporary tack welds provided during erection have been fully removed.
- All welded supports have been fully welded.
Page 566 of 1296

if ENGINEERS INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
$1g-ar f8151e-
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1.17R
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INDIA LIMITED
TESTING OF PIPING SYSTEMS Page 1 of 9
-crr-4Wr 19-*7-41 flzIT

f-49-k7

INSPECTION, FLUSHING AND
TESTING OF PIPING SYSTEMS
C 1
,1„1
REVISED & ISSUED AS STANDARD RN TD DM
4 01.07.13
SPECIFICATION
REVISED & ISSUED AS STANDARD RN ATD DM VC
3 27.08.07
SPECIFICATION
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03 RN DM BN SKG
REAFFIRMED AND ISSUED AS STD. BRB NS AS
1 15.09.98 SH
SPECIFICATION
0 06.04.83 ISSUED AS STANDARD SPECIFICATION DB DB SLG RSB

Standards Standards
Committee Bureau
Rev. Prepared Checked
No by by
Approved by
Page 567 of 1296

ENGINEERS
rtg-ar tt154-- eg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
eietnre 0,7 JT7.11 IA Govt of India Undeilak.9) TESTING OF PIPING SYSTEMS Page 2 of 9
Abbreviations:
ASME : The American Society of Mechanical Engineers
IBR : Indian Boiler Regulations
PMI : Positive Material Identification
ppm Parts per million
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. Ajay Shrivastava
Mr. G.K. Iyer (Construction)
Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0
Page 568 of 1296

■
31 ENGINEERS
fg-a(.77nr taf*reg INDIA LIMITED TESTINGINSPECTION, FLUSHING AND 6-44-0013 Rev. 4
G" °"'" Unde"'"g) OF PIPING SYSTEMS Page 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 INSPECTION 4
4.0 FLUSHING 4
5.0 PRESSURE TESTING 5
Page 569 of 1296

ENGINEERS
INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
NIRY1 esreM7F 3,10.1)
G" '11"" Unde"") TESTING OF PIPING SYSTEMS Page 4 of 9
1.0 SCOPE
This specification covers the general requirements for inspection, flushing and testing of
piping systems. However, testing of steam lines falling under IBR shall also be governed by
Indian Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.
2.0 REFERENCES
ASME B31.3 Process Piping
EIL SPEC 6-82-0002 : Standard Specification for Positive Material Identification

(PMI) at Construction Sites
3.0 INSPECTION
During various stages and after completion of fabrication and erection, the piping system shall
be inspected by the Engineer-In-Charge to ensure that:
Proper piping material has been used.
PMI has been performed as per EIL specification '6-82-0002'.
Piping has been erected as per drawings and instructions of Engineer-In-Charge.
All supports have been installed correctly.
Test preparations mentioned in this specification have been carried out.
4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by 'fresh potable water' or by 'dry compressed air wherever water
flushing is not desirable to clean the pipe of all dirt, debris or loose foreign material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing, the line/system shall be pressurized by compressed air at the
required pressure which shall be 3.5 kg/cm2g maximum. The pressure shall then be released
by quick opening of a valve, already in line or installed temporarily for this purpose. This
procedure shall be repeated as many times as required till the inside of the pipe is fully
cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and other
instruments like thermowells which may interfere with flushing shall not be included in
flushing circuit.
The screens/meshes shall be removed from all permanent strainers before flushing.
Screens/meshes shall be reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall be removed, cleaned and
reinstalled after flushing, but, before testing.
Page 570 of 1296

ENGINEERS
faf5reg
1.11R, ti,Prel>1393,1)
INDIA LIMITED INSPECTION, FLUSHING AND
6-44-0013 Rev. 4
G" In Unde"")
Page 5 of 9
In case any equipment such as column, vessel, exchanger etc. form part of a piping circuit
during flushing, this shall be done with the approval of Engineer-In-Charge. However,
equipments thus included in the circuit shall be completely drained and dried with compressed
air after flushing is completed.
During flushing discharged water/air shall be drained to the place directed by the Engineer-In-
Charge. If necessary, proper temporary drainage shall be provided by the contractor.
Care shall be taken during flushing so as not to damage/spoil work of other agencies.
Precautions shall also be taken to prevent entry of water/foreign matter into equipments,
electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed.
The contractor shall carry out all the activities required before, during and after the flushing
operation, arising because of flushing requirements, such as but not limited to the following:
Dropping of valves, specials, distance pieces, inline instruments and any other piping part
before flushing. The flanges to be disengaged for this purpose shall be envisaged by the
contractor and approved by the Engineer-In-Charge. These flanges shall be provided with
temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve distance pieces, piping specials etc. shall
be reinstalled by the contractor with permanent gaskets. However, flanges at equipment
nozzles and other places where isolation is required during testing, only temporary gaskets
shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each piping system
for the flushing done in the proforma provided/approved by the Engineer-in-Charge.
5.0 PRESSURE TESTING
Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless otherwise
specified, herein. Lines carrying highly hazardous/poisonous fluids must have a sensitive leak
test. For IBR lines, ÌBR Regulations' shall also be followed.
5.1 Extent of Testing
With the exclusion of instrumentation, piping systems fabricated or assembled in the field
shall be tested irrespective of whether or not they have been pressure tested prior to site
welding or fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be included in
the system with the prior approval of Engineer-In-Charge if the test pressure specified is equal
to or less than that for the vessels and other equipments.
Pumps, compressors and other rotary equipments shall not be subjected to field test pressure.
Lines which are directly open to atmosphere such as vents, drains, safety valves discharge
need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines
shall be tested by continuous flow of fluid to eliminate the possibility of blockage. However,
such lines if provided with block valve shall be pressure tested up to the last block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working
pressure of the valve. Test pressure applied to valves shall not be greater than the
manufacturer's recommendation nor less than that required by the applicable code. Where
allowable seat pressure is less than test pressure, test shall be made through an open valve.
Page 571 of 1296

0 ENGINEERS
fg-zir tif5leg
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INDIA LIMITED INSPECTION, FLUSHING AND
6-44-0013 Rev. 4
Page 6 of 9
Instruments in the system to be tested shall be excluded from the test by isolation or removals,
unless approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting, draining such as orifice plates etc. shall not
be installed unless testing is complete.
Control valves shall not be included in the test system. Where bypasses are provided test shall
be performed through the bypass and/or necessary spool shall be used in place of the control
valve.
Pressure gauges which are part of the finished system, but cannot withstand test pressure shall
not be installed until the system has been tested. Where piping systems to be tested are
directly connected at the battery limits to piping for which the responsibility rests with other
agencies, the piping to be tested shall be isolated from such piping by physical disconnection
such as valve or blinds.
5.2 General Requirements / Test Preparation for Testing
Testing shall be carried out with permanent gaskets installed unless specified otherwise or
instructed by the Engineer-in-Charge.
No pressure test shall be carried out against closed valve unless approved by the
Engineer-in-Charge
The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence
and programme, to enable him to be present for witnessing the test. The Contractor shall be
fully responsible for making arrangements with the local boiler inspector to witness the tests
for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the
relevant IBR forms and furnished to the Engineer-in-Charge.
Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale,
debris and other loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points and the
systems purged of air before the test pressure is applied.
Wherever in the line any void exists due to any reasons, like absence of control valves, safety
valves, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the test.
Before pressurizing the lines, each weld joint shall be cleaned by wire brush to free it from
rust and any other foreign matter.
Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted

between the companion flanges. Minimum thickness of the blank shall be designed in
accordance with applicable design code.
Open ends of piping system where blanks cannot be used, such as pumps, compressors,
turbines or wherever equipment or pipe spools have been recovered or disconnected prior to
hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the
piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest point in the
piping system to be tested, to avoid overstressing of any of the lower portions of the system.

Page 572 of 1296

ENGINEERS
ligaf fdWeg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
afIR'n ,eant „Ng.) Govt ol India uncieriakm) TESTING OF PIPING SYSTEMS Page 7 of 9
For longer lines and vertical lines, two or more pressure gauges shall be installed at locations
decided by the Engineer-in-Charge.
For lines containing check valves any of the following alternatives shall be adopted for
pressure testing:
Whenever possible pressurize up-stream side of valve.
Replace the valve by a temporary spool and reinstall the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. At these flanges, temporary gaskets shall
be provided during testing and shall be replaced by permanent gaskets subsequently.
For check valves in lines PA" and below flapper or seat shall be removed during
testing (if possible). After completion of testing the flapper/seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary supports
during testing as directed by the Engineer-in-Charge.
Piping which is spring or counter-weight supported shall be temporarily supported, where the
weight of the fluid would overload the support. Retaining pins for spring supports shall be
removed only after testing is completed and test fluid is completely drained.
When testing any piping system, air or steam of approximately 2 kg/ cm2g may be used as
preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the line
to make repairs. However, steam shall not be used for this purpose, if the steam temperature is
more than the design temperature of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is
continuously jacketed, before it is jacketed. The outer jacket shall be tested separately as a
system. For piping with discontinuous jacketing the core pipe and the jacket shall be tested as
separate continuous systems.
5.3 Testing Media, Test Pressure and Test Pressure Gauges
5.3.1 Testing Media
In general all pressure tests shall be hydrostatic using iron free water, which is clean and free
of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 15-
20 ppm.
Air shall be used for testing only if water would cause corrosion of the system or overloading
of supports etc. in special cases as directed by Engineer-in-Charge.
If operating fluid in the line is much lighter than testing fluid, the additional weight of testing
fluid may render piping supports (as designed) inadequate. This will call for additional
temporary supports. The typical examples are flare and vapor lines. It is preferable that
hydrostatic testing is avoided in such systems and instead pneumatic testing may be specified.
Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc.
shall be used as the testing medium, with due consideration to the hazards involved. These test
fluids shall be specified in the line list given to the contractor.
Page 573 of 1296

ara_it.-7 ENGINEERS
INSPECTION, FLUSHING AND
fg-zrr lafj4-d-
'g
1.17",eiecnIe SW{1,141
INDIA LIMITED
°""d' Uncle"") TESTING OF PIPING SYSTEMS
6-44-0013 Rev. 4
'A 6" Page 8 of 9
5.3.2 Test Pressure
The hydrostatic/ pneumatic test pressure shall be as indicated in the line list or as per the
instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the following:
Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress, maximum length
of piping shall be included in each test.
5.3.3 Test Pressure Gauge
All gauges used for field testing shall have suitable range so that the test pressure of various
systems falls in 35% to 65% of gauge scale range. Pressure gage dial shall be minimum of 150
mm. Size of Bourdon shall not be less than 75% of nominal diameter of dial range. Gauge
shall be of a good quality and in first class working condition.
Prior to the start of any test or periodically during the field test programme, all test gauges
shall be calibrated using a standard dead weight gauge tester or other suitable approved testing
apparatus. Any gauge showing an incorrect zero reading or error of more than ± 2% of full
scale range shall be discarded .The Engineer-in-Charge shall check the accuracy of master
pressure gauge used for calibration. Calibration certificate shall be furnished for the pressure
gages.
5.4 Testing Procedure
5.4.1 Hydrostatic Test
All vents and other connections used as vents shall be left open while filling the line with test
fluid for complete removal of air. In all lines for pressurizing and depressurizing the system,
temporary isolation valves shall be provided if valved vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved by the Engineer-in-
charge.
Pressure shall be applied by means of a suitable test pump or other pressure source which shall
be isolated from the system as soon as test pressure is reached and stabilized in the system.
A pressure gauge shall be provided at the pump discharge for guidance in bringing the system
to the required pressure.
The pump shall be attended constantly during the test by an authorized person. The pump shall
be isolated from the system whenever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time not less than 10minutes. Test
pressure shall be released only after physical checking of all the joints and attachments are
completed, to permit thorough inspection of all joints and connections for leakage or signs of
failure. Any joint found leaking during a pressure test shall be retested to the specified
pressure after repair.
The pump and the piping system to be tested are to be provided with separate pressure
indicating test gauges.

Page 574 of 1296

` It1-s
- w ENGINEERS
$/tgal taWreg l INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 4
WWI eic,
tal 451 Jgsr.) IA Govt of India Undertaking)
TESTING OF PIPING SYSTEMS Page 9 of 9
Care shall be taken to avoid increase in the pressure due to temperature variation during the
test.
5.4.2 Pneumatic Test
When testing with air, pressure shall be supplied by means of a compressor. The compressor
shall be portable type with a receiver, after cooler and oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so that the
joints can be examined for leaks.
All other details shall be same as per hydrotesting procedure (specified above).
5.5 Completion of Testing
After the hydrostatic test has been completed, pressure shall be released by opening the vents,
in a manner and at a rate so as not to endanger personnel or damage equipments.
All vents shall be opened before the system is to be drained and shall remain open till all
draining is complete, so as to prevent formation of vacuum in the system. After draining, lines
/ systems shall be dried by air. In services like dry air, ethylene etc., small traces of water can
cause problem. For such lines hot air drying is to be done after hydro-test.
After testing is completed the test blinds shall be removed and equipment / piping isolated
during testing shall be connected using the specified gaskets, bolts and nuts. These
connections shall be checked for tightness in subsequent pneumatic tests to be carried out by
the contractor for complete loop / circuit including equipments (except rotary equipments).
Pressure test shall be considered complete only after approved by the Engineer-in-Charge.
Defects, if any, noticed during testing shall be rectified immediately and retesting of the
system / line shall be done by the contractor at his cost.
5.6 Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping system,
for the pressure test done in the proforma provided/approved by the Engineer-in-Charge.
Records shall also be submitted for the PMI undertaken as per EIL Std. Specification No.
6-82-0002.
Page 575 of 1296

STANDARD SPECIFICATION NO.
ENGINEERS
k-11 el PIPING SPECIFICATION FOR
Ogell Rateg INDIA LIMITED PACKAGE UNITS 6 44 0015 Rev. 1
- -
IA Govt of India Undertaking)

Page 1 of 6
fffR
TOT 1-4-44-r
PIPING SPECIFICATION FOR

PACKAGE UNITS
REAFFIRMED AND ISSUED AS STANDARD

1 13.07.17 dLPK SH v MI RN
SPECIFICATION
0 21.10.10 ISSUED AS STANDARD SPECIFICATION SH ATD SC DM ND

Standards Standards
Committee Bureau
No by by
Approved by
Page 576 of 1296

ENGINEERS PIPING SPECIFICATION FOR
INDIA LIMITED PACKAGE UNITS 6 44 0015 Rev. 1
- -
10WR eiomre agral, (AG. of India Undertaking)
Page 2 of 6
Abbreviations:
PMS Piping Material Specification
VMS Valve Material Specification
ASME American Society of Mechanical Engineers
B/L Battery Limit
P&IDs Piping and Instrumentation Diagrams
Convenor : Mr. M. Ismaeel
Members : Mr. Amrendra Kumar

Mr. G. Balaji
Mr. Udayan Chakravarty
Mr. K.J. Harinarayanan (S&ME)
Mr. S. Ghoshal (Process-2)
Mr. G.K. Iyer (Projects)
Mr. Pankaj Kumar Rai (Construction)
Page 577 of 1296

el ENGINEERS PIPING SPECIFICATION FOR
Ogez fElf5teg INDIA LIMITED PACKAGE UNITS 6 44 0015 Rev. 1
- -
(A Govt of India Undertaking)

Page 3 of 6
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 PIPING DESIGN 4
4.0 DRAWINGS AND DOCUMENTS 6
5.0 DEVIATIONS 6
6.0 ATTACHMENTS 6
Page 578 of 1296

ot
ifaeit4 F7iMp
—. ENGINEERS PIPING SPECIFICATION FOR
Og en idigieg INDIA LIMITED PACKAGE UNITS 6-44-0015 Rev. 1
Page 4 of 6
1.0 SCOPE
This standard specification briefly covers the design requirements, materials and guidelines
for the design and engineering of piping systems inside package units. This standard
specification is generally applicable to following packages; however the same can be adapted
for other packages with similar scope of piping systems.
1. Dosing Skids
2. Nitrogen Package
3. Feed Filters
4. Air Dryers
5. Refrigeration Package
6. PSA
7. Filtration Package
8. Pelletizer
9. Extruders
This specification is not applicable for packages like process gas compressors, mounded
bullets, Heaters, Incinerator etc where extensive process piping is included in the vendor
scope. This specification is also not applicable for Utility packages like Raw Water Plant,
DM Plant, Cooling Tower, Captive Power Plant etc.
2.0 REFERENCES
The design and engineering shall conform to the following standards as applicable:
1. ASME B 31.3 "Process Piping"

2. ASME B 31.5 "Refrigeration Piping and Heat Transfer Components "
3. IBR " Indian Boiler Regulations"
3.0 PIPING DESIGN

3.1 Piping Design Basis
3.1.1 Preferred level of bottom of piping at grade shall be 500 mm.
3.1.2 Minimum level of overhead piping shall be such that a clear 2.2 M headroom is available
below pipe/insulation/supports.
3.1.3 Minimum height of equipment foundations shall be 300 mm from finished grade level.
3.1.4 All open vents to atmosphere shall be vented to safe location at least 3 M above nearest
operating floor or platform located within a radius of 6 M for steam and 8 M for
hydrocarbon/toxic discharge.
3.1.5 Hydrostatic test, Leak test, Non destructive Examination shall be carried out as per applicable
piping design codes.
3.1.6 Hydrostatic Vents and Drains shall be provided at High Point and Low points respectively as
per approved PMS and or good engineering practice.
3.1.7 Piping systems shall be adequately flexible to cater for thermal expansion/contraction under
start-up, operating and shut down conditions. A comprehensive computerized flexibility
analysis should be carried out for lines of sizes 6" & above with design temperature greater
than 120°C connected to rotating machines to ensure that the stresses and loads do not exceed
Page 579 of 1296

ENGINEERS PIPING SPECIFICATION FOR
fge_jiEffiiteg INDIA LIMITED PACKAGE UNITS 6-44-0015 Rev. 1
(A Govt 01 lottia Undoctolon9t
Page 5 of 6
the values permitted in the applicable code or those provided by equipment manufacturer. All
hydrocarbon lines shall be designed considering steam out temperature.
3.1.8 All instruments and valves requiring attention during normal operation shall be conveniently
operable.
3.1.9 Adequate space shall be provided for removal of equipment components for routine
maintenance.
3.2 Pipe Support Design Basis

All piping shall be adequately supported, guided or anchored so as to prevent undue vibration,
deflection/expansion or loads on connected equipment and leakage at flanged joints. Piping
at valves and equipments such as heat exchangers and pumps, requiring periodic
maintenance, shall be supported in such a way so that the valves and Equipments can be
removed with a minimum necessity of installing temporary pipe supports. Pedestal height
for pipe supports on paved area shall be 150mm above HPP. In case of unpaved area, the
pedestal height shall be 300 mm.
3.3 Piping Material Specification/ Valve Material Specification

The job piping material specification as applicable to incoming and outgoing lines is provided
as Annexure I, II. Vendor shall follow these piping classes if shown in P&IDs. Basic details
for valves are provided in the Piping Material Specification. Detail Valve material
specification shall be provided to the successful bidder. In case of variation in
material/components from this specification it shall be the responsibility of the vendor to
ensure suitability and establish equivalence of proposed material.
3.4 Battery Limit
All incoming and outgoing Piping shall be terminated by the vendor at one location with
isolation valves/flanges as per the approved P&IDs. B/L interface orientation shall be
finalized during detail engineering. Battery Limit Drawing shall indicate exact location,
levels and scope of package piping for all incoming and outgoing lines. All piping at Battery
Limit shall be anchored.
3.5 Insulation, Painting & Welding
3.5.1 Hot Insulation and Cold Insulation
3.5.1.1 Insulation with appropriate thickness shall be provided wherever required as per process and
safety requirements.
3.5.1.2 Insulation material, cladding, ancillaries etc shall be provided as per established industry
practice.
3.5.1.3 Suitable protective system shall be provided to eliminate the corrosion under insulation.
3.5.2 Painting
The protective paint system shall be provided to protect external surface of all alloy steel and
carbon steel piping and equipments which are not insulated. The painting system shall be
suitable for the type of environment where package unit is to be installed.
Page 580 of 1296

ei
101
Ogem fafgleg
.791 ENGINEERS
INDIA LIMITED
PIPING SPECIFICATION FOR
6-44-0015 Rev. 1
PACKAGE UNITS
Page 6 of 6
3.5.3 Welding
Welding procedure qualification, welder's qualification, all welding work, equipment for
welding, heat treatment, other auxiliary functions and the welding personnel shall meet the
requirements of the accepted national/international standards and practices.
4.0 DRAWINGS AND DOCUMENTS

Vendor shall furnish battery limit interface piping drawing for review. The drawing shall
have details as referred in clause 3.4 above.
5.0 DEVIATIONS
Vendor shall not take any deviations to the specifications included herein. However, if
absolutely necessary deviations shall be listed separately in appropriate format at the bidding
stage.
6.0 ATTACHMENTS
No. Description
1. Job Piping Material Specification
2. Job Piping Material Specification - General Notes
3. Job Valve Material Specification (will be provided to successful bidder)
4. List of standards/Specification referred in Job PMS
5. B/L Sketch
Page 581 of 1296

tll
$1g-ar j ENGINEERS
■7,
INDIA LIMITED
FOR FABRICATION OF PIPING 6-44-0018 Rev. 0
Gout of India Undertaking) SPOOLS Page 1 of 9
- crrf-tirr Tcff.
41114) rciP41

FABRICATION OF
PIPING SPOOLS
0 01.07.15 ISSUED AS STANDARD SPECIFICATION eH RN

Standards Standards
Committee Bureau
No by by
Approved by
Page 582 of 1296

ENGINEERS
Ifgar kifgrez INDIA LIMITED FABRICATION OF PIPING 6-44-0018 Rev. 0
tm lk Gov) o India Undertaking)
SPOOLS Page 2 of 9
Abbreviations:
ANSI American National Standards Institute

IS Indian Standards
LTCS Low Temperature Carbon Steel
MR Material Requisition
NDE Non-Destructive Examination
PMS Piping Material Specification
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.J. Harinarayanan (I-IMTD)
Mr. Mr. S. Ghoshal (Process)
Page 583 of 1296

el ENGINEERS
Ogen Miez INDIA LIMITED FABRICATION OF PIPING 6-44-0018 Rev. 0
town eivrenfer afl..IMM IA Goof of indict Undertaking)
SPOOLS Page 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 SCOPE OF WORK OF CONTRACTOR .4
3.0 BASIS OF WORK .4
4.0 SUPPLY OF PIPING MATERIALS .5
5.0 FABRICATION .6
6.0 INSPECTION AND TESTING 8
7.0 MARKING .8
8.0 DOCUMENTATION 8
9.0 HANDLING, STORAGE AND DESPATCH 8
Page 584 of 1296

15azre ir= ENGINEERS
0?e-u 004-'eu
lawn rara.T2 Jr107.1)
INDIA LIMITED
IA Govt of India linden-A.40
FABRICATION OF PIPING
SPOOLS
6-44-0018 Rev. 0
Page 4 of 9
1.0 SCOPE
This specification covers general requirements of fabrication of piping spools. The

specification covers the basis of work to be carried out by Contractor and standards,
specifications and normal practice to be followed during fabrication by the Contractor.
2.0 SCOPE OF WORK OF CONTRACTOR
Generally the scope of work of Contractor shall include the following:
2.1 Supply (unless mentioned otherwise) and fabrication of Piping materials including the
following
a. Pipes (All sizes and schedule)
b. Flanges (All sizes, types & Pressure ratings).
c. Fittings (All sizes, types and schedule)
d. Valves (<2", for vents, drains and instrument connections)
e. Attachments for supporting/branch reinforcement made of parent pipe/equivalent

material e.g., protection shields, dummy pipes, low supports, reinforcement pad, etc.
2.2 Shop fabrication of piping in accordance with documents listed under C1.3.0 i.e. 'BASIS OF
WORK'.
2.3 Obtaining approval for drawings prepared by Contractor from statutory authority, if
required.
2.4 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specifications attached.
2.5 Any spool joint which fails during Hydrostatic testing at site shall be replaced/repaired to
the satisfaction of Owner within Owner stipulated time frame with no cost implication.
2.6 All piping materials used for spool fabrication shall be identified and documented as
traceable.
2.7 The heat no. and Material Test Certificate of all piping bulk material supplied by Contractor
shall be recorded and filed for the material trace ability
3.0 BASIS FOR WORK
3.1 The complete piping work shall be carried out in accordance with the following:
3.1.1 "Approved for Construction" drawings and sketches issued by EIL to the Contractor - Plans
and/or Isometrics.
3.1.2 Approved standards and specifications.
3.1.3 Specifications/documents as below:
a. Job Piping Materials Specification (XXXX-6-44-0005)
Page 585 of 1296

ENGINEERS
$11g2II ideeg
lawn tw,A agjornso
INDIA LIMITED
(A Gout of India Undertaking)
SPOOLS
6-44-0018 Rev. 0
Page 5 of 9
b. Job Valve Material Specification (XXXX-6-44-0006)
c. Relevant Piping support standards.
d. Job specification of Non-destructive Requirement of Piping (XXXX-6-44-0016)
e. Standard specification for surface preparation and protective coating (new

construction), (6-79-0020)
f. Job Welding Specification Charts for Piping Classes (XXXX-6-77-0005)
g. Job Welding specification for fabrication of piping. (XXXX-6-77-0001)
h. Technical Notes for Purchase of piping items
i. Any other specifications attached with Piping Material Specification or special

condition of contract (such as standard for Dimensional Tolerances etc.)
J• Standard Specification for Positive Material Identification at Supplier's Works (6-81-

0001)
3.1.4 Following codes, standards and regulations
a. ASME B 31.3 Process Piping
b. ASME Sec. VIII Code for unfired pressure vessel.
c. ASME Sec. IX Qualification standard for welding and brazing

procedures, welders, brazers and welding and
brazing operators.
d. IBR Indian Boiler Regulations
Note : All codes referred shall be latest edition, at the time of award of contract.
3.2 Deviations
Where a deviation from the "Basis of Work" and approved job procedure described above is
required or where the basis of work does not cover a particular situation, the matter shall be
brought to EIL and the work carried out only after obtaining written approval in each case.
4.0 SUPPLY OF PIPING MATERIALS
4.1 Supply of all piping materials except for valves greater than 1.5", blinds, Spectacle blinds,
bolts, nuts and gaskets is in scope of Contractor unless otherwise specified.
4.2 All material used for fabrication shall be in line with PMS and shall be procured as per
applicable Technical specification for purchase of the same where supply of materials is in
Contractor's scope. The materials shall be procured from the approved Vendor list attached
with the MR.
4.3 Pipe, pipe fittings, flanges and valves used in a given piping system shall be strictly as per
the "Piping Material Specification" for the "Pipe Class" specified for that system. To ensure
the above requirement, all piping material supplied by the Owner / Contractor shall have
proper identification marks as per relevant standards / EIL specifications / Licensors
specification. Material traceability is to be maintained for S.S., LTCS and other exotic
Page 586 of 1296

,
r
41 ENGINEERS
'Ige.jr tilfalez INDIA LIMITED FABRICATION OF PIPING 6-44-0018 Rev. 0
latren evotore ovjoom) IA Govt o India lkolortakingj
SPOOLS Page 6 of 9
materials. This shall be in addition to colour coding for all piping materials to avoid mix-up.
The Contractor shall perform Positive material identification as per Standard Specification
for Positive Material Identification at Supplier's Works, 6-81-0001.
4.4 Supply of valves is limited to valves required for vents, drains and instrument connections.
4.5 The Contractor must note that BOM given in Isometric is the exact material requirement.
Any cutting/wastage allowance as required by Contractor needs to be taken separately. No
payment shall be made for this allowance which needs to be considered at the time of
quotation. No allowance shall be considered for fittings/flanges/valves.
4.6 In case Supply of Piping Materials is in the scope of Owner, Owner shall supply pipes
considering a cutting/wastage allowance on 2.5%. No allowance shall be considered on
fittings/flanges/valves.
5.0 FABRICATION
5.1 Pipe Spool Identification
It is the Contractor's responsibility to make detailed spool drawings based on the inputs
provided. Field welds shall be clearly marked.
All Spools shall have a unique Spool identification number.
Pipe Spools shall be identified so as to minimize field welds. In no case shall the field welds
exceed 30% of total welds in any isometric.
Pipe Spools are to be sectionalized to fit into a box 12.0m x 3.0m x 3.0m in accordance with
Shipping length.
5.2 Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per EIL Standard No. 7-44-0486.
The Contractor shall be responsible for working to the dimensions shown on the drawings.
Contractor shall provide an extra pipe length of 300mm for each axis in any of the spools of
the Isometric provided.
5.3 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general,
joining of lines 2" and above in process and utility piping shall be accomplished by butt-
welds. Joining of lines 1.5" and below shall be by socket welding/butt welding/threaded
joints as specified in "Piping Material Specifications".
5.4 Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating,
post-heating and heat treatment shall be as described in the Job welding specification
and NDE specification (XXXX-6-44-0016).
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation
is shown in the drawing.
Page 587 of 1296

i=1)
ENGINEERS
INDIA LIMITED FABRICATION OF PIPING 6-44-0018 Rev. 0
Wren egeaffennJaaml (A Govt of Indla Undertaking)
SPOOLS Page 7 of 9
5.6 Branch Connections
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using
forged tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
5.7 Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be
used.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles,
bulges, flat spots and other serious defects. They shall be true to dimensions. The flattening
of a bend, as measured by the difference between the maximum and minimum diameters at
any cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal
and external pressure respectively.
5.8 Forging and Forming
Forging and forming of small bore fittings, like reducing nipples for piping 1.5" and below,
shall be as per ASME B 31.3.
5.9 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabricated reducers shall be governed by
the Piping Material Specifications. The radiographic requirements shall be as per Material
Specifications for process and utility systems and NDE Specification.
5.10 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per drawings
and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight
length piping.
5.11 Cleaning of Piping
All pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and outside by
suitable means. The cleaning process shall include removal of all foreign matter such as
scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing with
compressed air/or flushing out with water. Special cleaning requirements for some services,
if any, shall be as specified in the piping material specification or isometric or line list. S.S
piping requiring pickling shall be pickled to remove oxidation and discolouring due to
welding.
Page 588 of 1296

ENGINEERS
Etaeg
ROM rim/AIM-mom)
INDIA LIMITED
IA Govt of India undertaking)
SPOOLS
6-44-0018 Rev. 0
Page 8 of 9
5.12 Vents and Drains
High point vents and low point drains shall be provided even if not shown on isometric
drawing. The details of vents and drains shall be as per piping material specifications / job
standards / Valve material Specifications.
5.13 If the pipe contains a longitudinal weld, this weld shall not be located at the bottom of the
pipe; it should be located at least 45° from the bottom of the pipe.
6.0 INSPECTION AND TESTING
6.1 Contractor shall submit the Quality Assurance procedure for approval. The Contractor shall
establish and maintain such quality assurance system as are necessary to ensure that goods
or services supplied comply in all respects with the requirements of this specification.
6.2 Refer to specification number 6-81-0153 for Inspection and Test Plan for Piping Spools.
7.0 MARKING
Surface preparation and shop primer application shall be as per painting specification. Line
number in black or white shall be stenciled on the pipe spool for identification purposes.
Spools are to be identified by their line number and spool suffix, which shall be painted or
stenciled as characters at least 50 mm high. The size of character shall be suitable with size
of the pipes. Painted numbers shall be located, and repeated as necessary, in such a manner
that any spool may be easily identified without turning or lifting it.
In addition, Line number with spool suffix shall be placed by cold rolling or low stress dot
marking on the outside surface of the spool at an approximate distance of 350mm from both
ends on each spool.
8.0 DOCUMENTATION
8.1 Documentation with Dispatch
a) List of Spools in Consignment

b) Spool Drawings
c) Inspection Release Note
d) Inspection and Testing Reports (Welding, NDE, Materials, PMI etc)
e) Line History Sheet
f) Any other document required for completion of dispatch formalities
8.2 Final Documentation
a) All documents sent with Dispatch

b) Documents as per Final Documentation Procedure.
9.0 HANDLING, STORAGE AND DESPATCH
The Contractor shall load, unload, transport and stockpile the piping material using suitable
means and in a manner to avoid damage. Branches shall be braced if required to prevent
damage during transit.
Pre-fabricated pipe spools shall be properly protected against corrosion and damage during
storage and transport to site. Flanges shall be fitted with flange protectors, including a
Page 589 of 1296

ENGINEERS
Ifgar lad&
' 07. ",""eo" , `,t,.'9
INDIA LIMITED
(A Goo of Indio UndertakIng)
SPOOLS
6-44-0018 Rev. 0
Page 9 of 9
proven protection against corrosion for the flange face. Plain and beveled pipe ends shall be
provided with plastic covers. Care shall be exercised and adequate precautions taken to
avoid damage and entry foreign matter during transportation, installation, testing etc.
Small pieces shall be boxed or wired together to avoid loss in transit.
Page 590 of 1296

STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
5fg-ar I~-3
dg INDIA LIMITED PIPES 6-44-0051 Rev. 6
IA GoN of Indo Undeflakng)
Page 1 of 10
lebri ch i•JA
TECHNICAL NOTES
FOR PIPES

6 25.09.14
SPECIFICATION SH' K ATD(‘'\:' SC
5 31.12.13
SPECIFICATION UK SH AK RN SC
4 04.07.08
SPECIFICATION RN SC DM VC
3 15.03.00 RN BRB NS AS
SPECIFICATION
HYDROTEST & I.G.C. TEST CLAUSES
2 04.04.94 AKG BPV GRR AS
REVISED
Standards Standards
Committee Bureau
No by by
Approved by
Page 591 of 1296

INDIA LIMITED PIPES 6-44-0051 Rev. 6
rivvottt.1.5trool, IA Govt ot Intha Undertalfing)
Page 2 of 10
Abbreviations:

API American Petroleum Institute
ASTM American Society for Testing & Materials
BHN Brinell Hardness Number
BIS Bureau of Indian Standards
E.FS.W Electric Fusion Weld
E.R.W Electric Resistance Weld
HAZ Heat Affected Zone
HIC Hydrogen Induced Cracking
IGC Inter Granular Corrosion
IS Indian Standard
LT Low Temperature
NACE MR National Association of Corrosion Engineers : Material Requirement
NB Nominal Bore
NPT Nominal Pipe Thread
PR Purchase Requisition
SMYS Specified Minimum Yield Strength
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Page 592 of 1296

$;fgW 2154- INDIA LIMITED PIPES 6-44-0051 Rev. 6
1+fV7R rwnrt ,151,70541, IA Govl of lodia Undeftalong)
Page 3 of 10
CONTENTS
1.0 GENERAL 4
2.0 IBR PIPES 6
3.0 ACCEPTABLE DEVIATIONS 7
4.0 HYDROSTATIC TEST 7
5.0 MARKING AND DESPATCH 10
6.0 REFERENCES 10
Page 593 of 1296

2f5le'g INDIA LIMITED
IA Govl ol lnaia Undertakog)
PIPES 6-44-0051 Rev. 6
Page 4 of 10
1.0 GENERAL
1.1 A11 pipes and their dimensions, tolerances, chemical composition, physical properties, heat
treatment, hydrostatic test and other testing and marking requirements shall conform to the
latest codes and standards specified in the material requisition (MR). Supplier shall strictly
comply with MR/PR stipulations and no deviations shall be permitted. Post Order
Concession/Deviation Permit 5-0000-0180-F1 as mentioned in Cl. 5.18 of Specification for
Quality Management System Requirements from Bidders (6-78-0001) is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the MR & Clauses 1.10 & 1.11.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the pipes supplied.
1.2.3 PMI shall be performed as per the scope and procedures as defined in the spec for PMI at
Supplier's Works (6-81-0001).
1.2.4 Refer to specification nos. 6-81-0002 and 6-81-0003 for Inspection & Test plans for welded
pipes and seamless pipes respectively.
1.3 Manufacturing Processes
1.3.1 Steel made by acid Bessemer process shall not be acceptable.
1.3.2 A11 longitudinally welded pipes should employ only automatic welding.
1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters
respectively.
1.5 a. Seamless and E.R.W. pipes shall not have any circumferential seam joint in a random
length. However, in case of E.FS.W pipe, in one random length one welded
circumferential seam of same quality as longitudinal weld is permitted. This weld
shall be at least 2.5 m from either end. The longitudinal seams of the two portions
shall be staggered by 90°. Single random length in such cases shall be 5 to 7 m.
b. Unless otherwise mentioned in the respective material code, E.FS.W pipes < 36" shall
not have more than one longitudinal seam joint and E.FS.W pipes 36" shall not
have more than two longitudinal seam joints.
1.6 Pipe with screwed ends shall have NPT external taper pipe threads conforming to
ASME/ANSI B1.20.1 up to 1.5" NB & IS 554 for 2" to 6" NB.
Page 594 of 1296

INDIA LIMITED PIPES 6-44-0051 Rev. 6
wlrrT t,vcrtV ItISOIstt ) IA Govt ol Intlia Gott000k,o9)
Page 5 of 10
1.7 Pipe with beveled ends shall be in accordance with ASME B16.25. Weld contours shall be as
follows:
Material Wall Thickness Weld Contour

Up to 22 mm Figure 2 Type A
Carbon Steel (Except
Low Temp. Carbon Steel) > 22 mm Figure 3 Type A
Up to 10 mm Figure 4
Alloy Steel,
Stainless Steel & > 10 mm & Up to 25 mm Figure 5 Type A
Low Temp. Carbon Steel
> 25 mm Figure 6 Type A
1.8 Galvanized pipes shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM
A 153.
1.9 All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types
of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to the normal solution annealing. Soaking time
& holding temp. for stabilizing heat treatment shall be 4 hrs & 900°C respectively.
1.10 I.G.C. Test for Stainless Steels
1.10.1 For all austenitic stainless steel pipes inter-granular corrosion test shall have to be conducted
as per following:
ASTM A262 Practice "B" with acceptance criteria of "60 mils/year (max.)".
OR
ASTM A262 Practice E with acceptance criteria of no cracks at 20X magnification and
microstructure to be observed at 250X magnification shall ensure the absence of any cracks/
fissures. When testing is conducted as per practice 'E' photograph of microstructure shall be
submitted for record.
1.10.2 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (eg.SS 309, 310, 316, 316H etc.) ASTM A262 Practice "C" with
acceptance criteria of "15 mils/year (max.)" shall have to be conducted.
1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from each
solution annealing lot; one set corresponding to highest carbon content and the other set
corresponding to the highest pipe thickness.
All welded pipes indicated as `CRY0' & `LT' in MR shall be impact tested per requirement
& acceptance criteria of ASME B31.3. The impact test temperature shall be -196°C & -45°C
for stainless steel and carbon steel respectively unless specifically mentioned otherwise in
MR.
1.12 NACE/HIC Requirements
1.12.1 Pipes under "NACE" category and those designated as "HIC1" shall meet the requirements
given in NACE MR-0103 unless mentioned otherwise.
1.12.2 Pipes made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless mentioned otherwise.
Page 595 of 1296

`51
1 ENGINEEFZS TECHNICAL NOTES FOR
5fga 02-eg INDIA LIMITED PIPES 6-44-0051 Rev. 6
1.11UR ertcnt ,TR,1-4.1) Ift Govt of UnciertaNingf
Page 6 of 10
1.13 Specified heat treatment for carbon steel and alloy steel and solution annealing for stainless
steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot
shall be restricted to maximum two by approved repair procedure.
1.14 For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be
20%.
1.15 All 1Cr-V2Mo and 11/4Cr-1/4Mo seamless pipes shall be normalised and tempered.
1.16 For all welded alloy steel pipes with mandatory requirement of heat treatment and
radiography, radiography shall be performed after heat treatment.
1.17 For Hydrogen service pipes following special requirements shall also be met:
1.17.1 All carbon steel pipes having wall thickness 9.53 mm (0.375") and above shall be normalised.
Cold drawn pipes shall be normalised after the final cold draw pass for all thicknesses.
1.17.2 All alloy steel (Cr-Mo) pipes shall be normalised and tempered. The normalising and
tempering shall be a separate heating operation and not a part of the hot forming operation.
The maximum room temperature tensile strength shall be 100,000 psig.
1.17.3 For carbon steel Pipes, hardness of weld and HAZ shall be 200 BHN (max.). For alloy steel
Pipes, hardness of weld and HAZ shall be 225 BHN (max.).
1.17.4 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
Ferrite No.(FN) not less than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by Ferritescope prior to post
weld heat treatment.
1.17.5 For all Carbon steel and Alloy steel pipes with wall thickness over 20mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-1 for weld metal and base metal from the thickest item per heat of material and per
heat treating batch. Impact test specimen shall be in complete heat treated condition and
accordance with ASTM A370. Impact energies at 0°Celsius shall average greater than 27J (20
ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).
1.18 For dual grades of SS where specified, chemical composition and mechanical properties of
both grades specified shall be ensured.
2.0 IBR PIPES
2.1 IBR Documentation
2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form III-A
duly approved and countersigned by IBR authority/local authority empowered by the Central
Boiler Board of India(Photocopy of the original certificate duly attested by the local boiler
inspector where the supplier is located is the minimum requirement for acceptance) or Form
III-D [for well known pipe manufacturers as per IBR] signed by Manufacturer's authorized
representative. Well known pipe manufacturers, as recognized by IBR, shall submit a duly
attested copy of Form XVI-G along with Form
2.1.2 For materials 11/4Cr - V2Mo (ASTM A335 Gr.P11 / A691 Gr.11/4Cr), 21/4Cr - 1Mo (ASTM
A335 Gr.P22 / A691 Gr.21/4Cr) & 9Cr -1Mo-V (A335 Gr.P91/A691 Gr.91), Form III-A
approved by IBR shall include the tabulation of Et, Sc & Sr values for the entire temperature
range given below. Et, Sc & Sr values shall be such that throughout the temperature range
Page 596 of 1296

$R-ar 22-eg
1.177, rrmrr an s~›
INDIA LIMITED
IA Govt ot India Undertalfingt
PIPES 6-44-0051 Rev. 6
Page 7 of 10
E,/ 1.5
Sr / 1.5 SA
Sc
where ,
SA Allowable stress at the working metal temperature.

Yield point (0.2% proof stress at the working metal temperature)
S, The average stress to produce elongation of 1%(creep) in 100000 hrs at the
working metal temperature.
Sr The average stress to produce rupture in 100000 hrs at the working metal
temperature and in no case more than 1.33 times the lowest stress to produce
rupture at this temperature.
SA (psi)
Temp(°F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
Material
A335 Gr.P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
A691 Gr.11/4Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
A335 Gr.P22 /
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A691 Gr.21/4Cr
A335 Gr.P91/
28100 27700 27300 26700 25900 24900 23700 22300 20700 18000 14000 10300
A691 Gr.91
Note : SA values shall be as per the latest edition prevai ing.
2.2 For carbon steel pipes under IBR the chemical composition shall conform to the following:
Carbon (max) 0.25%

Others (S, P, Mn) As prescribed in IBR.
The chemical composition as indicated in this clause is not applicable for pipes other than IBR
services.
3.0 ACCEPTABLE DEVIATIONS
3.1 Pipes to IS 3589 Gr.410 are acceptable in place of IS 3589 Gr.330.
3.2 Pipes of Grades SS317 of corresponding material are acceptable in place of Grades SS316 or
SS316(2.5 Mo min.).
3.3 Pipes of Grades SS317L of corresponding material are acceptable in place of Grades SS316L
or SS316L(2.5Mo min.).
3.4 Seamless pipes are acceptable in place of welded pipes except in the case of welded
SS321/SS321H pipes with nominal thickness greater than 9.53mm.
4.0 HYDROSTATIC TEST
4.1 A11 pipes shall be hydrostatically tested.
Page 597 of 1296

~_le7 ENGINEERS TECHNICAL NOTES FOR
• e5 INDIA LIMITED
IA Govt of Incha Undertalting)
PIPES 6-44-0051 Rev. 6
Page 8 of 10
4.2 The mill test pressure shall be as follows:
4.2.1 Seamless, E.R.W. & Spiral Welded
a) Carbon Steel
Material Std. Test Pressure Std.
ASTM A106 Gr.B ASTM A530
API 5L Gr.B, Seamless API 5L
API 5L, E.R.W. API 5L
API 5L, Spiral API 5L
ASTM A333 Gr.3 & 6, Seamless ASTM A530
ASTM A333 Gr.3 & 6, E.R.W. ASTM A530
b) Seamless Alloy Steel
ASTM A335 Gr.P1, P12, P11, P22, P5, P9 ASTM A530
ASTM A268 TP 405, TP410 ASTM A530
c) Seamless Stainless Steel

ASTM A312 Gr.TP 304, 304L, 304H, 316, ASTM A999
316L, 316H, 321, 347
d) Seamless Nickel Alloy
ASTM B161 UNS No. 2200 ASTM B161
e) Welded Nickel Alloy
ASTM B725 UNS No. 2200,4400 ASTM B725
Page 598 of 1296

0141
-eg INDIA LIMITED
IA Govt of Indo UnclertaNngt
PIPES 6-44-0051 Rev. 6
Page 9 of 10
4.2.2 Electric Fusion Welded
a) Carbon Steel & Alloy Steel E.FS.W (16" & above)

API 5L Gr.B P = 2ST/D
ASTM A671 Gr.CC65, 70 (C1.32) S = 90% of SMYS
ASTM A672 Gr.C60, 65, 70 (CI.12,22) Except for API 5L Gr.B
ASTM A671 Gr.CF60, 65, 66, 70 (C1.32) S = 85% of SMYS
ASTM A691 Gr.V2Cr, 1Cr, 11/4Cr, 21/4Cr, For API 5L Gr.B
SCr, 9Cr (C1.42) T = Nominal Wall Thickness
D = O.D of Pipe
b) Stainless Steel E.FS.W (2" to 6")
The hydrostatic test pressure in kg/cm2 for the following materials shall be as given
below :
Material Gr.1 :ASTM A312 TP 304 / 304H / 316 / 316H / 321 / 347 welded.
Material Gr.2 :ASTM A312 TP 304L / 316L welded.
Size Pipe Schedule : 10S Pipe Schedule : 40S Pipe Schedule : 80S
Material Material Material Material Material Material
Gr. 1 Gr.2 Gr.1 Gr.2 Gr.1 Gr.2
2" 100 80 155 130 230 190
3" 80 60 155 130 230 190
4" 80 50 155 130 230 190
6" 65 35 90 75 155 130
c) Stainless Steel E.FS.W (8" and above).

ASTM A358 TP 304L, 304, 304H, 316L, P = 2ST/D
316, 316H, 321, 347 (Classes 1, 3 & 4) S = 85% of SMYS
T = Nominal Wall Thickness
D = O.D of Pipe
ASTM A358 TP 304L, 304, 304H, 316L, P = 2ST/D
316, 316H, 321, 347 (Classes 2 & 5) S = 72% of SMYS
T = Nominal Wall Thickness
D = 0.D of Pipe
4.2.3 Carbon Steel Pipes to BIS Standards

IS 1239 IS 1239
IS 3589 IS 3589
4.3 Hydrostatic pressure testing shall be performed using iron free water, which is clean and free
of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 50
ppm.
Page 599 of 1296

OrcRes
1
.1,P+,,
M11 J457,01/
INDIA LIMITED
IA GoN ol India UnclettaMing)
PIPES 6-44-0051 Rev. 6
Page 10 of 10
5.0 MARKING AND DESPATCH
5.1 All pipes shall be marked in accordance with the applicable codes, standards and
specifications. In addition the purchase order number, the item code & special conditions like
"IBR", "CRY0", "NACE", "H2" etc. shall also be marked.
5.2 Pipes under "IBR","CRY0", "NACE" & "H2" shall be painted with one circumferential
stripe of colour red, light purple brown, canary yellow & white respectively for easy
identification. Width of stripe shall be 12mm for pipe sizes lens than 3" and 25mm for pipes
3" and above.
5.3 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead
or copper which cause corrosive attack on heating.
5.4 Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
5.5 Pipes shall be protected from rust & corrosion.
5.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a
petroleum solvent and the same shall not be harmful to welding.
5.7 Both ends of the pipe shall be protected with the following material:
Plain end Plastic cap

Bevel end Wood, Metal or plastic cover
Threaded end Metal or plastic threaded cap
5.8 Pipes may be provided with plastic push-fit type end caps/ steel caps without belt wire.
5.9 Steel end protectors to be used on galvanized pipes shall be galvanized. Plastic caps can also
be used as end protectors for galvanised pipe ends.
6.0 REFERENCES
6.1 6-81-0001: Specification for Positive Material Identification (PMI) at Supplier's Works.
6.2 6-81-0002: Inspection & test plan for welded pipes.
6.3 6-81-0003: Inspection & test plan for seamless pipes.
6.4 6-79-0013: Material requirements for carbon steel components used in sour service for
petroleum refinery environments
Page 600 of 1296

ENGINEERS TECHNICAL NOTES
fg0j1 fetWeg INDIA LIMI TED FOR VALVES 6-44-0052 Rev. 7
Page 1 of 12
vilcni rd uAluiii*
TECHNICAL NOTES FOR VALVES
7 13.07.17
REVISED AND ISSUED AS STANDARD 01/4
SPECIFICATION ‘ )t.144<-1 MI RN
6 04.08.10
SPECIFICATION RN ATD SC DM ND
5 04.07.08 RN SC DM VC
SPECIFICATION
4 15.11.00 RN BRB NS MI
SPECIFICATION
3 04.04.94 ISSUED IN LINE WITH GENERAL REVISION AKG NS GRR AS
Standards Standards
Committee Bureau
No by by
Approved by
Page 601 of 1296

taleg
ailErf t-recnr11513‘grai
INDIA LIMITED
FOR VALVES 6-44-0052 Rev.7
Page 2 of 12
Abbreviations:
AARH : Arithmetic Average Roughness Height

ASTM : American Society for Testing & Materials
BGO Bevel Gear Operator
BHN Brinnel Hardness Number
BS • British Standard
BVIS ▪ Bureau Veritas Industrial Services
BW • Butt Weld
CAT • Category
CEIL • Certification Engineers International Limited
CS Carbon Steel
DFT Dry Film Thickness
DNV Det Norske Veritas
DP Dye-Penetrant
eDMS : Electronic Document Management System
IS Indian Standard
LT • Low Temperature
LTCS • Low Temperature Carbon Steel
MOV • Motor Operated Valve
MP • Magnetic Particle
MR • Material Requisition
NDT • Non Destructive Testing
PMI • Positive Material Identification
PO Purchase Order
RFQ Request for Quotation
SCRD : Screwed
SS Stainless Steel
SW Socket Weld
Convenor : Mr M. Ismaeel
Members : Mr. Amrendra Kumar

Mr. G. Balaji
Mr. Udayan Chakravarty
Mr. K.J. Harinarayanan (S&ME)
Mr. S. Ghoshal (Process-2)
Mr. G.K. Iyer (Projects)
Mr. Pankaj Kumar Rai (Construction)
Page 602 of 1296

1f lots
Igar 0151-e-G INDIA LIMITED
tole,r rievore tri.ltrovn) (A Govt of India Undertaking)
Page 3 of 12
CONTENTS
1.0 GENERAL 4
2.0 DOCUMENTATION 4
3.0 DESIGN AND CONSTRUCTION 5
4.0 OPERATION 9
6.0 RADIOGRAPHY OF CAST VALVES 10
7.0 IBR CERTIFICATION 11
8.0 MARKING 11
9.0 DESPATCH 11
10.0 ATTACHMENTS 12
11.0 REFERENCES 12
Page 603 of 1296

LIIdel ENGINEERS TECHNICAL NOTES
$1gziT tif4leg INDIA LIMITED FOR VALVES 6-44-0052 Rev.7
MIRFC eleax, 45134115-41) IA Govt of Ind ia Undertaking)
Page 4 of 12
1.0 GENERAL
1.1 Vendor shall supply valves in accordance with the valve specification sheets along with
auxiliaries, if any, such as gear operator, bypasses, drains, locking arrangements etc. wherever
specified in the specification sheets, subject notes and other enclosures to the material
requisition (MR).
1.2 Vendor shall quote in strict accordance with the valve data / specification sheets, subject
technical notes and all other enclosures to the MR. For 'Cat-I valves', no deviations
whatsoever shall be accepted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as
mentioned in Cl. 5.17 of specification for Quality Management System Requirements from
Bidder (6-78-0001) is not applicable for Cat-I valves. For Cat-II Valves, if exceptions/
deviations become absolutely must, the same shall be requested as explained in clause 2.3.6
giving reasons for seeking such exceptions/ deviations.
1.3 All codes and standards for manufacture, testing, inspection etc. shall be of latest editions as
on issue date of RFQ.
2.0 DOCUMENTATION
2.1 All document submissions to EIL shall be through EIL eDMS.
2.2 For 'Cat-I' valves, no documents shall be submitted with the offer.
2.3 For 'Cat-IF valves, vendor shall submit the following documents with the offer:
2.3.1 Manufacturer's complete descriptive and illustrative catalogue / literature.
2.3.2 Detailed dimensioned cross section drawing with parts / material lists, weight etc.
2.3.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator,
motor, extension bonnet, extended stems with stands, bypass etc. giving major salient
dimensions.
2.3.4 One copy of the valve specification sheets signed as "Accepted" by the manufacturer.
Deviations, if any shall be marked as applicable on the valve specification sheet.
2.3.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve
specification sheets as "Regret" or "No Deviation".
2.3.6 For 'CAT-II' valves, if there is any deviation, the same shall be listed clausewise.
2.3.7 On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely
to be rejected.
2.4 The following documents shall be submitted through eDMS of EIL after placement of the
order:
2.4.1 For Cat-I valves to manufacturers' standard specified in MR/valve specification sheet,
detailed dimensioned cross section drawing with parts, materials, weight, etc. shall be
submitted for records/information.
Page 604 of 1296

laffaad ENGINEERS TECHNICAL NOTES
$/fg-ar kites INDIA LIMITED FOR VALVES 6-44-0052 Rev.7
(Merl e4tax,...13,63.0 (A Govt of India undertaking)
Page 5 of 12
2.4.2 For 'Cat-II' valves, Vendor shall submit for review drawings mentioned in clauses 2.1.2 &
2.1.3 before start of manufacture. No other drawings shall be submitted for review.
2.4.3 Test report shall be supplied for all mandatory tests as per the applicable code. Test reports
shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.
2.4.4 Material test certificates (physical properties, chemical composition & heat treatment report)
of the pressure containing parts shall be furnished for the valves supplied. Material test
certificates for the other parts shall also be furnished for verification during inspection.
2.5 In addition to submissions through EIL eDMS, Catalogues/Drawings shall be in submitted in

hard copies (6 sets) and soft copies (2 CDs/DVDs) along with delivery for Purchaser's record
for all categories/types of valves.
3.0 DESIGN AND CONSTRUCTION
3.1 Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing
standards, design codes and standards indicated in the respective valve specification sheets.
Any conflict between the requisition, enclosures, specification sheets and referred standards/
codes shall be brought to the notice of the purchaser for clarifications and resolution, before
proceeding with the manufacture. The purchaser's decision shall be final and binding to the
vendor. The drawings submitted for review shall not include any deviations except as
communicated in writing in Deviation permits. The Drawings shall be reviewed only for
design and construction features.
3.2 All flanged valves shall have flanges integral (except forged valves) with the valve body.
Flange face finish shall be normally specified in the valve specification sheet as 125 AARH
etc. The interpretation for range of face finish shall be as follows:
Stock Finish : 1000 p. in AARH max.

125 AARH : Serrations with 125 to 250 p in AARH
63 AARH : 32 to 63 p. in AARH
33 For all weld end valves with bevel end as per ASME B 16.25, the contour of bevel shall be as
follows:

Carbon Steel (Except Upto 22 mm Figure 2 Type A
Low Temp. Carbon Steel)
Alloy Steel, Upto 10 mm Figure 4
Stainless Steel &
Low Temp. Carbon Steel > 10 mm & Upto 25 mm Figure 5 Type A
Valve ends shall match thickness of the connecting pipe. Sloping of inside contour of valves
shall be done wherever necessary to achieve this.
Page 605 of 1296

r..11 feitReg
411M eiecnte J,,RfrA
INDIA LIMITED
IA Govt or India Undertaking)
Page 6 of 12
3.4 For flanged valves with ring joint flanges the hardness shall be as follows:
Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140
1% Cr to 5% Cr, 9% Cr 150
Type 304, 316, 321, 347 160
Type 304L, 316L 140
3.5 Following requirements for check valves shall be met over and above the valve specification
sheet requirements:
3.5.1 Unless specified otherwise in the data sheet all check valves 3" & above (except in 900#,
1500# & 2500# rating) shall have a drain boss at location "G" (Refer Fig.No.1 of ASME
B16.34) where pocket is formed in valve body. A tapped drain hole with plug shall be
provided as per ASME B 16.34. Threads shall be as per ASME B 1.20.1 (Taper) NPT.
3.5.2 For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and
other such standard devices.
3.6 If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion
resistance of the seat ring base material shall be at least equal to the corrosion resistance of the
material of the shell.
3.7 Following valve bypass requirements shall be met:
3.7.1 By-pass requirement for Gate valves shall be as follows unless otherwise mentioned.
ASME 150 Class On sizes 26" and above

3.7.2 The by-pass piping arrangement shall be such that clearance between main valve body and by-
pass assembly shall be the minimum possible for layout reasons. Vendor shall follow the
sketch enclosed in Specification No. 6-44-0052-Al.
3.7.3 By-pass valve shall be a globe valve. The sizes shall be as under:
On main valve 4" 1/2"

On main valve 6" to 8" 3/4"
On main valve 10" & above 1"
By-pass piping shall be of same metallurgy as main valve. The by-pass piping, fittings and
valve tag numbers shall be as specified in Specification No. 6-44-0052-A2. In case details of
by-pass arrangement for any Valve tag number is missing, Vendor shall bring the same to
notice of EIL and provide by-pass as per details specified.
3.7.4 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with
by-pass shall have the direction of flow marked on the main valve. By-pass attachment to the
Page 606 of 1296

, 31 ENGINEERS TECHNICAL NOTES
Ogell ttfaeg INDIA LIMITED
Page 7 of 12
main valve body shall not be screwed. All fillet welds for by-pass installation shall be 100%
examined by DP/MP test and Butt-weld joints shall be 100% examined by radiography.
3.8 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of
casting but not vice-versa.
3.9 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However,
integral stem of cast material is acceptable for Plug valves.
3.10 Stelliting / hardfacing by deposition, shall be minimum 1.6 mm.
3.11 Renewable seat rings shall be seal welded for valves of size 3" and above to prevent loosening
in service.
3.12 For Low Temperature & Cryogenic valve requirements, refer Specification.No.6-44-0052-A3
unless otherwise specified.
3.13 For Hydrogen service valve requirements, refer Specification.No.6-44-0052-A4 unless

otherwise specified.
3.14 Valves under `NACE' category shall meet the requirements specified in MR-0103 unless
3.15 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted
as per the following:
3.15.1 ASTM A262 Practice 'B' with acceptance criteria of '60 mils/year (max.)' for all materials -
forged, rolled, wrought and casting.
Or
ASTM A262 Practice È' with acceptance criteria of 'No cracks as observed from 20X
magnification' for all materials other than castings. 'Microscopic structure to be observed
from 250X magnification' in addition.
austenitic stainless steel (eg. SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with
acceptance criteria of ' 15 mils/year (max.)' shall be conducted.
3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn
from each solution annealing lot. One set shall correspond to the highest Carbon content and
the other to the highest pressure rating. When testing is conducted as per practice È',
photograph of the microscopic structure shall be submitted for record.
3.16 All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition.
Stabilising heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4
hours respectively.
3.17 Spiral wound bonnet gaskets are to be provided with inner/outer ring except when
encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in
case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of
spiral touches the bolts ascertaining the centering.
3.18 All Stainless Steel Castings shall be solution heat treated.
Page 607 of 1296

101 tGI J ENGINEERS TECHNICAL NOTES
Ogen EtOleg S INDIA LIMITED
IrkRer eteakeott3tratTO (A Govt of India Undertaking)
Page 8 of 12
3.19 Only normalized and tempered material shall be used in the following specifications :
Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217
Gr.WC9, A217 Gr.C5, A217 Gr.C12
Forgings : A182 Gr.F11 C1.2, A182 Gr.F12 C1.2
3.20 Ball / Plug / Butterfly Valves
3.20.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS EN ISO 10497 (Supersedes
BS 6755 Part II) shall be carried out on soft seated ball, plug & butterfly valves and also on
lubricated plug valves The test shall be witnessed and certified by a third party inspection
agency like Lloyds, BVIS, DNV or EIL/ CEIL unless otherwise specified. The vendor has to
submit test certificate for the particular design of the valve offered, if fire safe design is
required as per the Valve Material Specification sheet..
3.20.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated
valves.
3.20.3 Soft-seated ball, plug & butterfly valves shall be supplied with antistatic devices.
3.20.4 BW / SW end ball valves shall have a 100 mm long seamless pipe nipple welded to each end
of the valve. Nipples are to be welded prior to assembling Teflon seats / seals. Specifications
of the nipples shall be as indicated in the MR.
3.20.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the
corresponding ANSI class (except 10" onwards in Class 150 where the face-to-face
dimensions shall be as per API 6D long pattern).
3.20.6 The ball of ball valve shall not protrude outside the end flanges of valve.
3.20.7 Ball valves shall be of floating ball/trunnion mounted type as per following:
150# 8" & below Floating ball

10" & above Trunnion mounted
300# 4" & below Floating ball

6" & above Trunnion mounted
600# 1.5" & below Floating ball

& above 2" & above Trunnion mounted
3.20.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be
limited to one size lower than the nominal bore.
3.21 The MOVs are to be installed in an open area and the actuators shall be suitable for all
weather conditions. The testing of complete assemblies of MOVs along with the actuators
shall be done by the supplier at his works.
3.22 Ends of flanged valves of 22" size shall match corresponding flanges to MSS-SP44 unless
3.23 Yoke material shall be same as bonnet material where maximum temperature specified is
more than 427°C.
Page 608 of 1296

/gar Ea&
(ORR MEW MI 3‘17.3)
INDIA LIMITED
(A Govt. of India undertaking,
Page 9 of 12
4.0 OPERATION
4.1 Gear operation shall be provided as under:
Valve Type Class Size Requiring Gear-Operator

Gate Valve, Globe Valve & 150 Class 12" and larger
Diaphragm Valve 300 Class 12" and larger
600 Class 10" and larger
Ball Valve / Plug Valve 150 Class 6" and larger
(Other than pressure balance 300 Class 6" and larger
plug valves)
Butterfly Valve 150, 300 Class 6" and larger
For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure
balance plug valves manufacturer's recommendation shall be acceptable provided the
requirements specified in clause 4.6 are met.
4.2 Gear operator shall be provided, with position indicators for open / close positions and with
limit stops. (Limit stops are not applicable for gate and globe valves).
4.3 Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear
operator, the same shall be highlighted.
4.4 Gear operator shall be so designed as to operate effectively with the differential pressure
across the closed valve equal to the cold non-shock pressure rating.
4.5 Ball, plug and butterfly valves, shall have "Open" position indicators with limit stops.
4.6 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on
either side. Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing
to meet the above requirements, vendor shall offer gear operated valve and quote as per clause
4.3.
5.1 Every valve shall be subjected to all the mandatory tests and checks called in the respective
codes / data sheet by EIL inspection or any third party as approved by the purchaser. For IBR
valves refer clause 7.0.
5.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and
checks called for in the respective codes, data sheets etc. by the manufacturer.
5.3 Though the extent of inspection shall be as under, exact extent with hold points shall be
decided by EIL regional inspection office and recorded in the form of inspection plan. In case
of third party inspection, the inspection plan shall be approved by the purchaser.
Page 609 of 1296

Reie?(7
ENGINEERS
-A TECHNICAL NOTES
Ogelf idaeg INDIA LIMITED
eIreel ,too e MI OW.) IA Govt of India Undertaking)
Page 10 of 12
Forged Valves:
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Any mandatory or supplementary test.
4. Hydrostatic test on 10% valves selected on random basis.
5. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1
No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze
material valves with 13% Cr/ Brass/ Bronze trims.
Cast Steel Valves:
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Review of radiographs/radiographic reports or any other NDT tests wherever applicable
as per data sheet.
4. Any mandatory or supplementary test.
5. Hydrostatic test 100% for body, 10% other test.
6. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1
No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze
material valves with 13% Cr/ Brass/ Bronze trims.
Samples for strip check shall be selected at random and shall generally be in the highest
size in the lot.
5.4 In case of motor operated or actuator operated valves, functional / operational checks as per
the requirements of the specifications shall be made on each valve.
6.0 RADIOGRAPHY OF CAST VALVES
6.1 Valve castings shall undergo radiographic examination as specified below.
Material Rating Size Range Radiography

All 150# 24" and below NIL**
26" and above* 100%
300# 16" and below NIL**
18" and above 100%
600# & above All sizes 100%
* No radiography is required for valves of size 26" and above in cooling water service.
**For sizes 24" & below in 150# and 16" & below in 300#, radiography percentage if
specifically mentioned in individual valve material spec sheet shall govern.
Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies
10% or 20% etc. of number of valves ordered against each item number with a minimum of
one valve against each item.
Page 610 of 1296

rn~r el ENGINEERS TECHNICAL NOTES
fEff5teg INDIA LIMITED
(A Govt of India Unclertalcing)
Page 11 of 12
6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B 16.34 and
acceptance criteria shall be as per ASME B 16.34 Annexure-B. However for areas of casting
to be radiographed for types of valves not covered in ASME B 16.34, vendor shall radiograph
castings in line with ASME B 16.34.
6.3 For random radiography wherever specified in individual data sheets, the sampling shall be
per size of the quantity ordered for each foundry.
6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray /
'y-ray to get the required sensitivity.
7.0 IBR CERTIFICATION
7.1 For valves described "IBR", valves shall be in accordance with the latest IBR (Indian Boiler
Regulation) including the requirements specified in the specification.
7.2 For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to
the following:
Carbon (Max) 0.25%

Others (S, P, Mn) As per IBR
7.3 Valves coming under the purview of "IBR"(Indian Boiler Regulations) shall each be
individually accompanied by IBR certificate original in Form III-C duly approved by IBR
authority / local authority empowered by the Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
7.4 All "IBR" valves shall be painted red in body-bonnet / body-cover joint.
8.0 MARKING
8.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the
standard referred in specification sheet as applicable. Vendor's name, valve rating, material
designation, nominal size, direction of flow (if any) etc. shall be integral on the body.
8.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely
attached to the valve body.
8.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
8.4 Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).
9.0 DESPATCH
9.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
9.2 Valves shall be protected from rust, corrosion and any mechanical damage during
transportation, shipment and storage.
Page 611 of 1296

,511faeieì Lfth ENGINEERS TECHNICAL NOTES
Q41 k1Rs INDIA LIMITED FOR VALVES 6-44-0052 Rev.7
Page 12 of 12
9.3 Rust preventive on machined surfaces to be welded shall be easily removable with a
petroleum solvent or shall not be harmful to welding.
9.4 Each end of valve shall be protected with the following materials:
Flange Face Wood or Plastic Cover

Bevelled End Wood or Plastic Cover
SW & SCRD. End Plastic Cap
9.5 End protectors of wood / plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than the outside diameter of the flange. However, plastic caps
for SW & SCRD end valves shall be press fit type.
9.6 End protectors to be used on bevelled end shall be securely and tightly attached.
9.7 For special service valves additional requirement for despatch shall be as prescribed in data
sheet.
10.0 ATTACHMENTS
6-44-0052-A 1 Bypass Piping Arrangement
6-44-0052-A2 Specifications for Bypass Piping, Fittings and Valves
6-44-0052-A3 Special Requirements for Low Temperature and

Cryogenic Valves
6-44-0052-A4 Special Requirements for Hydrogen Service Valves
11.0 REFERENCES
6-78-0001 Specification for Quality management system

requirements from bidders
6-78-0003 Specification for documentation requirements from

suppliers
6-81-0001 Specification for Positive Material Identification

(PMI) at Supplier's Works
6-81-0004 Inspection and Test plan for Valves
Page 612 of 1296

1514-zA ENGINEERS BYPASS PIPING
51guttf54- ag
INDIA LIMITED
(4.,,,,,N,L15,78..) (A Govt of India Undertaking)
ARRANGEMENT 6-44-0052-Al Rev.7
Page 1 of 1
BYPASS PIPING ARRANGEMENT

L7
(minimum)
Bevel Gear
Operator (BGO)
L6
L5
L4
300 mm
(approx.)
Globe valve
for BOO valves
L3 as per spec.
sht. indicated
in the MR.
ote-8
150 mm
(approx.)
for non-BOO valves
L2 Pipe bend
Flow
L1
(minimum possible)
NOTES :
1. The orientation & location of handwheel of bevel gear operator & the bypass arrangement
shall be strictly as per this sketch.
2. The bypass connection ends shall be socket welded upto 600# and butt welded for 900#
and above rating.
3. The bypass arrangement shall be properly clamped to & supported by the body of the
main valve.
4. Basic design of bypass shall be to MSS-SP-45.
5. Material of bypass pipe & 90° elbows shall be same or equivalent to the body material as
indicated in Specification No. 6-44-0052-A2.
6. This sketch is applicable for both BGO & NON-BGO Valves.
7. Vendor shall furnish dimensions Ll to L8.
8. Stem shall not be horizontal in the case of CRYO Valves
Page 613 of 1296

ENGINEERS SPECIFICATIONS FOR BYPASS
INDIA LIMITED PIPING, FITTINGS AND VALVES 6-44-0052-A2 Rev.7
I etecnie ref 34ore) (A Govt of India Undertaking)
Page 1 of 3
SPECIFICATIONS FOR BYPASS PIPING, FITTINGS AND VALVES
Bypass
Class (Main Valve Sht.no.) Pipe Fittings Valve
Sht.no.
A1A(51301), A3A(51321),
A9A(51301), A10A(51301), ASTM A106 Gr.B (SMLS) ASTM A105
Al 1A(51301), A33A(51301), 0.5"-0.75": S160 0.5"-0.75": SW 6000# 52001
B1A(51401), B9A(51401), 1.0"-1.5" : XS 1.0"-1.5" : SW 3000#
D1A(51501), D9A (51501)
ASTM A106 Gr.B (SMLS) ASTM A105
A6A(51301), B6A(51401) 0.5"-0.5" : XXS 0.5"-0.5" : SW 9000# 52001
0.75"-1.5": S160 0.75"-1.5": SW 6000#
A13A(51301), B13A(51401) 52001
0.5"-1.5" : XXS 0.5"-1.5" : SW 9000#
ASTM A106 Gr.B (SMLS)- IBR ASTM A105 - IBR
A2A(51302), B2A(51402), 52002
0.5"-0.75": S160 0.5"-0.75": SW 6000#
D2A (51502) 1.0"-1.5" : SW 3000#
1.0"-1.5" : XS
ASTM A350Gr.LF2-
ASTM A333 Gr.6 (SMLS)- LT
A4A (51303), B4A (51403), LT
0.5"-0.75": S160 52003
D4A (51503) 0.5"-0.75": SW 6000#
1.0"-1.5" : XS
1.0"-1.5" : SW 3000#
ASTM A106 Gr.B (SMLS) -H2 ASTM A105 - H2
A5A (51304), BSA (51404), 52004
0.5"-0.75": S160 0.5"-0.75": SW 6000#
D5A (51504)
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
A7A (51307) 0.5"-0.75" : S160 0.5"-0.75": SW 6000# 52007
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM A106 Gr.B (SMLS) -
ASTM A105 - NACE
Al6A (51311), B16A (51411), NACE
0.5"-0.5" : SW 9000# 52011
D16A (51511) 0.5"-0.5" : XXS
0.75"-1.5": SW 6000#
0.75"-1.5": S160
A19A (51313), B19A (51413),
0.5"-0.75" : 5160 0.5"-0.75": SW 6000# 52013
D19A (51513) 1.0"-1.5" : SW 3000#
1.0"-1.5": XS
ASTM A234 Gr.WPB/
ASTM A106 Gr.B (SMLS)
ElA (51601), FlA (51701) ASTM A105 52101
0.5"-1.5" : S160
0.5"-1.5" : BW, S160
ASTM A234 Gr.WPB/
ASTM A106 Gr.B (SMLS) - IBR
E2A (51602), F2A (51702) ASTM A105 - IBR 52102
1.5 : S160
0.5"-"
0.5"-1.5" : BW, S160
ASTM A234 Gr.WPB/
ASTM A106 Gr.B (SMLS) - H2
E5A (51604), F5A (51704) ASTM A105 - H2 52104
0.5"-1.5" : S160
0.5"-1.5" : BW, S160
ASTM A106 Gr.B (SMLS) ASTM A234 Gr.WPB/
0.5"-1.5" : SCH XXS ASTM A105
E9A (51605), F9A (51705) 52105
0.5"-1.5" : BW, SCH
XXS
ASTM A106 Gr.B (SMLS) ASTM A234 Gr.WPB/
0.5"-1.5" : SCH XXS ASTM A105
E19A (51613), F19A (51713) 52113
0.5"-1.5" : BW, SCH
XXS
Page 614 of 1296

01 el ENGINEERS SPECIFICATIONS FOR BYPASS
Page 2 of 3
Bypass
Sht.no.
ASTM A106 Gr.B ;(SMLS) ASTM A105
A5Y (51384), A33Y (51384) 0.5"-1.5" : S160 ' 0.5"-1.5" : SW 6000# 52085
4
ASTM A182
ASTM A335Gr.P11(SMLS)
MD (51330), BM (51430), Gr.F11C1.2
0.5"-0.75" : S160 52030
D1D (51530) 0.5"-0.75": SW 6000#
1.0"-1.5": XS
1.0"-1.5" : SW 3000#
ASTM A335Gr.P11 (SMLS) - ASTM A182
IBR Gr.F11C1.2 - IBR
D2D (51531) 52031
0.5"-0.75" : S160 0.5"-0.75": SW 6000#
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM A182
ASTM 335Gr.P11(SMLS)- H2
Gr.F11C1.2 - H2
B5D (51432), D5D (51532) 0.5"-0.75" : S160 52032
0.5"-0.75": SW 6000#
1.0"-1.5": XS
1.0"-1.5" : SW 3000#
ASTM A182
ASTM A335Gr.P22(SMLS) 0.5"-
Gr.F22C1.3
BlE (51433) 0.75" : S160 52033
0.5"-0.75": SW 6000#
1.0"-1.5": XS
1.0"-1.5" : SW 3000#
ASTM A182
ASTM A335Gr.P22(SMLS) - H2
Gr.F22C1.3 - H2
D5E (51534) 0.5"-0.75" : S160 52034
0.5"-0.75": SW 6000#
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM A335 Gr.P5(SMLS) ASTM A182 Gr.F5
A4F (51336), B4F (51436) 0.5"-0.75" : S160 0.5"-0.75": SW 6000# 52036
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
B3F (51436) ASTM A335 Gr.P5(SMLS) ASTM A182 Gr.F5
52036
0.5"-1.5" : XXS 0.5"-1.5" : SW 9000#
ASTM A335 Gr.P9(SMLS) ASTM A182 Gr.F9 52039
A4G (51339), B4G (51439) 0.5"-0.75: SW 6000#
0.5"-0.75" : S160
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM
ASTM A335 Gr.P11 (SMLS) - A234Gr.WP11C1.1/
F2D (51731) IBR A182 Gr.F11C1.2 - 52131
0.5"-1.5" : S160 IBR
0.5"-1.5" : BW, S160
ASTM
ASTM A335 Gr.P22(SMLS) -
A234Gr.WP22C1.1/
H2 52134
E5E (51634) A182 Gr.F22C1.3 - H2
0.5"-0.75" : S160
0.5"-0.75" : BW, S160
1.0"-1.5": XS
1.0"-1.5" : BW, XS
ASTM A312 TP304(SMLS) ASTM A182 Gr.F304
A1K (51345), A3K (51345), 0.5"-1.5" : SW 3000# 52045
0.5-0.75" : 80S
B1K (51445), D1K (51545)
1.0"-1.5": 40S
ASTM A312 TP304(SMLS) - ASTM A182 Gr.F304
A2K (51346), B2K (51446), CRY() - CRYO
52046
D2K (51546) 0.5"-0.75" : 80S 0.5"-1.5" : SW 3000#
1.0"-1.5": 40S
ASTM A182
ASTM A312 TP304H (SMLS)
B4K (51448), B5K (51448) Gr.F304H 52048
0.5"-1.5" : 80S
0.5"-1.5": SW 3000#

Page 615 of 1296

dl ENGINEERS SPECIFICATIONS FOR BYPASS
(anen eienne aA 3vpRil (A Govt of India Undertaking)
Page 3 of 3
Bypass
Sht.no.
ASTM A182
ASTM A312 TP304L (SMLS)
Gr.F304L
Gr.
A6K (51350), B6K (51450) 0.5"-0.75" : 80S 52050
0.5"-1.5": SW 3000#
1.0"-1.5": 40S
AIM (51361), B1M (51461) 0.5"-0.75" : 80S 0.5"-1.5": SW 3000# 52061
1.0"-1.5": 40S
ASTM A312 TP316H (SMLS) - ASTM A182
H2 Gr.F316H - H2
B5M (51462) 52062
0.5"-0.75" : 80S 0.5"-1.5": SW 3000#
1.0"-1.5": 40S
B3M (51463) 0.5"-0.75" : 80S 0.5"-1.5": SW 3000# 52063
1.0"-1.5": 40S
ASTM A182
ASTM A312 TP 316L (SMLS)
Gr.
Gr.F316L
A1N (51366), 131N (51466) 0.5"-0.75" : 80S 52066
0.5"-1.5": SW 3000#
1.0"-1.5": 40S
ASTM A182
ASTM A312 TP316L (SMLS) Gr.F316L
B6N (51471) 0.5"-0.75" : 80S 0.5"0.5"-1.5": SW 52071
1.0"-1.5": 40S 3000#
Page 616 of 1296

SPECIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
iH6i ENGINEERS
51g-zufM5Veg INDIA LIMITED LOW TEMPERATURE & 6-44-0052-A3 Rev.7
own ,limiwre Mn .3P011) (A Govt of Me Undertaking)
CRYOGENIC VALVES Page 1 of 2
SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES
1.0 SCOPE
All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS
(CRYO) material are categorized as cryogenic valves. All these valves shall have
extended bonnet as per BS 6364 except check valves.
Following qualification criteria shall be met by the valve vendors to quote valves for
cryogenic services:
2.0 QUALIFICATION CRITERIA
i) Both cryogenic test (clause 2.1) and reference list (clause 2.2) together shall be
considered for vendor qualification and vendor shall furnish the same, along with his
offer.
ii) Vendors who do not have cryogenic test reports and reference list covering valves of
all sizes, materials and ratings required by MR, should confirm / furnish the following
for consideration of their offer:
a. Evidence of having conducted successfully at least one cryogenic test as per

BS 6364. Test certificate shall be furnished with the offer.
b. Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the
remaining valves not later than 12 weeks from the date of purchase order.
c. Vendor shall also furnish reference list for valves supplied for non-cryo
service if reference list referred in 2.2.1 does not cover all the sizes of MR.
Offers of vendors who do not comply with above requirements would be rejected.
2.1 Cryogenic Test
Vendors to furnish copies of cryogenic test certificate for tests conducted as per details
given below:
2.1.1 Test shall be as per BS 6364.
2.1.2 Test temperature, unless specifically called for otherwise in the individual MR,
shall be -45°C for LTCS and -196°C for all grades of austenitic stainless steel.
2.1.3. Tests carried out on a particular size of one type of valve, pressure rating and
material shall qualify all sizes equal to and below the test valve size for the
same type, pressure rating and material. In case of austenitic SS any one grade
would qualify for all other grades of austenitic SS.
2.1.4. Tests should have been witnessed and certified by any one of the following
third party inspection agencies; M/s Lloyd, BV, DNV, TUV or EIL/ CEIL.
2.1.5. Cryogenic test need not be conducted for every order. Test conducted
previously and witnessed by inspection agencies listed above shall be
considered acceptable and need not be repeated.
Page 617 of 1296

Gil ENGINEERS
eiC1 SPECIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
Ogeg tameg INDIA LIMITED
eieEDIZ an 3.7.1) IA Govt of India Undertaking)
LOW TEMPERATURE &
CRYOGENIC VALVES
6-44-0052-A3 Rev.7
Page 2 of 2
2.2 Reference List
Vendor shall furnish reference list for valves supplied for cryogenic service indicating the
name of client, year of supply, size, material, pressure rating, type of valve and quantity.
2.3 Post Order Testing Procedure
2.3.1. Before conducting post order testing, vendor shall submit the following for
approval:
a. Test procedure (as per BS 6364).

b. Cross-section drawing of the valve with material of construction.
c. Schematic of test rig (as per BS 6364) with complete details.
2.3.2. Test has to be conducted irrespective of the service on largest size for each type of
valve and for each material and class rating. Vendor shall offer one, two or three
valves for selection of test valve by inspector depending upon whether quantity of
largest valve in the order is one, two or three and more than three respectively.
In the event of failure of the test valve to meet the specification requirements, the
vendor shall conduct test on two more valves. These two valves which pass test
successfully, are of lower size, then the qualification will be valid only to sizes
upto which test has been conducted successfully.
2.3.3. In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the

test(s) conducted after receipt of order, the owner reserves the right to invoke any
of the provisions of the purchase order including cancellation of the purchase
order at the risk and cost of vendor.
3.0 Bonnet extension, wherever specified in the valve sheet to BS 6364 shall be for "non
cold box application" unless otherwise specified in the MR. Even if not called for in
valve sheet, valves indicated as "LT" or "CRYO" shall be supplied with bonnet
extension.
4.0 Bonnet and Gland extension joints shall be of butt welded/integrally cast construction. I
5.0 Repair welding procedure for austenitic stainless steel valves in "CRYO" service shall
have to be qualified for impact test as per ASME B31.3. Minimum acceptable impact
energy shall be 20 J or lateral expansion of 0.38 mm at temperature of -196°C.
6.0 Wherever impact test of SS studs / nuts is called for in the data sheet, the impact value
shall be 27 J at the intended service temperature specified in the data sheets.
Page 618 of 1296

‘31 ENGINEERS SPECIAL REQUIREMENTS FOR
Ogelftlf5teg INDIA LIMITED HYDROGEN SERVICE VALVES 6-44-0052-A4 Rev.7
OMR e9eeR2,1313‘10.1) (A Govt of India Undertaking)
Page 1 of 2
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
1.0 GENERAL
1.1 These requirements are applicable for valves used in Hydrogen service. These are in
addition to the requirements described in "Technical Notes for Valves" Spec. No. 6-44-
0052, and shall be read in conjunction with this specification.
1.2 All cast valve flanges & bodies with flange rating of Class 900 or greater shall be
examined in accordance with paragraphs 7.2 through 7.5 of Appendix-VII of ASME
SEC-VIII, DIV.1, regardless of casting quality factor.
1.3 Body / bonnet / cover joints & stuffing box of all valves shall have low emission. One
valve per metallurgy, per rating, per size shall be helium leak tested as per ASME Sec.V,
Subsection A, Article 10 (Detector Probe Technique), Appendix IV at a minimum of
25% of the allowable (rated) cold working pressure. Selection of valves for helium leak
test shall be at random. Test duration shall be as follows:
Test Duration in Minutes

Pressure Class
Nominal Size
Upto 300 600 800 & 900 1500 2500
Upto 2" 3 6 9 12 12
3" to 6" 6 9 12 15 18
8" to 16" 9 9 12 15 18
18" to 24" 9 12 15 18 21
The valve shall show no leakage. No leakage is defined as a total leakage rate of less than
0.0001 ml/s of helium.
2.0 Only normalized and tempered material shall be used in the following specifications:
Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217
Gr.WC9, A217 Gr.C5, A217 Gr.C12
Forgings A182 Gr.F11 C1.2
3.0 CS & AS VALVES
3.1 Bend test and Magnetic Particle inspection of the entire surface of body and bonnet
casting shall be in accordance with ASTM A217. Supplementary requirement S3 & S4
evaluation of magnetic particle, inspection shall be in accordance with MSS-SP-53
except that no linear discontinuities shall be allowed.
3.2 The Brinell hardness of heat treated casting shall not exceed 200 BHN for carbon steel &
225 for alloy steel.
3.3 Repair to defective casting shall be outlined in writing to the purchaser before repair
starts. Repair method to be approved prior to welding.
3.4 Casting shall be preheated to a minimum of 400°F prior to welding and all Chromium-
Molybdenum alloys shall be postweld heat treated after welding is complete. Stress
relieving is essential for welds.
Page 619 of 1296

t3t
77.1) ENGINEERS SPECIAL REQUIREMENTS FOR
fell5reg
(7
Oge.il INDIA LIMITED HYDROGEN SERVICE VALVES 6-44-0052-A4 Rev.7

Page 2 of 2
3.5 Carbon steel shall be normalised and alloy steels shall be normalised & tempered.
3.6 Dye Penetrant test of welds shall be in accordance with ASTM B165 Procedure B-2.
Interpretation as per Appendix-8 of ASME-VIII Div. 1.
3.7 The tensile stress for AS shall be less than 100,000 psi.
3.8 Charpy V-notch impact testing is to be done for valve material (average 20 ft-lb for set of
3 [minimum value 15 ft-lb] at 30°F).
3.9 For radiography and acceptance criteria for valve castings, refer Cl. 4.2.
4.0 SS VALVES
4.1 Valve casting shall be in solution heat treated and pickled condition.
4.2 Critical body and bonnet casing section typically defined by ASME B 16.34 shall be
radiographed and shall meet ASTM E446 (upto 2" thick) Category A, B & CA Level 2,
Category CB, OC & CD Level 3, Category D, B & F Level 0. For wall thickness 2" to
4.5" comparable plates of ASTM E186 shall be used. ASTM E94 and ASTM E142 shall
be used for recommended practice & controlling quality of radiography as guide. The
entire surface of all castings shall be dye-penetrant inspected after pickling.
4.3 Welds shall be 100% radiographed and evaluated in accordance with paragraph 344.5 of
ASME B31.3 with a minimum casting quality factor of 0.95. Dye Penetration test shall
be as per ASTM E165 Procedure B-2, Interpretation as per Appendix-8 of ASME-VIII
Div.l.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — An rights reserved
Page 620 of 1296

TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
, k31 ENGINEERS FLANGES, SPECTACLE BLINDS
$'1g-af INDIA LIMITED 6-44-0053 Rev. 6
237,1,
17 ,
151 ,R,A) IA GoN of Inda Undeflakng) AND DRIP RINGS Page 1 of 7
• •
4ct-cb(Net cs)(Yi
41
f- n1 CfrielChr FU I 1T
TECHNICAL NOTES FOR FLANGES,

SPECTACLE BLINDS AND DRIP RINGS
i
6 25.09.14 REVISED & ISSUED AS STD SPECIFICATION SH AK
/RN ATNNo SC
5 31.12.13 REVISED & ISSUED AS STD SPECIFICATION UK SH AK RN SC
4 04.07.08 REVISED & ISSUED AS STD SPECIFICATION RN SC DM VC
3 01.11.00 REVISED & ISSUED AS STD SPECIFICATION RN BRB NS MI
2 04.04.94 I.G.C. TEST CLAUSE REVISED AKG BPV GRR AS
Standards Standards
Committee Bureau
No by by
Approved by
Page 621 of 1296

ENGINEERS
5gar fa2eg INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
1.1r, vomooJosnytt IA Govt ot InO. Undellakoog)
AND DRIP RINGS Page 2 of 7
Abbreviations:
AARH Arithmetic Average Roughness Height

AWWA American Water Works Association
IS Indian Standard
MSS Manufacturer's Standardization Society

Mr. Amrendra Kumar
Mr. G. Balaji
Page 622 of 1296

k31•-1 ENGINEERS
$gt-LIE IM2-- INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
1.41,1c,,DrO0,
13OO,-.0 11, Tool ol InO. Undonok■o9)
CONTENTS
1.0 GENERAL 4
2.0 IBR REQUIREMENTS 6
5.0 REFERENCES 7
Page 623 of 1296

ENQNEERS
$fg-z1
- f d2-
'
1 dg INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
.117,1 rfrforr onJO'SOff in Go■ft of Indo Uncleflak,o9)
1.0 GENERAL
1.1 All items, their dimensions, tolerances, chemical composition, physical properties, heat
treatment and testing etc. shall conform to the latest codes and standards specified in the
requisition. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted. Post Order Concession/Deviation Permit 5-0000-0180-F1 as mentioned in Cl. 5.18
of Specification for Quality Management System Requirements from Bidders (6-78-0001) is
not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the requisition & Clauses 1.11, 1.12 & 1.15.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the flanges supplied.
1.2.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the `Specification for Positive Material Identification (PMI) at Supplier's Works'
(No. 6-81-0001).
1.2.4 Refer to specification no. 6-81-0006 for Inspection and Test plans for flanges, spectacle blinds
& drip rings.
1.3 Ends of weld neck flanges shall be beveled to suit the schedule / thickness of matching pipe,
as specified in the requisition.
1.4 Bevel end details for welding neck flanges shall be as per ASME B16.25. Contour of bevel
end shall be as follows:
Stainless Steel &
Low Temp. Carbon Steel
> 10 mm & Upto 25 mm Figure 5 Type A
1.5 Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and
schedule / thickness of matching pipe.
1.6 Bore of slip on flanges shall suit the outside diameter of matching pipe.
1.7 Flange face finish shall be normally specified in the requisition as serrated finish, 125 AARH
etc. The interpretation for range of face finish shall be as follows:
Stock Finish 1000 1.1 in AARH max.
Serrated Finish/125 AARH Serrations with 125 to 250gin AARH
63 AARH 32 TO 63 µ in AARH
Page 624 of 1296

+31 ENGINEERS
$'g-arWes INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
1.41771 051 A Gol ol ind. Undenak.9) AND DRIP RINGS Page 5 of 7
1.8 Galvanized flanges shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.
1.9 Ends of screwed flanges unless otherwise specified shall have taper threads as per
ASME/ANSI B1.20.1 (upto 1.5" NB) & IS 554 (for 2" to 6" NB).
1.10 For ring joint flanges, blinds and spacers the hardness shall be as follows:
Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140
1% Cr to 5%, 9% Cr 150
Type 304, 316, 321, 347 160
Type 304L, 316L 140
1.11 For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.
1.12.1 Flanges, blinds, drip rings under "NACE" category and those designated as "HIC1" shall meet
the requirements given in NACE MR-0103 unless otherwise specified.
1.12.2 Flanges, blinds, drip rings made from plates and designated as "HIC1" shall meet the HIC
requirements of EIL Specification 6-79-0013 unless otherwise specified.
1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition.
1.14 I.G.C. Test for Stainless Steels:
1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges intergranular
corrosion test shall have to be conducted as per following:
ASTM A262 Practice `B' with acceptance criteria of "60 mils/year (max.)".
OR
1.14.2 When specifically asked for in requisition for high temperature application of some grades of
austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with
acceptance criteria of "15 mils/year" shall have to be conducted.
1.14.3 For the IGC test as described in 1.14.1 & 1.14.2 two sets of samples shall be drawn from each
solution treatment lot; one set corresponding to highest carbon content and the other
corresponding to the highest rating / thickness.
1.15 All types of 321 or 347 stainless steel flanges shall be in a stabilized heat treated condition.
Stabilizing heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilizing heat treatment shall be 900 C and 4
hours respectively.
Page 625 of 1296

t31 ENGINEERS
$gelE f22e5 1NDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
el,ntetvrst,,cmt IA Govt ot Indo Undertaltng)
1.16 For dual grades of SS where specified, chemical composition and mechanical properties of
1.17 AWWA C207 flanges shall be hub type.
1.18 Dimensions for handle projection for Spacers & Blinds shall be as specified in EIL Std. 7-44-
0166.
1.19 Flanges of 22" size shall be as per MSS-SP44 unless otherwise specified
1.20 All 1Cr-V2Mo and 11/4Cr-'/2Mo flanges shall be normalised and tempered.
1.21 Ring Joint Fig-8 Flanges, Spacers & Blinds shall be female type only.
1.22 The handle for spacers & blinds for classes 900# & above shall be designed by the vendor.
The handle may be integral or attached to the line blank / spacer by welding. In case of
attachment by welding heat treatment & welding shall be in accordance with B31.3.
1.23 For Hydrogen service following special requirements shall also be met:
a. All carbon steel flanges having wall thickness 9.53 mm and above shall be normalised.
The normalising heat treatment shall be a separate heat treatment operation and not a part
of the hot forming operation.
b. All alloy steel (Cr-Mo) flanges shall be normalised and tempered. The normalising and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation.
c. For all carbon steels and alloy steels with wall thickness over 20mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-1 per heat of material and per heat treating batch. Impact test specimen shall be
in accordance with ASTM A370. Impact energies at 0 C shall average greater than 27J (20
ft-lb) per set of 3 specimens, with a minimum of 19J (15ft-lb).
2.0 IBR REQUIREMENTS
2.1 IBR Documentation
2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied
with IBR Certificate original in Form III C duly approved and countersigned by IBR
authority/ local authority empowered by Central Boiler Board of India. Photocopy of original
certificate duly attested by the local boiler inspector where the supplier is located is the
minimum requirement for acceptance.
Carbon (max) 0.25%
Others (S, P, Mn) • As prescribed in IBR.
services.
3.1 Blind Flanges and Spacers & Blinds if specified as plate materials are acceptable in forging
materials also in the corresponding material grades.
Page 626 of 1296

ENGINEERS
faaes
1.117,
1217-,5W.13tt0.11
INDIA
IA
LIMITED FLANGES, SPECTACLE BLINDS
Govt ol Indo Undertakingt
AND DRIP RINGS
6-44-0053 Rev. 6
Page 7 of 7
3.2 Flanges/Spectacle Blinds/Drip rings of Grades SS317 of corresponding material are

acceptable in place of Grades SS316 or SS316(2.5Mo min.).
3.3 Flanges/Spectacle Blinds/Drip rings of Grades SS317L of corresponding material are

acceptable in place of Grades SS316L or SS316L(2.5Mo min.).
4.1 A11 items shall be legibly and conspicuously stamped in accordance with the requirements of
applicable ASME, API and MSS Standards. In addition, EIL item code, purchase order
number & special conditions like "IBR", "CRY0", "NACE" "H2" etc. shall also be stamped.
4.2 A11 items coming under the purview of "IBR", "CRYO" , "NACE" & "H2"(hydrogen) shall
be painted with one stripe of colour red, light purple brown, canary yellow & white
respectively for easy identification. Width of stripe shall be 25mm and it shall be painted
longitudinally across the complete thickness of flange other than hub.
4.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
4.4 All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.
4.5 All items shall be protected from rust, corrosion and mechanical damage during
4.6 Rust preventive on machined surfaces to be welded shall be easily removable with a
4.7 Each end of flange shall be protected with the following materials:
Flange face Wood, metal or plastic cover

Bevelled end Wood, metal or plastic cover
Threaded end Plastic plug
Socket welding end Plastic cover or plug
4.8 Each size of flanges, blinds, etc. shall be supplied in separate packagings marked with the
purchase order number, item code number, material specification, size and rating.
5.0 REFERENCES
6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works.
6-81-0006 Inspection & test plan for flanges, spectacle blinds & drip rings
6-79-0013 Material requirements for carbon steel components used in sour

service for petroleum refinery environments
7-44-0162 Standard for Spacers & Blinds 26" (150CL, 300CL & 600CL FF)
7-44-0164 Standard for Spacers & Blinds 26" (For AWWA Flanges)
7-44-0166 Dimensions for Handle projection for Spacers & Blinds 1/2"-24"
Page 627 of 1296

TECHNICAL NOTES FOR BUTT STANDARD SPECIFICATION No.
ENGINEERS WELDED, SOCKET WELDED
,,cnf1,151,Pqd,,) IA Govt ol Intha UnooOok,o9) AND SCREWED FITTINGS Page 1 of 9
-rEFW1 rc-R dcb-ilcb1
TECHNICAL NOTES FOR BUTT

WELDED, SOCKET WELDED AND
SCREWED FITTINGS
6 25.09.14 REVISED AND ISSUED AS STD SPECN

SH .AK jRN ATD4 SC
5 31.12.13 REVISED AND ISSUED AS STD SPECN UK SH AK RN SC
4 04.07.08 REVISED AND ISSUED AS STD SPECN

RN SC DM VC
3 15/03/00 REVISED AND ISSUED AS STD SPECN RN BRB NS AS
HYDROTEST AND I.G. TEST CLAUSE

2 04/04/94 AKG BPV GRR AS
REVISED
Standards Standards
Comm ittee Bureau
No by by
Approved by
Page 628 of 1296

TECH. NOTES FOR BUTT STANDARD SPECIFICATION No.
ENG1NEERS
fg-;fr Êtfai INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
1.12R ,,c»,.13,70.1/
AND SCREWED FITTINGS Page 2 of 9
Abbreviations:

CS Carbon Steel
DP Dye Penetrant
IS Indian Standard
LT Low Temperature
MP Magnetic Particle
MSS Manufacturer's Standardisation Society
NB Nominal Bore
PO Purchase Order
SMYS Specified Minimum Yield Strength
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Page 629 of 1296

7tn ENGNEERS
5tgu faaeg1.17,1 ,rcnr1,1111.~1/
INDIA LIMITED WELDED, SOCKET WELDED
AND SCREWED FITTINGS
6-44-0054 Rev. 6
Page 3 of 9
CONTENTS
1.0 GENERAL 4
2.0 IBR REQUIREMENTS 8
5.0 REFERENCES 9
Page 630 of 1296

k71 ENGINEERS
Og'-ar 22-'dg INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
G" Unde""g) AND SCREWED FITTINGS Page 4 of 9
1.0 GENERAL
1.1 Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment
and marking shall conform to the applicable latest codes / standards / specifications as
specified in the material requisition (MR). Supplier shall strictly comply with MR/PR
stipulations and no deviations shall be permitted. Post Order Concession/Deviation Permit 5-
0000-0180-F1 as mentioned in Cl. 5.18 of Specification for Quality Management System
Requirements from Bidders (6-78-0001) is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the material specifications. Test
reports shall also be furnished for any supplementary tests as specified in the MR, Clauses
1.7.8, 1.9, 1.10 & 1.11. Material test certificates (physical properties, chemical composition &
heat treatment report) shall also be furnished for fittings supplied.
1.2.2 Positive Material Identification (PMI) shall be performed as per scope and procedures defined
in the Specification for Positive Material Identification (PMI) at Supplier's Works (6-81-
0001).
1.2.3 Refer to specification no.6-81-0005 for Inspection and Test plan for forged, seamless and
welded fittings.
1.3 All fittings shall be seamless in construction unless otherwise specified. If fittings are
specified as welded, the same shall conform to clause 1.7.
1.4 Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings
shall be in accordance with ASME B36.10 and ASME B36.19 as applicable.
1.5 For reducing butt weld fittings having different wall thicknesses at each end, the greater wall
thickness of the fitting shall be employed and inside bore at each end shall be matched with
the specified inside diameter.
1.6 Beveled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as
follows:


Stainless Steel &
1.7 Welded Fittings
1.7.1 A11 welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm.
Welds shall be ground smooth at least 25 mm from the ends.
Page 631 of 1296

ENGINEERS
INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
1.11,1 051~,
(A G" "d" Unde"''') AND SCREWED FITTINGS Page 5 of 9
1.7.2 For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be
manufactured with the addition of filler metal.
1.7.3 Welded tees shall not be of fabricated (stub-in) type.
1.7.4 All welded fittings shall be normalized & 100% radiographed by X-ray on all welds made by
fitting manufacturers & also on the parent materials.
1.7.5 Welded pipes employed for manufacture of fittings shall be made by automatic welding only.
1.7.6 Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after
weld repairs.
1.7.7 Irrespective of the material code requirement, all welded fittings indicated in the MR as
"Cryo"& "LT" shall meet impact test requirements of ASME B3I .3. The impact test
temperature shall be -196°C & -45°C for stainless steel & carbon steel respectively unless
specifically mentioned otherwise in the MR.
1.8 Stainless Steel Fittings
1.8.1 All stainless steel fittings shall be supplied in solution heat treated condition.
1.8.2 Solution annealing for stainless steel fittings shall be carried out again after weld repairs.
1.8.3 For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as
per the following:
ASTM A 262 Practice "B" with acceptance criteria of "60 mils/year (max.)".
Or
austenitic stainless steel (eg. SS309, 310,316,316H etc.) ASTM A 262 Practice "C" with
acceptance criteria of "15 mils/year" shall have to be conducted.
1.8.5 For the IGC test as described in Clauses 1.8.3 & 1.8.4, two nets of samples shall be drawn
from each solution treatment lot, one set corresponding to the highest carbon content and other
set to the highest fitting thickness.
1.8.6 For dual grades of SS where specified, chemical composition and mechanical properties of
1.9.1 Fittings under "NACE" category or those designated as "HIC1" shall meet the requirements of
NACE MR-0103 unless otherwise specified.
1.9.2 Fittings made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless otherwise specified.
1.10 Thickness/schedule lower or higher than specified for the finished product shall not be
accepted.
Page 632 of 1296

ENQNEERS TECH. NOTES FOR BUTT STANDARD SPECIFICATION No.
k31
5g"arfaidles INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
°Rna" Unde"«ng) AND SCREWED FITTINGS Page 6 of 9
For manufacturing of elbows from pipes, same size of pipe as that of elbow shall be used and
the nominal wall thickness of the starting pipes shall have positive tolerance only. However,
where the manufacturer has an established automatic/semi-automatic process for the
manufacture of elbows, the starting pipe may be permitted to be of Iower size with higher
schedule as required. Starting pipe of higher size than that of the elbow shall not be permitted.
1.11 The gasket contact surfaces of stub ends shall be flat with face finish specified in the
requisition. Interpretation on the specified face finish is as follows:
125 AARH Serrations with 125 to 250 µ in AARH
1.12 Seamless stub ends shall not have any welds on the body. Stub ends shall be long pattern type.
1.13 Galvanized fittings shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.
1.14 Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B1.20.1 up to
1.5" NB & IS 554 from 2" to 6" NB.
1.15 Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in
accordance with ASME B16.11 to the extent covered in the specification except for unions
which shall be in accordance with MSS-SP-83.
1.16 Special fittings like weldolet, sockolet, sweepolet, latrolet, elbolet etc., the dimensions of
which are not covered in ASME, MSS-SP & EIL Standards, shall be as per manufacturer's
std. Contours of these fittings shall meet the requirements of ASME B31.3. Manufacturer shall
submit drawings / catalogues of these items for records after acceptance of offer.
1.17 Length of all long half couplings shall be 100 mm unless otherwise specified in the MR.
1.18 For reducers to manufacturers' standard, length of reducer shall not be less than 0.7D where D
is the outside diameter of the larger end.
1.19 All seamless pipes employed for manufacturing of fittings shall be required to have undergone
hydrostatic test to ASTM A 530. Welded pipes employed for manufacture of fittings shall be
tested as given below :
Welded Pipe Employed For Manufacture Of Welded Fittings. Test Criteria
ASTM A671 Gr. C65,70 (C1.32) P=2ST/D

ASTM A672 Gr. C60,65,70 (C1.12, 22) S = 90% of SMYS.
ASTM A671 Gr. CF60,65,70,66 (C1.32) T = Nom. Wall Thickness
ASTM A691 Gr. 1/2Cr, 1Cr, 11/4Cr, 21/4Cr, 5Cr, 9Cr (C1.42), D = 0.D. of Pipe.
91 (C1.42)
API 5L P=2ST/D
ASTM A358 TP 304, 304L, 304H, 318, 318L, 318H, 321, S = 85% of SMYS.
347 (C1.1, 3, 4) T = Nom. Wall Thickness
D = 0.D. of Pipe.
ASTM B725 ASTM B725
ASTM B517 ASTM B517
ASTM B514 ASTM B514
1.20 The bevel ends of all butt weld fittings shall undergo 100% MP / DP test.
Page 633 of 1296

Odie`g cw INDIA LIMITED

ENGINEEFZS
WELDED, SOCKET WELDED
Ii 1.177, 2:12.72 ,151~)
Unde"") AND SCREWED FITTINGS
6-44-0054 Rev. 6
Page 7 of 9
1.21 Abbreviations for ends of swages and nipples shall be as follows:

PBE Plain Both Ends
TBE Threaded Both Ends
TOE Threaded One End
TSE Threaded Small End
TLE Threaded Large End
1.22 All types of SS321 or SS347 fittings shall be in stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to normal solution annealing. Soaking
temperature and holding time for stabilizing heat treatment shall be 900°C and 4 hours
respectively.
1.23 For Hydrogen service fittings following special requirements shall also be met:
a. All carbon steel fittings having wall thickness 9.53 mm (0.375") and above shall be
normalised. Cold drawn fittings shall be normalised after the final cold draw pass for all
thicknesses. In addition, fittings made from forgings shall have Carbon- 0.35 % max. and
Silicon- 0.35 % max. The normalising heat treatment shall be a separate heating operation
and not a part of the hot forming operation
b. All alloy steel (Cr-Mo) fittings shall be normalised and tempered. The normalising and
tempering shall be a separate heating operation and not a part of the hot forming
operation. The maximum room temperature tensile strength shall be 100,000 psi.
c. For carbon steel fittings, hardness of weld and HAZ shall be 200 BHN (max.). For alloy
steel fittings, hardness of weld and HAZ shall be 225 BHN (max.).
d. For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
Ferrite No.(FN) not lens than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by Ferritescope prior to post
weld heat treatment.
e. For all Carbon steel and Alloy steel fittings with wall thickness over 20mm, Charpy-V
Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME
Section VIII, Div-1 for weld metal and base metal from the thickest item per heat of
material and per heat treating batch. Impact test specimen shall be in complete heat treated
condition and accordance with ASTM A370. Impact energies at 0°Celsius shall average
greater than 27J (20 ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).
1.24 For all welded alloy steel fittings with mandatory requirements of heat treatment and
radiography, radiography shall be performed after heat treatment.
1.25 All 1Cr-0.5Mo & 1.25Cr-0.5Mo fittings shall be normalized and tempered. All 2.25Cr- 1 Mo,
5Cr-0.5Mo, 9Cr- 1 Mo & 9Cr- 1 Mo-V welded fittings shall be normalized and tempered.
1.26 Fitting material as per ASTM A234 Gr.WP5/WP9/WP91, wherever specified, shall be as per
'Cl.lt, unless otherwise specified.
1.27 Materials designated as structural steel grades like IS 2062, SA 36 etc. or similar specification
are not permitted for manufacture of fittings.
Page 634 of 1296

ENGINEERS
Ofaj- egIw INDIA LIMITED
I MTA <7,7.1,711,~
'flnd" Unde"")
6-44-0054 Rev. 6
Page 8 of 9
2.0 IBR REQUIREMENTS
2.1 IBR Documentation Required
2.1.1 Fittings under the purview of "IBR" (Indian Boiler Regulations) shall be accompanied with
original IBR certificate in Form III-C duly approved and countersigned by IBR authority /
local authority empowered by Central Boiler Board of India. Photocopy of the original
certificate duly attested by the local boiler inspector where the supplier is located is the
minimum requirement for acceptance.
2.1.2 For materials 11/4Cr - 1/2Mo (ASTM A 234Gr.WP11 & ASTM A234 Gr.WP11W) & 21/4Cr -
1Mo (ASTM A 234 Gr.WP22 & ASTM A234 Gr. WP22W) & 9Cr-lMo-V (A234 Gr.WP91/
A234Gr.WP91W),where fittings are manufactured from pipe, Form III-C approved by IBR
shall include the tabulation of Et, Sc, & Sr values for the entire temperature range given below.
Et, S„ & Sr values shall be such that throughout the temperature range
Et / 1.5
S, / 1.5 SA
Sc
SA Allowable stress at the working metal temperature.

E, Yield point (0.2% proof stress at the working metal temperature)
Sc The average stress to produce elongation of 1%(creep) in 100000 hrs at
the working metal temperature.
Sr The average stress to produce rupture in 100000 hrs at the working metal
temperature and in no case more than 1.33 times the lowest stress to
produce rupture at this temperature.
SA (psi)
Temp( F) 500 600 650 700 750 800 850 900 950 1000 1050 1100
Material
A234Gr.WP11/ 21700 20900 20500 20100 19700 19200 18700 13700 9300 6300 4200 2800
A234Gr.WP11W
A234Gr.WP22 / 17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A234Gr.WP22W
A234Gr.WP91/
28100 27700 27300 26700 25900 24900 23700 22300 20700 18000 14000 10300
A234Gr.WP91W
Note : SA values shall be as per the latest edition prevailing.
Carbon (max) 0.25%

Others (S, P, Mn) As prescribed in IBR.
services.
3.1 Seamless fittings are acceptable in place of welded fittings, however, welded fittings are not
acceptable in place of seamless fittings. Forged fittings are acceptable in place of wrought
Page 635 of 1296

ENGINEERS
aje- g
51g-ar fa INDIA LIMITED
IA
5" °"'" Un0en'''9)
6-44-0054 Rev. 6
Page 9 of 9
fittings. However, wrought seamless fittings are acceptable in place of forgings only in case of
swages.
3.2 Fittings of Grades SS317 of corresponding material are acceptable in place of Grades SS316
or SS316(2.5Mo min.).
3.3 Fittings of Grades SS317L of corresponding material are acceptable in place of Grades
SS316L or SS316L(2.5Mo min.).
4.1 Each fitting shall be legibly and conspicuously stamped in accordance with the requirements
of applicable standards along with special condition like "IBR", "Cryo", "NACE" and "H2"
etc.
4.2 Steel die marking with round bottom punch may be permitted on body of butt weld CS &
lower alloy steel fittings, but for SS & higher alloy steel fittings, the same should be marked
by electro-etching only.
4.3 Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead
or Copper which causes corrosive attack on heating.
4.4 Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.
4.5 Fittings shall be protected from rust, corrosion and mechanical damage during transportation,
shipment and storage.
4.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a
4.7 Fittings coming under the purview of "IBR", "CRYO" , "NACE" & "H2"(hydrogen) shall be
painted with one circumferential stripe of colour red, light purple brown, canary yellow &
white respectively for easy identification. Width of stripe shall be 12mm for sizes less than 3"
and 25mm for sizes 3" and above. Stripe shall be located centrally for elbows, diagonally for
caps, at the larger end for reducing fittings, longitudinally for couplings and at one end near to
the bevel/socket/screwed end for other fittings.
4.8 Each end of fitting shall be protected with a wood, metal or plastic cover.
4.9 Each size of fitting shall be supplied in separate packaging marked with the purchase order
number, item code number, material specification, size and schedule / thickness / rating. For
small quantities, fittings of different sizes may be packed in separate packing size-wise and
there packing may be packed in a bigger package/ container clearly identifying the contents.
5.0 REFERENCES
6-81-0001 : Specification for Positive Material Identification (PMI) at

Supplier's Works
6-81-0005 Inspection & test plan for forged, seamless and welded
fittings
6-79-0013 Material requirements for carbon steel components used in

sour service for petroleum refinery environments
Page 636 of 1296

Oa&
+rpm kgronre akrantl)
INDIA LIMITED
IA GovI of India Undertaking)
GASKETS 6-44-0056 Rev. 4
Page 1 of 5
Clcfri I 14) I I duLI
TECHNICAL NOTES
FOR GASKETS
REVISED & ISSUED AS STANDARD

4 21.03.13 '(
„yr UK yrSH z RN kTD DM
SPECIFICATION
3 23.07.07
SPECIFICATION RN ATD DM VC
REAFFIRMED & ISSUED AS STANDARD
2 15.06.98 SH BRB BN AS
SPECIFICATION
1 30.12.92 AKG BPV GRR AS
SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared
Date Purpose Checked by Convenor Chairman
No by
Approved by
Page 637 of 1296

Ogaf Rae
lg INDIA LIMITED GASKETS 6-44-0056 Rev. 4
anen efetpre ftst 3,70,1 IA Govt of India Undettatongt
Page 2 of 5
Abbreviations:
AARH : Average Arithmetic Root Height
BHN : Brinnel Hardness Number
CS Carbon Steel
RTJ Ring Type Joint
Members : Mr. Harish Chander

Mr. M. Ismaeel
Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.V.K Naidu (Projects)
Page 638 of 1296

fgar fafgeg
,ania riroreaw+i,
INDIA LIMITED
IA Goof of India Undertaking)
Page 3 of 5
CONTENTS
1.0 GENERAL 4
2.0 REFERENCES 5
Page 639 of 1296

$14-ar 051-eg
wren erecore 4513405141
INDIA LIMITED
(A Goer of India Undertaking)
Page 4 of 5
1.0 GENERAL
1.1 All gaskets shall conform to the codes/standards and specifications given in the
requisition. Supplier shall strictly comply with MR/PR stipulations and no deviations shall
be permitted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as mentioned in Cl.
5.18 of Specification for Quality Management System Requirements from Bidders (6-78-
0001) is not applicable.
1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall be in
accordance with the requirements of the manufacturer's standards.
1.3 Testing
1.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the standards
specified in the requisition.
1.3.2 Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of
test reports on samples.
1.3.3 For Spiral wound material following shall be furnished:
a. Manufacturer's test certificate for filler material and spiral material as per the relevant
material specifications.
b. Manufacturer's test certificate for raw materials and tests for compressibility/ seal-
ability & recovery as per the relevant material specifications.
1.3.4 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001) for ring type joint gaskets.
1.3.5 Refer Specification no 6-81-0008 for 'Inspection & Test Plan for Gaskets'.
1.4 Full face gaskets shall have bolt holes punched out.
1.5 Filler material for spiral wound gaskets shall not have any colour or dye.
1.6 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall
be CS unless otherwise specified in the MR.
1.7 For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip
material. In addition to the requirements as per code and as specified in the MR, inner
rings shall be provided for the following:
a. Sizes 26" and above.
b. Class 900 and above.
1.8 Hardness of metallic RTJ gaskets shall not exceed the values specified below unless
otherwise specified in MR:
Ring Gasket Material Maximum Hardness (BHN)
Soft Iron 90
Carbon steel 120
Page 640 of 1296

ligar 215ieg
rrecryrens,mn.,
NIVM
INDIA LIMITED
IA G0A of Incha Uncterlaiong)
Page 5 of 5
5 Cr. 1/2 Mo 130
Type 304, 316, 321, 347 140
Type 304L, 316L 120
1.9 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.
1.10 Gaskets of different types and sizes shall be placed in separate shipping containers and
each container clearly marked with the size, rating, material specification and item code.
1.11 All items shall be inspected and approved by EIL Inspector or any other agency
authorized by EIL.
1.12 Any additional requirements specified in the requisition, shall be fully complied with.
1.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto
24" (except 22" size) and to ASME B16.47B above 24" unless specified otherwise. For
22" size, the matching flange standard shall be MSS-SP44 unless specified otherwise.
1.14 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto
24"(except 22"size) and to ASME B16.47B above 24" unless specifically mentioned
otherwise. For 22" size, the matching flange standard shall be MSS-SP44 unless specified
otherwise.
1.15 The following abbreviations have been used in the Material Requisition for Spiral Wound
Gaskets :
(I) Inner Ring

(0) • Outer Ring
GRAFIL : Grafoil Filler
2.0 REFERENCES

Works
6-81-0008 Inspection & Test Plan for Gaskets
6-78-0001 Specification for Quality Management System Requirements from

Bidders
Page 641 of 1296

6-44-0057 Rev. 4
Igar tif5leg INDIA LIMITED
IA Govt of India Undettatongf
BOLTS AND NUTS
Page 1 of 5
64vd,N*1 -R-
47 7-
4‘k:r *
ocn i criI Idui 'J ig'
TECHNICAL NOTES
FOR BOLTS AND NUTS

9'°1A-)-
4 21.03.13 4, UK 4.7t5(H RN STD DM
SPECIFICATION
3 23.07.07
SPECIFICATION RN ATD DM VC
2 15.06.98 SH BRB BN AS
SPECIFICATION
REVISED & ISSUED AS STANDARD AS
1 30.12.92 AKG BPV GRR
SPECIFICATION
Standards Standards
Committee Bureau
No by by
Approved by
Page 642 of 1296

tg-ar 054-eg
1.71217 2T2a+re OP J73,A)
INDIA LIMITED
BOLTS AND NUTS 6-44-0057 Rev. 4
Page 2 of 5
Abbreviations:
ASTM : The American Society for Testing and Materials
MR : Material Requisition
SS Stainless Steel

Mr. M. Ismaeel
Mr. Amrendra Kumar
Mr. G. Balaji
Page 643 of 1296

INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 4
I ,lecnr, am award) (A Govt Of India Undertaking)
Page 3 of 5
CONTENTS
1.0 GENERAL 4
3.0 REFERENCES 5
Page 644 of 1296

Ogar 0144-eg
1.417M el,a,Je
INDIA LIMITED
IA Govt of India Undeilaking)
BOLTS AND NUTS 6-44-0057 Rev. 4
Page 4 of 5
1.0 GENERAL
1.1 The process of manufacture, heat treatment, chemical & mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the
codes/standards and specifications given in the requisition. The applicable identification
symbol in accordance with the material specification shall be stamped on each bolt and
nut. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as mentioned in Cl. 5.18
of Specification for Quality Management System Requirements from Bidders (6-78-0001)
is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
1.2.2 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and
Mechanical Requirement)
1.2.3 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001).
1.2.4 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453
bolting material irrespective of the temperature.
1.2.5 Refer Specification no 6-81-0007 for 'Inspection & Test Plan for Bolting Material'.
1.3 All bolting shall be as per ASME B 18.2.1 for studs, M/c bolts and jackscrews and ASME
B18.2.2 for nuts.
1.4 Threads shall be unified (UNC for 1" dia and 8UN for > 1" dia) as per ASME B1.1 with
class 2A fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.
1.5 Stud bolts shall be threaded full length with two heavy hexagonal nuts unless otherwise
specified. Length tolerance shall be in accordance with the requirement of Table D2 of
Annexure-D of ASME B 16.5.
1.6 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be
made by the hot forged process and stamped as per respective material specification.
1.7 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be
rounded.
1.8 Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in separate
containers marked with size and material specifications. `CRY0' shall be marked
additionally in case `CRY0' is specified in the requisition.
1.9 All items shall be inspected and approved (stagewise) by EIL inspector or any other
agency authorized by EIL.
1.10 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
1.11 All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed
condition unless specified otherwise in the material specification.
1.12 Any additional requirements specified in the requisition shall be fully complied with.
Page 645 of 1296

■
31 ENGINEERS TECHNICAL NOTES FOR
$2-al faReg INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 4
Govt 01 India Undenaking)
Page 5 of 5
1.13 Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material
specification and also where the material specification is indicated as "CRYO". For S.S.
nuts and bolts minimum impact energy absorption shall be 27 Joules and test temperature
shall be -196°C unless mentioned otherwise. For other materials impact energy and test
shall be as per respective code.
1.14 Bolts/nuts of material of construction B7M/2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A193.
1.15 When specified as galvanized, the studs, M/C bolts and nuts shall be 'hot dip zinc coated'
in accordance with requirements of 'class C' of ÀSTM A 153'. As an alternative, electro-
galvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable.
1.16 All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts
irrespective of whatever has been specified elsewhere in the MR.
1.17 Bolting shall be protected by non-corrosive oil or grease before dispatch to prevent
rusting.
2.1 'Nuts' to ASTM A194Gr.7 are acceptable in place of ASTM A194Gr.4.
3.0 REFERENCES

Works
6-81-0007 Inspection & Test Plan for Bolting Material

Bidders
Page 646 of 1296

k31 ENGINEERS TECHNICAL NOTES FOR
6-44-0067 Rev. 1
$gU1812 -g INDIA LIMITED STRAINERS
IA GoA ot Indta Undeflakng)
Page 1 of 9
RYI
ch 1-1 ch u I 41
TECHNICAL NOTES FOR

STRAINERS

1 23.09.2014 SH ,RN D SC
SPECIFICATION
0 29.06.2009 ISSUED AS STANDARD SPECIFICATION PK RN SC ND
Standards Standards
Com m ittee Bureau
No by by
Approved by
Page 647 of 1296

IM2— g INDIA LIMITED STRAINERS 6-44-0067 Rev. 1
aIIZ, rlecnW ast aamnl lA Govt ol Indo Undertakng)
Page 2 of 9
Abbreviations:

AISI American Iron and Steel Institute
BW Butt Weld
DP Dye Penetrant
FLGD Flanged
FN Ferrite Number
H2 Hydrogen
MOC Material of Construction
NACE National Association of Corrosion Engineers
SCRD Screwed
SW Socket Weld
UNC Unified Coarse
WN Weld Neck

Mr. Amrendra Kumar
Mr. G. Balaji
Page 648 of 1296

tg'-ar2f51-
dg INDIA LIMITED
IA Govt of Indo UndellaMing)
STRAINERS 6-44-0067 Rev. 1
Page 3 of 9
CONTENTS
1.0 PURPOSE & SCOPE 4

2.0 DESIGN & CONSTRUCTION 4
3.0 DOCUMENTATION 7
4.0 SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE 7
5.0 TESTING & INSPECTION 8
6.0 ACCEPTABLE DEVIATIONS 8 I
7.0 MARKING & DESPATCH 8
8.0 ATTACHMENTS FOR MR 9
9.0 REFERENCES 9
Page 649 of 1296

t-11 ENGINEERS TECHNICAL NOTES FOR
Og-ar a;es1~1 tY,CD11,613~
INDIA LIMITED
in Govt of Indu Unclellalong)
Page 4 of 9
1.0 PURPOSE & SCOPE
This specification covers the design and construction, IBR requirements, documentation,
testing, inspection, marking and despatch requirements for Strainers. Vendor shall supply
Strainers in accordance with the technical notes and details specified in the Data Sheet for
strainers. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted. Post order Concession/ Deviation format 5-0000-0180-F1 as mentioned in Cl. 5.18
of Specification for Quality Management System Requirements from Bidders (6-78-0001) is
not applicable.
2.0 DESIGN & CONSTRUCTION
2.1. All codes and Standards for manufacture, testing and inspection etc. shall be of latest editions.
2.2 The material of construction shall be as per the data sheet; for parts not mentioned in the data
sheet, vendor shall guarantee the material used for the service conditions specified.
For flanged strainers, MOC of end flanges shall correspond to the material specified in the
Data sheet.
For welding of dissimilar materials required for strainer assembly, welder qualification
procedure shall be done prior to welding.
2.3 The material composition, physical properties, heat treatment, mandatory test reports,
dimensions and tolerances shall confirm to the applicable codes/ standards/specifications as
specified in the requisition.
2.4 Design shall be based on EIL Std 7-44-0300 for temporary strainers, EIL Stds 7-44-0303/0304
for T-type permanent strainers and Manufacturer's std. for Y-type strainers.
2.5 Dimension Standards for various components are as follows:
Body - ASME B16.9/B16.11

Flanges - ASME B16.5/B16.47 Series B
Gaskets - ASME B16.20/B16.21
Bolts & Nuts - ASME B18.2.1 & B 18.2.2 respectively
2.6 Ends of body shall either be Flanged, BW, SW or Screwed as specified in the data sheet.
2.6.1 The ends for strainers shall correspond to the following standards:
FLGD ASME B16.5/B16.47 Series B

BW ASME B16.25
SW ASMEB16.11
SCRD ASME B16.11
2.6.2 Bevel end details for BW strainers shall be as per ASME B16.25. Contour of bevel end shall
be as follows:

Low Temp. Carbon
Steel) > 22 mm Figure 3 Type A
Page 650 of 1296

INDIA LIMITED STRAINERS 6-44-0067 Rev. 1
1.41Q, 2:17.77 ffil,m++1) IA Gov, 01 lrMia Under,ak,n9)
Page 5 of 9

Stainless Steel &
2.7 Flange face finish shall be normally specified in the strainer data sheet. The interpretation for
range of face finish shall be as follows:
Stock Finish 1000 p in AARH max.

Serrated/Smooth Finish/125AARH Serrations with 125 to 250 p in AARH
Extra Smooth Finish/63 AARH 32 TO 63 µ in AARH
2.8 For strainers with ring type joint flanged ends the hardness shall be as follows:
Flange Material Min. Hardness of Max. Gasket

Groove (BHN) Hardness (BHN)
Carbon Steel 140 90
1% Cr to 5% Cr, 9% Cr 150 130
Type 304, 316, 321, 347 160 140
Type 304L, 316L 140 120
2.9 For strainers with flanged ring type joint ends, the hardness shall be recorded in the test report.
2.10 Ends of screwed strainers unless otherwise specified shall have taper threads as per
ASME/ANSI B1.20.1 (upto 1.5" NB) & IS 554 (for 2" to 6" NB).
2.11 All 2" and higher size Y type strainers shall be provided with 3/4" screwed plug for drain
connection. For less than 2" this shall be 1/2" size.
For Y type, SW end Strainers (size 1.5" & below) to MNF'STD, blind end is also acceptable
with threaded plug cover instead of flanged end. In this case, plug shall be of forged material
equivalent to body material.
2.12 For Y type strainers, cast strainers with integrally cast flanges and with end cover / blind
flange in cast/forged construction is acceptable.
2.13 For flanged end strainers, weld-on flanges (WN) are acceptable.
2.14 Pressure drop calculations shall be furnished by vendor along with the offer, wherever
specified in the data sheet.
2.15 Stainless Steel Strainers
2.15.1 All Austenitic Stainless Steel items shall be supplied in solution annealed condition.
2.15.2 For all Austenitic Stainless Steel items Inter-granular Corrosion Test shall be conducted as per
following:
Page 651 of 1296

ENGINEEFZS TECHNICAL NOTES FOR
Og-ar faaes
1~, c.wen/C ,151,370M)
INDIA LIMITED
Ift Govt of InOla Undettakong)
Page 6 of 9
ASTM A 262 Practice 'B' with acceptance criteria of `60mils/year (max.)'

OR
ASTM A262 Practice E with acceptance criteria of no cracks at 20X magnification
and microstructure to be observed at 250X magnification shall ensure the absence of
any cracks/ fissures. When testing is conducted as per practice 'E' photograph of
microstructure shall be submitted for record.
2.15.3 When specifically asked for in MR for High Temp. application of some grades of Austenitic
Stainless Steel (like SS 309, 310, 316H etc.) ASTM A 262 practice 'C' with acceptance criteria
of "15mils/year" shall be conducted.
2.15.4 All types of SS321 or SS347 material shall be in stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to normal solution annealing. Soaking
temperature and holding time for stabilizing heat treatment shall be 900 °C and 4 hours
respectively.
2.16 IBR Requirements
2.16.1 For SW / BW end carbon steel strainers under IBR, the chemical composition shall conform to
the following :
Carbon (Max) 0.25%

Others (S, P, Mn) As per IBR regulations
2.16.2 Strainers coming under the purview of "IBR" (Indian Boiler Regulations) shall each be
individually accompanied by original IBR certificate in Form duly approved by IBR
authority / local authority empowered by the Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
2.17 In case of T-type strainer, body construction shall be `Seamless' unless otherwise specified in I
the data sheet.
2.18 Welded Tees shall not be of fabricated (Stub-in) type.
2.19 Strainers with welded body shall be in normalized condition & 100 percent radiographed by
X-ray.
2.20 All alloy steel strainers with welded body construction shall be normalized and tempered &
100 percent radiographed by X-ray.
2.21 Weld joints shall be stress relieved as per the requirement specified in the Strainer MR
Attachment..
2.22.1 Strainines under "NACE" category or those designated as "HIC1" shall meet the requirements
of NACE MR-0103 unless otherwise specified.
2.22.2 Strainers made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless otherwise specified.
2.23 Strainers of Hydrogen service category shall meet the requirements as specified in clause 4.0
below.
2.24 Galvanized strainers shall be coated with zinc by hot dip process conforming to IS 4736 / I
ASTM A153.
Page 652 of 1296

Og-arld2- g INDIA LIMITED
IA Govt of InOta Unclettakingt
Page 7 of 9
2.25 Gaskets
2.25.1 Non-metallic gaskets shall conform to B16.21 (corresponding to B16.5) up to 24" and B16.21
(corresponding to B16.47 Series `B') beyond 24", unless otherwise specified.
2.25.2 Spiral wound gaskets shall conform to B16.20.
2.25.3 Ring type and spiral wound gasket shall be self-aligning type.
2.25.4 Ring Joint gasket shall Octagonal type and shall conform to B16.20.
2.26 Bolting
2.26.1 All bolts shall conform to B18.2.1, nuts to B18.2.2. Reference shall also be made to B16.5 for
studs.
2.26.2 Threads shall be unified (UNC for upto 1"dia and 8UN for > 1"dia) as per ANSI B.1.1 with
class 2A fit for studs and M/C bolts and class 2B fit for nuts.
2.26.3 Nuts for Bolts & Studs shall be the American Standard Hexagon Heavy Series.
3.0 DOCUMENTATION
3.1 No documents shall be submitted with the offer.
3.2 Detailed dimensioned cross section drawing with parts, materials, weight, etc. shall be
submitted through EIL eDMS for records/information.
4.0 SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
4.1 Method of Manufacture
4.1.1 All carbon steel strainers having wall thickness 9.53 mm and above shall be normalized.
Carbon content shall be limited to .35% max. and Silicon .35% max. The normalizing heat
treatment shall be a separate heat treatment operation and not a part of the hot forming
operation. Normalizing shall be done after final cold draw pass for all thicknesses if cold
drawn.
4.1.2 All alloy steel (Cr-Mo) strainers shall be normalized and tempered. The normalizing and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation. The maximum room temperature tensile strength shall be 100,000 psig.
4.2 Impact Test
4.2.1 For all carbon steels and alloy steels with wall thickness over 20 mm, Charpy-V Notch impact
testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-1
per heat of material and per heat treating batch. Impact test specimen shall be in accordance
with ASTM A370. Impact energies at 0° C shall average greater than 27J (20 ft-lb) per set of 3
specimens, with a minimum of 19J (15ft-lb).
4.3 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
ferrite No (FN) not lens than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by ferritescope prior to post weld
heat treatment.
4.4 Hardness of weld and HAZ shall be 200 BHN (max) for carbon steel and 225 BHN (max) for
alloy steel.
Page 653 of 1296

, ENGINEERS TECHNICAL NOTES FOR
sig-ar rircortom.3oor.o
INDIA LIMITED
in Govt ol indLe Undenak,o9)
Page 8 of 9
5.0 TESTING & INSPECTION
5.1 A11 strainers shall be hydrostatically tested at the lower of twice the design pressure and 1.5
times the class rating as per ASME B16.5 at ambient temperature.
5.2 All BW joints shall be 100% Radiographed and Fillet welds shall be 100% DP/MP checked.
5.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the `Specification for Positive Material Identification (PMI) at Supplier's Works'
(No. 6-81-0001).
5.4 All welded Tees indicated in the MR as "Cryo" & "LT" shall meet Impact test requirements of
ASME B31.3. The Impact test temperature shall be (-)196°C & (-)45°C for Stainless Steel &
Low Temperature Carbon Steel respectively unless otherwise mentioned in the MR.
5.5 The stage wise inspection of non-IBR Strainers shall be done by EIL inspector before
despatch. EIL/Client's authorized representatives reserve full right to witness stagewise
inspection of all mandatory/applicable supplementary tests. However, for IBR items, the
tests/inspection shall be by IBR authority.
5.6 Material Test Certificates (Physical Properties, Chemical Composition and heat Treatment
Report) shall also be furnished.
5.7 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications/requisition. Test reports shall also be furnished for hydrotest and other
supplementary tests as specified in the requisition.
5.8 Refer Specification 6-81-0133 for Inspection & Test Plan for Strainers.
6.1 Following alternative body materials are acceptable :
AISI 420/AISI 410/A743 Gr.CA40/A743 Gr.CA15 in lieu of ASTM A105.

A182 F22 in lieu of A182 F11.
AISI 420/A182 Fl 1 in lieu of A182 F1.
6.2 Cast strainers with integrally cast flanges are also acceptable in lieu of equivalent forged
material. All castings offered in place of forgings shall be radiographed.
6.3 Forgings of equivalent material shall be acceptable in place of castings.
6.4 In the case of T type strainers, `Seamless' body is acceptable in place of "Welded" body.
`Welded' body shall not be acceptable in place of `Seamless'.
7.0 MARKING & DESPATCH
7.1 Each Strainer shall be legibly & conspicuously stamped on the body, in accordance with the
requirements of applicable standards along with special condition like IBR, CRYO, NACE,
H2 etc. Vendor shall also mark on the body the Location/Tag No. and Line Number
mentioned in MR attachment.
7.2 A11 items shall be dry, clean and free from moisture, dirt and loose foreign material of any
kind.
Page 654 of 1296

2-1 ENGINEERS TECHNICAL NOTES FOR
$'g-a r laWs INDIA
1.1RA. vivaxt As..AlcA.1>
LIMITED
IA Govt 01 Ind. Undellaking)
Page 9 of 9
7.3 All items shall be protected from rust, corrosion, and mechanical damage during
7.4 Rust preventive, on machined surfaces to be welded, shall be easily removable with a
petroleum solvent or shall not be harmful to welding.
7.5 Paint or ink for marking shall not contain any harmful metal or metallic salts such as Zinc,
Lead or Copper which causes corrosive attack on heating.
7.6 Strainers under "IBR", "CRYO", "NACE" & "H2" shall be painted in Red, Light Purple,
Canary Yellow and sea green strips respectively for easy identification. Width of strip shall be
25 mm. Strainers coming under the purview of "IBR", "CRYO" , "NACE" &
"H2"(hydrogen) shall be painted with one circumferential stripe of colour red, light purple
brown, canary yellow & white respectively for easy identification. Width of stripe shall be
12mm for sizes less than 3" and 25mm for sizes 3" and above. Stripe shall be located one end
near to the bevel/socket/screwed/flanged end.
7.7 After testing, one coat of inorganic zinc silicate (minimum DFT 65 to 75 microns) shall be
applied as primer over the external surface for carbon steel / alloy steel strainers.
7.8 Each end of strainer shall be protected with the following materials :
Flange Face Wood or Plastic Cover

Bevelled End Wood or Plastic Cover
SW & SCRD End Plastic Cap
End protectors of wood / plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than the outside diameter of the flange. However plastic caps
for SW & SCRD end strainers shall be press fit type. End protectors to be used on beveled end
shall be securely and tightly attached.
8.0 ATTACHMENTS FOR MR
Format No.3-1643-0093: Data Sheet for Strainers
9.0 REFERENCES
6-81-0001 Specification for PMI at Supplier's Works
6-81-0133 Inspection and Test Plan for Strainers
6-78-0001 Specification for Quality Management System Requirements

from Bidders
Page 655 of 1296

k3
e- _Jtii ENGINEERS TECHNICAL NOTES FOR
tg-a r 051-dg ' INDIA LIMITED SAMPLE COOLERS 6-44-0068 Rev. 1
,N7v a-leant tIlf,ossi, IA GOVT of 106. Under,* .9) Page 1 of 5
cto4 * icrR
cichl l ch 1dui ulql
TECHNICAL NOTES
FOR
SAMPLE COOLERS

11—}
1 21.03.13 \ i/UK .7-RN -R'ATD DM
SPECIFICATION
0 23.07.07 ISSUED AS STANDARD SPECIFICATION RN ATD DM VC

Standards Standards
Rev. Prepared Checked Committee Bureau
No by by
Approved by
Page 656 of 1296

-g
Iii' INDIA LIMITED SAMPLE COOLERS 6-44-0068 Rev. 1
eredverni,kvorvii IA Govt of India Undertaking)
Page 2 of 5
Abbreviations:
AARH : Average Arithmetic Root Height
AS Alloy Steel
CS Carbon Steel
DFT : Dry Film Thickness
DP Dye Penetrant
GTAW : Gas Tungsten Arc Welding
MR : Material Requisition
SS Stainless Steel

Mr. M. Ismaeel
Mr. Amrendra Kumar
Mr. G. Balaji
Page 657 of 1296

■
3Iei ENGINEERS TECHNICAL NOTES FOR
INDIA LIMITED SAMPLE COOLERS 6-44-0068 Rev. 1
• I eirvorlanJoso+0 IA Govt of India Uncle(taking)
Page 3 of 5
CONTENTS
2.0 DESIGN & FABRICATION 4
3.0 INSPECTION & TEST .4
4.0 DOCUMENTATION 5
5.0 MARKING & DESPATCH 5
6.0 REFERENCES 5
Page 658 of 1296

q-A ENGINEERS TECHNICAL NOTES FOR
$1g-af 215i-
eg INDIA LIMITED SAMPLE COOLERS 6-44-0068 Rev. 1
IA Govt of Ind. Undertaking)
Page 4 of 5
1.0 PURPOSE & SCOPE
This specification covers the design, fabrication, documentation, inspection & testing,
marking and dispatch requirements for Sample Coolers. Supplier shall supply Sample
Coolers in accordance with these technical notes, standards and drawings attached
with the Material/Purchase requisition. Supplier shall strictly comply with MR/PR
stipulations and no deviations shall be permitted. Post Order Waiver/ Deviation format
5-0000-0180-F1 as mentioned in Cl. 5.18 of Specification for Quality Management
System Requirements from Bidders (6-78-0001) is not applicable.
2.0 DESIGN & FABRICATION
2.1 All codes and standards referred in drawings, documents etc shall be of latest editions
on the date of offer submission.
2.2 Material, dimensions and tolerances shall conform to the applicable

codes/standards/specifications as specified in the requisition.
2.3 Supplier shall refer Data Sheet for Sample Coolers for additional details not covered in
standards/specifications/drawings attached with the requisition.
2.4 Unless otherwise specified dimension standard for end connections shall be as under
Flanged ends ASME B 16.5
Socket Welding ends : ASME B 16.11
Screwed ends ASME B 16.11/ASME B1.20.1
Bevel ends ASME B 16.25
2.5 The interpretation for range of face finish shall be as follows:

Stock Finish 1000 j.t in AARH max.
Serrated Finish/125 AARH : Serrations with 125 to 25011 in AARH
63 AARH 32 TO 63 µ in AARH
2.6 Screwed Pipe ends shall have external taper pipe threads conforming to ASME
B1.20.1.
2.7 As far as possible, coil shall be made from single straight pipe. However, one butt-
weld joint is permitted. Welding shall be done by GTAW process. The AS/CS coil
shall be normalized and tempered after bending. Solution annealing for stainless steel
coil shall be carried out after bending. The butt welded joint in the coil, if any, shall be
radiographed. All other welds shall be 100% MP tested for CS /AS and DP tested for
SS components.
2.8 External surface of sample coolers shall be brushed/ mechanically cleaned. After
testing, one coat of inorganic zinc silicate (DFT 75 microns) shall be applied as primer
over external and internal surface of the shell as well as over the carbon steel / alloy
steel coil surface.
3.0 INSPECTION AND TEST
3.1 Material test certificates (Chemical composition, physical properties and heat
treatment) shall be furnished for all pressure containing parts. Material test certificates
for other parts shall also be furnished for verification during inspection.
Page 659 of 1296

Ilf~iei ENGINEERS TECHNICAL NOTES FOR
$2-zir
(.112A
fetWeg
anJ70,71,
eirm,
INDIA LIMITED
(A Gov( of Ind,. Undertaking)
SAMPLE COOLERS 6-44-0068 Rev. 1
Page 5 of 5
3.2 Test reports shall be supplied for all mandatory tests as per relevant material
specifications. Test reports shall also be supplied for hydrostatic test and any other
supplementary test as specified in the requisition.
3.3 Sample cooler body shall be filled with water and leak tested at ambient temperature.
The coil shall be hydrostatically tested at a pressure specified in Data Sheet for
Sample Coolers. Hydrostatic test pressure shall be 1.5 times the class rating at ambient
temperature.
3.4 Positive Material Identification (PMI) shall be performed as per scope and procedure
as defined in 'Specification for Positive Material Identification (PMI) at Supplier's
Works (6-81-0001)' for other than CS components.
3.5 Refer Specification 6-81-0132 for Inspection & Test Plan for Sample Coolers.
4.0 DOCUMENTATION
4.1 No documents shall be submitted with the offer. However, drawings shall be furnished
alongwith final documentation for records through EIL eDMS (electronic Document
Management System).
4.2 In addition to document submissions through eDMS, 6 hard copies and 2 soft copies
(in CDs/DVDs) of the final documentation shall be submitted along with the delivery
of items.
5.0 MARKING & DESPATCH
5.1 Each sample coolers shall have corrosion resistant tag securely attached to the body
marked with Tag No., Line number, Job No. & P.R. number, coil material & thickness
(e.g. ASTM A106 Gr.B, S160). Paint or ink used for marking shall not contain any
harmful metal or metallic salts.
5.2 All sample coolers shall be dry, clean and free from moisture, dirt and loose foreign
materials of any kind. All nozzles shall be properly closed with wooden plank to avoid
ingress of foreign matter. All sample coolers shall be protected from rust, corrosion
and mechanical damage during transportation, shipment and storage.
6.0 REFERENCES
Format No 3-1643-0096: Datasheet for Sample Coolers.
6-81-0001: Specification for PMI at Supplier's Works
6-81-0132: Inspection and Test Plan for Sample Coolers
6-78-0001 : Specification for Quality Management System

Requirements from Bidders
Page 660 of 1296

ENGINEERS SPRING SUPPORT 6-44-0070 Rev. 1
2151e
-g INDIA LIMITED ASSEMBLIES
er22/517 Cit J,
1;trA) IA Govt of Inca Unoleflaking) Page 1 of 8
*ILI aTARrol- icvR

04) 11ch1 Idui ultil
TECHNICAL NOTES
FOR SPRING SUPPORT ASSEMBLIES
REVISED & ISSUED AS STANDARD cATD

i' DM
1 21.03.13 41/UK sOWSH RN
SPECIFICATION
0 23.07.07 ISSUED AS STANDARD SPECIFICATION RN ATD DM VC

Standards Standards
Rev. Prepared Checked Committee Bureau
No by by
Approved by
Page 661 of 1296

0 Q-1 ENGINEERS TECHNICAL NOTES FOR
f=g-zrr iaf5tes
evraqe AYl J4iF41)
INDIA LIMITED SPRING SUPPORT ASSEMBLIES
6-44-0070 Rev. 1
Page 2 of 8
Abbreviations:
AS Alloy Steel
BS British Standard
CS Carbon Steel
IS Indian Standard
SS Stainless Steel

Mr. M. Ismaeel
Mr. Amrendra Kumar
Mr. G. Balaji
Page 662 of 1296

161
-1 1_1 ENGINEERS TECHNICAL NOTES FOR
Ifgar Rift INDIA LIMITED
SPRING SUPPORT ASSEMBLIES 6-44-0070 Rev. 1
Page 3 of 8
CONTENTS
2.0 TECHNICAL REQUIREMENTS 4
3.0 PAINTING & GALVANIZING 7
4.0 DOCUMENTATION 7
5.0 TESTING & INSPECTION 7
7.0 REFERENCES 8
Page 663 of 1296

711tc el ENGINEERS TECHNICAL NOTES FOR
$1=
dzir cc' INDIA LIMITED SPRING SUPPORT ASSEMBLIES 6-44-0070 Rev.
1.117R e10,1, .71➢.11 IA Govt of India Undettaktngt
Page 4 of 8
1.0 PURPOSE & SCOPE
This document covers supply, material, fabrication, testing and inspection requirements for
`Spring Support Assemblies' with helical, hot coiled & heat treated compression type springs.
Detailed design of spring assemblies is Supplier's responsibility. Supplier shall guarantee
proper functioning of the Spring Assemblies under specified load & travel conditions. Items
not indicated clearly in Supplier's offer but required as per this requisition shall be considered
in Supplier's scope of supply. Supplier shall strictly comply with MR/PR stipulations and no
deviations shall be permitted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as
mentioned in Cl. 5.18 of Specification for Quality Management System Requirements from
Bidders (6-78-0001) is not applicable.
2.0 TECHNICAL REQUIREMENTS
2.1 Material Requirements
Unless otherwise specified, the material of construction shall be as follows.
Clamp (CS) IS 2062 Gr.A/B
Clamp (AS) — Note 1 ASTM A 387 Gr.11/22 or SS 316 / 321.
Clamp (SS) SS 316 / 321
Lugs (CS) — Note 2 IS 2062 Gr.A/B
Lugs (AS) — Note 3 ASTM A 387 Gr.11/22
Lugs (SS) — Note 3 SS 316 /321
Eye rod (CS Forged / Rolled Bar) IS 1875 CI-II/IIA / ASTM A 105 / IS 2062 Gr.A/B
Hanger Rod (CS) IS 1875 CI-II/IIA / ASTM A 105 / IS 2062 Gr.A/B
Turn Buckle IS 1875 CI-II/IIA, ASTM A 105 for sizes < M30. For
sizes > M30 these may be fabricated type of
equivalent material (refer clause 2.8.)
Plates 5, 10, 12, 20, 25 mm etc. IS 2062 Gr.A/B.
Stud / Bolt for CS Clamps ASTM A 193 Gr.B7
Stud / Bolt for AS Clamps ASTM A 193 Gr.B16
Stud / Bolt for SS Clamps ASTM A 193 Gr.B8
Nuts for CS Clamps ASTM A 194 Gr.2H
Nuts for AS Clamps ASTM A 194 Gr.4/Gr.7
Nuts for SS Clamps ASTM A 194 Gr.8
Spring Coil BS 970 EN 42, 45-45A, 47, 50 Cr.V4, 51 Cr.Mo.V4,

IS-4454-Part 1 (for springs up to 40 mm coil dia.
Only)
Page 664 of 1296

-If laf5ieg)
1AXJEdna
INDIA LIMITED
(A Govl of India Undertaking)
Page 5 of 8
Casing IS 1239-1 (Medium) / IS 2062 Gr. A, 5.00 mm thk.

(Min.) / API 5L Gr. A/B ERW, 5.00 mm (Min.) / IS
3589 Gr. 330 ERW, 5.00 mm (Min.)
Name Plate SS / Aluminum
Load Indicator SS / Aluminum
Welding Electrode IS 814
Other Bolts / Nuts IS 1367 Cl. 4.6 / IS 1367 Cl. 4.0
Roller / Ball arrangement SS 304 / 316 / SAE 52100

(Note — 4)
Notes:
1. In case of Alloy Steel Clamps Supplier can alternately supply SS Clamps.

2. Lug material for both pipe side & structure side attachments.
3. Lug material for pipe side attachment.
4. Balls shall be provided in a semi encapsulated type enclosure with separators for each
ball. The balls shall be protruding above the enclosure so that the pipe support plate
rests on the balls & the balls remain at the same location and move on their axis in
case of movement of pipe. Sliding of balls in case of pipe movement is not acceptable.
2.2 Design & Manufacturing Requirements
2.2.1 Design & manufacture of Hot coiled helical compression spring shall be to BS 1726, Part 1 /
MSS-SP-58 & ASTM A 125. All requirements of the specification must be met.
2.2.2 Unless otherwise stated all joints shall be of welded construction and shall be in accordance
with IS 816 / ASME Sec IX.
2.2.3 All weld sizes shall be 6 mm or 0.8 times the thickness of metal (whichever is more) to be
connected.
2.2.4 All bolt holes shall be minimum 2 mm larger than the bolt dia.
2.2.5 All threads shall be metric type to IS 4218 — Standard Coarse Pitch, alternatively ISO Metric
threads may be employed.
2.3 The springs shall be coiled, ensuring that the coils are uniformly spaced and are parallel to the
axis of the spring.
2.4 The springs shall have their ends ground flat and smooth at right angles to the axes of the
springs over the full circumference so that they stand perpendicular when placed on a
horizontal plane.
2.5 All springs shall be enclosed in a robust casing of specified material with two 6 mm dia holes
or equivalent at lowest point 180 deg apart for drainage.
2.6 The entire spring assembly including attachments & preset locking device shall be designed
for 2 times the service load or the hydro test load whichever is higher and shall be of the nut—
bolt type for variable spring assemblies and pin type for constant spring assemblies. The
Page 665 of 1296

atae1t.1 ENGINEERS TECHNICAL NOTES FOR
254-dg
WWI eieqW 111,..11
INDIA LIMITED
(A Govt of India Undettakolgt
Page 6 of 8
springs shall also have suitable features so that they can be locked in any position within the
range of load capacity of the hangers.
2.7 Each spring shall be factory preset to the load given in the spring schedule.
2.8 All springs shall be supplied with lengths as specified in the MR. Deviation in lengths is not
acceptable. Each spring shall also be provided with a means of adjusting the installed length
by a minimum of 25 mm. Rod and turnbuckle assembly shall be designed for +/- 50 mm
adjustment over the specified length of spring support assembly. Turnbuckles shall be made
from forged material for sizes up to M30 and for sizes above M30 they can be forged type or
machined from rolled bar or fabricated type.
2.9 All springs shall have an affixed load and travel plate on which hot and cold positions are
clearly marked. The load on the spring at any instant shall be indicated by an integral pointer
on a load position plate.
2.10 All hanger type spring assemblies shall allow minimum 4 Deg. Horizontal movement of pipe
in any direction. Variable springs shall have max 15% load variation on operating load unless
otherwise specified. However for constant springs load variation shall not exceed 5%.
Supplier may offer springs with lesser % load variation than specified above. The value of
spring constant if specified is the maximum value spring can have, Supplier may offer springs
with up to 6% lesser spring constant but not vice versa. For springs with preset load & spring
constant, max % variation is not restricted to 15%.
2.11 If both upward and downward deflections are mentioned in spring schedule, springs shall be
designed accordingly considering deflection in both upward and downward directions.
2.12 All springs shall be provided with a means of positively and firmly locking the piston plate for
hydrostatic testing of the pipe.
2.13 Teflon / Graphite pads for reducing lateral frictional force shall be provided when specified in
the requisition. Wherever temperature is greater than 204°C, only graphite pad shall be used.
Thickness of Teflon / Graphite pads shall be minimum 10 mm / 12.7 mm respectively.
Retainer plate of 8 mm / 10 mm thickness respectively shall be welded around the pads so that
the pads are projected minimum 2 mm above the retainer plates. It must be ensured that the
low friction material is bonded with the steel base plate and remains in place at the specified
load conditions by using suitable adhesives. Adhesives used for pads should be capable of
withstanding the line temperatures. Additionally two or more countersunk screws shall also be
installed to avoid dislocation in case of Graphite pads.
2.14 The hanger support, except for the spring shall be designed with a safety factor of 5.
2.15 All Constant & Variable spring supports weighing more than 45 Kg. shall be provided with
lifting lugs.
2.16 All spring coils shall be neoprene or polyeurethane coated to prevent corrosion. Alternatively,
equivalent or superior coating of spring coil is also acceptable. However, corrosion protection
of spring through electroplating is not acceptable.
2.17 All Alloy Steel Springs shall be shot-peened.
2.18 Springs with free height to mean diameter ratio of more than 4 shall not be used without
external guiding arrangements.
2.19 Drawing showing arrangement of spring hangers shall be considered for overall guidance. The
individual components shall be designed by the Supplier to meet the requirements of the
requisition.
Page 666 of 1296

k31 ENGINEERS TECHNICAL NOTES FOR
$fgar klieg
17-1107 271111!21111 X711
INDIA LIMITED
A Govt of India Undellakingj
Page 7 of 8
3.0 PAINTING & GALVANIZING
The spring support shall be thoroughly scrapped and Wire brushed on all surfaces to remove
dust, mill scales etc. All external & internal surfaces shall be given two coats of Zinc
Chromate Red Oxide Primer to IS-2074. All threaded parts / components shall be galvanized
to ASTM A153 / A123 / IS-1573 / IS-1367, Part XIII.
4.0 DOCUMENTATION
4.1 All document submissions to EIL shall be through EIL eDMS (electronic Document
Management System)
4.2 After placement of order and before commencement of manufacturing, Supplier shall obtain
approval on design calculations and detailed dimension drawings complete with material for
different parts only if specified in the material requisition.
4.3 Material test certificates (physical properties) report, Heat treatment report (wherever
specified or required as per code) and chemical composition shall be furnished for all
materials other than coil. For coil material, chemical composition load deflection, cramp test
certificate shall also be furnished.
4.4 Test reports for each spring for all mandatory tests and other supplementary tests as specified
in the requisition shall be submitted.
4.5 Final Documents to be submitted, in addition to submission through eDMS, along with
delivery of the springs.
- 6 Hard Copies and 2 CDs/DVDs of As Built drawings of spring assemblies.

- 6 Copies and 2 CDs/DVDs of Catalogues, Operation Manual & Installation Procedure.
5.0 TESTING & INSPECTION
5.1 Testing of springs shall be as per BS-1726 Part 1.
5.2 A compression test shall be made by pressing the spring solid at least three times in
succession. The spring should thereafter conform to dimensional requirements.
5.3 A cramp test shall be made by holding the spring compressed to the minimum working
compressed length for a period of not less than 12 hours with full load. The spring shall show
a reduction of not more than 5% in its free length.
5.4 The manufacturer shall conduct tests to establish the spring rate, and the measurement shall be
carried out within 30% to 70% of the maximum deflection of the spring (free height minus
solid height). The actual load test shall be conducted on the spring supports in the final
assembled condition and shall be witnessed by the purchaser's representative.
5.5 All alloy steel springs shall be examined by magnetic particle method.
5.6 Refer Specification no 6-81-0137 for 'Inspection & Test Plan for Spring Support Assemblies'.
6.1 In addition to standard marking, each spring support shall be marked with MR number and
Spring Number / Tag Number with white weather proof paint on the casing or punched on a
SS / Aluminum tag attached securely to the support with a rust proof wire.
Page 667 of 1296

Olfaele-i ENGINEERS TECHNICAL NOTES FOR
,2--ar fagitg w INDIA LIMITED SPRING SUPPORT ASSEMBLIES 6-44-0070 Rev. 1
1.-11,,ert.T2111,74:n. IA Govt of India UndettakIngl
Page 8 of 8
6.2 Paint or ink used for marking shall not contain any harmful metal or metallic salts.
6.3 All items shall be dry, clean and free from moisture, dirt & loose foreign material of any kind.
6.4 All items shall be properly packed in Wooden boxes / Crates and shall be protected from rust,
corrosion and mechanical damage during transportation, shipment & storage.
7.0 REFERENCES
3-1643-0717 : Spring Schedule
3-1643-0717A : Spring Schedule (Spring Support Types)
6-81-0137 Inspection and Test Plan for Spring Support Assemblies

Bidders
Page 668 of 1296

SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS FOR
**ta u tlf5Ereg INDIA LIMITED
IA Govt a India Undertaking)
FLAMEPROOF
6-51-0006 Rev. 5
CONTROL STATIONS Page 1 of 7
afT9-trtw fier-Tir
WRT
SPECIFICATION
FOR
FLAMEPROOF CONTROL STATIONS

5 24.02.16 NN /AK NP BRB SC
SPECIFICATION
4 11.04.11 PS ANPS UAP DM
SPECIFICATION
3 24.08.07 ANPS UAP JMS VC
SPECIFICATION
2 30.01.02 UAP AAN VPS GRR
SPECIFICATION
1 19.08.96 AP VPS SG AS
SPECIFICATION
Standards Standards
Prepared Checked
No by by
Approved by
Page 669 of 1296

$' gar
,alert RA&
eiraxe anaamslt
ENGINEERS
INDIA LIMITED
FOR
FLAMEPROOF 6-51-0006 Rev. 5
Abbreviations:
AC Alternating Current
BS British Standards
CEA Central Electricity Authority
CIMFR Central Institute of Mines and Fuel Research (formerly CMRI)
CT Current Transformer
DGMS Directorate General of Mines Safety
ERTL Electronics Regional Test Laboratory
FM Factory Mutual Research Corporation
GI Galvanised lion
IEC International Electro-technical Commission
IEEE Institute of Electrical and Electronics Engineers
IP Ingress Protection
IS Indian Standards
LCIE Laboratoire Central des Industries Electriques
LED Light Emitting Diodes
NEMA National Electrical Manufacturers Association
PESO Petroleum and Explosives Safety Organisation
PVC Poly Vinyl Chloride
SWG Standard Wire Gauge
VDE Verband Der Electrotechnik, Elecktronik and Information Stechnik
UL Underwriters Laboratory
Electrical Standards Committee
Convenor: Mr. B. R. Bhogal
Members: Ms. Sumita Anand

Mr. Parag Gupta
Mr. M. K. Sahu
Ms. N. S. Bhattacharya
Mr. Saeed Akhtar (Inspection)
Ms. N. P. Guha (Projects)
Format No. 8-00-0001-F1 Rev. 0 Copyright DL — All rights reserved
Page 670 of 1296

ENGINEERS
5,2-ar owe, INDIA LIMITED
INDIA FOR
6-51-0006 Rev. 5
1.ION (A Good coda Undertaking) FLAMEPROOF
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 GENERAL REQUIREMENTS 4
4.0 SITE CONDITIONS 4
5.0 CERTIFICATION 5
6.0 TECHNICAL REQUIREMENTS 5
7.0 INSPECTION, TESTING AND ACCEPTANCE 6
8.0 PACKING AND DESPATCH 6
Page 671 of 1296

ENGINEERS FOR
Ogeir 22-eg INDIA LIMITED 6-51-0006 Rev. 5
IA Govt of India Undertaking) FLAMEPROOF
1.0 SCOPE
This specification covers the requirements of design, manufacture, testing, packing and supply
of flameproof control stations and accessories suitable for installation in locations handling
flammable liquids and gases / vapours.
2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS:
IS-5 : Colours for ready mixed paints and enamels.

IS-1248 : Direct acting indicating analogue measuring instruments and
their accessories.
IS / IEC 60079-0 : Electrical apparatus for explosive gas atmospheres (General
Requirements).
IS / IEC 60079-1 : Electrical apparatus for explosive gas atmospheres
(Equipment Protection by Flameproof Enclosures "d").
IS / IEC 60079-7 : Electrical apparatus for explosive gas atmospheres
(Equipment Protection by Increased Safety "e").
IS / IEC 60529 : Degree of protection provided by enclosures (IP Code).
IS / IEC 60947 : LV switchgear and control gear.
2.2 In case of imported equipment, standards followed in the country of origin shall be applicable,
if these standards are equivalent or more stringent than the applicable Indian Standards.
2.3 The equipment shall also confirm to the provisions of CEA Regulations with latest
amendments and other statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent requirement shall govern. However, Owner's/EIL's decision in this
regard will be final and binding.
3.0 GENERAL REQUIREMENTS
3.1 The offered equipment shall be brand new with state of art technology and having proven field
track record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 10 years from the date of supply.
4.0 SITE CONDITIONS
The equipment shall be suitable for installation and satisfactory operation in classified
hazardous locations in tropical, humid and corrosive atmosphere as prevalent in refineries,
petrochemical and fertilizer plants. Unless otherwise specified, a design ambient temperature
of 40° C and an altitude not exceeding 1000 m above mean sea level shall be considered.
Page 672 of 1296

. 11
`11ae_fel ENGINEERS
oprez
leter, eliekerleJnevA)
INDIA LIMITED
IA Govt Or India Undertaking)
FOR
FLAMEPROOF
6-51-0006 Rev. 5
5.0 CERTIFICATION
The equipment shall have test certificates issued by recognised independent test house
(CIMFR/ ERTL/ Baseefa/ LCIE/ UL/ FM or equivalent). All equipment (indigenous &
imported) shall also have valid statutory approvals as applicable for the specified location. All
indigenous flameproof equipment shall have valid BIS license and marking as required by
statutory authorities.
6.0 TECHNICAL REQUIREMENTS
6.1 Construction
6.1.1 The enclosures of the control stations shall be made of cast light metal alloy.
6.1.2 The control stations shall be suitable for use in outdoor open locations and shall have IP-55
degree of protection. They shall preferably be provided with integral canopy. However, where
the enclosure has been certified without integral canopy, a separate canopy can be accepted.
The separate canopy shall be made of at least 14 SWG (2mm) galvanised sheet steel. The
canopy shall be suitable for providing protection against rain from top and two sides.
6.1.3 The control stations shall be provided with gaskets made of non-inflammable and self-
extinguishing material.
6.1.4 All metal surfaces shall undergo manufacturer's standard cleaning/ painting cycle. After
preparation of under surface, the equipment shall be painted with two coats of epoxy based
final paint with colour shade as below:
Flame proof (Gas group IIA/ IIB) : Dark admiralty grey shade 632 of IS-5/
RAL 7031
Flame proof (Gas group IIC) : Light yellow shade 355 of IS-5/ RAL-1012
All unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are
moving elements then these shall be greased.
6.1.5 A warning inscription "DO NOT OPEN WHEN ENERGIZED" shall be provided on each
enclosure. The warning inscription shall be embossed on the enclosure or a separate warning
plate with above inscription shall be fixed to the enclosure with screws. The warning plate
shall be of nickel plated brass or stainless steel.
6.1.6 All accessories like nuts, bolts, washers etc. and operating shaft of pushbuttons, switches etc.
shall be made of stainless steel SS-304.
6.1.7 The control stations shall be provided with two earthing studs with lugs on the external
surface of the enclosures suitable for termination of 8 SWG GI wire.
6.1.8 The control station shall be provided with bottom cable entries. Required number of
flameproof double compression nickel plated brass cable glands and flameproof nickel plated
brass sealing plugs shall be provided.
6.1.9 The control stations shall have external fixing lugs for mounting on wall or column. The holes
provided on these lugs shall be of oblong type.
6.1.10 A nameplate indicating Tag Number shall be provided on each control station. Separate
nameplate shall also be provided to indicate the details of testing agency (CIMFR or
equivalent), test certificate reference, statutory approval agency (PESO / DGMS) and
reference, BIS license number, applicable gas group etc. The nameplates shall be engraved
type and permanently fixed on the equipment. In case the standard details given above are
embossed on the enclosures, the same need not be repeated on the name plate.
6.1.11 All flameproof control station shall be suitable for 240V AC as well as 110V/220V DC
control supply.
Page 673 of 1296

ENGINEERS FOR
idtalreg
INIVRelETIA241313WITA)
INDIA LIMITED
IA Gov' of India Undertaking) FLAMEPROOF
6-51-0006 Rev. 5
6.2 Component Specification

6.2.1 Push buttons for START and STOP shall be of GREEN and RED colour respectively. Each
push button shall have two NO and two NC contacts. The STOP push button shall be
mushroom type with stay put feature and lockable in pressed position.
6.2.2 All control switches shall be provided with a pistol grip handle. Circuit breaker control switch,
wherever specified, shall have three positions (START - NEUTRAL - STOP) with spring
return to neutral from START position and stay put in STOP position. All control/ selector
switches shall have minimum two poles for each position. Each position of switch shall be
indelibly marked on the control station. Exact configuration of selector switch (LOCAL-OFF-
REMOTE or AUTO-OFF-MANUAL) shall be as per datasheet / MR requirement.
6.2.3 All ammeters shall be of moving iron type having an accuracy class of 3 and suitable for I
Ampere CT secondary. Minimum size of ammeter shall be either 72mm x 72 mm or 65 mm
diameter. 80% of the scale length shall cover 100% of the CT primary current uniformly and
the balance 20% of the scale shall cover 100-800% of the CT primary. A red mark
corresponding to the full load current of the motor shall be provided on the ammeter dial. The
ammeter front glass shall be toughened.
6.2.4 Indicating lamp(s) wherever provided shall be clustered LED type (with minimum 3 numbers
LEDs, preferably connected in parallel), mounted inside an enclosure of minimum diameter of
15mm.
6.3 Terminals & Wiring
6.3.1 The control stations shall be provided with sufficient number of terminals. More than 2 wires
per terminal shall not be permitted. If required, additional terminal with shorting link may be
used. Each terminal for external cable connection shall be suitable for termination of 2.5 mm 2
solidcpernut.Tdcoperlgshabvidforcletmnawhvr
applicable.
6.3.2 All internal wiring shall employ 1.5 mm 2, 660V grade, FR type, PVC insulated copper
conductor wires.
6.3.3 For flameproof equipments, terminal box can be provided in Èxe' or Èxd' execution.
7.0 INSPECTION, TESTING AND ACCEPTANCE
7.1 During fabrication, the equipment shall be subjected to inspection by HU Owner or by an

agency authorized by the Owner, if specified/ agreed in Inspection Test Plan. Manufacturer
shall furnish all necessary information concerning the supply to ELL/ Owner's inspector. All
routine/acceptance tests shall be carried out at manufacturer's works under his care & expense.
7.2 Type test certificates from CIMFR or equivalent test house, applicable PESO/DGMS approval
certificates, BIS license and original drawings referred in type test certificates shall be shown
to the inspection agency on demand during inspection. The certificates and BIS license must
be valid at the time of despatch.
7.3 Test certificates of bought out components shall be shown to the inspection agency on demand
during inspection.
7.4 All equipments shall be subjected to various routine / acceptance tests as per Inspection &
Test plan no. 6-81-1006.
8.0 PACKING AND DESPATCH
All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship/ rail or trailer, and shall be wrapped in polythene sheets before
being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid
bottom for handling. Special notations such as 'Fragile', 'This side up', 'Center of gravity',
Page 674 of 1296

.11 ENGINEERS FOR
lataleg)
QOM alosai
INDIA LIMITED
(A Govt of India Undortalong) FLAMEPROOF
6-51-0006 Rev. 5
`Weight', 'Owner's particulars', 'PO no.' etc., shall be clearly marked on the packages
together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should be suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed. A set of instruction manuals for installation, testing and
commissioning, a set of operation & maintenance manuals and a set of final drawing shall be
enclosed in a waterproof cover along with the shipment.
Page 675 of 1296

42:E4
/ati= ENGINEERS FOR
ei 051,1s3,41 (A Govt of India Undettakingf
MEDIUM AND HIGH VOLTAGE
CABLES AND ACCESSORIES Page 1 of 10
TR-714 74 d'ucl
c;c1(1 "On a#R:rft7
Fri 1-49-4r
SPECIFICATION
FOR
CABLES & ACCESSORIES

8 20/01/17 MKS BRB SRN
SPECIFICATION
REVISDANU STDAR
7 01/04/16 RG MKS BRB RN
SPECIFICATION
REVISDANU STDAR
6 11,704/11 PS ANPS UAP DM
SPECIFICATION
REVISDANU STDAR
5 20/04/09 PB UAP JMS ND
SPECIFICATION
REVISDANU STDAR
4 15/03/0 RKM AAN VPS SKG
SPECIFICATION
StandardsCommitteeC Standards
Bureau
Rev. Prepared Checked onvenor
Date Purpose Chairman
No by by
Approved by
Page 676 of 1296

ei ENGINEERS FOR
tilire g INDIA LIMITED 6-51-0051 Rev. 8
IA Govt al India Unde[taking) MEDIUM AND HIGH VOLTAGE
Abbreviations:
ASTM American Society for Testing and Materials

BS British Standard
DGMS Director General of Mines and Safety
EPR Ethylene Propylene Rubber
FR Flame Retardant
FRLS Flame Retardant Low Smoke
FS Fire Survival
HR PVC Heat Resistant Polyvinyl Chloride
ICEA Insulated Cable Engineers Association
IEC International Electro technical Commission
IS Indian. Standards
PVC Polyvinyl Chloride
UV Ultra Violet
XLPE Cross linked Polyethylene
Convener: Mr. B.R:Bhogal

Members: Ms. S. Anand
Mr. Parag Gupta
Mr. M. K. Sahu
Ms. N S Bhattacharya
Ms. N.P. Guha (Projects)
Page 677 of 1296

(31 eit4ENGINEERS FOR
Igzu kif5i-eg INDIA LIMITED
GOVT c/I InAjA UnderIAA ,A9) MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 8
CONTENTS
1.0 SCOPE 4
2.0 STANDARDS 4
3.0 GENERAL CONSTRUCTION 5
4.0 CABLE ACCESSORIES 7
5.0 INSPECTION, TESTING AND ACCEPANCE 8
Page 678 of 1296

ENGINEERS FOR
tg-ar tameg
eit'aNt e61.390.3)
INDIA LIMITED
(A Govt of India Undertaking) MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 8
1.0 SCOPE
This specification along with data sheets covers requirements for design, manufacture, testing
at works and supply of Fire survival Medium voltage cables and Flame Retardant Low Smoke
Medium & High Voltage cables and cable jointing / terminating accessories for medium and
high voltage systems.
2.0 STANDARDS
2.1 The cables and cables jointing & terminating accessories shall comply with the latest edition
of the following standards as applicable:
IS: 209 Specification for zinc.

IS: 1554 PVC insulated (heavy duty) electric cables.
IS: 3961(Pt-2) : Recommended current ratings for cables: Part - 2 PVC Insulated and
PVC sheathed heavy-duty cables.
IS: 3975 Mild steel wires, strips and tapes for armouring of cables.
IS: 5831 PVC insulation and sheath of electric cables.
IS: 6380 Specification for elastomeric insulation and sheath of electric cables.
IS: 7098 Cross-linked polyethylene insulated PVC sheathed cables.
IS: 8130 Conductors for insulated electric cables and flexible cords.
IS: 10418 Drums for electric cables.
IS: 10462 (Pt-1): Fictitious calculation method for determination of dimensions of
protective coverings of cables: Part - I Electrometric and thermo-
plastic insulated cables.
IS: 10810 Methods of test for cables:
Part 41: Mass of zinc coating on steel armour
Part 58: Oxygen index test
Part-61: Flame retardant test
Part-62:Fire resistance test for bunched cables.
Part-63: Measurement of Smoke density of Electric cables
under fire conditions
IS: 13573 Joints and terminations for polymeric cables for working voltages
from 6.6kV up to and including 33kV.
IEC: 60331-21: Tests for electric cables under fire conditions circuit integrity —
Pro:..edure..; and r..:q1; ,,m-ients - Cables of rated voltage up and
including 0.6/1.0kV.
IEC: 60332-1 Test of the fire behaviour on single core or single cable (flame
retardancy)
IEC: 60332-3 : Tests of the fire behaviour on bunched cables (reduced flame
propagation)
IEC: 61034 Measurement of smoke density of cables burning under defined
condition
NEMA-WC70 : Standard for non shielded power cables rated 2000V or less for
the distribution of electrical energy.
NEMA-WC53 : Standard test methods for extruded dielectric power, control,
instrumentation and portable cables for test.
ASTM-G-1 54 : Standard practice for operating fluorescent light apparatus for UV
exposure of non metallic materials.
ASTM-D-2863 : Measurement of minimum oxygen concentration to support candle
like combustion of plastics
BS: 7846 Electric cables- 600/1000V armoured fire resistant cables having
thermosetting insulation and low emission of smoke and corrosive
gases when affected by fire.
Page 679 of 1296

k.11 el ENGINEERS FOR
g-ar QCs INDIA LIMITED
6-51-0051 Rev. 8
I 41R7I ,flecrAt +.1,3c10..1) Govt of In&. Uodettak ,N)
2.2 The cables and accessories shall also conform to the provisions of CEA Regulations and other
statutory regulations, as applicable.
2.3 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However, Owner's decision in this regard will be
final and binding.
3.0 GENERAL CONSTRUCTION
3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for
underground-buried installation with uncontrolled backfill and possibility of flooding by water
and chemicals.
3.2 Outer sheath of all cables shall be black in colour and the minimum value of oxygen index
shall be 29% at 27 ± 2 ° C. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack. However,
for earthing cables; colour of outer sheath shall be green.
3.3 All cables covered in this specification shall be Flame Retardant Low Smoke (FRLS) or Fire
Survival (FS). The outer sheath of FRLS cables shall possess flame propagation properties
meeting requirements as per IS-10810 (Part-62) category AF. FRLS cable shall be identified
by indenting, embossing or printing the appropriate legend i.e. 'FRLS, Category — C2'
throughout the cable length. FRLS properties shall be as per IS:10810 Part 61 & 62, IEC-
60332 Part 1 & Part 3, IEEE-383, IEC-61034, IEC-60754 Part 1, ASTM-D-2863.
3.4 Sequential marking of the length of the cable in metres shall be provided on the outer sheath at
every one metre. The embossing/engraving shall be legible and indelible.
3.5 The overall diameter of the cables shall be strictly as per the values declared by the
manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to
overall diameter of 60mm and ±3mm for beyond 60mm.
3.6 PVC/ Rubber end caps shall be supplied free of cost for each drum with a minimum of eight
per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to
avoid ingress of water during transportation and storage.
3.7 The joints in armour wire/strips shall be made by brazing or welding and any surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300mm. from the
nearest joint in any wire/strip in the complete cable.
3.8 The cables meant to be used in mining area under the jurisdiction of DGMS shall satisfy the
following
(a) "DGMS CERTIFIED" to be embossed at outer sheath at regular interval.

(b) Cables to be used in Mines shall have copper conductor only.
(c) The resistance of armour shall not exceed that of the conductor as specified in IS-8130
by more than 33%. To satisfy this, substitution of galvanised steel wire/strip in
armouring by the required number of tinned copper wires/strips is permissible.
(d) For mining cables, the size and type of armour shall be such that the combined
conductance of armour shall be equivalent to 75 percent of the conductance of the
largest conductor of the cable.
Page 680 of 1296

ENGINEERS FOR
051-eG INDIA
INDIA
LIMITED 6-51-0051 Rev. 8
(A Gov( al India Undet(aking) MEDIUM AND HIGH VOLTAGE
3.9 Medium Voltage Cables
3.9.1 All power/control cables for use on medium voltage systems shall be heavy-duty type,
650/1100V grade with aluminium/ copper conductor, PVC/XLPE (as mentioned in datasheet /
Material requisition) insulated, inner-sheathed, armoured/ unarmoured and overall PVC
sheathed. XLPE insulated cables shall meet the requirement specified in IS-7098 (Part-1).
3.9.2 The conductors shall be solid for conductor of nominal area up to and including 6mm 2 and
stranded beyond 6mm 2. Conductors of nominal area less than 16 mm 2 shall be circular only.
Conductors of nominal area 16 mm 2 and above may be circular or shaped as per IS 8130.
Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-1).
3.9.3 The core insulation shall be with PVC/XLPE compound applied over the conductor by
extrusion. PVC compound shall conform to the requirements of type 'C compound as per IS:
5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 1554 (Part-1). Control cables having 6 cores and above shall be identified with
prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the
numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm
between two consecutive numbers. Colour coding for cables up to 5 cores shall be as per
Indian standard.
3.9.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of Type ST-2 PVC compound as per IS: 5831. The minimum
thickness of inner sheath shall be as per Table-4 of IS: 1554 (Part-1). Single core cables shall
have no inner sheath.
3.9.5 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-thagnetic
material. For multicore cables, the armour shall be by single round galvanised steel wires
where the calculated diameter below armouring does not exceed 13 mm and by galvanised
steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for
armour material and uniformity of galvanisation shall be considered as per IS - 3975 and IS -
10810 (Part 41). The dimensions of armour shall be considered as per method (b) of IS - 1554
(Part -1). For single core cables, the armour shall be with H4 grade hard drawn aluminium
round wire of 2.5 mm diameter.
3.9.6 The outer sheath for the cables shall be applied by extrusion and shall be formulated for lower
smoke and shall be of PVC compound conforming to the requirements of type ST-2
compound as per IS: 5831. The minimum and average thickness of outer sheath for
unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per
Table-7 of IS: 1554 (Part -1).
3.9.7 If heat resisting PVC cables are specified in the data sheet, it shall be possible to continuously
operate the cable at a maximum conductor temperature of 85°C under full load condition and
160°C under short-circuit condition.
3.9.8 For XLPE insulated cables, it shall be possible to continuously operate the cable at a
maximum conductor temperature of 90°C under full load condition and 250°C under short-
circuit condition.
3.9.9 The fire survival cables shall meet the following additional requirements :
i) The insulation shall be of EPR or equivalent material with glass mica tape below or
above insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950 0 C.
Page 681 of 1296

ENGINEERS
N FOR
oge.n Emeg
(ailvA ofrowe an A)
INDIA LIMITED
IA Govt of India Unde MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 8
3.10 High Voltage Cables
3.10.1 Power cables from 3.3kV and up to and including 33kV systems shall be Aluminium/ Copper
conductor, XLPE insulated, sheathed, armoured/ unarmoured and overall PVC sheathed.
3.10.2 The conductors shall be stranded and compacted circular for all cables.
3.10.3 All cables rated 3.8/ 6.6kV and above shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-metallic extruded semi
conducting screen.
3.10.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured,
applied by extrusion. It shall be free from voids and shall withstand all mechanical and
thermal stresses under steady state and transient operating conditions. It shall conform to the
properties given in Table-1 of IS: 7098 (Part -2).
3.10.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in
combination with a non-magnetic metallic copper screen. The copper screen for all the three
cores together shall be capable of carrying the single line to ground fault current value and the
duration specified in the data sheet. For single core cable, copper screen provided shall be
capable of carrying the single line to ground fault current value and the duration specified in
the data sheet.
3.10.6 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one
operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core
identification shall be by coloured strips or by printed numerals.
3.10.7 The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the
requirements of type ST 2 compound of IS: 5831. The extruded inner sheath shall be of
uniform thickness. In case of single core cables, there shall be extruded inner sheath between
insulation metallic screen and armouring.
3.10.8 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by galvanised steel strips. Requirement and
methods of tests for armour material and uniformity of galvanisation shall be as per IS - 3975
and IS -10810 (Part 41). The dimensions of armour shall be as per method (b) of IS - 7098
(Part -2). For single core cables, the armour shall be with H4 grade hard drawn aluminium
round wire of 2.5 mm diameter.
3.10.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of
PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The
minimum and average thickness of outer sheath for unarmoured cables and minimum
thickness of outer sheath for armoured cables shall be as per IS: 7098 (Part-2).
3.10.10 The thickness of the insulation, inner sheath shall be governed by values given in Table-4 and
Table-5 of IS: 7098 (Part -2).
4.0 CABLE ACCESSORIES
4.1 The termination and straight through jointing kits for use on the systems shall be suitable for
the type of cables offered as per this specification and shall meet requirements of IS 13573.
4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturer's mark of origin.
Page 682 of 1296

err ta-eg
ENGINEERS FOR
eiecnie 0,1347.0 IA Govt of India Undeltaiong) MEDIUM AND HIGH VOLTAGE
4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor
fittings and consumable items. An installation instruction sheet shall also be included in each
kit.
4.4 The contents of the accessories kit including all consumable shall be suitable for storage
without deterioration at a temperature of 45° C, with shelf life extending to more than 5 years.
4.5 Terminating Kits
The terminating kits shall be suitable for termination of the cables to an indoor switchgear or
to a weatherproof cable box of an outdoor mounted transformer/ motor. For outdoor
terminations, weather shields/ sealing ends and any other accessories required shall also form
part of the kit. The terminating kits shall be from one of the makes/ types mentioned in the
data sheet.
4.6 Jointing Kits
The straight through jointing kits shall be suitable for installation on overhead trays, concrete
lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility
of flooding by water and chemicals. These shall have protection against any mechanical
damage and suitably designed to be protected against rodent and termite attack. The inner
sheath similar to that provided for cables shall be provided as part of straight through joint.
The jointing kits shall be from one of the makes/ types mentioned in the data sheet.
5.0 INSPECTION, TESTING AND ACCEPTANCE
The cables shall be tested and inspected at the manufacturer's works. Manufacturer shall
furnish all necessary information concerning the raw material supply to EIL/ Owner's
inspectors. The inspector shall have free access to the manufacturer's works for the purpose of
inspecting the process of manufacture in all its stages and will have the power to reject any
material, which appears to be of unsuitable description or of unsatisfactory quality. For HV
cables, the vendor shall give at least 2 weeks advance notice to the purchaser, regarding the
date of testing to enable purchaser's representative to witness the tests.
5.1 Cables
5.1.1 After completion of manufacture of cables and prior to despatch, the cables shall be subjected
to type, routine, acceptance and special tests as detailed below. The test reports for all cables
shall be got approved from the Engineer before despatch of the cables.
5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out as listed in IS: 1554 (Part-1) and IS: 7098 (Part-2) on PVC
and XLPE insulated cables respectively.
5.1.3 The test requirements for PVC insulation and sheath of cables shall be as per latest revision of
IS: 5831.
5.1.4 Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per ASTM-G-53
or ASTM-G-154 on outer sheath. The retention value of tensile strength and ultimate
elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation
before the test. Test certificates with respect to this test (not older than one year) from
recognised testing laboratory to be furnished for review by EIL before despatch clearance of
cables. In case test certificates are not available, test is to be conducted by vendor at his own
cost in any recognised test laboratory or in house testing laboratory, before despatch clearance
Page 683 of 1296

ENGINEERS FOR
Ogeji t115ieg INDIA LIMITED 6-51-0051 Rev. 8
1.12PI 2:12M2 .710.1) A Coot 04 India Undertaking) MEDIUM AND HIGH VOLTAGE
of cables. Sampling for this test is to be done randomly once for each order, provided outer
sheath remains same.
5.1.5 Acceptance tests as per IS-1554 (Part-1) and IS-7098 (Part-2) and the following special tests
to be performed on the cables as per sampling plan for all cables. However these tests are
required to be witnessed by EIL/ Owner for HV cables.
a. Accelerated water absorption test for insulation as per NEMA-WC-70. (For PVC
insulated cables) and as per NEMA-WC-53 (for XLPE/ EPR insulated cables). Test
certificates with respect to this test (not older than one year) from recognised testing
laboratory to be furnished for review by EIL before despatch clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in house testing laboratory, before despatch clearance of
cables. Sampling for this test is to be done randomly once for each order, provided type of
insulation remains same.
b. Dielectric Retention Test: The dielectric strength of the cable insulation tested in
accordance with NEMA-WC-70 at 75 ± 1° C shall not be less than 50 % of the original
dielectric strength. (For PVC insulated cables). Test certificates with respect to this test
(not older than one year) from recognised testing laboratory to be furnished for review by
EIL before despatch clearance of cables. In case test certificates are not available, test is
to be conducted by vendor at his own cost in any recognized test laboratory or in house
testing laboratory, before despatch clearance of cables. Sampling for this test is to be done
randomly and once for each order.
c. Oxygen Index Test: The test shall be carried out as per IS-10810 (Part 58). Sampling to
be done for every offered lot/size as per sampling plan.
d. Flammability Test: The test shall be carried out on finished cable as per IS-10810 (Part 61
& 62). Sampling for these tests is to be done randomly once for each order, provided
outer sheath remains same. The acceptance criteria for tests conducted shall be as under:
Part-61-The cable meets the requirement if there is no visible damage on the test
specimen within 300 mm from its upper end
Pan-62-The maximum extent of the charred portion measured on the test ample should
not have reached a height exceeding 2.5 m above the bottom edge of the burner at the
front of the ladder.
e. Test for rodent and termite repulsion property shall be done by analysing the property by
chemical method.
5.1.6 Following tests shall be carried out to prove FRLS property of the cable.
a. Critical oxygen index as per ASTM-D-2863 i.e. Determination of % of oxygen required

for combustion at room temperature of FRLS sheath which shall remain as 29%(min.)
b. Temperature index as per ASTM-D-2863 i.e. to determine at what temperature normal

oxygen content of 29% in air will support combustion of FRLS sheath which shall remain
as 250°C.
c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. to determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)
Page 684 of 1296

/-1 ENGINEERS FOR
015teg INDIA LIMITED 6-51-0051 Rev. 8
Myer, vleotte 41,1J4ZeM (A Govt of Ind. Under!Moog) MEDIUM AND HIGH VOLTAGE
d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).
5.1.7 The test for circuit integrity for fire survival cables shall be carried out as per lEC-60331
(Part-21).
5.2 Cable Accessories
Type tests should have been carried out to prove the general qualities and design of a given
type of termination/ jointing system as per IS-13573. The type test certificates from
independent testing laboratory shall be submitted before despatch.
6.1 Cables shall be despatched in non-returnable steel drums of suitable barrel diameter, securely
packed, with the take-off end fully protected against mechanical damage. Ferrous parts used
shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit
or storage.
6.2 On the flange of the drum, necessary information such as project title, manufacturer's name,
type, size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS
certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum
with suitable instructions to show the direction of rotation of the drum.
6.3 Cables shall be supplied in drum lengths as follows:
6.3.1 MV Cables
- Multicore Power cables upto 6 mm 2 1000 m
Multicore Power cables from 10 mm 2 up to 500 mm 2 500 m
Single Core Power cables upto 630 mm 2 1000 m
Control cables upto 61 cores 1000 m
6.3.2 HV Power Cables Upto 11kV Grade
Three Core cables upto 400 mm 2 500 m

Single Core cables upto 100 mm 2 1000 m
Single Core cables above 400 mm 2 and upto 1000 mm 2 750 m
6.3.3 HV Power Cables Above 11kV Grade and upto 33kV Grade
Three Core cables upto 300 mm 2 grade 350 m

Single Core cables upto 400 mm 2 1000 m
Single Core cables above 400 mm 2 and upto 1000 mm2 500 m
However exact drum lengths shall be finalised during order execution. A tolerance of ± 3 %
shall be permissible for each drum. However overall tolerance on each size of cable shall be
limited to ±2%.
Page 685 of 1296

, k31 ENGINEERS FOR
$iga fèiffl-
eg INDIA LIMITED ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
1.12M ~I, 4,1 JvA,N, IA Govt of Ind,a Underlaking)
VOLTAGE INDUCTION MOTORS Page 1 of 12
d»71E. -gurg
Wf"kil 11
fqw
SPECIFICATION
FOR
ENERGY EFFICIENT
MEDIUM VOLTAGE
INDUCTION MOTORS

SS/SHIRALI KJ BRB SC
1 12.08.14 SPECIFICATION
0 20.04.09 ISSUED AS STANDARD SPECIFICATION SD BRB JMS ND

Standards Standards
Rev. Checked Committee Bureau
Date Purpose Prepared by Convenor Chairman
No by
Approved by
Page 686 of 1296

■
31 ENGINEERS FOR
fa;1W5 w INDIA LIMITED
1.177T s'1,,
,q51.7~1) ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
Abbreviations:
AL Aluminium
BASEEFA British Approvals Service for Electrical Equipment in Flammable Atmospheres
CIMFR Central Institute of Mines and Fuel Research
CPRI Central power research institute
CU Copper
DOL Direct On Line
EIL Engineers India Limited
ERTL Electronics Regional test laboratory
FM Factory Mutual
FRP Fiber Reinforced Plastic
IEC International Electro-technical Commission
IEEE Institute of Electrical & Electronics Engineers
IS Indian Standard
JEC Japanese Electro-technical Committee
KLPL Karandikar laboratories Pvt. Ltd.
PESO Petroleum and Explosive Safety Organisation
PO Purchase Order
RPM Revolutions per Minute
UL Underwriter's Laboratories
VFD Variable Frequency Drive
VDE Verband Deutscher Elektrotechniker
Convenor: Mr. B.R. Bhogal

Mr. Parag Gupta
Mr. M.K. Sahu
Mr. A.K. Chaudhary (Inspection)
Ms. N.P. Guha (Project)
Page 687 of 1296

--1 ENGINEERS FOR
gzx Wes
i
INWR 290O 2151JY4M,
w INDIA LIMITED
ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
CONTENTS
1.0 SCOPE 4
4.0 OPERATING CONDITIONS 5
5.0 PERFORMANCE 6
6.0 CONSTRUCTION DETAILS 7
7.0 MISCELLANEOUS ACCESSORIES 10
8.0 CRITICAL SPEEDS 10
9.0 PAINTING 10
11.0 CERTIFICATION 11
Page 688 of 1296

‘31 ENGINEERS FOR
02-'
eg
2.1~,151~11
INDIA LIMITED
6-51-0064 Rev. 1
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of energy
efficient-High efficiency (IE2) three phase medium voltage squirrel cage induction motors.
2.1 The squirrel cage induction motors and their components shall comply with the latest editions of
following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified:
IS - 5 Colours for ready mixed paints and enamels.

IS - 325 Three phase induction motors.
IS - 1076 Preferred numbers.
IS - 1231 Dimensions of three phase foot mounted induction motors.
IS - 1271 Electrical insulation- Thermal evaluation and designation.
IS - 2223 Dimensions of flange mounted AC Induction motors.
IS - 2253 Designation for types of construction and mounting arrangement of
rotating electrical machines.
IS - 2254 Dimensions of vertical shaft motors for pumps.
IS - 2968 Dimensions of slide rails electric motors.
IS - 4029 Guide for testing three phase induction motors.
IS - 4889 Method of determination of efficiency of rotating electrical machines.
IS - 6362 Designation of methods of cooling of rotating electrical machines.
IS - 7816 Guide for testing insulation resistance of rotating machines.
IS - 8223 Dimensions and output series for rotating electrical machines.
IS - 8789 Values of performance characteristics for three phase induction
motors.
IS - 9283 Motors for submersible pump sets.
IS - 12065 Permissible limits of noise level for rotating electrical machines.
IS - 12075 Mechanical vibration of rotating Electrical Machines with shaft
heights 56 mm and higher - measurement, evaluation and limits of
vibration severity.
IS — 12615 Energy Efficient induction motors - Three phase squirrel cage.
IS - 12824 Type of duty and classes of rating assigned to rotating electrical
machines.
IS - 13529 Guide on effects of unbalanced voltages on the performance of three
phase cage induction motors.
IS - 13555 Guide for selection and application of three phase induction motors
for different types of driven equipment.
IS - 14568 Dimensions and output series for rotating electrical machines, frame
numbers 355 to 1000 and flange numbers 1180 to 2360.
IS / IEC60079-0: Electrical apparatus for explosive gas atmospheres (General
requirements)
IS/IEC-60079-1: Explosive atmospheres-Equipment protection by flame proof
enclosures "d".
IS/IEC60079-2 : Explosive protection by pressurized enclosure "p".
IS/IEC60079-7 : Explosive atmospheres-Equipment protection by increased safety —
IS/IEC-60079-15: Construction, test & marking of type of protection "n" electrical

apparatus.
IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code)
IS/IEC 60034-1 : Rotating electrical machines:-Rating & Performance
IS/IEC-60034-5: Degrees of protection provided by the internal design of rotating

electrical machines.
Page 689 of 1296

k31 --1 ENGINEERS FOR
5g-u f&IJeg INDIA LIMITED
1.7E,, c-1,cnr1,711.3~11 ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
IS/IEC 60034-8: Rotating electrical machines-Terminal marking and direction of rotation

IS/IEC 61241: Electrical apparatus for use in the presence of combustible dust
2.2 In case of imported motors, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.
2.3 The motors shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.4 In case Indian Standards are not available, standards issued by IEC/ BS/ VDE/ IEEE/
JEC/NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents, the
most stringent one shall prevail. However, owner's decision in this regard shall be final and
binding.
3.1 The offered equipment shall be brand new with state of the art technology and proven field track
record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment at least for 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to ensure the end user for placement of order for spares and
services.
4.0 OPERATING CONDITIONS
4.1 Ambient Conditions
Motors shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in
refineries, petrochemical, fertilizer and metallurgical plants. Service conditions shall be as
specified in the motor data sheet. If not specifically mentioned therein, a design ambient
temperature of 40 ° C and an altitude not exceeding 1000 meters above mean sea Level shall be
taken into consideration.
4.2 Frequency and Voltage Variations
Unless otherwise agreed, motors shall be designed for continuous operation at rated output
under the following conditions:
a) The terminal voltage differing from its rated value by not more than + 6 % or
b) The frequency differing from its rated value by not more the + 3 % or
c) Any combination of (a) and (b)
4.3 Starting
a) Motors shall be designed for direct-on-line starting or other method of starting as

specified in datasheet.
b) Motors shall be designed for re-acceleration under full load after a momentary loss of
voltage with the residual voltage being 100% and is in phase opposition to the applied
voltage.
c) Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds
under cold conditions and 8 seconds under hot conditions. In addition, Locked Rotor
Page 690 of 1296

ENGINEERS FOR
$'fg-ar fafai
e5
two,/, ‘151,19M,
INDIA LIMITED
IA Govt of Indo Undertaking) ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
withstand time under hot conditions at 75% & 100% voltages, shall be minimum 1.4
times the starting time at the corresponding voltage.
d) Unless otherwise specified, all motors shall be suitable for starting under specified load
conditions with 75 % of the rated voltage at the motor terminals.
e) Motors shall be designed to allow the minimum number of consecutive starts indicated
in Table below:
Starts Min. no. of consecutive starts

No. of consecutive start-ups with initial temp. of the
3
motor at ambient level (cold)
No. of consecutive start-ups with initial temp. of the
2
motor at full load operating level (hot).
4.4 Direction of Rotation
Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided for
motors, direction of rotation for which the motor is designed shall be permanently indicated by
means of an arrow. Directional arrow should be manufactured from corrosion resistant material.
When a motor is provided with bi-directional fans, a double-headed arrow should be provided.
Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the
terminals UVW are connected to a power supply giving a terminal phase sequence in the order
UVW. Counter-clockwise rotation of the motor shall be obtained by connecting the power
supply to terminals so that the phase sequence corresponds to the reversed alphabetical
sequence of the terminal letters. Ample space shall be provided at the terminal box for
interchanging any two external leads for obtaining the reverse phase sequence.
5.0 PERFORMANCE
5.1 Motors shall be rated for continuous duty (Si), unless otherwise specified.
5.2 Unless specified, the starting current (as % rated current) shall be limited to maximum 600-
700% (based on number of poles and KW rating) as per IS 12615:2011, subject to IS tolerance
5.3 In particular cases, when the starting current is to be limited, care shall be taken such that the
design values of torque meets the load requirement while at the same time complying to clause
4.3 above of this specification. Unless otherwise specified the minimum pull-up torque of
motors, at rated voltage & frequency shall be minimum 50% of the rated full load torque.
5.4 In particular cases, when the starting with reduced voltage is specified, care shall be taken such
that the design values of torque meets the load requirement while at the same time complying to
clause 4.3 above of this specification.
5.5 Starting torque and minimum torque of the motor shall be compatible with the speed torque
curve of the driven equipment under specified starting and operating conditions.
In case where characteristics of driven equipment are not available while selecting the motor,
minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be 90%
of rated value for motors above 75 kW.
5.6 The breakdown torque at the rated voltage shall be not less than 175% of the rated load torque
with no negative tolerance. Unless otherwise agreed, the breakdown torque shall not exceed
300% of the rated load torque.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 691 of 1296

ENGINEERS FOR
IA GoN oi Unde■tak.91 ENERGY EFFICIENT MEDIUM
In case of motors driving equipment with pulsating loads (e.g. reciprocating compressors,
crushers, ball mills) the minimum value of pull out torque at 75% of the rated voltage shall be
more than the peak value of pulsating torque and the current pulsation shall be limited to 40%.
5.7 Motors fed by variable frequency drive shall additionally meet the following requirements.
5.7.1 The motors shall be suitable for the current wave forms produced by the power supply including
harmonics generated by the drive. The necessary coordination by motor manufacturers with
drive manufacturers regarding harmonics generated by VFD shall be taken care and
incorporated in motor design suitably.
5.7.2 The motors shall be designed to operate continuously at any speed over the range as per process
requirement with minimum range as 10-100% of rated speed or as specified in data sheet. The
characteristics shall be baked on the application — in terms of constant torque / variable torque as
per the driven equipment. Additional cooling fan shall be provided if required to limit the
temperature rise to specified limits, alternatively option of applying suitable de-rating may be
considered.
5.7.3 The motors shall withstand torque pulsation resulting from harmonics generated by the solid
state power supply.
5.7.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.
5.8 The minimum values for performance characteristics of these motors shall be as given in the
tables 1, 2 & 3 of IS 12615-2011 for 1E2 motors, subjected to tolerance as per IS/IEC. Motor
meant for application with VFD, the efficiency value can be one class lower as per IS.
6.0 CONSTRUCTIONAL DETAILS
6.1 Windings
6.1.1 Unless otherwise specified, motors shall be provided with class 'B' insulation as a minimum. In
case of motors with class 'F' insulation, the permissible temperature rise above the specified
ambient temperature shall be limited to those specified in the applicable Indian standards for
class 'B' insulation.
6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated.
Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for
operating satisfactorily in humid and corrosive atmospheres.
6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In this
respect, particular care shall be taken for the stator windings for direct-on-line starting squirrel
cage motors. Insulation shall be provided between coils of different phases that lie together.
Core laminations must be capable of withstanding burnout for rewind at 350 °C without damage
or loosening.
6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the
joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses.
6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star
connection may be accepted. In case of motors with star-delta starting, the motor windings shall
be fully insulated for delta connection.
Page 692 of 1296

ENGINEERS FOR
5Igur fdaeg
--
--,,,,,,aw,ansmsn.
INDIA LIMITED
6-51-0064 Rev. 1
6.1.6 The ends of the windings shall be brought out into a terminal box. These shall be terminated by
means of terminals mounted on an insulating base made of non-hygroscopic and non-flammable
material.
6.1.7 All motors shall be provided with six terminals and suitable links to connect them in star or in
delta except for motors rated up to and including 2.2 kW which may be accepted with three
terminals.
6.2 Terminal Box and Cable Entries
6.2.1 Unless otherwise agreed, the terminal box shall be located on the right hand side as viewed from
the driving (coupling) end. The terminal box shall have side cable entry from non-driving end.
However, as a special case, terminal box located on top may also be accepted, particularly for
hazardous area motors, in case manufacturer has only top mounted terminal box design which is
duly tested/certified by CIMFR and approved by PESO for installation in hazardous area. The
terminal box design shall allow rotation in steps of 90 ° C to facilitate cable entry from any
direction at site.
6.2.2 Terminal box cover shall be provided with handles to facilitate easy removal. However, for
terminal box covers weighing less than 5 kg., terminal box covers without handles can be
accepted.
6.2.3 The terminal box shall be provided entries for suitable cable glands corresponding to the size of
the specified cable. Crimp type tinned Copper lugs and nickel-plated brass (or aluminum if
specifically required), double compression type cable glands shall be supplied along with the
motors for the specified cable sizes for power and space heater cables.
6.2.4 For flameproof motors, terminal box can be provided in increased safety Èxe' execution.
6.2.5 The terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the
maximum cables sizes as specified below for 2 pole, 4 pole or 6 pole motors:
Motor rating up to and including Size of phase conductor (mm2)

2.2 kW and below 2.5 cu
3.7 kW 6 cu
5.5 kW 10 cu
7.5 kW 16 cu
9.3 kW 16 cu
11.0 kW 16 cu
15.0 kW 50 Al.
18.5 kW 70 Al
22.0 kW 70 Al
30.0 kW 95 Al
37.0 kW 120 Al
45.0 kW 150 Al
55.0 kW 240 Al
75.0 kW 2x95 Al
90.0 kW 2x120 Al
110.0 kW 2x240 Al
125.0 kW/132 kW 2x240 Al
160.0 kW 2x240 Al
6.2.6 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed
between the purchaser and manufacturer.
Page 693 of 1296

ENGINEERS FOR
rr fa2es
1.12,f elvostVO51,~11
INDIA LIMITED
IA Govt of Indo Undertalong) ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
6.3 Motor Casing and Type of Enclosure
6.3.1 The minimum degree of motor enclosures including terminal boxes and bearing housing shall
be IP-55 as per IS.
6.3.2 Motors for outdoor use shall be suitable for installation and satisfactory operation without any
protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal of
condensed moisture except in case of flameproof motors (Type Ex d/Exde).
6.3.3 A11 internal and external metallic parts, which may come into contact with cooling air, shall be
of corrosion resistant material or appropriately treated to resist the corrosive agents, which may
be present in the atmosphere. Screws and bolts shall be of rust proof material or protected
against corrosion.
6.3.4 Unless otherwise agreed, motors shall have standard frame sizes (min.) for various output
ratings as stipulated in IS.
6.4 Bearing and Lubrication
6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be
chosen to provide a minimum L-10 rating life of 5 years, (40, 000 hours) at rated operating
conditions
(The L-10 rating life is the number of hours at constant speed that 90% of a group of identical
bearings will complete or exceed before the first evidence of failure).
6.4.2 The bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft
expansion. Motors designed to handle external thrust from the driven equipment shall be
supplied with a thrust bearing at the non-driving end.
6.4.3 In cases such as pumps for hot liquids where the driven equipment operates at high
temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient
ventilation of the bearing and disperse the heat transmitted from the driven equipment by
conduction or convection.
6.4.4 Bearings shall be capable of grease injection from outside without removal of covers with
motors in the running conditions. The bearing boxes shall be provided with necessary features
to prevent Loss of grease or entry of dust / moisture e.g. labyrinth seal/ oil seal/ V seal. Where
grease nipples are provided, these shall be associated, where necessary, with appropriately
located relief devices, which ensure passage of grease through the bearings.
6.4.5 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5
years of trouble-free service without the necessity of re-lubrication.
6.5 Cooling System
All motors shall be self ventilated, fan cooled. Fans shall be corrosion resistant or appropriately
protected. They shall be suitable for motor rotation in either direction without affecting the
performance of the motor. If this is not possible for large outputs, it shall be possible to reverse
the fan without affecting the balancing of the motor.
For motors operating in hazardous area, the fans shall be of an anti-static non-sparking material.
Page 694 of 1296

ENG1NEERS FOR
Ogzrr
Mt c-lecnrc' 411
w INDIA LIMITED ENERGY EFFICIENT MEDIUM
6-51-0064 Rev. 1
6.6 Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration Level
and long service life for the bearings. Die cast aluminum rotors for motors in hazardous areas
may be accepted provided the same are type tested and approved by competent authorities.
6.7 Shaft Extension
Motors shall be provided with a single shaft extension with key-way and full key. Motor shaft
shall be sized to withstand 10 times the rated design torque.
6.8 Lifting Hooks
A11 motors weighing more than 30 kg. shall be provided with lifting hooks of adequate capacity.
6.9 Earth Terminals
Two earth terminals located preferably on diametrically opposite sides shall be provided for
each motor. Necessary nuts and spring washers shall be provided for earth connection.
7.0 MISCELLANEOUS ACCESSORIES
7.1 Anti-Condensation Heaters
All motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters,
sized and located so as to prevent condensation of moisture during shutdown periods.
For motors with heaters installed in hazardous atmospheres (Zone - 1 or Zone - 2), such heaters
shall conform to the provisions of applicable Indian Standards and temperature classification
specified in the motor data sheet.
The heater leads shall be brought out, preferably, to a separate terminal box which shall be of
the same specification and grade of protection as the main terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate that the
heater supply shall be isolated before carrying out any work on the motor.
7.2 Name Plates
In addition to the motor rating plate, a separate number plate for motor tag number shall be
fixed in a readily visible position. This number shall be as per the motor data sheets.
8.0 CRITICAL SPEEDS
The first actual critical speed of stiff rotors shall not be lower than 120 % of the synchronous
speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed; the
second actual critical speed shall be above 120 % of the synchronous speed.
9.0 PAINTING
A11 metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy based
final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All unpainted steel parts
shall be suitably treated to prevent rust formation. If these parts are moving elements, then these
shall be greased.
Page 695 of 1296

ENGINEERS FOR
f laZ5 la INDIA LIMITED 6-51-0064 Rev. 1
Govt o7 Indo Undertaking) ENERGY EFFIC1ENT MEDIUM
10.1 All tests shall be carried out at manufacturer's shop under his care and expense.
10.2 The manufacturer shall submit all internal test records of the tests carried out by him on the
bought-out items, motor sub-assembly and complete motor assembly.
10.3 The manufacturer shall carry out the following routine and acceptance tests as per applicable
Standards/ITP on all the motors.
a) Visual check (Nameplate, terminal box location, terminal type, clearance, size, entries,
space adequacy & gland size, direction of rotation etc.)
b) Dimension check (shaft height etc.)
c) Cable glands, cable lugs size and no. of entries in terminal box.
d) Winding resistance
e) No load test & measurement of voltage, speed, current, power input
f) Measurement of starting torque, starting current, full load torque, breakdown torque
g) Reduced voltage starting & running
h) Insulation resistance before and after high voltage test
i) High voltage
i) Vibration
10.4 The manufacturer shall submit the following type test certificates (one sample from each
type/rating):
a) Full load test & measurement of voltage, current, power slip, power factor, bearing,
noise
b) Efficiency & pf at 100%, 75% and 50% load
c) Temperature rise test
d) Momentary overload test
e) Vibration
f) Noise Level
g) Over speed
h) Measurement of starting torque, starting current, full load torque.
10.5 For VFD fed motors, all tests as specified in the VFD specification shall be followed in addition
to the above.
11.0 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ BASEEFA/ LCIE/ UL/ FM/ KLPL or
equivalent). All indigenous motors shall conform to Indian standards and shall be certified by
recognised testing agencies. A11 motors (indigenous & imported) shall also have valid statutory
approvals (e.g. PESO, DGMS etc). as applicable for the specified location. All indigenous
fiameproof motors shall have valid BIS license and marking as required by statutory authorities.
A11 the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/rail or
trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases
to prevent damage to the finish. Crates/cases shall have skid bottom for handling. Special
notations such as `Fragile', `This nide up', `Center of gravity', Weighe, Òwner's particulars',
`PO Nos.' etc. shall be clearly marked on the package together with other details as per purchase
order.
Page 696 of 1296

ENGINEERS FOR
fg".2x w INDIA LIMITED 6-51-0064 Rev. 1
13~1)
elvOrt'4, (A Govt ot InOla Undertahmg) ENERGY EFFICIENT MEDIUM
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature,
unless otherwise agreed.
Page 697 of 1296

■31 eit§ ENONEERS FOR
e..41 fdialeg
ttE.11)/
eliTUR.L.PIPM) IA Govt of India undenaxing) CABLE INSTALLATION Page 1 of 11
c; c4 cti s fry feikr
SPECIFICATION
FOR
CABLE INSTALLATION
REVISED AND ISSUED AS STANDARD tt`

5 26.02.18 DC/RM RS B
SPECIFICATION
4 21.11.13 REVISED AND ISSUED AS SPECIFICATION FA SA UAP/JMS SC
3 25.04.08 REVISED AND ISSUED AS SPECIFICATION RKS SSM JMS VC
2 28.02.03 REVISED and ISSUED AS SPECIFICATION HKM RSG VPS SKG

REVISED and ISSUED AS STANDARD
1 04.08.97 RR VPS SG AS
SPECIFICATION
Standards Standards
Prepared Checked
No by by
Approved by
Page 698 of 1296

15ilf&RY ff ENGINEERS SPECIFICATION No.
ee.41
101R. 192497 ,913,10M)
INDIA LIMITED FOR 6-51-0082 Rev. 5
IA Goal al India Undertaking>
CABLE INSTALLATION
Page 2 of 11
Abbreviations:

CCOE Chief Controller of Explosives
CD Compact Disc
CIMFR Central Institute of Mining and Fuel Research
DC Direct Current
DGFASLI Directorate General Factory Advice Service & Labour Institutes
DGMS Directorate General of Mines and Safety
EHV Extra high voltage
ET Electrical Thread
FGL Finished Ground Level
FLP Flame Proof
FRP Fibre Reinforced Plastic
GI Galvanized Iron
HV High Voltage
IS Indian Standards
ISMC Indian Standard Medium Channel
MS Mild Steel
OISD Oil Industry Safety Directorate
RCC Reinforced Concrete Cement
Convenor: Mr. BR Bhogal

Mr. Parag Gupta
Mr. MK Sahu
Ms. NS Bhattacharya
Mr. Saeed Akhtar
Ms. N.P. Guha
Page 699 of 1296

15i1RZIef , ENGINEERS SPECIFICATION No.
*Igen 051-eg
IiNKTIEWEIRE, 0131W1)
INDIA LIMITED
IA Govt In Undertaking)
FOR 6-51-0082 Rev. 5
CABLE INSTALLATION
Page 3 of 11
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL SPECIFICATIONS 4
4.0 CABLE LAYING 6
5.0 TERMINATIONS 10
6.0 TESTING AND COMMISSIONING 11
Page 700 of 1296

OffIZEIT ENGINEERS SPECIFICATION No.
Oa?Al faReg
IMIE7T IRWIE•MI3,10.1)
INDIA LIMITED
IA Govt of Oxka Undertaking)
FOR 6-51-0082 Rev. 5
CABLE INSTALLATION
Page 4 of 11
1.0 SCOPE
This specification defines the requirements for supply of materials, wherever applicable,
installation, testing and commissioning of cable installation.
2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed below
SP:30 (BIS) Special Publication - National Electrical Code.

IS:1255 Code of practice for installation and maintenance of power cables
upto and including 33 KV rating.
IS:10810(Part 43) Method of Test for cables ; Part 43 Insulation resistance.
IS :10810(Part45) Method of Test for cables ; Part 45 High voltage test.
OISD RP- 147 Inspection and safe practice during electrical installation
OISD 173 Fire prevention and protection system for electrical installation
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of
the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCOE/DGMS/DGFASLI (as applicable).
d. The petroleum rules (Ministry of Industry, Government of IndiaXAs applicable)
e. Any other regulations laid down by central/state/local authorities and insurance
agencies
3.0 MATERIAL SPECIFICATIONS
All materials and hard wares to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the latest specifications of Bureau of Indian Standards.
3.1 Cable Trays
These shall be ladder type trays either prefabricated hot dip galvanised sheet steel trays or site
fabricated angle iron painted trays or FRP trays as specified in job specification.
3.1.1 Pre-fabricated hot dipped galvanised trays
The cable trays shall comply with the requirements specified in EIL installation standard
enclosed with the specification/Tender.
3.1.2 Site fabricated angle iron trays
Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size
75x75x8 for runners for supporting spans limited to 3000 mm. Cross support shall be 25 x 6
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—AIL rights reserved
Page 701 of 1296

5i1R-zre? 1=di ENGINEERS SPECIFICATION No.
.11 0151-eg
IaiRl1 2RQMonaog
INDIA LIMITED
IA GolA of India undedaking)
FOR 6-51-0082 Rev. 5
CABLE INSTALLATION Page 5 of 11
mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm wide
and spacing between two cross supports shall not exceed 250 mm.
3.1.3 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated out
of ISMC 100 and horizontal supports shall be with 65 x 65 x 6 mm angle iron sections.
Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against
physical damage to cables. Bottom most cable tray shall also be provided with GI sheet from
the bottom side for the protection of the cables from the hydrocarbon pipes located below. GI
Covers also shall be provided for the top most cable trays located outdoors.
Cable racks and trays shall be covered by removable top covers on upper most tiers allowing
adequate ventilation in following cases where:
Mechanical damage of cables is likely to occur during maintenance in the plant.

Oil or spillage of chemicals can be expected.
Protection from exposure to sun is required.
GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of
3000 mm, flanged on both sides for fixing on cable tray.
3.1.4 FRP type cable trays
The cable trays shall comply with the requirements specified in EIL standard specification and
installation standard enclosed with the specification/Tender
3.2 Cable Glands
Cable glands shall be of nickel plated brass unless otherwise specified. The single compression
type cable glands shall be used for indoor panels/equipment (e.g. substation, control room etc).
The cable glands for outdoor terminations shall be weather protected, double compression type.
Cable glands forming a part of relevant FLP enclosure shall be FLP type, tested by CIMFR or
any other recognized independent testing laboratory and approved by CCoE/DGMS or any
other statutory authority as applicable. Indigenous FLP glands shall have valid BIS license as
per the requirements of statutory authorities. All cable glands shall comply with the
requirements given in IS/IEC-60079 Part 0.
Entry thread of cable gland shall be compatible to the entry thread provided in the equipment
(BS, ET, NPT, PG as applicable). If required, suitable reducers/adopters shall be used.
3.3 Connectors
Terminations of cables with stranded conductor shall be made with crimped type tinned copper
solder less lugs which shall be suitable for the cable size mentioned in cable schedule.
3.4 Ferrules
Ferrules shall be of approved type and of size to suit core size mentioned and shall be employed
to designate the various cores of control/signal cable by the terminal numbers to which the cores
are connected, for ease of identification.Furrule shall be printed type.
Page 702 of 1296

15F4Z1Eq ENGINEERS SPECIFICATION No.
I es kiReU INDIA LIMITED FOR 6-51-0082 Rev. 5
laileMewenzelaocom IA Govt India UnOeftalung)
CABLE INSTALLATION
Page 6 of 11
4.0 CABLE LAYING
4.1 General
Cable installation shall include power, control, lighting, fire alarm, telephone and
communication cables. These shall be laid in trenches/ cable trays /Duct as detailed in the cable
layout drawings. Cable routing given on the cable layout drawings shall be checked in the field
so as to avoid interference with structures, heat sources, drains, piping, air-conditioning duct
etc. Any change in routing shall be done to suit the field conditions wherever deemed
necessary, after obtaining approval of Engineer-in-charge.
4.1.1 EHV, High voltage, medium voltage power and control cables shall be separated from each
other by adequate spacing or by running through independent pipes, trenches or cables trays,
as shown on layout drawings/installation standards. Details of cable routes and cable spacing
not shown in detail on these drawing shall be determined by the contractor and approved by the
engineer- In-charge.
The individual cable fixing clamps and spacers for laying of single core cables shall be of non-
magnetic material. As a general practice, the metallic sheath, screen and armour of single core
cables shall be earthed at one point to keep the same at earth potential unless otherwise stated.
The continuity of armour and semiconductor screen shall be broken at each joint. Single core
cables, when laid in trefoil formation shall be braced by suitable clamps at a distance, not
exceeding 3 meters along the cable routing.
If straight through joints are required to be provided on single core cables, armour shall be
broken at joints as per manufacturer's recommendations. For single core cables, armour shall
be earthed at one end for the cable run length as per manufacturer's recommendation. The
armour & screen of EHV cables shall be earthed at one end/both end and surge voltage limiters
shall be installed at the straight through joints as specified in job specification/data sheet.
The Telephone, Communication and Fire alarm cables shall run on instrument trays/ducts/
trenches in the units. Wherever these are not available, cables shall be taken in a separate
trench/tray with a minimum spacing of 300 mm from power and control cables
Telephone, fire alarm and plant communication cables shall be directly buried in road berm
area, (unless otherwise specified in cable layout drawings). These cables shall cross power
cables preferably at right angles. Street lighting cables shall be laid on the other side of road
berm area.
Fire barriers shall be deployed at locations where cable enter/exit the substation above ground
or/and cable enter/exit between cable cellar to switchgear room through cutouts. Fire barriers
shall be as per job specification.
At every 30 meter distances cable tray shall be painted with tray numbers as per cable layout
drawings for identification purpose.
The earth continuity of cable trays shall be maintained by providing bonding jumpers (25 mm2
flexible cu cable) while changing the level of cable trays.
4.1.2 The lengths indicated in the cables schedule are only approximate. The contractor shall ascertain
the exact length of cable for a particular feeder by measuring at site. All cable routes shall be
carefully measured .Before the start of cable laying, the contractor shall prepare cable drum
schedule and get that approved by Engineer-in-charge to minimize/avoid straight through joints
and then the cables cut to the required lengths, leaving sufficient lengths for the terminations
Page 703 of 1296

15dfRae? ENGINEERS SPECIFICATION No.
LEI Elfiteg
iaW eli.RLDIJW.i)
IA Gout ci India Undertaking)
of the cable at both ends. The various cable lengths cut from the cable reels shall be carefully
selected to prevent undue wastage of cables. Extra loop length shall be given for feeder cables
where required as per the directions of Engineer-in-charge to meet contingencies
Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in cable
tray along pipe sleepers or in over head trays as shown on cable layout drawings. RCC covers
of trenches shall be effectively sealed to avoid ingress of chemicals and oils.
Overhead trays shall be installed 2700 mm (minimum) above grade level and 300mm above
FGL in case cable trays are installed along with pipe sleepers. At road crossings overhead trays
shall be installed at 7000 mm (minimum) above grade level or cables shall be routed through
cable tray culvert/ Electrical road crossings as per layout drawings.
Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc. in
order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables.
Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer.
4.1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that criss-crossing is
avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables within
the trenches / trays shall be in line with cable layout drawings. Cable routing between cable
trench and equipment/motors shall be taken through GI pipe sleeves of adequate size or branch
cable trench as indicated in cable layout drawing. Pipe sleeves shall be laid at an angle of
maximum 45 to the trench wall. Bending radii of pipes shall not be less than 12D. It is to be
ensured that both the ends of GI pipe sleeves shall be sealed with approved weather proof
sealing plastic compound after cabling. In places where it is not possible, cables shall be laid in
smaller branch trenches. Different rows of cable trays in cable cellar below the cutout shall be
so fixed such that the trays don't obstruct cable entry to the panels.
4.1.4 All cables shall be identified close to their termination point by cable tag numbers as per cable
schedule. Cable tag numbers shall be punched on stainless steel straps (2mm thick, 20 mm wide
and of enough length) securely fastened to the cable and wrapped around it.
Each underground cable shall be provided with cable tags of stainless steel straps securely
fastened every 30 m of its underground length with at least one tag at each end before the cable
enters/leaves the ground. In unpaved areas, cable trenches shall be identified by means of cable
markers as per installation drawing. These cable markers shall be placed at location of changes
in the direction of cables and at intervals of not more than 30 m and also at cable straight through
joint locations. Cable route markers shall extend 600mm above ground.
4.1.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to
the insulation. For this purpose, ends of cables shall be covered with an approved PVC end cap
or rubber insulating tape.
4.1.6 Each row of cables shall be laid in place and before covering with sand. All wall openings/pipe
sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside
building/lined trench. Every cable shall be given an insulation test in presence of Engineer-in-
charge/Owner before filling the cable trench with sand Any cable which is found defective shall
be replaced.
4.1.7 Where cables pass through foundation walls, the necessary openings shall be provided in
advance for the same by another agency. However, should it become necessary to cut holes in
Page 704 of 1296

el
k./ ENGINEERS SPECIFICATION No.
oges f&IReg IN LIMITED
Natant etetere on mown
FOR 6-51-0082 Rev. 5
IA Govt of In Undertaking)
CABLE INSTALLATION
Page 8 of 11
existing structures for example floor slab etc., the electrical contractor shall determine their
location and obtain approval of the Engineer-in-charge before carrying out the same.
4.1.8 Cables for road crossings shall be taken through ERC (Electrical Road Crossing)/cable duct as
shown in the cable layout drawings and sleeves/ducts shall be effectively sealed thereafter.
At road crossing and other places where cables enter pipe sleeves, adequate bed of sand shall
be given so that the cables do not slack and get damaged by pipe ends.
4.1.9 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken
through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200
mm, cables shall be taken over the drain on cable trays supported suitably using ISMC 150/200
sections.
4.1.10 Ends of cables leaving trench shall be coiled and capped and provided with protective cover till
such time the final termination to the equipment is completed.
4.2 Cables Laid Direct in Ground
Cables shall be laid underground in excavated cable trenches where specified in cable layout
drawings. Trenches shall be of sufficient depth and width for accommodation of all cables.
Cables shall be properly spaced as per installation standards. Maximum number of cable layers
in trench shall be preferably limited to 6 layers.
Minimum depth of directly buried cable trench shall be 750 mm for medium voltage and 900
mm for I-IV Cables. The depth and the width of the trench shall vary depending upon the number
of layers of cables as per EIL installation Standards.
Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is to
be ensured by the contractor that the bottom of buried trenches shall be cleared of all rocks,
stones and sharp objects before cables are placed. The trench bottom shall be filled with a layer
of sand or stone dust. This sand /stone dust shall be leveled and cables laid over it. These cables
shall be covered with 150 mm of sand on top of the largest diameter cable and sand shall be
lightly compacted. A flat protective covering of 75 mm thick second class red bricks or concrete
tiles as per specification shall then be laid and the remainder of the trench shall then be back -
filled with natural soil, rammed and leveled.
43 Cables Laid in Concrete Trench
Cables shall be laid in 5 or 6 tiers in concrete trench as shown on layout drawings. Concrete
cables trenches shall be filled with sand /stone dust in hazardous area, switchyard and in
transformer bay to avoid accumulation of hazardous gases and oil. RCC covers of trenches shall
be effectively sealed to avoid ingress of chemical and oil in process area. Removal of concrete
covers where required for the purpose of cable laying and reinstating them in their proper
position after cables are laid shall be done by electrical contractor.
Minimum depth of RCC cable trench shall be 500mm for all voltage grades with 300mm
clearance between the bottoms of the trench cover and top of the cable. The depth and the width
of the trench shall vary depending upon the number of layers of cables and bending radius
required for cables as per EIL installation Standards
All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid
seepage of water.
Page 705 of 1296

lafaae? ENGINEERS SPECIFICATION No.
fElfWleG
Men mew Mager.
INDIA LIMITED
IA God of India Undertaking)
FOR 6-51-0082 Rev. 5
CABLE INSTALLATION
Page 9 of 11
4.4 Above Ground Cables
4.4.1 Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or structures
and shall be run parallel or at right angles to beams, walls or columns. Cable routing shall be
planned to be away from heat sources such as hot piping, gas, water, oil drainage piping, air-
conditioning duct etc. Each cable tray shall contain only one layer of cables as far as possible
for power cables. However control cables may be laid in multiple layers in the cable trays. For
power & control cables at least 20% space shall be kept as spare in cable trays after completion
of cable laying for future use.
4.4.2 Individual/small group of cables which run along steel/concrete structures shall be taken
through 60/100/150 mm slotted channel tray or channel ISMC-75/100.
4.4.3 Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable
trays shall be suitably clamped by means of GI saddles / clamps, whereas cables in horizontal
run of cable trays shall be tied by means of nylon cords. Distance between supporting angles
shall not exceed 600 mm.
4.4.4 All cable trays (other than galvanized/FRP trays) and supporting steel structures shall be painted
before laying of cables. The under surfaces shall be properly degreased, derusted, descaled and
cleaned. The painting shall be done with one coat of redoxide zinc chromate primer. Final
painting shall be done with two coats of approved bituminous aluminium paint unless otherwise
specified.
4.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they
shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade
for outdoor area. Cable ends shall be carefully pulled through conduit to prevent damage to
cable.
4.4.6 All GI Pipes shall be laid as per layout drawings and site conditions. Before fabrication of
various profiles of pipes by hydraulically operated bending machine (which is to be arranged
by the contractor) all the burrs from the pipes shall be removed. GI Pipes having bends shall be
buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I. pipes
buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I. pipes
shall be undertaken well before paving is completed and necessary co ordination with paving
agency shall be the responsibility of Electrical Contractor.
Following guide shall be used for sizing of GI. pipe.
a) 1 cable in a pipe - 53% of pipe cross-sectional area occupied by cables.
b) 2 cables in a pipe - 31% of pipe cross-sectional area occupied by cables.
c) 3 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.
4.4.7 After the cables are installed and all testing is complete, conduit ends above grade shall be
plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound.
Alternatively rubber bushes shall be employed for the purpose of sealing.
4.4.8 Fire proofing of end of power cables at least 1 meter at each end as per OISD norms for the
refinery and Petroleum industry, shall be carried out as per the recommendation of the paint
supplier .Rates for the fire proofing of cables shall be included in the cable installation and no
separate payment shall be made for the painting.
Page 706 of 1296

laftek ENGINEERS SPECIFICATION No.
tge.x faiReg
eieenennanannt
INDIA LIMITED
IA Govt at India Undertaking)
FOR 6-51-0082 Rev. 5
CABLE INSTALLATION
Page 10 of 11
5.0 TERMINATIONS
5.1 All cables up to 1100V grade and higher levels shall be terminated at the equipment by means
of compression type cable glands suitable for the cable size. They shall have a screwed nipple
with electrical threads and check nut. The cables shall be identified close to their termination
points at both the ends of cable(cable numbers shall be punched on stainless steel straps 2mm
thick and securely fastened to the cable, wrapped around it) and also along the route at regular
intervals, by cable tag numbers.
All cable entries for outdoor termination shall be through bottom/side. Outdoor cable
termination through top of equipment shall not be permitted.
5.2 Power cables cores wherever colour coding is not available shall be identified with red, yellow
and blue PVC tapes. Where copper to aluminium connections are made, necessary bimetallic
washers shall be used.
5.3 In case of control cables, all cores shall be identified at both ends by their terminal numbers by
means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/
wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly
bunched and ferruled with cable tag at both ends, for future use.
5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of non-
magnetic material/ aluminium sheet in case of single core cables. All unused cable entries on
equipment/panels shall be plugged/sealed.
5.5 The cable shall be terminated at electrical equipment/switchboards through glands of proper
size. The individual cores shall then be dressed and taken along the cables ways or shall be
fixed to the panels with polyethylene straps. The cable glanding shall be done as per
manufacturer's instructions. Cable armour shall not be exposed after termination is complete.
In case of termination of cables at the bottom of a panel over a cable trench having no access
from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line,
then gland plate shall be split in two parts along the centre line of holes. After fixing bottom
plate, uncovered cable holes/gaps shall be sealed with cold setting compound.
5.6 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool as
per requirement. Insulation of the leads shall be removed before crimping. Conductor surface
shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied on the
conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall not be
allowed.
5.7 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands,
lugs provided with the equipment vis-à-vis to the cable size indicated in cable schedule for
taking corrective action.
5.8 The cable joints shall be avoided as far as possible . In case a joint is unavoidable, the following
shall be insured:
- The number of joints shall be restricted to minimum as far as possible.
- The location of joints shall be identified with permanent markers.
- No joints shall be allowed in hazardous areas without the approval of Engineer-in-

charge.
Page 707 of 1296

lafRaeq ENGINEERS SPECIFICATION No.
fgeir EVeg
lawn etaorumiammn
INDIA LIMITED
(A Govt d In Undeltakingl
FOR 6-51-0082 Rev. 5
The jointing and termination of medium voltage power cables shall be carried out by trained
personnel only. Jointing and termination of high voltage and EHV cables shall be done by
skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested jointing
and termination kits of approved make shall be used.
5.9 No unauthorized repairs, modifications shall be carried out on the hazardous area equipment
terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be
brought to the notice of Engineer-in-charge by contractor. After termination is complete, all the
bolts, nuts, hard wares of terminal box shall be properly placed in its position and tightened.
5.10 All cables glands installed outdoor shall be provided with suitable sized shrouds and rates for
the same shall be included in the scope of the termination of the cable glands. No separate
payment is envisaged for the same.
6.0 TESTING AND COMMISSIONING
6.1 Field testing and commissioning of electrical installation shall be carried out as per EIL
specification.
6.2 Before energising, the insulation resistance of every circuit shall be measured from phase to
phase, phase to neutral and from phase/neutral to earth.
6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation
resistance of each length of cable shall be measured before splicing and or / terminating. After
completion of splices and /or terminations, measurements shall be repeated.
6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are
backfilled. Measurements shall be repeated after back filling.
For cables upto 1.1 KV grade 1000 V Megger and for H.V. Cables 2.5 KV / 5 KV Megger shall
be used.
6.5 D.C. High Voltage test shall be conducted on cables given below after installation.
a) All 1100 volts grade power cables in which straight through joints have been made.
b) All cables above 1100 V grade.
The DC High Voltage test shall be performed as detailed below in the presence of the Engineer-
in-charge or his authorized representative only.
Cables shall be installed in final position with the entire straight through joints complete. During
the high voltage test, all other electrical equipment related to the cable installation, such as
switches, instrument transformers, bus bars, etc., must be earthed and adequate clearance shall
be maintained from the other equipment and framework to prevent flash over.
In each test, the metallic sheath/screen/armour shall be connected to earth.
6.6 All checks and tests shall be made as per EIL standard test Performa available with site engineer.
All test readings shall be recorded and submitted to EIL in triplicate sets.
6.7 Cable schedule, cable layout drawings, Interconnection drawings shall be revised and marked
by contractor for 'AS BUILT STATUS' and two sets of copies along with CD shall be
submitted to EIL.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL— All rights reserved
Page 708 of 1296

ENGINEEFZS FOR
laaleg INDIA LIMITED 6-51-0084 Rev. 4
C1,7,W MI,~) (A Govt of lndw Undertaking) EARTHING INSTALLATION Page 1 of 7
3Trztrr f«R-r
SPECIFICATION
FOR
EARTHING INSTALLATION
4 26.03.14 REVISED AND ISSUED AS SPECIFICATION

FA SA BRB SC
3 25.04.08 REVISED AND ISSUED AS SPECIFICATION
RKS SSM JMS VC
2 28.02.03 REVISED & ISSUED AS SPECIFICATION HKM RSG VPS SKG
REVISED & ISSUED AS STANDARD AS
1 16.07.97 RR VPS SG
SPECIFICATION
0 25.07.94 ISSUED AS STANDARD SPECIFICATION RR SGC SCG SCG
Standards Standards
Committee Bureau
No by by
Approved by
Page 709 of 1296

ENGINEERS SPECIFICATION
ffig"ar fl2eg
1.11271 21~ 9>f JOCFA)
INDIA LIMITED
(A Govt ot Inda Undertakng)
FOR 6-51-0084 Rev. 4
EARTHING INSTALLATION Page 2 of 7
Abbreviations:

PESO Petroleum and Explosive safety organization.
CD Compact Disc
DGMS Director General Mines and Safety
GI Galvanized Iron
IS Indian Standard
MS Mild Steel
UPS Uninterrupted Power Supply

Mr. Parag Gupta
Mr. M.K. Sahu
Page 710 of 1296

" ENGINEERS SPECIFICATION
122e5IVWINDIA LIMITED FOR 6-51-0084 Rev. 4
013, I
1;15711 A Govt of Inda undertaking)
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL SPECIFICATIONS .4
4.0 EARTHING NETWORK .4
5.0 INSTALLATION OF EARTH ELECTRODE .5
6.0 CONNECTION 6
7.0 TESTING AND COMMISSIONING .7
Page 711 of 1296

sf " INDIA LIMITED
1.1,271232x1Wqs~.1) IA Govt ot Intha Undeltalong)
FOR 6-51-0084 Rev. 4
1.0 SCOPE
This specification defines the requirements for the supply of earthing and lightning protection
materials and installation of the earthing and lightning protection systems.
2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL Installation Standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD Standards listed
below :
SP:30 (BIS) Special Publication-National Electrical Code

IS:2309 Protection of buildings and allied structures against lightning.
IS:3043 Code of practice for earthing
IS:7689 Guide for control of undesirable static electricity.
OISD 110 Recommended practices on static electricity
OISD 147 Inspection and safe practice during electrical installation.
OISD GDN 180 Lightning protection.
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by PESO/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
3.0 MATERIAL SPECIFICATIONS
3.1 All materials and hardware to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the specifications given here under and to latest specifications of
Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved
by Engineer-in-charge before installation.
3.2 The main earth grid conductor shall be hot dip galvanised M.S. flat unless otherwise specified.
Sizes for main conductors shall be as indicated on the earthing layout drawing .Amount of
galvanizing shall be 610gm per sq.metre. Earth electrodes and Earth plate shall be as per EIL
Installation Standards.
4.0 EARTHING NETWORK
4.1 This consists of main earth conductor (grid conductor) forming a closed ring network with
required number of earth electrodes connected to it to provide a common earth for electrical
devices and metallic structures. From each earth electrode two distinct connections shall be
made to the main earth conductor. The earth plates shall be used for taking multiple earth
connections to two or more equipment.
4.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks/ buried in
Page 712 of 1296

A"ENGINEERS SPECIFICATION
2151egglii/
VINDIA LIMITED
1~1 ,h,f, CrA 3,10,
A
FOR 6-51-0084 Rev. 4
IA Govt of Indo Undertaking)
pavement/ below finished grade level as indicated on the earthing layout drawing. Where
lined cable trenches are available, the earth conductor shall be preferably laid in the trenches
and shall be firmly cleated to the sidewall of concrete trenches using GI clamps at interval of
400 mm to 500 mm and near to the termination end. The earthing conductor shall run along
one of the cable trays along the overhead cable route. The earthing conductor shall be suitably
cleated and electrically bonded to all the other cable trays on the same cable route at a regular
interval of 25 to 30 meter. The earthing for equipment shall be tapped from the main earth
conductor and not from cable tray support structure. Earth conductor when laid underground
shall be at a depth of 500mm below finished grade level.
4.3 Joints and tapping's in the main earth loop shall be made in such a way that reliable and good
electrical connections are permanently ensured. All joints below grade shall be welded and
shall be suitably protected by giving two coats of bitumen and covering with Hessian tape.
Earth strip laid above ground shall be welded across straight through joints and joints shall be
suitably protected by giving two coats of bitumen to avoid oxidation and insulation film
formation of the strip surface. When two earth strips are to be jointed by means of welding,
lap welding with an overlapping of strip equivalent to double the width of the strip and all
four sides shall be continuously welded. All joints at tappings above ground shall be by
means of connector/lugs. A minimum of two bolts of adequate size shall be used for this
purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.
5.0 INSTALLATION OF EARTH ELECTRODE
5.1 Earth Electrode shall be installed as shown on installation standard and layout drawings.
The location shown on the layout drawings are indicative.
The exact location of earth electrodes in the field shall be determined by contractor in
consultation with the Engineer-in-charge, depending on the soil strata and resistivity. Earth
electrodes shall be located avoiding interferences with road, building foundation, column,
pipelines etc. The civil area drawings shall be referred for this. The distance between two
electrodes shall not be less than twice the depth of electrode.
5.2 Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and
distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones
removed from the immediate vicinity of the electrodes and soil packed by watering and
ramming as tight as possible.
5.3 The electrodes shall have a clean surface, not covered by paint, enamel, grease or other
materials of poor conductivity.
5.4 All earth electrodes shall be tested for earth resistance by means of standard earth test meter.
The tests shall take place in dry months, preferably after a protracted dry spell.
5.5 The disconnect facility shall be provided for the individual earth electrode to check its earth
resistance periodically.
5.6 Location of earth electrodes shall be marked by permanent markers for easy identification. All
earth Electrodes shall be serial numbered and also marked on Às Built' drawing for future
reference.
5.7 Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.
5.8 Earthing system provided for concrete paved area by other agency where applicable; shall be
connected to the plant earthing system below ground by minimum two earth connections.
Page 713 of 1296

ENGINERS
E SPECIFICATION
INWR ei2LIW C151JPC1,74, IA Govt ot Intha undertaifing)
6.0 CONNECTION
The earth system connections shall generally cover the following:

Equipment earthing for personnel safety
- System neutral earthing
Static and lightning protection
6.1 The following shall be earthed.

System neutral
- Current and potential transformer secondary neutral
- Metallic non-current carrying parts of all electrical apparatus such as transformers,
switchboards, bus ducts, motors, neutral earthing resistors, capacitors, UPS, battery
charger panels, welding receptacles, power sockets, lighting/power panels, control
stations, lighting fixtures etc.
- Steel structures/columns, rail loading platforms etc.
- Cable trays and racks, lighting mast and poles
- Storage tanks, spheres, vessels, columns and all other process equipment.
Fence and Gate for electrical equipment (e.g. transformer yard etc.)
- Cable shields and armour
Flexible earth provision for Wagon, Truck
- Shield wire
Conductor size for branch connection to various equipment shall be as per EIL Installation
Standards unless otherwise stated on earthing layout drawings.
6.2 A11 process pipelines shall be bonded and earthed at the entry and exist points of battery limit
of hazardous area.
6.3 Steel pipe racks in the process units and offsite area shall be earthed at every 24 meters.
6.4 Equipment/street light pole etc. located remote from main earth network may be earthed by
means of individual earth electrode and earth conductor unless otherwise stated in job
specifications/earthing layout drawing.
6.5 Lightning protection shall be provided for the equipment, structures and buildings as shown
on layout drawing. Self conducting structures shall not require separate aerial rod and down
conductors. These shall however be connected to the earthing system at two or more points as
shown on layout drawing. Each down conductor shall be provided with an earth electrode and
all earth electrodes shall be interconnected through underground strip. Lightning protection
earthing system may be bonded to electrical safety earthing system, inside ground. Lightning
down conductor shall be brought to earth electrode in shortest straight path as feasible to
minimise surge impedance.
6.6 The main earthing network shall be used for earthing of equipment to protect against static
electricity.
6.7 All medium and high voltage equipment (above 250V) shall be earthed by two separate and
distinct connections with earth.
Page 714 of 1296

0&.ff OfJlegw'INDIA LIMITED
tem", IA Govt of lneha Undettaking)
FOR 6-51-0084 Rev. 4
6.8 Plant instrument system clean earthing, UPS system clean/safety earth, Data concentrator
panel, HMI etc shall be separate from the electrical earthing system, if mentioned in job
specification/ layout drawings.
6.9 All paint, scale and enamel shall be removed from the contact surface before the earthing
connections are made.
6.10 All earthing connections for equipment earthing shall be preferably from the earth plate
mounted above ground wherever provided
Equipment foundation bolts shall not be used for earthing connection.
6.11 Earth connections shall be made through compression type cable lugs/by welded lugs.
6.12 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated.
Spring washers shall be used for all earthing connections and all connections adequately
locked against loosening.
6.13 Lighting fixtures and receptacles shall be earthed through the extra core provided in the
lighting circuit/cable for this purpose.
6.14 The reinforcements of sub-station building and the sub-station floor shall be connected to
main earth grid.
7.0 TESTING AND COMMISSIONING
7.1 Field inspection, testing and commissioning of electrical installation shall be done as per EIL
standard specification.Earthing systems/connections shall be tested as follows:
7.2 Resistance of individual earth electrodes shall be measured after disconnecting it from the grid
by using standard earth test meggar.
7.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to
the grid. The resistance value of an earth grid to the general mass of earth shall be as follows:
- For the electrical system and equipment a value that ensures the operation of the
protection device in the electrical circuit but not in excess of 4 ohm. However for
generating stations and large sub-systems, the value shall not be more than 1 ohm.
- For lightning protection, the value of 5ohms as earth resistance shall be desirable, but
in no case it shall be more than 10 ohms
7.4 The resistance to earth shall be measured typically at the following points:
a) At each electrical system earth or system neutral earth.
b) At each earth provided for structure lightning protections.
c) At one point on earthing system used to earth electrical equipment enclosures.
d) At one point on earthing system used to earth wiring system, enclosures, such as
metal conduits and cable sheaths or armour.
e) At one point on fence enclosing electrical equipment.
7.5 All earthing layout drawings shall be marked by contractor for ÀS BUILT STATUS' and
two sets of hard copies plus 1 set of soft copy, shall be submitted to EIL. For projects, where
layout drawings have been prepared based on 3D modeling, contractor shall carryout
necessary changes for ÀS BUILT STATUS' in the 3D model.
Page 715 of 1296

SPECIFICATION FOR FIELD SPECIFICATION No.
ENGINEERS INSPECTION, TESTING AND
gfga faWs INDIA LIMITED 6-51-0087 Rev. 3
lair,i237,15,2,131,05.) IA Govt of Indla Undertalong)
COMMISSIONING OF
ELECTRICAL INSTALLATIONS Page 1 of 8
-ftw #f-~
PiRkurr, -crftwr
SPECIFICATION
FOR
FIELD INSPECTION, TESTING
AND
COMMISSIONING OF ELECTRICAL
INSTALLATIONS

3 10.6.14
SPECIFICATION AKG SA BRB *". SC
2 03.03.09
SPECIFICATION RKS NS JMS ND
1 14.07.03 HKM RSG VPS SKG
SPECIFICATION
0 02.08.01 ISSUED AS STANDARD SPECIFICATION UAP RR VPS MI
Standards Standards
Committee Bureau
No by by
Approved by
Page 716 of 1296

k31 ENGINEERS INSPECTION, TESTING AND
laW5 INDIA LIMITED 6-51-0087 Rev. 3
iairerf r-freA, asl,~7,) A GoN of Indla Undeltaking) COMMISSIONING OF
Abbreviations:
AFC Approved for Construction
CCOE Chief Controller of Explosives
DC Direct Current
DCS Distributed Control System
DGMS Director General for Mines and Safety
ECS Electrical Control Station
GI Galvanized Iron
HV High Voltage
IS Indian Standard
MV Medium Voltage

Mr. Parag Gupta
Mr. M.K. Sahu
Page 717 of 1296

ENG1NEERS
fawres, INDIA LIMITED
IA Govt ol Ind. Undertaiong)
INSPECTION, TESTING AND
COMMISSIONING OF
6-51-0087 Rev. 3
CONTENTS
1.0 SCOPE 4
3.0 FIELD INSPECTION, TESTING AND COMMISSIONING 4
4.0 RECORDS 8
Page 718 of 1296

k`51
12..itq ENGINEERS INSPECTION, TESTING AND
$'1gz:IT ft- s INDIA LIMITED 6-51-0087 Rev. 3
I.R77 c`F,1,4, CA3PC1171) IA Govt of India Undertalong) COMMISSIONING OF
1.0 SCOPE
This specification covers the requirements for the field inspection, testing and commissioning
of Electrical Equipment and Installation, forming part of electrical power distribution and
utilisation system.
2.1 The field inspection, testing and commissioning of electrical equipment shall be carried out in
line with this specification and the latest edition of following Indian Standards and OISD
standards.
SP-30(BIS) National Electrical Code.

IS 1255 Code of practice for installation and maintenance of power cables up
to & including 33 kV rating.
IS-7816 Guide for testing Insulation resistance of rotating machines.
IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistance.
IS 10810(Part 45) Method of Test for cables; Part 45 High voltage test.
IS 12729 HV Switchgears
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practice during electrical installation.
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of
the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA / Electrical Inspectorate.
c. Regulations laid down by Tariff Advisory Committee/Loss prevention council.
d. Regulations laid down by CCoE/DGMS (as applicable).
e. The petroleum rules (Ministry of Industry, Government of India).
f. Any other regulations laid down by central / state / local authorities / insurance
agencies
3.0 FIELD INSPECTION, TESTING AND COMMISSIONING
3.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical
equipment as per Inspection & Test plans.
3.2 Before the completed installation or an addition to the existing installation is put into service,
inspection / pre-commissioning checks and tests shall be carried out by contractor. In the
event of defects being found out, the same shall be rectified and the installation retested as
applicable.
3.3 The pre-commissioning inspection among other requirements shall include visual inspection,
checking the workmanship of the installation, the rating of equipment, safety clearances, sizes
of cables installed, conformance to the AFC document, soundness of switchgear bus
connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of
all safety interlocks, control/interface functions as per requirement etc.
3.4 Visual inspection for soundness of bus bar connections of busducts, terminal connections of
equipment/motor shall be carried out. It shall be ensured that no foreign materials are present
inside busduct and equipment terminal boxes. After the visual inspection, all the covers of
terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per
equipment manufacturer's instructions.
Page 719 of 1296

k31 ENGINEERS INSPECTION, TESTING AND
Og-ar 2f5:1- g
~srz as,:ror.)
(~1
INDIA LIMITED
(A GoN cd InEia Und<rlAk(A9) COMMISSIONING OF
6-51-0087 Rev. 3
3.5 Pre-commissioning tests shall include but not be limited to the following:
Continuity test for each winding and power and control circuits.
Insulation test for each winding and power and control circuit
High voltage test for cables
- Dielectric strength test on transformer oil.
- Checking the correctness of wiring schemes, control circuit interlocks for intended
functioning.
- Verification of phase sequence.

Testing of all types of relays/releases for required operation.
- Testing of measuring instruments for proper functioning.
- Earth continuity test for all circuits.
Checking of safety features for correctness of operation, etc.
Checking of all wired interface contacts (analogue, digital input/output contacts) for DCS
and ECS interface, at panel and equipment terminal chambers as applicable.
(Electrical contractor shall co-ordinate with other agencies involved for the above and
provide support services for checking interfaces of electrical equipment and the intended
functioning)
Earth resistance measurement for each earth electrode, and the earthing system as a whole.
Lighting installation shall be tested for correct illumination levels, with fittings installed.
Fittings shall be operated only with specified type of a lamp or tube.
3.6 After the above tests and inspection are completed, control circuits shall be tested for correct
operation under all operating combinations and proved correct before applying power to
main circuit.
3.7 Plant Communication, Fire alarm detection and telephone system shall be checked for correct
operation and intended function.
3.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure
that equipment is suitable for the classified zone and gas group and correctly installed, with all
covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the
enclo sure
3.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective
equipment vendor. The contractor shall provide necessary assistance to the equipment vendor
to perform Site acceptance testing to enable the equipment vendor to perform the same.
3.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer-
in-charge. In addition to the equipment manufacturer's instructions, pre-commissioning check
requirements shall also be complied. All tests shall be carried out by contractor in the presence
of EIL/Owner' s representatives
3.11 The contractor shall bring to site all required tools, tackles, and testing instruments for
carrying out field testing. Contractor shall use only calibrated measuring and test instruments
and shall maintain valid calibration records.
Page 720 of 1296

$tigzrr
IN■fn
fa2es INDIA LIMITED
IF GoN of lndN Underfakrogf COMMISSIONING OF
6-51-0087 Rev. 3
3.12 The Insulation Resistance test values for various electrical equipment shall be as below:
3.12.1 Cables
The insulation resistance test values for cables shall be as per following table:
Rated voltage of the Cable DC Test Voltage in Volts Minimum Insulation

resistance in Mega ohms
Lighting and power circuit
250 1
wiring
650/1100V grade cables 1,000 10
1,900/3,300V grade cables 1,000 200
3,800/6,600V grade cables 1,000 200
6,350/11,000V grade cables 5,000 200
8,700/15,000V grade cables 5,000 200
12,700/22,000V grade cables 5,000 200
19,000/33000V grade cables 5,000 200
3.12.2 IIV, MV and Miscellaneous Switchboards
The insulation resistance test values for the switchboards shall be as per following table:
Rated voltage of the DC Test Voltage in Volts Minimum Insulation

Switchboard resistance in Mega ohms
33,000V 5,000 200
11,000V 5,000 200
6,600V 1,000 200
3,300V 1,000 200
415V 1,000 100
240V 500 10
110V 500 10
3.12.3 Generators and Motors
3.12.4 The insulation resistance test values for the Generators and Motors shall be as per following
table:

Generators and Motors resistance in Mega ohms at
40 °C
11,000V 5,000 120
6,600V 1,000 80
3,300V 1,000 50
415V 1,000 15
240V 500 12
Page 721 of 1296

I f ~5)
irr0n twor,on
INDIA LIMITED
in Govt ol IndU Undertalong) COMMISSIONING OF
6-51-0087 Rev. 3
3.12.5 Transformers
3.12.6 The insulation resistance test values for the Transformers shall be as per following table:

Transformers resistance in Mega ohms at
40 °C
Up to 600V 1,000 100
601 to 5000V 2,500 1,000
5001 to 15,000V 5,000 5,000
15001 to 35,000V 5,000 10,000
3.12.7 It shall be ensured that during insulation tests, electronic devices and components that are
liable to get damaged on applied test voltage shall be disconnected from circuit. The
instructions of equipment/panel manufacturer shall be followed strictly in this regard.
3.13 High-voltage Testing
3.13.1 DC high voltage test shall be conducted as per following table on all HV feeder cables and
also on 1100 V grade cables where straight through joints have been made.
Rated Voltage of TEST VOLTAGE (kV) BETWEEN Duration

Cable (kV) (Minutes)
U. / U* Any Conductor and Metallic Conductor to Conductor
Sheath/ Screen/Armour (For Unscreened Cables)
0.65/1.1 3 3 5
1.9/3.3 5 9 5
3.3/3.3 9 9 5
3.8/6.6 10.5 18 5
6.6/6.6 18 18 5
6.35/11 18 30 5
11/11 30 30 5
12.7/22 37.5 - 5
19/33 60 - 5
*U. : Phase Voltage
U : Line Voltage
The cable cores must be discharged on completion of DC high voltage test and cable shall be
kept earthed until it is put into service.
DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage
shall not be less than the rated voltage.
Page 722 of 1296

mar faZ5 INDIA LIMITED
l aiWn 23~ ag,o.) IA Gosn of Intha Undertakog) COMMISSIONING OF
6-51-0087 Rev. 3
3.13.2 AC high voltage test shall be conducted as per following table on all HV Switchboards.
Rated Voltage Rated 1 Min. Power Frequency Withstand Voltage Duration in

(rms Value in (rms Value in kV) Minutes
kV)
U To Earth, Between Across the Isolating
Poles and Across Open Distance
Switching Device
3.6 10 12 1
7.2 20 23 1
12 28 32 1
24 50 60 1
36 70 80 1
72.5 140 160 1
The withstand voltage values across the isolating distances are valid only for switching
devices, where the clearance between open contacts is designed to meet the safety
requirements specified for disconnectors.
3.14 All protective relays including thermal overload relays shall be tested by secondary injection
current. Primary injection tests shall be carried out for differential protection, restricted earth
fault protection at full/reduced current to ensure correctness of complete wiring.
3.15 Before energizing any equipment, `COMMISSIONING CLEARANCE FORM' as per

standard format shall be duly filled in by contractor and submitted to EIL/owner.
3.16 It shall be ensured that the electrical inspectorate approval is available before energizing the
equipment
4.0 RECORDS
Contractor shall keep up-to-date records of all activities carried out and test results. Field
inspection / test reports shall be submitted to EIL / Owner by the contractor in bound volumes
(triplicate copies).
Page 723 of 1296

SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS ELECTRICS OF
sigzir acs CIA LIMITED 6-51-0093 Rev. 5
100171 eizottitOtlJtIO.it IA Govt of !Witt Undertalongt PACKAGE EQUIPMENT Page 1 of 10
4c; w Wi t-chit reNcl digichtua
t -Wu
SPECIFICATION
FOR
ELECTRICS OF PACKAGE
EQUIPMENT
5 21.03.18 Revised and issued as standard specification NV/GK VKJ BRB
4 21.11.13 Revised and issued as standard specification VB VKJ UAPJMS SC
3 25.04.08 Revised and issued as standard specification RS IKG JMS VC
2 28.03.03 Revised and issued as standard specification LS AAN VPS SKG
1 03.04.97 Re-firmed and issued as standard specification VCB VPS SG AS

Standards Standards
Committee Bureau
No by by
Approved by
Page 724 of 1296

laatzie tr-r ENGINEERS
tatAeg WA LIMITED
1.7r■ 2/20512 +WAWA)
l
IA Govt of Wide Undertaking)

ELECTRICS OF
PACKAGE EQUIPMENT
6-51-0093 Rev. 5
Page 2 of 10
Abbreviations:
AC Alternating current
ASB Auxiliary Service Board
BASEEFA : British Approval Service for Electrical Equipment's in Flammable
Atmosphere
BIS Bureau of Indian Standard
CIMFR Central Institute of Mines and Fuel Research
CRCA Cold Rolled Cold Annealed
DC Direct current
DCDB Direct Current Distribution Board
EIL Engineers India Limited
ELCB Earth Leakage Circuit Breaker
FM Factory Mutual
GI Galvanised Iron
HRC High Rupturing Capacity
IE Indian Electricity
IEC International Electrotechnical Commission
IEEE Institute of Electrical & Electronics Engineer
KW Kilo Watt
LDB Lighting Distribution Board
LED Light Emitting Diode
MCB Miniature Circuit Breaker
MCC Motor Control Centre
MCCB Moulded Case Circuit Breaker
MDB Main Distribution Board
MS Mild Steel
MV Medium Voltage
NEC National Electric Code
PCC Power Control Centre
PMCC Power- Cum- Motor Control Centre
PTB Physikalisch- Technische Bundesanstalt
V Volt
VDE Verband Deutscher Elektrotechniker
Convener: Mr. B R Bhogal

Mr. Parag Gupta
Ms. N S Bhattacharya
Mr M K Sahu
Ms. N. P. Guha (Project)
Page 725 of 1296

ENGINEERS
51gar idtaleg INDIA LIMITED ELECTRICS OF 6-51-0093 Rev. 5
1.22 rtecorl of1JOirol) (A Govt of India Undertaking(
PACKAGE EQUIPMENT Page 3 of 10
CONTENTS
1.0 SCOPE 4
2.0 STATUTORY REQUIREMENTS 4
4.0 SITE CONDITIONS 5
5.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION 5
6.0 EQUIPMENT SPECIFICATIONS 6
7.0 CABLING SYSTEM 8
8.0 EARTHING SYSTEM 9
9.0 LIGHTING SYSTEM 9
10.0 INSPECTION, TESTING AND COMMISSIONING 9

Page 726 of 1296

ei ENGINEERS SPECIFICATION FOR STANDARD SPECIFICATION No.
sigeirkiWg INDIA UMITED ELECTRICS OF 6-51-0093 Rev. 5

(A Govt India Undertaking)
1.0 SCOPE
1.1 This specification defines the requirements for design, engineering, shop-supervision,
testing, supply, installation, testing and commissioning of electrical equipment and facilities
for package equipment as covered in the job Specifications and data sheets.
1.2 For the purpose of this specification, the term 'package equipment' or 'package' denotes the
complete integrated equipment to be supplied by the vendor comprising of all main and
auxiliary equipment and associated local panel(s). The package equipment may be mounted
on a common skid and/or installed on a common platform/area in the field, as specified
elsewhere. Unless otherwise specified, the local panel shall include the power distribution to
various loads along with the necessary controls, interlocks, indications and alarms. The local
panel may either be mounted on the equipment skid/platform or separately but not very far
from the main equipment.
1.3 It is not intended to cover all aspects of design but to indicate the basic requirements only.
Vendor shall ensure that the design and installation on the skid is carried out as per good
engineering practice, relevant codes and shall meet the requirements of safety, reliability,
ease of maintenance and operation, aesthetics, scope of future expansion and maximum
interchangeability of the equipment. Vendor shall acquaint himself with EIL standards,
specifications, inspection test plans and field testing procedures as deemed necessary for
proper execution of work.
1.4 Compliance with this specification and /or review of any of the vendor documents shall not
relieve the vendor of his responsibility and his contractual obligations with regard to the
completeness and satisfactory operation of the package.
2.0 STATUTORY REQUIREMNTS
2.1 All electrical equipment and the complete package shall meet the requirements of this
specification and enclosed data sheets, in addition to the relevant Publications and Codes of
Practice of Bureau of Indian Standards, EIL Standards, statutory regulations and good
engineering practices. Complete system must also conform to the latest revisions of the
following:
a) CEA Regulations
b) Fire Insurance Regulations
c) Petroleum Rules and any other regulations laid down by Chief Controller of
Explosives
d) The Factory Act and regulations laid down by Factory Inspectorate
e) Regulations laid down by local statutory authorities and Electrical Inspectorate
2.2 In case of imported equipments, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 Vendor shall provide all assistance required for obtaining approvals from statutory
authorities for materials, plant design/ drawings and complete installation.
2.4 Where Indian Standards do not exist, the relevant IEC/ BS/ VDE/ IEEE/ NEMA standards
shall apply. Any other international standard may also be followed provided it is equivalent
to or more stringent than the standards specified above.
2.5 In case of any contradiction between various referred standard / specification /datasheet and
statutory regulations, most stringent requirement shall prevail. However owner's /EIL's
decision in this regard will be final and binding.
Page 727 of 1296

ENGINEERS SPECIFICATION FOR STANDARD SPECIFICATION No.
INDIA IJMITED ELECTRICS OF 6-51-0093 Rev. 5
(A Gout of India Undertalong)
3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment at least for 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/ spares to enable the end user for placement of order for spares and
services.
4.0 SITE CONDITIONS
The equipment shall be suitable for continuous operation under the site conditions specified
elsewhere. If not specifically mentioned, a design ambient temperature of maximum 40°C
and an altitude not exceeding 1000 meters above mean sea level shall be considered for
design purpose.
5.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION
5.1 In case of storage, handling or processing of flammable materials within the battery limits of
the package, area classification shall be carried out in line with IS: 5572, Indian Petroleum
Rules, OISD standard-113 and DGMS guidelines where applicable. Where specified, the
vendor shall furnish an 'Area Classification Drawing' indicating the zones of hazardous area
and the applicable gas groups and temperature class (T rating). A list of flammable materials
handled along with their properties like flash point, ignition temperature, explosive limits
etc. shall also be furnished.
5.2 All the electrical equipment installed in hazardous areas shall be selected as per IS-5571,
where applicable, and shall meet the requirements of relevant IS, IEC or NEC Standards and
statutory regulations. However, electrical equipment for Zone-2 areas as a minimum shall be
Ex 'eV Ex 'n' type as specified in data sheet, subject to the same being acceptable to the
concerned statutory authorities. Increased safety (Type Ex è') equipment shall not be used in
zone-1 areas. Ordinary industrial electrical equipment (even though permitted for use in
Div.2 area as per NEC, USA) shall not be used in Zone-2 areas.
5.3 Electrical equipments for hazardous areas shall be certified by CIMFR/ ERTL/ Karandikar
Lab or equivalent recognised independent test house of country of origin such as BASEEFA
/ ATEX/ LCIE / PTB / UL / FM. All equipment (indigenous and imported) shall also have
valid statutory approvals i.e. PESO as applicable for use in the specified hazardous area. All
indigenous flameproof equipments shall have valid BIS license and marking as required by
statutory authorities
5.4 Electrical equipment for hazardous areas shall, generally, be suitable for gas groups IIA and
BB and temperature Class -T3 as applicable to the selected type of explosion protection. In
case of hydrogen or hydrogen-hydrocarbon mixtures having more than 30% hydrogen, the
gas group to be considered, shall be IIC.
5.5 All electric motors for agitators/mixers and metering pumps handling flammable materials
and oil sump pumps, shall be flameproof (Type Ex-de), irrespective of the area being
classified as Zone-2 or Zone-1.
5.6 In case the package equipment is to be located in a classified hazardous area, the same shall
be indicated in the data sheet. In such a case, the offered equipment/package shall conform to
whichever are the more stringent requirements, i.e. either due to materials being handled in
the package or hazardous location in which package is installed.
Page 728 of 1296

15iffazreq ENGINEERS
ELECTRICS OF
1615teg INDIA LIMITED 6-51-0093 Rev. 5
1441,27, 2Ra2M1.3,10.1) (A Govt of India Undertakong)
6.0 EQUIPMENT SPECIFICATIONS
6.1 General Requirements
6.1.1 Specifications of all equipments/items, shall be furnished by the vendor for owner's review.
However, certain minimum requirements for the major equipment are highlighted in this
section.
6.1.2 All equipments and components shall be new and supplied by approved reputed
manufacturers. Equipment requiring specialised maintenance or operation shall be avoided
as far as possible and prototype equipment shall not be accepted. All equipments shall be
complete with all necessary weather and anticorrosion protection including tropicalization to
prevent damage due to climate, saline atmosphere, dust and corrosive vapours.
6.1.3 All equipment / material shall be protected for inland / marine transport, carriage at site and
outdoor storage during transit and at site. Vendor shall be responsible for any damage to the
equipment during transit. All packages shall be clearly, legibly and durably marked with
uniform block letters giving the relevant equipment/ material details. Each package shall
contain a packing list in a waterproof envelope.
6.1.4 All electrical components and equipment shall be sized to suit the maximum load under the
most severe operating conditions. Rated voltage and frequency for the equipment shall be as
indicated in enclosed data sheet.
6.1.5 All spares required for testing and commissioning the package shall be included by vendor in
his scope of supply along with any special tools and tackles required for operation and
maintenance.
6.2 Medium Voltage Motors
All medium voltage induction motors shall meet the requirements of the enclosed data sheet
and ElL standard specification.
6.3 Power Distribution Board/Local Panel
6.3.1 This shall meet the requirements of data sheets and the following specific requirements.
6.3.2 Unless otherwise specified, the Power Distribution Board (PDB) may be incorporated as part
of the Local Panel. The PDB shall include necessary power distribution equipment as
applicable for the package equipment in addition to the associated controls, interlocks,
indications and alarms. All motor starters shall be Direct-on-line type unless specified
otherwise. In case of skid-mounted package equipment located in hazardous area, this panel
shall also be installed on skid unless specified otherwise to install elsewhere in a safe area
and the emergency stop push buttons to be provided near the equipment.
6.3.3 The panel shall be free standing, metal enclosed, dust and vermin proof type having
minimum 1P-42 degree of protection as per IS:13947 (Part-1). Panels for outdoor locations
shall be weatherproof and supplied with a sheet steel kiosk or have internal and external
doors with a rain shelter. The panel shall be designed to ensure maximum safety during
operation, inspection, connection of cables and maintenance with energised busbars and
without any special precautions. Ample space shall be provided inside the panel for any
future addition of components in the panel. Power and control equipment shall be segregated
inside the panel as far as practicable. The maximum height of the operating handle/switches
shall not exceed 1800mm and the minimum height shall not be below 300mm.
Page 729 of 1296

OWE'? ENGINEERS
ELECTRICS OF
Oge.n iilf5teg INDIA IJMITED 6-51-0093 Rev. 5
Mien 2retere magi/rad (A Govt ot India Undertaking)
6.3.4 The panel shall have an integral base frame and shall be sheet steel clad, fabricated out of 14
SWG CRCA sheet steel except that doors and covers may be of 16 SWG thickness.
Necessary stiffeners shall be provided on doors / covers to prevent buckling. Large size
doors and covers or those on which substantial relays/meters are mounted shall be fabricated
out of 14 SWG CRCA sheet steel. All doors shall be hinged type, and all covers, doors,
openings and gland plates shall be provided with neoprene gaskets. All hardware shall be
corrosion resistant. All bolts, nuts and washers shall be secured against loosening and shall
be made of galvanized, zinc passivated or cadmium plated high quality steel. Unless
otherwise specified, the panel shall be suitable for bottom cable entry. The gland plate and
cable glands shall be provided with the panel.
6.3.5 The panels, to be installed in a hazardous area, shall be of flameproof type Ex(de). All
hazardous area equipment (except motors) shall be provided with cast light metal alloy
enclosure.
6.3.6 Outgoing motor feeders shall be provided with switch, fuse, thermal overload relay with
single phasing preventor or Motor Protection Relay and contactors for operation / safety
isolation. All switches shall be load-break, heavy duty, air-break type with the operating
handle mounted on the compartment door. Load break switch or MCCB shall be provided as
main incoming switch complete with necessary mechanical interlocks, door interlock and
defeat mechanism. Motor duty switches of AC-23 duty are also acceptable for outgoing
motor feeders.
6.3.7 All fuses shall be non-deteriorating HRC cartridge, pressure fitted, link type. The contactors
shall be air-break having AC-3 duty rating. Power contactors shall be rated for 100% of the
maximum continuous current (e.g. rated current of motor) with a minimum rating of 16
Amperes with AC-3 duty. Contactor coils shall be suitable for 240V AC control supply.
6.3.8 Thermal overload relays shall be three element, positive acting, ambient temperature
compensated type with adjustable setting range and built-in protection feature against single
phasing which can operate even with 50% rated current. The relays shall be manual reset
type with the reset push button provided on the cubicle door.
6.3.9 All indicating instruments shall be moving iron, flush mounting type of 72mm x 72mm
square pattern of at least 1.5 accuracy class. LEDs provided for indication shall be cluster
type with adequate brightness and minimum 2Nos LEDs chips per light. LEDs shall be
connected in parallel and each LED chip having diameter not less than 3mm.
6.3.10 All control/selector switches shall be rotary back connected type having a cam-operated
contact mechanism with knob type handle. Ammeter selector switches shall have contacts
with make before break feature and additional locking facility shall be provided where
required.
6.3.11 All motor feeders shall be provided with a STOP (red) push button and necessary START
(green) push button and control/interlock switches. STOP push buttons shall have stay put
feature and additional locking facility shall be provided where required.
6.3.12 Current transformer fed ammeter shall be provided for all motors, which may have variable
loading or are required for process control. Feeders of 30 Amperes rating and above shall be
provided with a CT and ammeter as a standard. The current transformers shall have an
accuracy class 1.0 and instrument security factor not greater than 5.
6.3.13 All auxiliary devices for control, indication, measurement and alarm such as push buttons,
control and selector switches, indicating lamps, metering instruments, annunciators etc. shall
be mounted on the front door of the panel. Components requiring frequent inspection shall
be easily accessible.
Page 730 of 1296

ENGINEERS
Ogez EtOleg INDIA LIMITED ELECTRICS OF 6-51-0093 Rev. 5
eixenrz tIAJW.I) (A Govt of India UnOettaktng)
6.3.14 Control supply for the equipment shall normally be derived from an adequately sized
transformer in the panel connected across two phases.
6.3.15 Adequate number of potential-free contacts shall be provided in the control panel for any
remote control monitoring of the package equipment.
6.3.16 The panel shall be provided with an anti-condensation heater controlled through a switch
fuse /MCB and an adjustable thermostat.
6.3.17 Inside the panel, the wiring for power, control and signaling circuits shall be done with BIS
approved flame retardant PVC insulated copper conductors having 660/1100V grade
insulation. Power wiring shall be sized for the nominal rating of associated switch/contactor.
Minimum size of control wires shall be 1 5mm 2 copper for control circuits having fuse rating
10 amperes or lesser. For control circuits with higher fuse rating, minimum 2.5mm 2 copper
conductor shall be used. Wiring for AC and DC circuits shall have different colour coding.
Clamp type terminals shall be acceptable for direct termination of wires upto 1 Omm 2 size.
For conductors larger than 10 mm 2, bolted type terminals with crimping lugs shall be
provided. Each wire shall be terminated at a separate terminal. A minimum of 10% spare
terminals shall be provided on each terminal block. All incoming and outgoing wires from
the panel shall terminate on a suitable terminal strip/block. No such wire shall
terminate/emanate directly from a panel component. However, in case power supply
connections are to be looped, the loop wires are to be crimped together before fixing on
terminal strip, such that loop continuity is not lost in case wire is removed from terminal
strip.
6.3.18 An adequately sized earth bus shall be provided in the panel for connection to the main earth
grid. All non-current carrying metallic parts of the mounted equipment shall be earthed.
Doors and movable parts shall be earthed using flexible copper connections. The earth bus
shall be provided with alternate bands of yellow and green. All earth connection wires shall
be suitably colour coded.
6.3.19 Engraved nameplates shall be provided for all auxiliary devices mounted on the front of the
panel. Nameplate or polyester adhesive stickers shall be provided for each equipment inside
the panel.
6.3.20 All metal parts shall be thoroughly cleaned degreased and made free from rust. After
application of the primer, the panel shall be spray painted with two coats of final paint.
Colour shade of the final paint shall be RAL 7032 for indoor Electrical Equipment and RAL
7031 for Outdoor Electrical equipment, unless otherwise specified. Powder coating of panel
shall also be acceptable.
6.3.21 At least one outgoing feeder of each rating and type shall be provided as spare in the PDB.
7.0 CABLING SYSTEM
7.1 Unless otherwise specified, a single point power supply shall be provided by the owner
through an aluminium/copper conductor, PVC insulated, armoured cable terminated at the
Power Distribution Board/Local Panel. The vendor shall provide all power and control
cabling between the PDB/.Local panel and the package equipments.
7.2 Power and control cables for 415V system shall be of 1100V grade Fire retardant low smoke
type PVC insulation with copper conductors up to 16mm 2 and aluminum conductors beyond
16mm2, PVC inner sheath, armouring and overall PVC sheath as per IS: 1554 (Part-I). The
conductor size shall be minimum 2.5mm 2 copper. All power and control cables shall have
extruded inner and outer sheaths. Outer sheath of cables shall be black in colour and the
minimum value of oxygen index shall be 29 at 27+ 2 °C. In addition, suitable chemicals shall
be added into the PVC compound of the outer sheath to protect the cable against rodent and
Page 731 of 1296

OWE.? ENGINEERS
*Ig elf tliWiez INDIA LIMITED ELECTRICS OF 6-51-0093 Rev. 5
INE7fefenre
MIJ,R1.9) IA Gov, al Ma Undertaking)
termite attack. Adequate derating factors shall be used for sizing the cables. At least one
spare core shall be provided in all control cables. All cable / wire shall be BIS approved.
XLPE insulation, if specified in the data sheet shall be provided for 1100V grade power and
control cables instead of PVC.
7.3 All cabling on the equipment skid/platform shall be in GI cable trays/conduits. All cable
trays and accessories shall be prefabricated and hot dip galvanised. The minimum amount of
galvanising shall be 610g/m 2. All cables shall be identified close to their termination point by
cable number punched on 2mm thick aluminium straps securely fastened to each cable. In
case of control cables, all cores shall be identified at both ends by their terminal numbers
using PVC ferrules as per interconnection diagrams. All equipments shall be supplied with
double compression type nickel plated—brass cable glands and tinned copper lugs.
7.4 In case, PDB/Local Panel installed away from the equipment skid/platform, necessary cable
trenches/trays between panel and equipment shall be in owner's scope, unless otherwise
specified.
8.0 EARTHING SYSTEM
8.1 Earthing system design and installation shall generally be as per IS: 3043. One or more
number of G.I. earth plates shall be provided for the package equipment depending upon its
size. All metallic non-current carrying parts of electrical apparatus, current and potential
transformer secondaries, structural steel, vessels etc. shall be connected by at least two
distinct separate earth conductors to an earth plate. All earth plates shall be bonded together
and shall have the provision for interconnection to owner's main earth grid at two points.
Earth plates shall be of 360x80x10rnm size and shall be provided with adequate number of
tapped holes. Earth continuity bonding shall be provided across all pipe flange joints.
8.2 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated. The
amount of galvanizing shall be min. 610 g/m 2. Specially provided bolts, lugs and spring
washers shall be used for all earthing connections of equipment.
83 Unless specified otherwise in data sheet, equipment earthing shall be as per standard
equipment earthing schedule.
8.4 Earthing connections to equipment shall be made by means of bolts, lugs and spring washers
provided specifically for this purpose.
9.0 LIGHTING SYSTEM
9.1 General lighting for area in which package is to be installed shall be provided by purchaser,
unless specified otherwise in data sheet.
9.2 Any other lighting requirements such as Local panel lighting shall be provided by vendor and
shall be with LED fixtures. Power for such local lighting shall be obtained from a suitable
feeder in PDB/Local Panel. All lighting circuits shall have provision for isolation in both
phases and neutral for packages to be installed in hazardous areas.
10.0 INSPECTION, TESTING AND COMMISSIONING
10.1 All equipment shall be tested and inspected at vendor's works before dispatch to ensure
compliance with the relevant specifications and agreed quality assurance/ testing plan. The
owner or his authorized representative may visit the works during manufacture of various
electrical equipment / materials to assess the progress of work as well as to ascertain that
only quality raw materials are used for the same. He shall be given full assistance to carry out
the inspection. Purchaser's representative shall be given minimum two weeks' advance
notice for witnessing the final testing. The minimum testing / inspection requirements for all
Page 732 of 1296

lar&A ENGINEERS
1 ex EtOteua WA LIMITED
(Wry eRoxv =Jowl) (A Govt of India Uncleflakeg)
ELECTRICS OF
PACKAGE EQUIPMENT
6-51-0093 Rev. 5
Page 10 of 10
components /equipments shall conform to the requirements stipulated in applicable codes and
standards. Test certificates including test records and performance curves etc. shall be
furnished by the vendor.
10.2 Vendor shall submit the field testing procedures for purchaser's approval. Field tests as per
the approved procedures shall be performed on the electrical system/ equipment before its
being put into service. All test equipment required for this purpose shall be arranged by the
vendor, in case testing and commissioning at site is included in his scope, and test reports
shall be approved by the site-in-charge before acceptance of the complete package.
Page 733 of 1296

ENGINEERS FOR ELECTROMAGNETIC
LITG dlMeg INDIA LIMITED 6-52-0002 Rev. 4
Wrier IA Goof of India Undertaking) FLOWM ETERS Page 1 of 10
(b)ct-Oii*Nectri fffq
II:TrW
ELECTROMAGNETIC FLOWMETERS
4 04.04.16 Revised and Reissued as Standard Specification RN
29.11.10 Revised and Reissued as Standard Specification RK RG TGM/JMS ND
2 02.05.05 Revised and Reissued as Standard Specification RSD TGM PM VJN
1 15.01.97 Revised and Reissued as Standard Specification RK BRS RB AS
0 11.3.85 Issued as Standard Specification PVS TSN AKV AK
Standards Standards
Committee Bureau
No by by
Approved by
Page 734 of 1296

ei ram ENGINEERS
e.11 laiWreg
Wren Pii4572 ..1.7X79
INDIA LIMITED
(A Go rt o India Undertaking)
FOR ELECTROMAGNETIC
FLOWMETERS
6-52-0002 Rev. 4
Page 2 of 10
Abbreviations

FISCO Fieldbus Intrinsic Safe Concept
HART Highway Addressable Remote Transducer
LCD Liquid Crystal Display
NPT National Pipe Threads
PA Process Automation
PID Proportional, Integral and Derivative
PTFE Poly Tetra Fluoro Ethylene
Instrumentation Standards Committee
Convener: Mr. Rajiv Gupta
Members: Mr. M. Nandi

Mr. Sandeep Arora
Mr. A.S.D Barman
Mr. S. Mahesh Kumar
Ms. N. P. Guha (Proj.)
Page 735 of 1296

ENGINEERS
Af 051-ez INDIA LIMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
lawn lier.2
re13.107.0 IA Govt of India Undertaking)
FLOWM ETERS Page 3 of 10
CONTENTS
1.0 GENERAL 4
3.0 NAMEPLATE 9
5.0 SHIPPING 10
Page 736 of 1296

151R-zr&ft ENGINEERS
Ogeir 251--ag W INDIA LIMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
I MRS anima MI J,1171711 IA Govt of India Undertaking) FLOWMETERS Page 4 of 10
1.0 GENERAL
1.1 Scope
1.1.1 This specification, together with the data sheets describes the requirements for the design,
materials, nameplate marking, inspection, testing and shipping of electromagnetic flow
meter and its accessories.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest edition of
the following codes, standard practices and publications unless otherwise specified:-
ASME American Society of Mechanical Engineers.

B 1.20.1 Pipe Threads General Purpose (Inch)
B 16.5 Pipe Flanges and Flanged Fittings
B 16.20 Metallic Gaskets for Pipe Flanges-Ring Joint,
Spiral wound and Jacketed.
AWWA American Water Works Association - Steel Pipe Flanges for Water Works
C207 CL.D Services
EN European Standards
10204 Inspection Documents for Metallic Products.
IS/IEC Indian Standards/International Electrotechnical Commission

IS/IEC-60079 Electrical Apparatus for Explosive Gas
Atmosphere.
IEC 60085 Electrical Insulation - Thermal Evaluation and
Designation
IS/IEC-60529 Degree of Protection Provided by Enclosures (IP
code).
IEC-61000-4 Electromagnetic Compatibility for Industrial
Process Measurement and Control Equipment.
IEC-61158-1 Industrial Communication Networks - Fieldbus
Specifications - Part 1: Overview and Guidance for
the IEC 61158 and IEC 61784 series.
IEC-61158-2 Industrial Communication Networks - Fieldbus
Specifications - Part 2: Physical Layer
Specification and Service Definition.
IEC-61508 Functional Safety of Electrical / Electronic /
Programmable Electronic safety related system.
IS Indian Standards
1271 Electrical Insulation-Thermal Evaluation and
Designation.
ISO International Organisation for Standardisation

6817 Measurement of Conductive Liquid Flow in closed
Conduit — Method using Electromagnetic
flowmeters
9104 Measurement of Fluid Flow in Closed Conduits —
Methods of evaluating the Performance of
Electromagnetic Flow meters for Liquids.
1.1.3 In the event of any conflict between this standard specification, job specification/data sheets,
statutory regulations, related standards, codes etc. the following order of priority shall
govern:
a) Statutory Regulations
b) Job Specification/ Data Sheets
c) Standard Specification
d) Codes and Standards
Page 737 of 1296

ENGINEERS
51fgai fafaeg INDIA LIMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
INIVN eivax,1,1,71,40.1) (A Gov( 01 (n11,0 1-(00000k(1 ,9) FLOWMETERS Page 5 of 10
1.1.4 In addition to compliance to purchaser's specifications, vendor's extent of responsibility

shall include the following:
a) Purchaser's data sheets specify the material for the metering tube, tube liner,
electrodes etc. of the magnetic flow meter. Alternate superior material of
construction shall also be acceptable provided vendor assumes complete
responsibility for the selected materials for compatibility with the specified fluid
and its operating conditions.
b) Selection of magnetic flow meter of the proper size suitable for the indicated flow
rate and turndown.
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to the vendor attached
with the Material Requisition.
1.2.2 Vendor's quotation shall include the following;
a) Detailed specification sheet for each item which shall provide the information
regarding material of construction, flow range, performance specifications, end
connection details etc. The material of specification and the units of measurement,
for various parts in vendor's specification sheets shall be to the same standards as
those indicated in purchaser's data sheets.
b) Sizing calculation indicating the velocity at which the meter has been sized for
each tag number.
c) Minimum and maximum fluid velocity permitted through the offered flow meter.
d) Cable specifications and the maximum permissible cable length between the flow
meter and associated receiver instruments.
e) Recommended grounding techniques.
f) Upstream and downstream straight length requirements for installation.
g) Proven references for each offered model in line with clause 1.2.3 of this
specification.
h) A copy of approval for installation of electromagnetic flow meter in electrically
hazardous area, from local statutory authority as applicable such as Chief
Controller of Explosives (CCE)/ Petroleum and Explosives Safety Organisation
(PESO), Nagpur or Director General of Mines Safety (DGMS) in India, along
with;
i) Test certificate from recognised house Central Institute of Mining and fuel
Research (CIMFR) / Electromechanical Regional Testing Laboratory
(ERTL) etc for the specified hazardous protection class as per relevant
standard for all Indian manufactured equipments or equipments requiring
DGMS approval.
ii) Certificate of conformity from agencies like Laboratorie Central Des
Industries Electriques (LCIE), British Approval Service for Electrical
Equipment in Flammable Atmospheres (Baseefa), Factory Mutual (FM),
Physikalisch-Technische Bundesanstalt (PTB), Canadian Standards
Association (CSA), and Underwriter's Laboratory (UL) for compliance to
ATEX or other recognised standards for all equipments manufactured
outside India.
i) Deviation on technical requirements shall not be generally entertained. In case
vendor has some valid technical reason for not complying with the specific
requirements due to superior alternatives and materials, tag wise deviation list must
be provided along with the technical justification.
Page 738 of 1296

ENGINEERS
idOtez INDIA LIMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
J,111.1) IA Govt of India Undertaking) FLOWMETERS Page 6 of 10
j )
Catalogues giving detailed technical specifications, model decoding details and
other related information for electro magnetic flow meters covered in the bid.
k) Two years operational spares for each electromagnetic flow meter and its
accessories covered in the bid, which shall include electrode, electronic card set,
gasket/o-ring set etc. as a minimum.
1) Any special tools needed for maintenance work on the flow meter and its
accessories. In case no special tools are necessary for the offered electromagnetic
flow meters, vendor must certify in their offer.
1.2.3 All items, as offered, shall be field proven and should have completed trouble free
satisfactory operation for a period of minimum 6 months on the bid due date in the similar
application with process conditions similar to those as specified in the purchaser's data sheet.
Items with proto-type design or items not meeting provenness criteria specified above shall
not be offered.
1.2.4 Whenever specified, vendor must furnish tested values of failure rates, Probability of Failure
on Demand (PFD) and test intervals for the Safety Integrity Level (S1L) analysis.
1.2.5 All documentation submitted by the vendor including their quotation, catalogue, drawings,
installation manual, operation and maintenance manuals etc., shall be in English language
only.
1.3 Drawings and Data
1.3.1 Detailed drawings, data, catalogues and manuals required from the vendor are indicated by
the purchaser in vendor data requirement sheets of Requisition.
1.3.2 Final documentation consisting of design data, installation manual, operation and
maintenance manual submitted by the vendor after placement of purchase order as per
vendor data requirement which shall include the following, as a minimum;
a) Certified drawing for each flow meter which shall provide;

i) Dimensional details in mm.
ii) Weight of flow meter in kilograms
iii) Material of construction
iv) Installation requirements
v) Detailed wiring drawing for the whole system including recommended
grounding techniques for the offered meters.
b) Clearance required for maintenance work.
c) Installation procedures for electromagnetic flow meter
d) Calibration and maintenance procedure for electromagnetic flow meters including

replacement of internal parts, as applicable.
2.1 Flow Meter
2.1.1 Unless otherwise specified, flow meter shall be of in-line mounting design. Insertion type of
magnetic flow meter shall not be offered.
2.1.2 Flow direction should be clearly marked on the magnetic tube to ensure correct installation
of the flow meter.
2.1.3 Vendor to note that the location and orientation of installation of electromagnetic flow meter
in the line shall not affect the calibration, accuracy and performance of the meter.
Page 739 of 1296

ENGINEERS
Itgar fdaiez INDIA LIMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
1.1177f eiecure ok „loam) IA Govt of India Undertaking)
FLOWMETERS Page 7 of 10
2.1.4 End Connection

2.1.4.1 Flow meter shall be of flanged body construction with material of construction as specified
in the purchaser's data sheet. In case of welded end connection design, the weld joint shall
be of radiography quality.
2.1.4.2 Unless otherwise mentioned, end connection details shall be as below: -
a) Threaded end connections shall be to NPT as per ASME B 1.20.1
b) Flanged end connections shall be as per ASME B 16.5 or AWWA C207 Cl. D as
per related Piping Specification
c) Grooves of ring-type joint flanges shall be octagonal as per ASME B 16.20.
d) Flange face finish shall be as per ASME B 16.5. The face finish as specified in the
data sheets, shall be as follows:
125 AARH 125 to 250 microinch AARH

63 AARH 32 to 63 microinch AARH
2.1.5 Unless specified otherwise, the flow meter tube shall have PTFE liner. The liner shall hold
tightly and rigidly against the flow meter tube without any air gap.
2.1.6 Magnetic Coils

2.1.6.1 The field coils shall operate on an alternating supply voltage as indicated in the purchaser's
data sheets. The performance of the flow meter shall not be affected by the following
variations in the supply voltage;
a) Voltage variation off 10% of nominal value.
b) Frequency variation of ± 3Hz of nominal value.

2.1.6.2 Coil insulation should be class F suitable as per IEC 60085/IS 1271.
2.1.6.3 Unless otherwise specified, the coil housing shall be of carbon steel construction fully
welded to the meter body to avoid ingress of moisture, dust and corrosive gases.
2.1.6.4 Coil excitation technique shall be pulsed DC type or dual frequency type. In case of slurry
applications, the meters shall have high coil current and high frequency excitation.
In case of slurry applications, grounding ring shall act as lining protector.
2.1.7 Electrodes
2.1.7.1 Electrodes shall have good corrosion resistance and shall be welded to meter body. Field
replaceable electrode construction shall be offered only when specifically indicated in the
purchaser's data sheet.
2.1.7.2 Vendor shall offer on line removable electrodes where cleaning of electrodes, is necessary
due to coating characteristics of the process fluid.
2.1.7.3 The vendor shall ensure that for potential equalisation between sensor and liquid, the flow
meter shall be provided with integral earthing reference electrode when installed in non-
lined pipe and an earthing plate / ring when installed in lined pipe. Vendor's scope of
supply shall also include earthing cables and cable accessories like earthing lugs for
interconnection with meter electronics. Unless specifically indicated, earthing electrode
shall not be acceptable in place of earthing ring.
2.1.7.4 The electrodes including earthing ring shall be connected in the intrinsically safe circuit
for flow meter handling electrically hazardous fluids.
Page 740 of 1296

15111M-41e ENGINEERS
ligar iatileg INDIA LIMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
21241%7 CAJ.M.1) IA Govt o India Undertaking'
FLOWM ETERS Page 8 of 10
2.1.8 Sizing Considerations

2.1.8.1 Meter shall be capable of measuring process fluid of conductivity 5 micromhos /
microsiemens per centimetre unless specified otherwise in the data sheet.
2.1.8.2
a) When flowmeter size is specified in the Purchaser's datasheet, vendor shall select the
flowmeter size accordingly and shall indicate the minimum & maximum fluid
velocities permitted through the offered sensor in the bid.
b) For meter sizing, velocity limits for the various flows in the data sheet shall be
typically in the range 0.3 m/s to 3 m/s complying to the accuracy as per clause 2.3
below. Velocity beyond these limits shall not be considered for sizing.
2.1.9 Terminal Housing

2.1.9.1 Following shall apply for both integral as well as for remote meter electronics:
a) All connections shall be terminated on the terminals brought out in the terminal
housing located on the flow meter body. Flying leads shall not be provided.
b) All intrinsically safe terminals shall be properly identified and shall be separate
from the non-intrinsically safe terminals.
c) Separate cable entry shall be provided in the terminal housing for power and
intrinsically safe signals.
d) The flow meter enclosure, housing the electrical parts shall be suitable for the area
classification indicated in the purchaser's data sheets. Unless otherwise specified,
the enclosure shall conform to the following standards:
Weatherproof housing - IP 65 to IS/lEC-60529.

Flameproof housing - Flame proof / Ex (d) as per IS/IEC-60079.
Flameproof housing shall also be made weatherproof.
2.1.9.2 Proper terminal blocks shall be provided in the transmitter unit for the termination of
purchaser's cables. Separate terminal blocks shall be provided for power and signal
connections.
2.2 Meter Electronics
2.2.1 Meter electronics includes all the associated electronics like pre-amplifiers, transmitter /
converters etc. Where the vendor is supplying the complete meter electronics, vendor shall
ensure that the input/output signals and performance characteristics of individual item are
compatible with each other.
2.2.2 When meter electronics is specified for installation in electrically classified area, the
transmitter shall be flameproof with intrinsically safe sensor. Safety barrier as required for
the sensor shall be provided by the vendor and shall be part of transmitter enclosure.
2.2.3 The electronic transmitter shall be two (2) wire micro-process based and shall be capable of
providing 4 to 20mA analog output superimposed with diagnostic data in digital mode (i.e.
HART output). When specified, flow meter shall provide field-bus output conforming to the
standard specified in the purchaser's specification sheets.
2.2.4 For smart transmitters with HART output or for field bus based transmitter the following
features must be ensured;
a) It shall allow multi-master (primary and secondary) for configuration, calibration,

diagnosis and maintenance. The primary could be the control system or host
computer, and the secondary could be the hand held communicator.
b) It should be capable of implementing universal commands.
2.2.5 In addition to the requirements specified above, field bus based transmitter shall meet the
following requirements;
Page 741 of 1296

15tRzie ENGINEERS
FOR ELECTROMAGNETIC
laPeg WA LIMITED
IA Goat of India Undertaking)
FLOWMETERS
6-52-0002 Rev. 4
Page 9 of 10
a) All instruments must satisfy the requirements of the field bus registration laboratory
with applicable checkmark like foundation field bus, profibus PA, or as specified in
the purchaser's data sheets.
b) All instruments shall have two analog input blocks, as a minimum. In addition,
when specified the transmitter shall also have PID controller block.
c) All instruments must be interoperable and shall have valid interoperability test
clearance for foundation field bus or equivalent for PA, as applicable.
d) The field bus instruments shall support peer-to-peer communication.
e) Field bus instruments as offered shall not be polarity sensitive.

The field bus instruments in hazardous area shall be certified as per Intrinsic Safe (entity
concept) or shall be FISCO approved as per the requirements specified in the purchaser's
specification.
2.2.6 Field mounted converters/transmitters shall have an integral output LCD meter. Local
indication of the output meter shall be digital with engineering units.
2.2.7 The span of the transmitter shall be field adjustable. In case separate device is required, to
make such a change, the same shall be included.
2.2.8 The configurational data for the instrument shall be stored in a non- volatile memory or in a
battery backed RAM such that the data remains unchanged because of power fluctuations or
power off condition. In case, vendor standard instrument has battery backed RAM vendor to
ensure that battery drain alarm is available and shall be provided as maintenance alarm.
2.2.9 When the purchaser's data sheets indicate the presence of permeable solids in the stream
(e.g. slurries containing magnetic materials like iron) vendor shall offer a flow meter system
whose circuitry compensates for signal changes induced by the presence of permeable
solids.
2.2.10 When specified, the meter electronics shall be protected against transients induced by
lighting and power supply surges. Transient protection electronics shall preferably be
provided in the terminal block.
2.2.11 Where remote mounted converter/ transmitter is offered a minimum of 10 metre of

interconnecting cable shall be included for both measuring electrode and earthing electrode /
plate, unless specified otherwise.
2.2.12 Purchaser shall provide one number of feeder for power supply at the meter electronics i.e.
converter / transmitter. Further distribution if any shall be taken care of by vendor.
Accessories like cable gland, conduit and junction box as required to interconnect sensor,
transmitter signal cable, power supply cables etc., shall be supplied by the vendor.
2.3 Performance Requirements

Unless otherwise specified, the magnetic flow meter shall meet the following performance
specifications;
a) Magnetic flow meter accuracy inclusive of linearity, repeatability and hysteresis

shall be better than ±0.5% of flow rate.
b) Repeatability of the magnetic flow meter shall be better than ± 0.1% of flow rate.
3.0 NAMEPLATE
Each electromagnetic flow meter and its accessories shall have a stainless steel nameplate
attached firmly to it at a visible place, furnishing the following information:
a) Tag number as per purchaser's data sheet.
Page 742 of 1296

ENGINEERS
$ig-ar iaReg
man ■;.aw m,yg..1)
INDIA IJMITED FOR ELECTROMAGNETIC 6-52-0002 Rev. 4
IA Gov o India Undertaking)
FLOWMETERS Page 10 of 10
b) Manufacturers serial number and model number.

c) Manufacturer's name/ trademark.
d) Nominal end connection size and rating in pounds.
e) Tube, tube liner and electrode materials.
f) Calibrated range of flow.
g) Area classification for which the equipment is certified for installation.
h) Hazardous area certification number and marking
i) Operating power supply voltage and frequency.
j) Specified range and units of measurement for flow.
Purchaser reserves the right to inspect and witness testing at vendor's works as per
Inspection Test Plan. All these tests shall be completed by the vendor and test reports shall
be submitted to Purchaser for scrutiny.
5.0 SHIPPING
5.1 All threaded and flanged openings shall be suitably protected to prevent entry of foreign
material. The flow transmitter shall be suitably protected to prevent any damage to its liner
during shipment or storage at site.
5.2 The flow transmitter and accessories shall be packed separately.
Page 743 of 1296

ei ENGINEERS FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
Ogar 251eg INDIA LIMITED FLANGES
+wen es1"2,2 471 (A Govt ot India Undertaking) Page 1 of 7
atirkfch-g .tAt t4r•Tilc‘t)
tr4Ri
ORIFICE PLATES AND FLANGES
4 09.11.15 Revised and Reissued as Standard Specification
3 29.11.10 Revised and Reissued as Standard Specification RS RG TGM/JMS ND
2 02.05.05 Revised and Reissued as Standard Specification AR TGM PM VJN

Standards Standards
Committee Bureau
No by by
Approved by
Page 744 of 1296

el ENGINEERS
ir &Reg
5'fg-e,mren INDIA LIMITED FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
ramie (A Govt of India Undertaking(
FLANGES Page 2 of 7
Abbreviations:

NPT National Pipe Thread
Members: Mr. M Nandi

Mr. Sandeep Arora
Mr. A S D Barman
Mr. S Mahesh Kumar
Ms. N P Guha (Proj.)
Page 745 of 1296

t_11 ENGINEERS
iEt5rdGW INDIA LIMITED FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
eiZasr?telanirni)
Govt of India Undertaking)
FLANGES Page 3 of 7
CONTENTS
1.0 GENERAL 4
3.0 NAMEPLATE 6
5.0 SHIPPING 6
Page 746 of 1296

k31 ENGINEERS
fetPleg INDIA LIMITED FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
mren virotte on JO if Mt (A Goof of India Undertalvngt
FLANGES Page 4 of 7
1.0 GENERAL
1.1 Scope
materials, nameplate marking, inspection, testing and shipping of orifice plates and flanges.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest edition of
the following codes, standard practices & publications unless specified otherwise:-

B 1.20.1 Pipe Threads General purpose (Inch)
B 16.20 Metallic gaskets for Pipe flanges- Ring joint, Spiral wound
and jacketed.
B 16.36 Orifice Flanges
MFC 14M Measurement of Fluid Flow using Small Bore Precision
Orifice Meters
AGA American Gas Association

Report No 3 Orifice metering of natural gas and other related hydrocarbon
fluids.
Part 1: General equations and uncertainty guidelines
10204 Inspection Documents For Metallic Products
IBR Indian Boiler Regulation
ISO International Organisation For Standardisation

5167 Measurement of fluid flows by means of orifice plates, nozzles
and venturi tubes inserted in circular cross-section conduits
running full.
Flow Measurements Engineering Handbook by R.W. Miller
Principles and Practice of Flow Meter Engineering by L.K.Spink

1.1.3 In the event of any conflict between this standard specification, data sheets, statutory
regulations, related standards, codes etc., the following order of priority shall govern:
b) Data Sheets

1.1.4 In addition to compliance to purchaser's specifications in totality, vendor's extent of
responsibility shall include the following:
a) Purchaser's data sheets specify the material for orifice plate and flanges. Unless
specifically indicated otherwise, alternate superior material of construction shall
also be acceptable provided vendor assumes complete responsibility for the
selected materials for their compatibility with the specified fluid and its operating
conditions.
b) Sizing of orifice plates, whenever specifically indicated in the purchaser's data sheets.
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instruction to the vendor attached with
the Material Requisition.
Page 747 of 1296

7- 1 ENGINEERS
sigar 02ft INDIA LIMITED FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
(NWT eleake meson.( (A Govl of India Undedaking)
FLANGES Page 5 of 7
1.2.2 All documentation submitted by the vendor including their quotation, drawings, installation,
operation and maintenance manuals etc. shall be in English language only.
1.3.1 Detailed drawings, data, specification sheet and manuals shall be submitted by vendor as per
vendor data requirement attached with Requisition.
maintenance manual etc., shall be submitted by the vendor after placement of purchase order
as per vendor data requirement attached with Requisition.
2.1 Orifice Plate
2.1.1 The design of orifice plates shall be in accordance with the specifications and standards
specified in the purchaser's datasheets.
2.1.2 Unless otherwise specified by the purchaser, orifice plate and flanges shall be manufactured
as per standard drawing number 7-52-0041. The type of orifice, internal and external
diameters of the pipe, the orifice bore diameter etc. shall be as indicated in the purchaser's
data sheets
2.1.3 The thickness of orifice plates shall be as specified in purchaser's data sheets, as a minimum.
However wherever Quadrant edge type of orifice plate is specified, the thickness of the
orifice shall be equal to the radius of curvature of the orifice, as a minimum.
2.1.4 Orifice assemblies having ring-type joint flanges shall be supplied with a plate-carrying
holder. Even when only the orifice plate has been ordered, vendor shall supply the plate
with the holder for use with ring type joint flanges. Plate holder hardness shall meet the
requirements specified in the data sheet.
2.1.5 Flanges/ fasteners/ plug type/ size/ MOC/ Qty/ thickness/ schedules/ finish must be clearly
mentioned in vendor drawing.
2.2 Flange Assembly
2.2.1 Unless otherwise specified, orifice flanges shall be fabricated in accordance with the
standards mentioned in the specification sheets. Minimum pressure rating for the flanges
shall be 300 Class.
2.2.2 Flange bore diameter shall be the same as pipe's internal diameter.
2.2.3 Unless otherwise specified, the following shall govern: -

a) Threaded end connections shall conform to NPT as per ASME B 1.20.1.
b) Flanged end connections shall be as per ASME B 16.5.
c) Grooves of the ring type joint flanges shall be octagonal as per ASME B16.20.
d) Flange face finish shall be as per ASME B 16.5. The face finish as specified in the
data shall be as follows:
125 AARH 125 to 250 micro inch AARH

63 AARH 32 to 63 micro inch AARH
2.2.4 Where flange taps have been specified, the centre lines of the tap-holes shall be at a distance
of 25.4 millimetres from the nearest face of the orifice plate, taking into account the gasket
thickness mentioned in the specification sheets.
Page 748 of 1296

it ENGINEERS
Ifgar feVits INDIA LIMITED FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
(>1reTr rieme A71 PTA) (A Go let of India Undedalong)
FLANGES Page 6 of 7
2.2.5 Where conical entrance type of orifice plates have been specified in purchaser's datasheet,
only corner taps shall be offered. Flange taps shall not be permitted.
2.3 Orifice Surface Finish
2.3.1 The inlet face finish shall be as per standard drawing number 7-52-0041/ISO-5167 as
applicable.
2.3.2 The fluid outlet surface of the plate should be flat and smooth and shall not have roughness
and scores that can be ascertained by touch or sight.
2.4 Honed Flow Meter Tube
2.4.1 For low flow rate measurement requiring high accuracy in line sizes less than 2" NB special
honed Flow meter tubes with corner tap orifice flanges shall be used. The sizing of the
orifice shall be as per ASME MFC 14M.
2.4.2 All honed flow section material shall be 316 Stainless Steel or superior.
2.4.3 Entire honed flow section (meter tubes & flanges) shall be bored and honed to 5-10 micro
inch or better roughness and shall have tube internal diameter, tolerance within 0.001inches.
2.4.4 Outer ends of meter tubes shall be fitted with forged steel pipe flanges as per ASME B 16.5
compatible with the specified orifice flange.
2.5 Orifice plates in oxygen and chlorine service shall be thoroughly degreased using reagents
like trichloro-ethylene or carbon tetrachloride and all connections shall be plugged after
degreasing process in order to avoid entrance of grease or oil particles.
3.0 NAMEPLATE
3.1 Each orifice plate shall have nameplate information punched on its handle as per attached
standard drawing number 7-52-0041. The information shall be clearly visible after assembly
of the flanges with bolts, nuts and gaskets.
3.2 Each flange shall have following information stamped on it at a visible place:
a) Tag number as per purchaser's data sheets.
b) Nominal flange size in inches and rating in pounds.
c) Plate and Flange material to ASTM specifications.
d) Bore diameter
Inspection Test Plan and approved quality documents. All these tests shall be completed by
the vendor and test reports shall be submitted to Purchaser for scrutiny.
PMI on all incoming material shall be carried out as per Inspection and Test Plan as
applicable.
5.0 SHIPPING
material.
5.2 Pairs of flanges shall be packed separately. Each pair of flanges shall be assembled,
inserting a disc of suitable soft material between them, for the protection of gasket bearing
surfaces during transport with the stud bolts and nuts slightly tightened. Internal pipe threads
shall be fitted and protected by plastic plugs before dispatch.
Page 749 of 1296

n./M
-) ENGINEERS
5i'lgzrr ia5reg W7 INDIA LIMITED FOR ORIFICE PLATES AND 6-52-0004 Rev. 4
WWI erezarz cni3O0.1) (A Govt of India Undeitakmg)
FLANGES Page 7 of 7
5.3 Orifice plate holders, ring spacers, and flanges shall be protected with a rust preventer
removable by trichloroethylene or petrol.
5.4 Orifice plate shall be packed inside thick polythene bags with suitable protective packing
outside. Each plate shall be packed separately.
5.5 After fabrication the honed meter tube assembly with orifice plate and flanges shall be
protected adequately with proper packaging to prevent the same from rust, deformation and
mechanical damage during shipment and storage in warehouse.
5.6 All orifice plates in oxygen and chlorine service shall be separately packed along with a
certificate indicating 'SUITABLE FOR OXYGEN/CHLORINE SERVICE', as applicable.
Page 750 of 1296

ts-dra_it-s ENGINEERS STANDARD SPECIFICATION
6 - 52 - 0031 Rev. 4
2151-eg INDIA LIMITED FOR CONTROL VALVES
Govt of India UndeftAk , o9)
Page 1 of 21
T-4ff curcii* fry RA411

CONTROL VALVES
pjit af
4 27.03.17 Revised and Reissued as Standard Specification AM AB
3 11.04.11 Revised and Reissued as Standard Specification MN RG RP/JMS DM
2 15.02.07 Revised and Reissued as Standard Specification SM TGM HCJ VC

Standards Standards
Date Prepared Checked
Purpose Convenor Chairman
No by by
Approved by
Page 751 of 1296

ENGINEERS STANDARD SPECIFICATION
$'tgrar tit5ift
1.77 elecnre 0s13q7.1)
INDIA LIMITED
IA Gov, of India Undertaking)
FOR CONTROL VALVES 6-52-0031 Rev. 4
Page 2 of 21
Abbreviations:
EDDL Electronic Device Description Language
ERTL Electronics Regional Testing Laboratory
FDT/DTM Field Device Tool/Device Type Manager
FF Fieldbus Foundation
FISCO Fieldbus Intrinsic Safety Concept
HHT Hand Held Terminal
NPS Nominal Pipe Size
SS Stainless Steel
TSO Tight Shutoff
Members: Mr. M Nandi

Mr. ASD Barman
Mr. Sandeep Arora
Mr. S Mahesh Kumar
Page 752 of 1296

_.1t17
- ENGINEERS STANDARD SPECIFICATION
coed, att
INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
r (A Govt of India Undellaking)
Page 3 of 21
CONTENTS
1.0 GENERAL 4
3.0 NAMEPLATE 20
5.0 SHIPPING 21
ANNEXURES:
ANNEXURE — 1: STUD-BOLT AND NUT MATERIAL REQUIREMENT
ANNEXURE — 2: GASKET MATERIAL REQUIREMENT
Page 753 of 1296

$1gZIT fat5ift
etraAv
INrr
051,R75.11 IA Govt of India Undertaking)
Page 4 of 21
1.0 GENERAL
1.1 Scope
materials, fabrication, documentation, nameplate marking, inspection, testing and shipping
of control valves.
1.1.2 The related standards referred herein and mentioned below shall be of the latest edition of
the following codes, standard practices and publications, unless otherwise specified.;
ASME American Society of Mechanical Engineer.
B 1.20.1 Pipe Threads, General Purpose (Inch)

B 16.20 Metallic Gaskets for Pipe Flanges, Ring Joint, Spiral wound
and Jacketed.
B 16.34 Valves — flanged, Threaded and Welding End.
B 16.47-B Large Diameter Steel Flanges
ANSI/FCI American National Standard Institute/Fluid Control Institute

FCI 70-2 Control Valve Seat Leakage
6D Pipelines valves (Gate valve, Plug, Ball and Check valves)

598 Inspection Requirements
609 Lug and wafer type, Butterfly valves.
AWWA American Water Works Association - Steel Pipe Flanges For Water Works
C207 CL.D Services
6364 Valves in cryogenic service
10204 Inspection Documents For Metallic Products.

61056-1 Specification for performance, design and construction of
valve,regulated sealed type.
IBR Indian Boiler Regulation.
IS/IEC Indian Standards/International Electro-Technical Commission
IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere.

IS/IEC 60529 Degree of Protection Provided by Enclosures.
IEC 60534-3-2 Face to Face dimension of rotary valves except butterfly
valves.
IEC 60534-4 Seat leakage
IEC 60534-8.3 Industrial process control valves, noise consideration,
control valve aerodynamic noise prediction method
IEC 60534-8.4lndustrial process control valves, noise consideration,
prediction of noise generated by hydrodynamic flow
IEC-61158 Fieldbus Standard for use in Industrial Control System
Page 754 of 1296

gar 0511-'eg
INT-
tm edecord
INDIA LIMITED FOR CONTROL VALVES 6 52 0031 Rev. 4
- -
,ARKAII (A GoN of India Undertaking)
Page 5 of 21
1EC-61158-2 Physical layer specification and Service definition for

Fieldbus
FF 890 Function Block Application Process Part 1
IEC 61508 Functional Safety of Electrical/Electronic/Programmable
Electronic Safety related Systems.
IEC-61511 Functional safety instrumented system for the process
industry sector
IEC-61804 Function Blocks (FB) for Process Control: Electronic
Device Description
ISA International Society of Automation

75.01.01 Flow equation for sizing control valves.
75.02 Control valve capacity test procedure.
TR75.04 Control Valve positioner stability
75.05.01 Control Valve terminology
75.07 Laboratory measurement of aerodynamic noise generated
by control valves
75.08.01 Face to face dimensions for integral flanged Globe-style
control valve bodies (ASME Class 125,150,300 and 600)
75.08.02 Face to face dimensions for flangeless control valve
(ASME Class 150,300 and 600)
75.08.04 Face to face dimensions for Buttweld-end globe style
control valve (ASME Class 4500)
75.08.05 Face to face dimensions for Buttweld-end globe style
control valve (ASME Class 150,300,600,900,1500 and
2500)
75.08.06 Face to face dimensions for flanged Globe-style control
valve bodies (ASME Class 900,1500 and 2500)
75.11.01 Inherent flow characteristic and Rangeability of control
valves.
75.19.01 Hydrostatic testing of control valves.
75.22 Face to centre-line dimensions for flanged Globe-style
Angle control valve bodies (ASME Class 150,300 and
600)
75.25.01 Test Procedure for Control valve response measurement
for step inputs
TR 75.25.02 Control valve response measurement for step inputs
75.13 Method of evaluating the performance of positioners with
analog input signals and pneumatic output.
75.17 Control valve aerodynamic noise prediction.
RP75.23 Considerations for evaluating control valve cavitation
ITK Interoperability Test Kit (latest version)
MSS Manufacturer's Standardisation Society
SP25 Standard Markings System for Valves, Fittings, Flanges and

Unions
NACE National Association of Common Engineers
Page 755 of 1296

ogez 'Meg
1411, ele'Lme r151,10,1,
(A Govt of inO(a Uocleflakfog)
Page 6 of 21
MR0103 Materials Resistant to Sulphide stress cracking in Corrosive

Petroleum Refinery Environments
OSHA Occupational Safety and Health Authority
1.1.3 In the event of any conflict between this standard specification, job specifications/data
sheets, statutory regulations, related standards, codes etc., the following order of priority
shall govern:
a) Statutory regulations
b) Job Specifications/Data Sheets
c) Standard specification
d) Codes and standards
1.1.4 In addition to meeting purchaser's specifications in totality, vendors' extent of responsibility

shall also include the following:
a) Purchaser's data sheets specify the minimum acceptable materials for the control
valve body and trim. Alternate superior materials of construction shall also be
acceptable with consent of purchaser provided vendor assumes complete
responsibility for proper selection of material for these parts for their compatibility
with the process fluid and its operating conditions.
b) Purchaser's data sheets specify the control valve size, flow coefficient (Cv) and
required flow rangeability. Vendor shall be responsible for selecting their
standard valve flow coefficient suitable for the specified service and process
conditions specified in the purchaser's data sheets.
c) Selection of actuator to meet the shut off differential pressure indicated in the
purchaser's data sheets.
d) Checking for cavitation, flashing and noise generated and provide suitable trim
and treatment to limit these within appropriate limits.
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached with
the Material Requisition.
1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the
following:
a) Compliance to the specifications.
b) Whenever specifically indicated, a detailed specification sheet for each control

valve which shall provide information regarding type, material of construction,
capacity sizing code, inlet and outlet type, size and rating, etc. of the control valve
and its valve accessories. The material specifications and units of measurement
indicated in the specification sheet shall be to the same standards as those in
c) Whenever the requirement of sizing calculation is specifically indicated in the

materials requisition, vendor shall furnish sizing calculation for each tag number
clearly highlighting the standard used for calculation, noise level, cavitation or
Page 756 of 1296

0 el ENGINEE RS STANDARD SPECIFICATION
Oaf fagreg
wire elearrem,ketankr
INDIA LIMITED
rn Govt or India Undertaking}
Page 7 of 21
flashing, Cv selected, percentage opening at minimum, normal and maximum

flow, inlet and outlet velocity etc.
d) Proven references in line with clause no. 1.2.3 of this specification specifically for
valves with ASME Class 600 and above, temperature more than 250°C and below-
29°C, pressure drop greater than 50 kg/cm 2 and special application like hydrogen,
NACE ,Cryogenic etc.
e) A copy of approval for items such as limit switches, solenoid valves, electro-
pneumatic converters, electro-pneumatic positioners, smart positioners ,Fieldbus
positioners from local statutory authority, as applicable, such as Petroleum and
Explosives Safety Organization (PESO)/Chief Controller of Explosives, Nagpur
(CCE) or Director General of Mining Safety (DGMS) in India, along with:
i) Test certificate from recognised test house like Central Institute of Mining
and Fuel Research (CIMFR) / Electronics Regional Testing Laboratory
(ERTL)etc. for flameproof enclosure and/ or intrinsic safety, as specified
in the data sheets as per relevant Indian Standard for all Indian
manufactured equipments.

Equipment in Flammable Atmospheres (Baseefa), Factory
Mutual (FM), Physikalisch-Technische Bundesanstalt (PTB), Canadian
Standards Association (CSA), Underwriters Laboratories (UL) etc., for
compliance to ATEX directives or equivalent recognised standards for all
equipments manufactured outside India.
f) Limitation, if any, in changing actuator orientation at site.
g )
Deviations on technical requirements shall not be entertained. In case vendor has
any valid technical reason, they must include a list of deviations tag number wise,
summing up all the deviations from the purchaser's data sheets and other technical
specification along with the technical reasons for each of these deviations.
h) Published catalogues giving detailed technical specifications (i.e. available sizes,

ratings, sizing codes, approvals & certifications, MOC, etc), model decoding
details and other information for each type of control valve and accessories
covered in the bid. For fieldbus positioners, information shall include, but not
limited to, product certification, power supply, current drawn,
Standard/Advanced/Enhanced function blocks available and the execution time
for each block, device type, number of link objects, Virtual Communication
Relationships, Basic and advanced diagnostic features, failure mode etc. In case
catalogues do not provide all such technical details, vendor shall submit
supplementary technical literature.
1.2.3 For valves in cryogenic service, vendor shall meet the following acceptance criteria:
a) Vendor shall furnish, along with the offer, type test certificate, duly witnessed by
Third Party Inspection agency like M/S LRIS, DNV BV, TUV, CEIL etc. of having
successfully conducted the cryogenic test as per BS 6364 on the offered valves
(same model, size, rating and material) in cryogenic service. Further vendor to note
the following:
i) Test temperature shall be -45 °C for LTCS and -196 °C for all grades of austenitic
Stainless Steel.
Page 757 of 1296

5fgal 015Veg
t4/1-1m viva', tot ,o,ost
INDIA LIMITED
(A Govt of India Untlettaktrogt
Page 8 of 21
ii) Test carried out on a particular size of one type of valve, pressure rating and
material shall qualify all sizes equal to and below the test valve size for the same
type, pressure rating and material. In case of austenitic Stainless Steel any one
grade would qualify for other grades of austenitic Stainless Steel.
b) In case vendor does not have cryogenic type test certificate for the offered valves as
mentioned above, vendor shall confirm to conduct the cryogenic test on the offered
valves and furnish type test report meeting requirements specified in Clause 1.2.3
a) above.
i) Vendor must have proven references as per clause 1.2.4 of this specification for
each of the offered valves (same model, size , rating and material) in cryogenic
service. The references with details shall be furnished with the offer.
ii) In case the vendor fails to conduct cryogenic test(s) within 12 weeks or failure in
the test(s) conducted after receipt of order, the purchaser reserves the right to
invoke any of the provisions of the purchase order including cancellation of the
Purchase Order at the risk and cost of vendor.
1.2.4 All items, as offered, shall be field proven and should have been operating satisfactorily
individually for a period of minimum six months on the bid due date in the process
conditions similar to those as specified in the purchaser's data sheets. Items with proto-type
design or items not meeting provenness criteria specified above shall not be offered.
1.2.5 Whenever specified, vendor must furnish certified values of failure rates, probability of
failure on demand (PFD) and test intervals for the safety integrity level (SIL) analysis.
1.2.6 All documentation submitted by the vendor including their quotation, catalogues, drawings,
installation, operation and maintenance manuals etc., shall be in English language only.
1.2.7 Vendor shall specifically note that the quote for control valves shall include the following:
a) One extra set of packing and bonnet gasket with each tag.
b) One extra set of stem seal 0-ring for each actuator and piston 0-ring additionally
for each piston actuated valve.
c) Line bolting (set of studs and nuts) and set of gasket, in case of flangeless valves as
per material given in Annexure-1 and Annexure-2 with each such tag number.
1.2.8 Vendor shall separately quote for the following:
a) Control valve diagnostic package for seat ring, gland packing and actuator
diagnostic with smart positioner.
b) Two years' operational spares for offered control valve and its accessories, which
shall include plug, seat ring, gasket set, packing set, diaphragm/o-ring set etc. as a
minimum.
c) Any special tools needed for maintenance work. Vendor must certify in their offer
in case no special tools are necessary for the offered control valves and their
accessories.
d) Required software for operation and diagnosis of the control valve shall be
provided separately in the physical device such as CD/DVD/pendrive.
Page 758 of 1296

$fgaf ta5reg INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
f.f127 orroore as,FgrJ, f Govt of InOta Undettakog)
Page 9 of 21
1.3 Drawing and Data
1.3.1 Detailed drawings, data, catalogues and manuals required shall be submitted by the vendor
as per Vendor Data Requirements (VDR) attached with the requisition.
maintenance manual etc. shall be submitted by vendor after placement of purchase order
which shall include the following as a minimum:
a) Specification sheet for each control valve, positioner and other accessories and
sizing calculation.
b) Certified drawings and technical catalogues for each control valve and its
accessories, which shall provide dimensional details (face-to-face and height of
completely assembled valve). Dimensions of clearance space for maintenance
work, weight of completely assembled valve, internal constructional details,
materials of construction of actuator, wiring diagram, installation procedure for
control valves and their accessories, orientation with respect to flow direction
marked on the body, sizing codes, approvals & certifications.
c) Copy of the type test certificates and the test certificates for all tests indicated in
Inspection Test Plan.
d) Calibration, configuration and maintenance procedures including replacement of

its parts/ internals wherever applicable.
e) Control valve operating signatures whenever smart positioners or fieldbus based

positioners are specified.
f) Device Descriptor (DD) Files for configuring Smart positioner /Fieldbus

parameters
g) Common File Formats (CFF) for integrating the fieldbus positioner into the control
system.
2.1 Body
2.1.1 Control valves shall have flanged end connections integral to the valve body. Split body type
valve design shall not be offered unless specifically indicated in the purchaser's data sheets.
Whenever flangeless control valve body design is specified in the purchaser's data sheet,
following shall apply:
a) Wafer type or lug type body design for control valves body size up to 6 inches.
b) Lug type body design for butterfly type of control valve body size more than 6
inches.
2.1.2 The minimum control valve body size shall be 1 inch. Control valve body size of less than 1
inch shall be offered only when specifically indicated in the purchaser's data sheet. The
control valve body size shall be adhered to the size mentioned in the data sheet, if due to
process condition and other parameters the same size is not suitable than higher size can be
offered with reason. Only after acceptance of offered higher size by client/EIL, vendor shall
proceed.
Format No 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
Page 759 of 1296

011 1_1 ENGINEERS STANDARD SPECIFICATION
Ogaf lagreg INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
14-11:27 ,1,7>T2 CA Govt of India Unde[taking)
Page 10 of 21
2.1.3 The valve body rating should be equal to or higher than the flange rating specified in the
data sheets. As a minimum, control valve body shall be rated for ASME Class 300.
However, end connection shall be as specified in purchaser's data sheet.
2.1.4 The control valves shall be suitable for installation in horizontal as well as in vertical lines.
2.1.5 For all applications, where full port valves are specified, following shall apply:
a) Port size shall be equal to line size for rating up to ASME Class1500.
b) Port size shall not be smaller than one size lower than that of the line size for body
rating ASME Class 1500 and above.
2.1.6 Vendor to note that there shall not be any price or time implications in case the valve port
size need to be changed to accommodate minor process changes while keeping the valve size
and other specifications same.
2.1.7 Flow Direction
2.1.7.1 In general, flow direction shall be as below:
a) Flow tending to open for single seated unbalanced valve design.
b) Flow entering between the seats for double seated valves.
c) Flow entering at the side and leaving at the bottom for angle valves.
For valves design other than those specified above, flow direction shall be as per
manufacturer standard.
2.1.7.2 Flow direction shall be clearly marked on the control valve body.
2.1.7.3 For 3-way control valves, service like mixing or diverting, shall be clearly identified with inlet
and outlet end connection clearly marked on the control valve body.
2.1.8 End Connections
2.1.8.1 Unless otherwise specified, the following shall govern:
a) Threaded end connections shall be to NPT as per ASME B1.20.1.
b) Flanged end connections shall be as per ASME B 16.5/ B 16.47B/ AWWAA C207
CL.D.
c) Flange face finish shall be as per ASME B16.5. The face finish shall be as follows:
125 AARH : 125 to 250 micro inch AARH
d) Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20
2.1.8.2 Face-to-face dimensions of globe type control valves shall be in accordance with ISA 75.08.
2.1.8.3 Where provided, control valve bottom drains shall be plugged off or blind flanged. Where a
plug is used, threads shall correspond to ASME B 1.20.1 (NPT). Where a flange is used, its
dimensions and rating shall correspond to ASME B16.5.
Page 760 of 1296

~'OtltGzltl ENGINEERS STANDARD SPECIFICATION
$1g-aititateg INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
(A Gov! of India Undertaking)
Page 11 of 21
2.1.9 Material of Construction
2.1.9.1 The material of construction of control valves body shall be as specified in the data sheet. No
material shall be substituted by vendor without specific written approval from purchaser.
2.1.9.2 Control valve body, bonnet, bottom flange, line flanges and other pressure containing
assemblies shall be of the same material of construction as specified for valve body in the
2.1.9.3 The bonnet flange and bottom flange shall have metallic spiral wound gaskets suitable for the
specified service. The gaskets with asbestos bearing fillers shall not be used.
2.1.9.4 Vendor shall be responsible for selecting proper material for the internal parts of control
valve. All such materials shall have the same or better specification than specified in the
2.1.9.5 The material of construction of silencers, diffuser plates, diffuser plate assembly etc shall be
as per the body material specified in the purchaser's data sheets, as a minimum.
2.2 Trim
2.2.1 The term 'trim' covers those parts of valve assembly (excluding the body, bonnet and
bottom flange) which are exposed to and are in contact with the line medium consisting of
but not limited to the seat ring, valve stem, valve plug, valve plug guide, guide bushing and
cage.
In case of rotary type of control valves like butterfly, ball, segmental ball, rotary plug,
eccentric disc and rotary disc, the term trim covers disc/ball, seat ring, shaft and bearing.
2.2.2 Guiding
2.2.2.1 Single seated globe and angle type control valves shall have heavy top plug guiding or cage
guided design as per data sheets. The cage shall provide a continuous plug guiding
2.2.2.2 Double seated valves shall have top and bottom or cage guiding and shall be of the pressure
balanced type.
2.2.2.3 Whenever cage type control valves are specified, top guided or top and bottom guided
control valves can be offered provided it meets all other process and functional
requirements. But whenever top or top and bottom type of guiding is specified, cage type
control valves shall not be offered. However, if the service requires the anti-cavitation trim
or low noise trim then in place of top or top and bottom guiding the cage type control valve
can be accepted only after reviewing the control valve sizing.
2.2.2.4 Rotary control valves like butterfly, segmental ball, eccentric rotary plug etc shall have
blowout proof shaft guiding design.
2.2.3 Trim Design
2.2.3.1 Control valve manufacturer/vendor shall be responsible for trim selection and trim design of
the control valve. However it must meet the following minimum requirements:
a) Control valve trim design shall suit the type of guiding specified in the data sheet.
b) The trim design and material of construction shall be selected to minimize the risk
of galling particularly in case of cage guided valves. Vendor shall select proper
Page 761 of 1296

kriitRai& ENGINEERS STANDARD SPECIFICATION
Ogzlit1154-Cg INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
c11,a/le' c151,111/i15.1 Govt of India Undertaking)
Page 12 of 21
material pairs, surface finish, hardness and clearances wherever possibility of

galling exist.
c) Under extreme temperature conditions, vendor shall consider increased clearances

at room temperature and seal welding of threaded seat rings etc. Hard facing of
trim shall be used in high temperatures. For very low temperature application,
material used shall have adequate cold impact strength.
d) For globe/angle/3-way type of control valves, stem and plug shall be detachable and
shall be attached together by suitable threaded design secured with a pin to avoid
plug rotation during operation.
e) For top and bottom guided control valves with sizes above 8", post and guide
bushing design shall be used to prevent rotation of plug and stem.
f) Whenever cavitation conditions are expected, vendor shall select a special anti-
cavitation trim design and shall use trim material of sufficiently high hardness.
g) Whenever the possibility of aerodynamic noise in a control valve exists under any
operating condition specified in purchaser's data sheet, vendor shall select a special
low noise trim for that application.
2.2.3.2 The plug inherent characteristics shall be as indicated in the purchaser's data sheet.
However, following shall be followed unless otherwise specified:
a) Control valves with low noise and anti-cavitation trim design shall have modified
equal percentage or linear characteristics.
b) Rotary type control valves shall have modified equal percentage or equal
percentage characteristics.
c) Control valves with flow co-efficient less than 0.4 shall have equal percentage or
linear characteristics.
d) All other control valves shall have equal percentage characteristics.
Whenever linear or modified equal percentage characteristics are specified, equal percentage
characteristics shall also be acceptable. Characterized positioner cam design to meet
specified inherent control valve characteristics shall not be offered.
2.2.3.3 Trim Material
2.2.3.3.1 Whenever stellited trim is specified in the data sheets following material of construction for
the trim parts shall be acceptable.
a) Plug and seat Stellite sheathing/hard alloy coating or solid stellite
b) Cage Nitrided or stellite sheathing/hard alloy coating or solid

stellite.
c) Guide bushing Stellite coating/sheathing or solid stellite
d) Valve stem Hardened SS /Inconel X-760
In case of steam, water, air and other non-hydrocarbon utility services 17-4 PH SS or 440C
is also acceptable.
Page 762 of 1296

ks-lit-a_io• ENGINEERS
g
efragt =Jam-Fp
LIMITED
Page 13 of 21
Special material requirements, if specified in the datasheets, shall supercede the above
mentioned requirements.
2.2.3.3.2 Minimum acceptable hardness in case of stellited or hardened trim shall be of the order of
RC 38 (BHN 352) to RC 45 (BHN 429).
2.2.3.4 Leakage class
a) Leakage class as per ANSI FCI 70.2 shall be specified in the purchaser's data sheet
for each control valve. Where no leakage class is specified, the same shall be
considered as Class IV. Higher leakage class shall be provided wherever indicated in
b) For control valves specified with Class VI leakage class, vendor shall select the soft
seat (elastomer) material suitable for the process conditions i.e., shut off pressure,
maximum temperature and process fluid.
2.2.3.5 Control valve experiencing cavitation, flashing and noise are generally identified in the
purchaser's data sheet. In case vendor's calculation show occurrence of cavitation, flashing
or noise under any of the specified process condition, vendor shall select proper type of
valve trim to suit such process conditions.
2.2.3.6 Minimum acceptable materials of construction to be considered by vendor for valve

components are already specified in datasheets.
However, alternate superior materials may be provided if they meet all process conditions
(operating, design, fluid properties, corrosion, etc), testing (ASME, API, radiography, etc)
and statutory requirements (ASME, API, IBR, NACE, etc) specified by purchaser.
Accordingly, the following alternate materials can be accepted:Body & bonnet: ASTM A
105, ASTM A 216 gr. WCB / WCC in place of carbon steel.
2.3 Sizing
2.3.1 The control valve capacities in terms of flow coefficient (Cv) shown in the purchaser's data
sheets have been calculated based on the formulae given in the standard ISA 75.01 "Control
valve sizing equations".
All factors used while arriving at the sizing are also as per ISA 75.01. Vendor must resize
the control valves considering various factors specific to the offered valves.
2.3.2 Purchaser's data sheet indicates calculated flow co-efficient values at minimum, normal and
maximum operating conditions. Vendor shall calculate this co-efficient as per the offered
control valve and select the size considering valve openings as under:
At maximum flow less than 90% open
At normal flow typically 75% open
At minimum flow more than 10% open
2.3.3 Rangeability of globe type of valves shall be 30:1, as a minimum. Vendor shall ensure that
the actual rangeability of offered valves shall meet these requirements. For other types of
offered control valves, vendor to specify that the available rangeability of the offered valves
meet the requirements specified in the purchaser's data sheets.
2.3.4. Conventional Butterfly valves shall be sized assuming a 60° opening at maximum flow.
Wherever high performance butterfly valves are specified, these shall be sized considering
maximum opening of 90° at maximum flow.
Page 763 of 1296

itiajeg INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
I 2,2151", 39,171, IA Govt of India Undertaking)
Page 14 of 21
2.4 Noise
2.4.1 Vendor shall examine each control valve for noise generation possibilities. The noise level
shall be calculated as per ISA 75.17 or any other equivalent standard.
2.4.2 Noise generated by control valve during operation shall be limited to OSHA specified levels
i.e. the maximum allowable noise shall be less than 85 dBA, when measured at a distance
governed by ISA 75.17.
2.4.3 If the predicted noise level is found to exceed 85 dBA SPL, control valve shall be treated for
noise. Source treatment for noise shall be resorted to. When source treatment for noise is not
sufficient to reduce the noise level below 85 dBA, vendor shall provide path treatment like
diffuser plate/silencer etc in addition to source treatment so as to reduce the level below
85dBA. Whenever additional path treatment is recommended, the maximum differential
pressure across the silencer/diffuser plate shall not exceed 40% of the specified differential
pressure.
2.4.4 Vendor shall also furnish noise calculations with and without the use of these devices and
the noise abatement achieved in individual components.
2.4.5 Diffuser plate shall be inserted between control valve body and pipe flanges. Vendor shall
supply long studs and nuts along with a pair of gaskets on the downstream side with material
as per Annexure-1 and Annexure-2 attached with this specification.
In cases where the diffuser plate size is higher than the valve body size or there is a need of
multiple diffuser plates, vendor shall supply the complete diffuser assembly with flanged
end connections matting with the control valve flange and downstream line size.
2.4.6 The silencer whenever offered for noise abatement shall always be supplied with flanged
end connections.
2.5 Packing Box, Bonnet and Stem
2.5.1 Packing Box
2.5.1.1 The packing box shall be flanged bolted to the bonnet and shall meet the requirements
specified in purchaser's data sheet.
2.5.1.2 Generally low friction type packing like braided teflon will be used wherever operating
conditions permit. For high temperature application (>200°C), Grafoil or equivalent gasket
suitable for the specified service shall be selected. Asbestos based packing material shall not
be used.
2.5.1.3 Where specifically indicated, control valve shall have its packing box drilled and tapped to
1/4" NPT (F) for connecting external lubricator. When external lubricator is not provided,
this hole shall be plugged.
2.5.1.4 An isolating valve shall be provided with all valves having external lubrication provision.
Vendor shall specify the lubricator stick material used in each case.
2.5.1.5 For application in vacuum service, vendor to provide inverted packing design suitable for
vacuum service. For pressure-cum-vacuum service, the control valve shall have dual
packing design suitable for the application. Dual packing design shall also be provided for
control valves in toxic service.
2.5.1.6 Wherever environmental packing design is specified vendor shall supply special packing
design suitable to minimize fugitive emission.
Page 764 of 1296

ENGINEERSS STANDARD SPECIFICATION
$fgal
1 ,f7n
kiPteg
(751,05-A
INDIA LIMITED
IA Go, of India UnOeff.k , ff91
Page 15 of 21
2.5.2 Bonnet
2.5.2.1 The bonnet shall be flanged bolted to the body. Threaded bonnets are not permitted.
2.5.2.2 Wherever the operating temperature of the fluid is above 200°C, extension or radiation
finned bonnet shall be provided. Vendor standard bonnet design shall also be acceptable if
these are suitable for higher temperatures.
2.5.2.3 For the operating temperature below 0°C, vendor shall provide extended bonnet design.
Vendor standard bonnet design shall also be acceptable if these are suitable for lower
temperatures. For valves in cryogenic application bonnet extension shall be as per BS-6364
as a minimum.
2.5.3 Stem
2.5.3.1 The stem surface finish shall be fine. Extra fine surface finish shall be provided wherever
the packing material is PTFE.
2.5.3.2 The stem/shaft shall be designed for the maximum thrust of the actuator without any
measurable deflection.
2.5.3.3 The valve stem/shaft shall be connected to the actuator stem/shaft by suitable arrangement to
avoid backlash problem.
2.6 Actuator
2.6.1 Pneumatic Actuator
2.6.1.1 Actuator shall be sized for the shut-off differential pressure indicated in purchaser's data
sheets. However, for 3-way type control valve, the actuator shall be sized for maximum
differential pressure, unless specifically indicated otherwise.
2.6.1.2 The actuator shall be designed to move the valve to the failure position specified in the
purchaser's data sheet. For failure position specified as 'fail-locked', vendor shall provide
fail-lock relays to meet the requirement.
2.6.1.3 Actuator casing shall be made of pressed steel or anodised aluminium. Non-metallic
actuator casings shall not be offered.
2.6.1.4 Springs shall be corrosion-resistant and shall be cadmium or nickel-plated. Alternately

vendor standard coating shall also be acceptable. These shall be of the enclosed type. The
compression of the springs shall be adjustable.
2.6.1.5 In general, an actuator operating range of 0.2-to 1.0 kg/cm 2g is preferred. However when
vendor standard actuator model is not able to meet the specified shutoff pressure, higher
actuator operating range may be offered.
2.6.1.6 In general, spring opposed diaphragms type actuators shall be used. Only when this type of
actuator becomes extremely unwieldy, based on the data specified in the purchaser's
datasheet, should a piston and cylinder type of actuator be considered.
2.6.1.7 Whenever piston and cylinder actuator is considered, single acting spring return type shall be
used.
2.6.1.8 Whenever double acting springless type of actuator is unavoidable, all accessories like pilot
valves, booster relays, non-return valve, pressure gauge, volume tank etc. shall be provided
to ensure desired action on air failure. The volume tank shall be sized considering full
Page 765 of 1296

fieg
el,4,11 451,R1,191
INDIA LIMITED FOR CONTROL VALVES 6 -52 - 0031 Rev. 4
(A Govt of India Untiottak , o9(
Page 16 of 21
stroking of the valve for two complete cycles. The volume tank shall be of carbon steel
construction and sized as per ASME Section VIII with design pressure of 10kg/cm 2 g as a
minimum. Accessories like pressure relief valves and tubing shall be of 316 Stainless steel
construction. Other accessories can be of Cast Aluminium.
2.6.1.9 The actuator casings and diaphragms shall be designed for minimum twice the maximum
pneumatic operating pressure of the control valve.
2.6.1.10 Valve stem position indicator shall be provided for every control valve. The position
indicator scale shall be marked from 0 to 100% in steps of 10%.
2.6.1.11 In general, side-mounted handwheels will be used. Hand wheels shall provide manual
control in both opening and closing directions independent of spring action. Hand-wheels
shall be of non-rising type suitable for accurate valve positioning .The hand-wheel actuator
shall be sized to provide the required thrust for valve positioning with 178N force applied to
the hand-wheel.
2.6.1.12 Actuator orientation shall be as per purchaser's requirements, in general. When, no

requirements are indicated by purchaser, vendor shall provide recommended actuator
orientation. It shall be possible to change this orientation at site for the offered valve-
actuator combination in case it is found necessary.
2.6.2 Actuator Sizing
2.6.2.1 Vendor shall be fully responsible for the sizing and selection of the correct actuator for the
specified control valve. Any change in actuator model number necessary to meet MR/PR
requirements after placement of order shall be taken care of by vendor without any price or
time implication. While sizing the actuator, vendor shall ensure that the actuator is able to
develop sufficient thrust to properly seat the control valve plug/disc at the actuator air
pressure (lowest specified pressure) and shut-off conditions specified in the purchaser's data
sheets.
2.6.2.2 While sizing the actuator, vendor must ensure that the sizing factors indicated below are
fully complied. Higher sizing factor may be considered if found necessary by vendor.
a) For control valves with leakage class IV and below, the actuator shall be sized
considering actuator thrust more than 1.3 times the total force induced by shut-off
conditions specified in the data sheet and the force required to overcome packing
friction. Vendor shall utilize this factor as 1.5 in case the control valve is operating
between 80% to 90% or 10% to 20% in any of the specified conditions.
b) For control valves with leakage class V and above, the actuator shall be sized
considering actual thrust more than 1.7 times the total force induced by specified
shut-off conditions in the purchaser's data sheet and the force required to overcome
packing friction.
2.6.2.3 Vendor shall indicate the recommended actuator orientation. In addition other allowable
orientations shall also be provided along with the offer. The orientation of the actuator may be
changed after order. The vendor shall do the same without any price or time implication.
2.7 Accessories
2.7.1 Positioners
Format No. 8-00-0001-F1 Rev. 0 Copyright EL — All rights reserved
Page 766 of 1296

NeerR2 Jrr.-4,4 (A Gov, Of India Unded ak mg)
Page 17 of 21
2.7.1.1 Positioners shall be of force-balance type or smart digital type or fieldbus type as specified
in the purchaser's datasheet. They shall be direct acting, with an adjustable gain unless
2.7.1.2 The pneumatic positioner shall be provided with an integral by-pass switch whenever the
operating range of the actuator is the same as that of the control signal.
2.7.1.3 Every positioner shall have two pressure gauges mounted on it, one each for air supply and
for positioner output to actuator. In addition , pneumatic positioner shall have third pressure
gauge for control signal.
2.7.1.4 Pneumatic connections shall be 1/4" NPT (F) and cable entry shall be 1/2" NPTF . If
connection for cable entry is different than that specified, suitable adapters shall be provided.
2.7.1.5 Positioners shall be side-mounted on the control valve and shall have corrosion resistant
linkages and rugged brackets.
2.7.2 Smart type and fieldbus type positioners
Digital smart positioners or fieldbus type of positioners with diagnostic capabilities shall be
supplied whenever specified in the purchaser's data sheets. These shall meet the following
minimum requirements:
a) The positioner sensor and sensing mechanism shall be rugged and shall not be
affected by the line/valve vibration. The performance of the positioners shall be
immune to above vibration.
b) The positioner's output and input range shall be field adjustable without any
hardware modification. The output from the positioners shall be available for both
single acting as well as double acting actuator.
c) Each positioner shall be operable, configurable and accessible through HART

compatible hand held configurator/fieldbus configurator as applicable.
d) Unless otherwise specified, vendor shall offer smart positioner for control valves in
critical applications such as split range, high pressure drop (>50kg/cm 2) high
temperature (>250°C), low temperature (<-29°C), tight shut off leakage (leakage
class ANSI class V and VI) and where vendor's calculations indicate phenomenon
like cavitation, flashing and high noise level (>85 dBA) irrespective of
requirements specified in purchaser's data sheet for such control valves.
e) The positioner shall be a two-wire device, which shall operate on two-way digital
communication mode. All engineering, configuration, diagnostic and maintenance
related data shall be provided by the positioner.
f) The smart positioner shall provide HART protocol of latest version and shall be
capable of implementing commands from Instrument Asset Mangement System /
hand-held HART configurator.
g) Positioners with fieldbus output shall meet the following requirements:
i) All positioners must satisfy the requirements of the fieldbus registration

laboratory with applicable checkmark like FieldBus foundation , Profibus
Nutzerorganisation e.v (PNO) or as specified in the purchaser's data sheets.
ii) All positioners shall have analog output (AO) and controller blocks (PID).
Page 767 of 1296

Utz
gof letOleg
14.177-A 2,2e512 MI J90,0
Govt o, India undettakingt
Page 18 of 21
iii) All positioners must be interoperable and shall have valid interoperability
test clearance like ITK latest version for foundation fieldbus or equivalent
for profibus PA, as applicable.
iv) The fieldbus positioners shall support peer-to-peer communication with two
wire communicator and bus powered supply.
v) Fieldbus positioners as offered shall not be polarity sensitive.
vi) The fieldbus positioners in hazardous area shall be certified as per entity
concept or shall be FISCO approved as per the requirements specified in the
purchaser's specification.
vii) Internal software shall be configured by the vendor including the following
information:
-Serial Number
-Device tag(Tag No.)
-Process Description/service
viii) Positioners shall be capable of supporting incremental Device

Description(DD) for extra functionality and/or software revisions in Device
memory.
h) The positioners shall be suitable to operate with commercially available asset

management softwares and shall support the following features, as a minimum:
i) It shall allow multimaster for configuration, calibration, diagnosis and

maintenance. The primary could be a host computer and secondary could
be a hand held communicator.
ii) It shall be capable of implementing universal commands. It shall be

possible to communicate all commands of commercially available asset
management system to/ from smart positioner.
i) The offered positioners shall meet the following performance characteristics: -
i) Overall control accuracy shall be better that ±0.5% of span.
ii) Repeatability shall be less than ± 0.25% of span.
iii) Hysteresis shall be less than ± 0.5% of span.
iv) Vendor shall supply the valve's operating signatures in the form of hard
copy and soft copy for each control valve supplied with smart positioners.
The necessary software for advanced control valve diagnostics like seat
ring condition, gland packing condition, actuator leakage etc. shall also be
included.
j) All positioners shall have metallic casing and cover either of stainless steel or of
anodized aluminium.
k) Fieldbus positioners shall support EDDL requirements as per IEC

61804/FDT/DTM requirements, as specified in job specifications..
2.7.3 Electro-Pneumatic Converter

Page 768 of 1296

ligof fagreg w INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
eieage c1N.17,11 IA Govt of InOta Undertakmg)
Page 19 of 21
2.7.3.1 Electro-pneumatic converter shall be of electronic feedback type unless specified otherwise
and shall be yoke mounted.
2.7.3.2 It shall have an integral terminal housing. Electro pneumatic converter with flying leads
shall not be acceptable.
2.7.3.3 Unless otherwise mentioned, it shall be intrinsically safe.
2.7.3.4 Pneumatic connections shall be 1/4" NPT (F). The electrical connections shall be 1/2" NPT
(F). If they are different, suitable adapters shall be provided.
2.7.3.5 The overall accuracy of the electro-pneumatic converter shall be better than ±0.3%.
2.7.4 Air Filter Regulator
2.7.4.1 Vendor shall supply air filter regulator with each positioner complete with an integral output
gauge.
2.7.4.2 Air filter regulator shall be sized considering the air supply pressure and flow required to
meet requirements specified in the purchaser's data sheets.
2.7.4.3 Filter material shall be sintered bronze. Filter size shall be maximum 5 microns. However,
lower filter mesh size shall be considered to suit the electro pneumatic converter vendor's
requirement.
2.7.5 Valve Jacketing
2.7.5.1 The jacketed valves shall have steam inlet/outlet connections as flanged.
2.7.5.2 The valve end connections shall be one size higher than the normal valve connections for
jacketed valve.
2.7.6 Hand held configurator for Smart Instruments
Hand Held configurator shall be universal type and shall be able to communicate with all
make and models of smart instruments with HART output like transmitters, smart
positioners etc., and shall be capable of carrying out all engineering functions like
calibration, configuration and diagnostics. The hand held configurator shall be certified
intrinsically safe when used in hazardous area. Carrying case shall be supplied with each
configurator.
2.7.7 Fieldbus configuration :
The fieldbus configuration, whenever specified in datasheet, shall be provided with

hardware and software for configuration and maintenance of fieldbus devices and also to
perform diagnostics and troubleshooting of the fieldbus segments.
2.7.8 Battery charger
Both Fieldbus and HART configurations shall be supplied with battery charger for battery
charging. Unless otherwise specified, battery charger shall operate at 220V 50Hz supply.
2.7.9 Wherever solenoid valves have been asked for control valves in modulating service, the
control valves are for modulating cum shutdown application. For all such cases, solenoid
valve shall be installed between positioner output and actuator. The de-energisation of
solenoid valve shall bring the control valve to failure position by venting the actuator
Page 769 of 1296

- -

Ogzx laires w INDIA LIMITED FOR CONTROL VALVES 6-52-0031 Rev. 4
(A Govt of India Unctertakm
Page 20 of 21
2.8 Control valve accessories like Air Filter Regulators (AFR), Smart Positioners, Foundaton
Fieldbus Positoners , Solenoid valves, Limit switches, Pneumatic lock relay etc. (Wherever
applicable) shall be supplied in fully assembled conditions with minimum of 8.0 mm OD
with 1 mm wall thickness SS air tubing. Material for mounting part/bracket shall be SS as
minimum. Tube fittings shall be of flareless compression type of SS material. Tubing of
higher size of 12mm OD / 18mm OD (if required) for proper actuation of actuator / control
valve shall be provided by vendor. Accessories like AFR shall be selected to match the air
tubing requirements. This shall have no price or time implication.
2.9 Special Service Valves
All control valves in oxygen and chlorine service shall be thoroughly degreased using
reagents like trichloro-ethylene or carbon tetra-chloride. End connections shall be blinded /
plugged after this degreasing process in order to avoid entrance of grease and oil particles.
2.10 Finish
2.10.1 The body shall be painted as below:
Carbon steel body Light grey
Alloy steel body Canary yellow
Stainless steel body Natural
Above 150°C - Aluminium paint (white colour)
Items like silencers, diffuser plate assemblies etc., shall be painted as per respective control
valve body requirements.
2.10.2 The actuator shall be painted as below:
Direct action (open on air failure) valves Green
Reverse acting (close on air failure) valve Yellow
Actuator for shutdown valves Red
Items like air volume tanks etc., supplied as an accessory along with the actuators, shall be
painted as per corresponding actuator.
3.0 NAMEPLATE
Each control valve shall have a stainless steel nameplate attached firmly to it at a visible
place, furnishing the following information:
b) Body and port sizes in inches.
c) Valve flow coefficient (Cv).
d) Stem travel in millimetres.
e) Action on air failure.
f) Spring range.
Page 770 of 1296

Ogar taaeg
0417n s-le.re 451,17FA,
INDIA LIMITED
IA Govl of India undertaktng)
Page 21 of 21
g) Air supply pressure.
h) Manufacturer's model number for the valve body, actuator and positioned.
Inspection Test Plan. All these tests shall be completed by the vendor and test reports shall
be submitted to purchaser for scrutiny.
5.0 SHIPPING
5.1 The control valve and its accessories shall be supplied pre-assembled and pre-tubed.
material.
5.3 Valves with external lubricators shall be lubricated prior to shipment.
5.4 Valves in oxygen and chlorine service shall be packed separately along with a certificate
indicating 'CERTIFIED FOR OXYGEN / CHLORINE SERVICE', as applicable.
Page 771 of 1296

tEra ENGINEERS STUD-BOLTS AND NUTS Annexure 1 to
fge.a rum*ries
r- INDIA LIMITED MATERIAL REQUIREMENT STANDARD SPECIFICATION NO.
IA Gov! of India UnOeflalung)
6-52-0031 Rev. 4
Page 1 of 1
Sr. No. Piping Classes Nut and Bolt Material
1 AIA, A2A, A5A, A6A, A7A, A8A, A9A, A-193 Gr. B7

A10A, Al IA, A13A, A14A, A15A, A-194 Gr. 2H
A19A, A20A, A32A, A33A, A1K, A6K,
AIM, AIN, B IA, B2A, B5A, B6A, B9A,
B13A, B18A, B19A, B32A, B1K, B6K,
BI8K, BIM, B3M, B5M, BIN, B6N,
DIA, D2A, D5A, D18A, D1K, D18K,
D18P, E1A, E2A, E5A, E5E, F5A
2 A16A, BI6A A-193 Gr. B7M

A-194 Gr. 2HM
3 A1B, AID, A4F, A4G, BIB, BID, 135D, AI-193 Gr. B16
B1E, B3F, B4F, B4G, D1B, D2B, DID, A-194 GR. 4
D2D, D5D, D5E, F2D
4 A2K, B2K, D2K A-320 Gr. B8 CL.2

A-194 Gr. 8
5 A4A, A1H, B4A, B1H, D4A, D1H A-320 Gr. L7

A-194 Gr. 4
6 A3Y A-307 Gr. B

A-563 Gr. B
7 A3A, A3K, A3Y, A4Y, J3A A-307 Gr. B

A-563 Gr. B
8 A1Z, A4Z, A5Y, A5Z, J2A, J5A A-307 Gr. B (Galv)

A-563 Gr. B (Galv)
9 B4K, B5K A-193 Gr. B8 M CI I

A-194 Gr. 8 MA
10 A32Y A-193 Gr. B (Galv)

A-194 Gr. 2H (Galv)
11 B3M, B4K, B5K, B5M A-453 Gr. 660 CL.A

A-453 Gr. 660 CL.A
Note : Bolts & Nuts material mentioned above is applicable for loose supply of nuts/bolts.
Format No. 8-00-0001-F1 Rev. 0 Copyrights EIL - All rights reserved
Page 772 of 1296

150TielENGINEERS GASKETS MATERIAL Annexure 2 to
sla It faAeg
{
INDIA LIMITED
rnA 3,772.31 IA Gout of India Undenakog) REQUIREMENT STANDARD SPECIFICATION No.
6-52-0031 Rev 4
Page 1 of 1
Sr.
Piping Classes Gasket Material
No.
1 AlA, A6A, A9A, A10A, Al 1A, A13A, AI4A, AI9A, SP WND SS 316 + Grafil
AIB, AID, A1H, AIK, AIM, A4A, A4F, A4G, B IA,
BIH, B2A, B4A, B6A, B9A, B13A, B18A, B19A, B32A,
B18K, D1A, D2A, D1H, D1K, D4A, D18A, D18K, DI8P
2 B5M SP WND SS316H+ GRAFIL + I RING
3 A2K, B2K, D2K SP WND SS 316+GRAFIL+SS 316 I/O
RING
4 B IN SP WND SS 316L+GRAFIL + I RING
5 B6N SP WND SS 316L + GRAFIL
6 Al Z, A3Y, A4Y, A4Z, J2A BUTYL RUBBER
7 E1A, E2A, E5A, F5A SOFT IRON
8 E5E, F2D 5% CR, 0.5% MO
9 B4K, B5K SS 3 I6H+GRAFIL+I RING SS 316 0 RING
10 A5Z PTFE JACKETED ASBESTOS
11 A5Y, A8A, AI5A, A32Y, A33Y IS 2712 Gr. A/1
12 B3M SP WND SS 321+GRAFIL+I RING
13 AIN, A6K, Al6A, B16A SP WND SS 316 + CAF
14 A3A, A3K, A33A, J3A, J5A IS 2712 Gr. W/3
15 A2A, A20A, A32A IS 2712 Gr. W/1
16 A5A, B5A, D5A SP WND SS 316 + CAF + I RING
17 A7A, BIB, BID, BIE, B1K, B3F, B4F, B4G,B5D, D1B, SP WND SS 316 + GRAFIL + I RING
D1K, D2B, DID, D2D, D5D, D5E
18 B6K, BIM SS 316 + GRAFIL
Note : Gasket material mentioned above is applicable for loose supply of gasket.
Page 773 of 1296

er ENGINEERS STANDARD SPECIFICATION
S1 JTtifitez INDIA LIMITED FOR ON OFF VALVES
-
6-52-0037 Rev. 2
(NW, 212.7N74.3.13.31, IA Govt of Ode Undenakng)
Page 1 of 1$
affff afftff fa7 Trriffii rarrakii

ON-OFF VALVES
0*
4
27.03.17 Revised and Reissued as Standard Specification RM RN
1 11.04.11 Revised and Reissued as Standard Specification SM RG RP/ JMS DM
0 15.05.07 Issued as Standard Specification SM TGM HCJ VC

Standards Standards
Prepared Checked
No by by
Approved by
Page 774 of 1296

5 eff Rift.
1411,27■ 2:1201t7 J.IITA
INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
Page 2 of 18
Abbreviations:
DD Device Description
DPDT Double Pole Double Throw
ERTL Electronics Regional Testing Laboratory
MVT Manual Valve Testing
NPS Nominal Pipe Size
PFD Probability of Failure on Demand
PST Partial Stroke Testing
SS Stainless Steel
TSO Tight Shutoff

Mr. Sandeep Arora
Mr. Anand Barman
Mr. S. Mahesh Kumar
Page 775 of 1296

■1- 1 ENGINEERS STANDARD SPECIFICATION
51g .. INDIA LIMITED FOR ON - OFF VALVES 6-52-0037 Rev. 2
GOA d India Undertkng)
Page 3 of 18
CONTENTS
1.0 GENERAL 4
3.0 NAME PLATE 18
5.0 SHIPPING 18
ANNEXURES:
ANNEXURE — 1 : STUD - BOLTS AND NUTS MATERIAL REQUIREMENT
ANNEXURE — 2 : GASKET MATERIAL REQUIREMENT
Page 776 of 1296

laliaZiel ENGINEERS STANDARD SPECIFICATION
sigeg5teg INDIA UMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
mkt?, f2vise ✓ toJottottit IA Govt of India undenakm)
Page 4 of 18
1.0 GENERAL
1.1 Scope
1.1.1 This specification, together with the data sheets attached herewith describes the requirement
for the design, materials, nameplate marking, inspection, testing and shipping of on-off
valves.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions
prior to the date of the purchaser's enquiry:
B 1.20.1 Pipe Threads, General Purpose (Inch)

B 16.5 Pipe Flanges and Flanged Fittings NPS'/2 through NPS24
Metric/Inch Standard
B 16.10 Face-to-face and End-to-End Dimensions of Valves
B 16.20 Metallic Gaskets for Pipe Flanges, Ring-Joint, Spiral-wound
and Jacketed.
B 16.34 Valves — Flanged, Threaded and Welding End
B 16.47 Large diameter Steel Flanges: NPS 26 through NPS 60
FCI 70-2 Control Valve Seat Leakage

API 6D Specification for Pipeline and Piping Valves
API 6 FA Specification for Fire Test of Valves
API 598 Valve Inspection & Testing
API 607 Fire Test for Quarter-Turn Valves and Valves Equipped with
Non-Metallic seats
API 608 Metal Ball Valves — Flanged, Threaded and Welding Ends
API 609 Butterfly Valves: Double-Flanged, Lug- and Wafer-type
AWWA American Water Works Association

C207 CL.D Steel Pipe Flanges for Water Works Services
6364 Specification for Valves for Cryogenic Service

6755 Part 2 Testing of Valves, Specification for Fire Type-testing
Requirements
EN European Standard
10204 Metallic Products — Types of Inspection Documents
IBR Indian Boiler Regulation
IS/IEC Indian Standards/International Electro Technical Commission
IEC 60079-16 Electrical Apparatus for Explosive Gas Atmospheres

IS/IEC 60529 Degrees of Protection Provided by Enclosures (IP Code).
IEC-60534-4 Inspection & Routine Testing
Page 777 of 1296

1511MTRT ENONEERS STANDARD SPECIFICATION
215teg
1./VN URCIA2
INDIA LIMITED
FOR ON-OFF VALVES 6-52-0037 Rev. 2
Page 5 of 18
IEC-61508 Functional Safety of Electrical/ Electronic/ Programmable

Electronic Safety-related systems
IEC-60534-3-2 Face-to-face Dimension for Rotary Control Valves Except
Butterfly Valves
IEC-61511 Functional Safety - Safety Instrumented Systems for the
Process Industry Sector
75.01.01 Industrial — Process Control Valves — Part 2-1: Flow

Capacity — Sizing Equations for Fluid Flow under Installed
Conditions
75.02.01 Control Valve Capacity Test Procedures
TR75.04 Control Valve Position Stability
75.05.01 Control Valve Terminology
75.08.01 Face-to-Face Dimensions for Integral Flanged Globe-style
Control Valve Bodies (Classes 125,150,250,300 and 600)
75.08.02 Face-to-Face Dimensions for Flanged and Flangeless
Rotary Control Valves (Classes 150,300 and 600)
75.08.04 Face-to-Face Dimensions for Buttweld-end Globe-style
Control Valves (Class 4500)
75.08.05 Face-to-Face Dimensions for Buttweld-end Globe-style
Control Valves (Classes 150,300,600,900,1500 and 2500)
75.08.06 Face-to-Face Dimensions for Flanged Globe-style Control
Valve Bodies (Classes 900,1500 and 2500)
75.11.01 Inherent Flow Characteristic and Rangeability of Control
Valves.
75.19.01 Hydrostatic Testing of Control Valves
75.08.08 Face-to-centreline Dimensions for Flanged Globe-style
Angle Control Valve Bodies (Classes 150,300 and 600)
75.25.01 Test Procedure for Control from Step Inputs
TR 75.25.02 Control Valve Response Measurement from Step Inputs
75.13.01 Method of Evaluating the Performance of Positioners with
Analog Input Signals and Pneumatic Output
MSS Manufacturers Standardization Society

SP 25 Standard Marking System for Valves, Fittings, Flanges
and Unions
MR0103 Petroleum, Petrochemical and Natural Gas Industries —

Metallic Materials Resistant to Sulphide stress Cracking in
Corrosive Petroleum Refining Environments.
OSHA Occupational Safety and Health Authority
b) Job specification/data sheets
c) Standard specification
Page 778 of 1296

Of=4-4€q ENGINEERS STANDARD SPECIFICATION
Oge_jr faOleg INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
(WM FETRR4R3,437.1, IA Govt of India UnOonaloo9)
Page 6 of 18
d) Codes and standards
1.1.4 In addition to meeting purchaser's specifications in totality, vendor's extent of responsibility

a) Purchaser's data sheets specify the minimum acceptable materials for the on-off
valve body and trim. Alternate superior materials of construction shall also be
acceptable, with the consent of purchaser, provided vendor assumes complete
responsibility for proper selection of material for these parts for their compatibility
with the process fluid and its operating conditions
b) Purchaser's data sheets specify the on-off valve size and open / close operation
time. Vendor shall be responsible for selecting their standard valve suitable for
the specified service and process conditions and operation time specified in the
c) Purchaser's datasheet specify the shut-off differential pressure and fire safe
requirements. Vendor shall be responsible for correct selection of Actuator for
the offered valves.
1.2 Bids
the material requisition.
following:
a) Compliance to the specifications. Deviations on technical requirements shall not be

entertained. In case vendor has any valid technical reason, they must include a list
of deviations tag number wise, summing up all the deviations from the purchaser's
data sheets and other technical specification along with the technical reasons for
each of these deviations.
b) Whenever the requirements of a detailed specification sheet for each on-off valve
is specifically indicated, the specification sheet shall provide information regarding
type, material of construction, capacity, open/close operation time etc. of the on-off
valve and its accessories. The material specifications and units of measurement
indicated in the specification sheet shall be to the same standards as those in
Proven references for each offered model, in line with clause no. 1.2.4 of this
specification, specifically for valves with ANSI rating 600# and above,
temperature more than 250°C and below -29°C , special applications like
hydrogen, NACE, cryogenic, fire safe and metal seated valves with class VI
leakage etc.
d) A copy of approval for items such as limit switches, solenoid valves, smart
positioner, whenever specified from local statutory authority, as applicable, such as
Petroleum & Explosives Safety Organisation (PESO) / Chief Controller of
Explosives, Nagpur (CCE) or Director General of Mining Safety (DGMS) in India,
along with:
i) Test certificate from recognised test house like Central Institute of Mining
and Fuel Research (CIMFR) / Electronics Regional Testing Laboratory
(ERTL) etc. for flameproof enclosure and/ or intrinsic safety, as specified
Page 779 of 1296

18ilfazA ENGINEERS STANDARD SPECIFICATION
ige..11 Rift INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
1.12/7 a a'mr3PAA1 I A Govt a India Undertaking)
Page 7 of 18
in the data sheet, as per relevant Indian Standard for all Indian
manufactured equipments.

Equipment in Flammable Atmospheres (Baseefa), Factory
Mutual (FM), Physikalisch-Technische Bundesanstalt (PTB) , Canadian
Standards Association (CSA), Underwriters Laboratories (UL) etc. for
compliance to ATEX directives or equivalent recognised standards for all
equipments manufactured outside India.
e) Type test certificate for fire safety for on-off valve and of actuator, wherever
applicable.
0 Limitation, if any, in changing actuator orientation at site.
g) Catalogues giving detailed technical specifications, model decoding details and

other technical information for each type of on-off valve and accessories covered
in the bid.
1.2.3 For valves in cryogenic service, vendor shall meet the following acceptance criteria:
a) Vendor shall furnish, along with the offer, type test certificate, duly witnessed by
Third Party Inspection agency like M/S LRIS, DNV, BV, TUV etc. of having
successfully conducted the cryogenic test as per BS6364 on the offered
valves(same model, size, rating and material) in cryogenic service.
b) In case vendor does not have cryogenic type test certificate for the offered valves
as mentioned above, vendor shall conduct the cryogenic test on each of the offered
valves as per clause Inspection Test Plan and shall meet one of the following
requirements:
i) Vendor has successfully carried out the cryogenic type test as per BS 6364 on
the same series (model) of the valves as offered and type test certificate duly
witnessed by Third Party Inspection agency for same has been furnished with the
offer.
ii) Vendor has furnished proven references as per clause 1.2.4 of this specification
for each of the offered valves (the same model, size, rating and material) in
cryogenic service.
1.2.4 All items, as offered, shall be field proven and should have been operating satisfactorily
individually for a period of minimum 6 months on the bid due date in the process conditions
similar to those as specified in the purchaser's data sheets. Items with proto-type design or
items not meeting provenness criteria specified above shall not be offered.
1.2.5 Whenever specified, vendor must furnish certified values of failure rates, probability of failure
on demand (PFD) and test intervals for valve and its accessories for the safety integrity level
analysis.
installation, operation and maintenance manuals etc., shall be in English language only.
1.2.7 Vendor's quote shall include the following:
a) Partial Stroke Testing positioner with license software for loading in purchaser's
JAMS, when specified.
Page 780 of 1296

Weg INDIA LIMITED
1.•777 AZURE,. 3.146.11
IA Govt. India Undertak.9)
Page 8 of 18
b) Two years' operational spares for each on-off valve and its accessories, which shall
include plug, seat ring, gasket set, packing set, diaphragm, o-ring set etc. as a
minimum.
1.2.7.1 Each valve quoted shall include the following:
a) One extra set of packing and bonnet gasket with each tag.
b) One extra set of stem seal o-rings for each actuator and piston o-rings additionally
for each piston actuator.
c) Seat insert (soft part) for each ball valve.
d) Line bolting (set of studs and nuts) and set of gasket, in case of flangeless valves as
per material given in Annexure-1 and Annexure-2 with each such tag number
1.3.1 Detailed drawings, data, catalogues and manuals required shall be submitted by the vendor
as per vendor data requirements attached with the requisition.
1.3.2 Final documentation consisting of design data, installation manual/procedure, operation and
maintenance manual/calibration procedure etc., submitted by the vendor after placement of
purchase order shall include the following, as a minimum -
a) Specification sheet for each on-off valve and its accessories.
b) Certified drawings for each on-off valve and its accessories, which shall provide
dimensional details (face-to-face and height of completely assembled valve), hook-
up and wiring details, dimensions of clearance space for maintenance work, weight
of completely assembled valve, internal constructional details, materials of
construction, fire box/jacket dimensions and actuator orientation with respect to
flow direction marked on the body.
c) Copy of the type test certificates.
d) Copy of the test certificates for all tests indicated in Inspection Test Plan.
e) Device Description (DD) Files for configuring PST positioner parameters.
2.1 Body
2.1.1 On-off valves shall have flanged end connections integral to the valve body. Top entry valve
design shall not be offered unless specifically indicated in the purchaser's data sheets.
Whenever flangeless on-off valve body design is specified in the purchaser's data sheet,
following shall apply:
a) Wafer type or lug type body design for on-off valves body size up to 6 inches.
b) Lug type body design for butterfly type of on-off valve body size more than 6
inches.
However, for on-off valves with fire safe design, flanged body construction shall only be
acceptable.
Page 781 of 1296

lattma-eY ENGINEERS STANDARD SPECIFICATION
oaeirtaweg
INR 10,1,TE,151JWS*1.1
INDIA LIMITED
(A Govt of India UnOertaang)
Page 9 of 18
2.1.2 Unless specifically indicated otherwise, the minimum on-off valve body size shall be 1 inch.
2.1.3 The valve body rating shall be equal to or higher than the flange rating specified in the
data sheets.
2.1.4 Whenever flanged body is mentioned in the purchaser's datasheet, the same shall be double-
flanged and suitable for connecting to Purchaser's flanges on both sides through standard
length stud bolts & nuts.
2.1.5 Unless otherwise specified, the on-off valves shall be suitable for horizontal pipe
installation. When vertical pipe installation is found necessary at site, it shall be possible to
suitably modify the valve assembly at site for vertical mounting.
2.1.6 For all services where full port valves are specified, following shall apply:
a) Port size shall be equal to line size for rating up to ASME Class 1500.
b) Port size shall not be less than one size than the line size for rating ASME Class
2500 and above.
2.1.7 For steam jacketed valves, the body and port size shall be one size lower than the on-off
valve end connections.
2.1.8 Flow Direction
2.1.8.1 Flow direction shall be clearly marked on the on-off valve body preferably either
stamped or cast on the valve body.
2.1.8.2 3-way on-off valves shall be clearly identified with inlet and outlet end connection.
2.1.9 End Connections
2.1.9.1 Unless otherwise specified, the following shall govern:
a) Threaded end connections shall be to NPT as per ASME B 1.20.1.
b) Flanged end connections shall be as per ASME B 16.5 for sizes up to 24". For sizes
26" and above AWWA-C207 CL.D shall be followed for water applications &
ASME B-16.47B for all other applications.
c) Flange face finish shall be as per ASME B16.5. The face finish shall be as follows:
d) Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20
2.1.9.2 Face-to-face dimensions of on-off valves shall be in accordance with the relevant standard
indicated in clause 1.1.2 of this standard specification.
2.1.9.3 Where provided, on-off valve bottom drains shall be blind flanged only with dimensions
and rating corresponding to ASME B 16.5. Material of blind flanges shall be same as valve
body material.
Page 782 of 1296

Igar I oilk, 2i013F2 .300711
INDIA IJMITED
IA Govt of Inda Undeltaiong)
Page 10 of 18
2.1.10 Material of Construction
2.1.10.1 The material of construction of on-off valves shall be as specified in the data sheet.
Alternate superior materials of construction shall also be acceptable, with the consent of
purchaser, provided vendor assumes complete responsibility for proper selection of material
for the internal parts of on-off valve and compatible with the process fluid and conditions
specified in the purchaser's data sheets.
2.1.10.2 On-off valve body, bonnet, bottom flange, line flanges and other pressure containing
assemblies shall be of the same material of construction as specified for valve body in the
2.1.10.3 The bonnet flange and bottom flange shall have metallic spiral wound gaskets suitable for
the specified service. The gaskets with asbestos bearing fillers shall not be used.
2.2 Trim
2.2.1 The term 'trim' covers those parts of valve assembly (excluding the body, bonnet and
bottom flange) which are exposed to and are in contact with the line medium consisting of
but not limited to the seat ring, valve stem, valve plug/disc/ball, valve plug guide, cage
guide bushing etc.
2.2.2 In case of ball-type of on-off valves;
a) The valve design shall ensure valve seat and body protection against thermal
expansion of the entrapped fluid when the on-off valve is fully close.
b) In case of ball-type of on-off valves for size up to 4" and rating up to ASME
Class 300, the on-off valve shall have floating ball design. For ratings ASME
Class 600 and above, floating ball is acceptable for sizes less than 2". For higher
sizes trunion mounted ball design shall be provided.
2.2.3 Guiding
2.2.3.1 Single seated globe (unbalanced) and angle type on-off valves shall have heavy top plug
guiding. Stem guided on-off valve design shall not be acceptable.
2.2.3.2 Rotary type on-off valves like Ball valves, butterfly valves etc. shall have blow out proof
shaft guiding design.
2.2.3.3 Guide bushing shall be of a sufficiently hard material to resist side thrust on the plug or
shaft.
2.2.4 Trim Design
2.2.4.1 Vendor shall be responsible for trim design and selection of the on-off valve. However, it
must meet the following minimum requirements:
a) On-off valve trim design shall suit the type of guiding specified in the data sheet.
b) Unless specifically indicated otherwise in purchaser's data sheets, the valve

characteristics shall be quick-opening (on-off) type.
c) Vendor shall select proper material pairs, surface finish, hardness and clearances to
avoid galling.
Page 783 of 1296

151073€11 ENGI NEERS STANDARD SPECIFICATION
Rift INDI A LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
4 ..7F ....357. ) IA Govt of India Undertakm)
Page 11 of 18
d) For on-off valves operating under extreme temperature conditions, vendor shall
consider increased clearances at room temperature and seal welding of threaded
seat rings etc whenever required. Hard facing of trim including guide bushing
shall be considered for all on-off valves operating at high temperatures (i.e.
temperature more than 200°C). For very low temperature application, material
used shall have adequate cold impact strength.
e) For all on-off valves including 3-way type of valves, stem and plug shall be
detachable and shall be attached together by suitable threaded design secured with
a pin to avoid plug rotation during operation.
2.2.4.2 For all bi-directional types of on-off valves like ball, butterfly and plug type, the valve seat
design shall provide tight shut off for flow in either directions.
2.2.5 Trim Material
2.2.5.1 Whenever stellited trim is specified in the data sheets following material of construction for
the trim parts shall also be acceptable.
a) Ball/Disc/Plug and seat Stellite sheathing/Chromium Carbide/Tungsten

Carbide/Alloy 6 coating or solid stellite
b) Guide Stellite sheathing/Chromium Carbide/Tungsten

Carbide/Alloy 6 coating, solid stellite or SS 440C
c) Stem/Shaft 17-4 PHSS, Hastelloy
2.2.5.2 Minimum acceptable hardness in case of stellited or hardened trim shall be of the order of
RC38 (BHN 352) to RC45 (BHN 429).
2.2.5.3 In case of rotary valves, vendor shall select the stem bearing type and material as per the
process conditions. Material of construction shall be as per the wetted part material
specified in the purchaser's data sheet, as a minimum.
2.2.5.4 Leakage class of on-off valves shall be as specified in purchaser's data sheet, where no class
is specified in data sheet it shall be Class IV.
2.2.5.5. For on-off valves specified with Class VI leakage class, vendor shall select the soft seat
(elastomer) material suitable for the process conditions i.e., shut off pressure, maximum
temperature and process fluid. Metal seated on-off valves meeting the leakage class shall
also be acceptable.
2.3 Sizing
2.3.1 Unless specifically indicated otherwise in purchaser's data sheet, no sizing shall be carried
out for the on-off valve, body size of on-off valve shall be same as the line size. Valve
sizing shall be carried out only for those on-off valves where purchaser data sheet specify
the same.
2.3.2 Vendor shall indicate the offered on-off valve flow coefficient i.e. Cv . Wherever the
requirement of valve sizing is indicated, the control valve capacities in terms of Cv when
shown in the purchaser's data sheets have been arrived at using the formulae given in the
standard ISA S 75.01.01-"Control valve sizing equations". In case vendor's sizing formulae
differ from above, purchaser shall be provided with the details.
Page 784 of 1296

ISIMTE7ENGINEERS STANDARD SPECIFICATION
s ofateg
eir INDIA LIMITED
IA God of India Undertaking)
Page 12 of 18
2.3.3 Rangeability of valves shall be as per manufacturers' standard. However, where purchaser's
data sheet indicate the sizing requirement, the rangeability of the offered valves shall be
suitable to meet specified rangeability.
2.4 Packing Box, Bonnet and Stem
2.4.1 Packing Box
2.4.1.1 The packing box shall be flanged bolted to the bonnet and shall meet the requirements
specified in purchaser's data sheet.
2.4.1.2 Generally low friction type packing like braided teflon is preferred wherever operating
conditions permit. For high temperature application (>200°C), Grafoil or equivalent gasket
suitable for the specified service shall be selected. Asbestos based packing material shall
not be used.
2.4.1.3 Whenever the on-off valve is offered with external lubricator, it shall have its packing box
drilled and tapped to 1/4" NPT (F) as per ASME B 1.20.1 for connecting external lubricator.
2.4.1.4 An isolating valve shall be provided with all such valves having external lubrication
provision. Lubricator sticks shall be supplied by the vendor as consumable spare.
2.4.1.5 For application in vacuum service, vendor to provide inverted packing design suitable for
vacuum service. For pressure-cum-vacuum service, the on-off valve shall have dual
packing design suitable for the application. Dual packing design shall also be provided for
on-off valves in toxic service, with a facility to connect inert fluid between the packings.
2.4.1.6 Wherever environmental packing design is specified vendor shall supply special packing
design suitable to minimize fugitive emission.
2.4.1.7 3-way on-off valves of either diverting or mixing type shall have PTFE box rings.
2.4.2 Bonnet
2.4.2.1 The bonnet shall be flanged bolted to the body. Threaded bonnets are not permitted.
2.4.2.2 Wherever the operating temperature of the fluid is above 200°C, extension or radiation
finned bonnet shall be provided. Vendor standard bonnet design shall also be acceptable if
these are suitable for higher temperatures.
2.4.2.3 For temperature below 0°C, vendor shall provide extended bonnet design. For valves in
cryogenic application bonnet extension shall be as per BS-6364 as a minimum.
2.4.3 Stem
2.4.3.1 The stem surface finish shall be fine. Extra fine surface finish shall be provided wherever
the packing material is PTFE.
2.4.3.2 The stem/shaft shall be designed for the maximum thrust of the actuator without any
measurable deflection.
2.4.3.3 The valve stem/shaft shall be connected to the actuator stem/shaft by suitable arrangement
to avoid backlash problem.
2.5 Actuator
2.5.1 Pneumatic Actuator
Page 785 of 1296

zt~ ENGINIEERS STANDARD SPECIFICATION
sigeirweg
I .11I'M eveereaR.71,175A)
INDIA LIMITED
IA Govt of India Undertakm)
Page 13 of 18
2.5.1.1 Actuator shall be sized for the shut-off differential pressure indicated in purchaser's data
sheets. However, for 3-way type on-off valve, the actuator shall be sized for maximum
differential pressure, unless specifically indicated otherwise.
2.5.1.2 The actuator shall be designed to move the valve to the failure position specified in the
purchaser's data sheet. For failure position specified as 'fail-locked', vendor shall provide
air reservoir with all required accessories to meet the fail lock position of the valve. The air
reservoir shall be sized considering full stroking of the valve for minimum one complete
cycle. Air reservoir shall be of carbon construction and sized as per ASME Section VIII with
design pressure of 10 kg/cm2g as a minimum. All accessories and tubing shall be SS 316.
2.5.1.3 Actuator casing shall be made of pressed steel or anodised aluminium. Non-metallic
actuator casings shall not be offered.
2.5.1.4 Springs shall be corrosion-resistant and shall be cadmium or nickel-plated. These shall be of
the enclosed type. The compression of the springs shall be adjustable.
2.5.1.5 In general, actuator operating range shall be 0.2 to 1.0 kg/cm 2g, higher actuator operating
range shall be acceptable provided vendor standard actuator model fails to meet specified
shutoff pressure.
2.5.1.6 In general, spring opposed diaphragms type actuators shall be used. Only when this type of
actuator becomes extremely unwieldy, based on the data specified in the purchaser's data
sheet, should a piston and cylinder type of actuator be considered.
2.5.1.7 Whenever piston and cylinder actuator is considered, single acting spring return type is
preferred.
2.5.1.8 Whenever double acting springless type of actuator is unavoidable, all accessories like pilot
valves, booster relays, non-return valve, pressure gauge, volume tank etc. shall be provided
to ensure desired action on air failure. The volume tank shall be sized considering full
stroking of the valve for three complete cycles. The volume tank shall be of carbon steel
construction and sized as per ASME Section VIII with design pressure of 10kg/cm 2g as a
minimum. All accessories and tubing etc shall be of 316 Stainless Steel constructions. Other
accessories can be of Cast Aluminium. Minimum tubing length of 10 meters shall be
considered for volume tank mounted separate from the actuator assembly.
2.5.1.9 The actuator casings and diaphragms shall be designed for minimum twice the maximum
pneumatic operating pressure of the on-off valve.
2.5.1.10 Valve stem position indicator shall be provided for every on-off valve, when specified. The
position indicator scale shall be calibrated from 0 to 100%.
2.5.1.11 In general, side-mounted handwheels are preferred when specified. Hand wheels shall
provide manual on-off in both opening and closing directions independent of spring action.
Hand wheels shall be of non-rising type suitable for accurate valve positioning .The hand
wheel actuator shall be sized to provide the required thrust for valve positioning with 178N
force applied to the hand wheel.
2.5.1.12 Actuator orientation shall be as per purchaser's requirements, in general. When, no

requirements are indicated by purchaser, vendor shall provide recommended actuator
orientation. It shall be possible to change this orientation at site for the offered valve-
actuator combination in case it is found necessary.
2.5.1.13 For the on-off valves where operating times are specified in the purchaser's data sheets,
vendor shall design the actuator and its accessories to meet these requirements. Whenever
no operating time is specified, the same shall not exceed 1 second per inch of valve.
Page 786 of 1296

lapzEg ENGINEERS STANDARD SPECIFICATION
Oge.4100leg
1.2,1 ?WOW arlIJciVal,
INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
IA Govt of India Undertalong)
Page 14 of 18
2.5.1.14 Actuator Sizing
a) Vendor shall be fully responsible for sizing and selection of correct actuator for the
specified on-off valve, while sizing the actuator, vendor shall ensure that the
actuator is able to develop sufficient thrust to properly seat the on-off valve at the
lowest specified air pressure.
b) While sizing the actuator vendor shall consider actuator thrust equal to two times
(2) the total force induced by shut off condition specified in purchaser's data sheet
and the force required to overcome packing friction.
2.6 Valve Jacketing
2.6.1 The jacketed valves shall have steam inlet/outlet connections as flanged.
2.6.2 The valve end connections shall be one size higher than the normal valve connections for
jacketed valve.
2.7 Accessories
2.7.1 Partial Stroke Testing(PST) Positioners
Partial stroke testing positioners with HART Protocol shall be supplied whenever specified
in purchaser's datasheet. These shall meet the following minimum requirements:
a) Every positioner shall have two pressure gauges mounted on it, one each for air
supply and for positioner output to actuator.
b) Pneumatic connections shall be 1/4" NPT (F) and cable entry shall be 1/2" NPTF to
ASME B1.20.1. If connection for cable entry is different than that specified,
suitable adapters shall be provided.
c) Positioners shall be side-mounted on the ON-OFF valve and shall have corrosion
resistant linkages and rugged brackets.
d) The positioner sensor and sensing mechanism shall be rugged and shall not be
affected by the line / valve vibration. The performance of the positioners shall be
immune to above vibration.
e) The positioner's output and input range shall be field adjustable without any
hardware modification. The output from the positioners shall be available for both
single acting as well as double acting actuator.
f) Each positioner shall be operable, configurable and accessible through HART

compatible hand held configurator.
g) The positioner shall be a two-wire device with HART protocol of latest version
and shall be capable of implementing commands from Instrument Asset
Management system/hand-held HART configurator.
h) The positioners shall be suitable to operate with commercially available asset

management softwares and shall support the following features, as a minimum:
i) It shall allow multimaster for configuration, calibration, diagnosis and

maintenance. The primary could be a host computer and secondary could
be a hand held communicator.
Page 787 of 1296

-

Ziel ENGINEERS STANDARD SPECIFICATION
51geff tifitag INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
, NR,feWaff?=.3q0.0 IA Govt of lode Undertaking)
Page 15 of 18
ii) It shall be capable of implementing universal commands. It shall be

possible to communicate all commands of commercially available asset
management system to/ from smart positioner.
i) The offered positioners shall meet the following performance characteristics: -
i) Overall accuracy shall be better that ±0.5% of span.
ii) Repeatability shall be less than ± 0.25% of span.
iii) Hysteresis shall be less than ± 0.5% of span.
j) All positioners shall have metallic casing and cover either of stainless steel or of
anodized aluminum.
k) The PST Positioner model shall be suitably selected to ensure that failure or
closure of PST positioner does not result in the valve going to its fail safe position.
2.7.2 Air Filter Regulator
2.7.2.1 Vendor shall supply air filter regulator with each ON-OFF valve complete with an integral
output gauge. Air filter regulator shall be downstream regulator type, in general.
2.7.2.2 Air filter regulator shall be sized considering the minimum air supply pressure and flow
required to meet requirements specified in the purchaser's data sheets.
2.7.2.3 Filter material shall be sintered bronze. Filter size shall be maximum 5 microns.
2.7.3 Limit Switches
2.7.3.1 Unless otherwise specified, limit switches shall be proximity type and shall meet NAMUR
standard. Mechanical type limit switches shall only be used when specifically indicated.
2.7.3.2 The limit switches shall be Weather proof to IP 65 and intrinsically safe. Certificates to this
effect indicating the entity parameters shall be furnished from statutory body.
2.7.3.3 Suitable terminal blocks shall be provided for cable termination. Flying leads shall not be
acceptable.
2.7.4 Solenoid valves provided with all On-Off valves shall be direct acting type only. Pilot
operated solenoid valves shall not be acceptable unless specifically indicated in the job
specifications / data sheets.
2.8 Finish
2.8.1 The body shall be painted as below:
Carbon steel body Light grey
Alloy steel body Canary yellow
Stainless steel body Natural
Above 150°C - Aluminium paint (white colour)
Page 788 of 1296

ISIPTAc ENGINEERS STANDARD SPECIFICATION
51ge_ji fat5leg INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
OK" (A Govt of Ma Undedaking)
Page 16 of 18
Direct action (open on air failure) valves Green
Reverse acting (close on air failure) valve - Yellow
Actuator for shutdown valves Red
2.9 Special Requirements:
2.9.1 On-Off Valve stroke testing:
Whenever specified in the purchaser data sheet / specifications, the operational integrity of
the on-off valves shall be verified at regular intervals by performing physical testing without
upsetting the process / operation. The methodology of testing adopted shall also be
indicated in the purchaser's data sheets. The testing scheme shall be designed by the vendor
to meet specified operational functional and safety requirements specified below;
2.9.1.1 Manual Valve Testing (MVT)
Manual valve testing scheme shall be designed by the vendor to ensure operational integrity
of actuating components i.e. solenoid valves etc without stroking the on-off valve. The test
hardware shall meet the following requirements;
The manual valve testing scheme shall be designed and supplied complete with minimum
two solenoid valves, a two position (normal test) manual switch (with lock) and a pressure
gauge (50mm dial). The scheme shall meet the following functional requirements;
a) There shall be no upset or disturbance in the process while carrying out MVT. The
solenoid valves, therefore shall be pneumatically tubed in 2 out of 2 configuration.
While in test mode, the switch shall supply air supply to actuator bypassing the
accessories. The solenoid valves are manually actuated one by one with their
operational status indicated by pressure gauge.
b) No software for MVT is in vendor's scope, however, an electrical contact rated for
110V, 0.5 A DC shall be provided to purchaser for audit trail when in test position.
2.9.1.2 Partial Stroke Testing (PST)
Partial stroke testing shall be performed to ensure satisfactory operation of on-off valve
including all accessories on demand. The test shall be performed automatically by partially
(around 10%) stroking the valve while these valves are in service. The test hardware and
software shall meet the following minimum requirements;
a) Partial stroke test scheme shall be complete with all hardware and software which
shall include solenoid valves, valve positioner and logic solver. All components
used in PST shall be fail safe and shall not affect the on-off valve performance
under any circumstances.
b) The PST design shall ensure;
i) The testing shall be carried out automatically at pre-defined intervals which shall
be adjustable.
ii) The shutdown demand shall always over-ride if PST is in operation at that time.
Page 789 of 1296

lataae7 ENGINEERS STANDARD SPECIFICATION
Ifgar feliWieg INDIA LIMITED FOR ON-OFF VALVES 6-52-0037 Rev. 2
2120,9V 0,13031.1) V1 Gov! of India Undertaiong)
Page 17 of 18
iii) The valve shall not operate beyond a predefined maximum allowable stroke
valve under any condition or failure. When valve positioner is used to realise
PST, the positioner output shall be limited beyond the allowable value in case of
valve struck condition.
iv) Audit trail shall be available to indicate time and date of PST, test results (OK /
fail), reason of failure, changes made etc as a minimum.
v) Upward connectivity to purchaser's Host system.
Vendor shall supply the complete testing assembly duly tubed / piped / wired on a SS
mounting plate of thickness 3.2mm suitable for 2" pipe stanchion mounting. Standard pre
designed rigidly mounted components shall also be acceptable for PST assembly.
2.9.2 Fire Safe Design Requirements
2.9.2.1 Wherever the valves are indicated as fire safe on the data sheets they shall be tested for fire
safe as per BS 6755 (Part-2) when the valves are supplied with metal-to-metal seats and
shall be tested as per API 607 latest edition when the valves are provided with soft seats. In
case soft-seated valves with fire safe design are offered, vendor's design shall be such that
soft seat is not damaged while closing/opening of the valve.
2.9.2.2 Wherever fire safe actuator and controls have been asked for, actuators and all accessories
such as solenoid valves, air volume bottles etc. shall meet the fire proof requirement to
ensure normal valve operation even during and after exposure to fire. Vendor shall clearly
define the schemes they propose to achieve the above requirements and ensure that the
proposed schemes shall meet the requirement in terms of type of exposure and exposure
time of the testing procedure given in BS 6755/API 607.
Vendor must note that all items i.e. actuators, its accessories and interconnecting tubing
including Volume bottles is required to be protected under fire exposure conditions. The
fire protection methodologies like fully enclosed fireboxes or special material coverage are
acceptable provided fire safe certification is provided for complete assembly as indicated
above.
2.9.2.3 Vendor shall furnish type test certificate duly witnessed by third party inspection agency like
M/S LRIS,BV,DNV,TUV etc. for fire safe testing of valve, actuator and controls for the
offered models along with the offer. When fire safe box is offered, vendor to note that fire
safe box up to maximum twice the surface area of fire box already satisfactorily fire safe
type tested is acceptable provided the clearance inside the fire box with all accessories duly
mounted are maintained equal to or greater than those maintained in fire safe box
successfully type tested. In case, earlier fire safe test carried out by vendor is not applicable
for quoted size/rating of the valve, fire safe box, then vendor shall carry out the test for fire
safe design for the offered valves / actuators & controls.
2.9.2.4 Backup volume bottles for the valve operation shall be designed inline with ASME Sec. VIII
requirement. Each volume bottle shall be sized at minimum air supply pressure for a
minimum of 3 valve strokes. Backup volume bottles and interconnecting tubing shall also
meet the requirement of fireproofing in case fireproof actuators and controls have been asked
for.
2.9.3 Special Service Valves
All on-off valves in oxygen and chlorine service shall be thoroughly degreased using
reagents like trichloro-ethylene or carbon tetra-chloride. End connections shall be blinded /
plugged after this degreasing process in order to avoid entrance of grease and oil particles.
Page 790 of 1296

laftel 4m) ENGINEERS STANDARD SPECIFICATION
eg f6ifWz
WWI ?VOW 031.71;1.1)
INDIA LIMITED
IA Govt of India UnOortalong)
Page 18 of 18
3.0 NAMEPLATE
Each on-off valve shall have a stainless steel nameplate attached firmly to it at a visible
place, furnishing the following information:
b) Body and port sizes in inches.
c) Stem travel in millimetres.
d) Action on air failure.
e) Spring range.
f) Air supply pressure.
g) Manufacturer's model number for the valve body, actuator and positioner.
Inspection Test Plan and approved quality documents. All these tests shall be completed by
the vendor and test reports shall be submitted to purchaser for scrutiny.
5.0 SHIPPING
5.1 The on-off valve and its accessories shall be supplied pre-assembled and pre-tubed.
material.
5.3 Valves with external lubricators shall be lubricated prior to shipment.
5.4 Valves in oxygen and chlorine service shall be packed separately along with a certificate
indicating 'CERTIFIED FOR OXYGEN / CHLORINE SERVICE', as applicable.
Page 791 of 1296

ENGINEERS STUD-BOLTS AND NUTS Annexure 1 to
INDIA LIMITED STANDARD SPECIFICATION NO.
tRtg,
IaaFlf IA Govt o India Unclettalongt MATERIAL REQUIREMENT
6-52-0037 Rev. 2
Page 1 of 1
Sr. No. Piping Classes Nut and Bolt Material
1 A1A, A2A, A5A, A6A, A7A, A8A, A9A, A-193 Gr. B7

A10A, Al 1A, A13A, AI4A, A15A, A-194 Gr. 2H
A19A, A20A, A32A, A33A, AIK, A6K,
AIM, A1N, BIA, B2A, B5A, B6A, B9A,
B13A, B18A, BI9A, B32A, BIK, B6K,
B18K, BIM, B3M, B5M, BIN, B6N,
D1A, D2A, D5A, D18A, D1K, D18K,
DI8P, E1A, E2A, E5A, E5E, F5A
2 A16A,B16A A-193 Gr. B7M

A-194 Gr. 2HM
3 A1B, MD, A4F, A4G, BM, B1D, B5D, A1-193 Gr. B16
B1E, B3F, B4F, B4G, D1B, D2B, DM, A-194 GR. 4
D2D, D5D, D5E, F2D
4 A2K, B2K, D2K A-320 Gr. B8 CL.2

A-194 Gr. 8
5 A4A, AlH, B4A, BIH, D4A, D1H A-320 Gr. L7

A-194 Gr. 4
6 A3Y A-307 Gr. B

A-563 Gr. B
7 A3A, A3K, A3Y, A4Y, J3A A-307 Gr. B

A-563 Gr. B
8 A1Z, A4Z, A5Y, A5Z, J2A, J5A A-307 Gr. B (Galv)

A-563 Gr. B (Galv)
9 B4K, B5K A-193 Gr. B8 M Cll

A-194 Gr. 8 MA
10 A32Y A-193 Gr. B (Galv)

A-194 Gr. 2H (Galv)
11 B3M, B4K, BSK, B5M A-453 Gr. 660 CL.A

A-453 Gr. 660 CL.A
1. The nuts and bolt material shall be applicable for loose supply of nuts and bolts.
Page 792 of 1296

ENGINEERS GASKETS MATERIAL Annexure 2 to
Oge.a feli5leg
21i.2 dB J.17.41
INDIA LIMITED
(A Govt of India Undertalung) REQUIREMENT STANDARD SPECIFICATION No.
6-52-0037 Rev 2
Page 1 of 1
Sr.
Piping Classes Gasket Material
No.
1 AlA, A6A, A9A, A10A, AllA, Al3A, A14A„ Al9A, SP WND SS 316 + CAF
A1B, MD, All, A1K, A1M, A4A, A4F, A4G, B1A,
B1H, B2A, B4A, B6A, B9A, B13A, B I8A, B19A, B32A,
B18K, D1A, D2A, D1H, D1K, D4A, D18A, D18K, D18P
2 B5M SP WND SS316H+ GRAFIL + I RING
3 A2K, B2K, D2K SP WND SS 316+GRAFIL+SS 316 I/O
RING
4 B IN SP WND SS 316L+GRAFIL + I RING
5 B6N SP WND SS 316L + GRAFIL
6 A1Z, A3Y, A4Y, A4Z, J2A BUTYL RUBBER
7 E1A, E2A, E5A, F5A SOFT IRON
8 E5E, F2D 5% CR, 0.5% MO
9 B4K, B5K SS 3 I6H+GRAFIL+I RING SS 316 0 RING
10 A5Z PTFE JACKETED ASBESTOS
11 A5Y, A8A, AI5A, A32Y, A33Y IS 2712 Gr. A/1
12 B3M SP WND SS 321+GRAFIL+I RING
13 AIN, A6K, Al6A, B16A SP WND SS 316 + CAF
14 A3A, A3K, A33A, J3A, J5A IS 2712 Gr. W/3
15 A2A, A20A, A32A IS 2712 Gr. W/1
16 A5A, B5A, D5A SP WND SS 316 + CAF + I RING
17 A7A, BIB, BID, BIE, B IK, B3F, B4F, B4G,B5D, DIB, SP WND SS 316 + GRAFIL + I RING
D1K, D2B, DID, D2D, D5D, D5E
18 B6K, BIM SS 316 + GRAFIL
1. The gaskets material shall be applicable for loose supply of gaskets.
Page 793 of 1296

■31 eitq ENGINEERS FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
Oge-ff tifirdg INDIA LIMITED CONTROLLERS
f A Govt of India UnOntalong) Page 1 of 36
VA •
$i i di ei ch ch 5. el i
rag- TITRW ftrAmbrA.
PROGRAMMABLE LOGIC
CONTROLLERS
2 30.06.15 Revised and Reissued

I t4R
MA SC
1 24.11.09 Revised and Reissued ND

MN RP TGM
0 22.04.98 ISSUED AS STANDARD SPECIFICATION PM RK BRS AS
Standards Standards
Rev committee Bureau
Prepared Checked
Date Purpose Convener Chairman
by by
No Approved by
Page 794 of 1296

*• ENGINEERS
•gen EttalegNmiir-/ INDIA LIMITED
lee7r, erensre axJwifm)
-
Govt of India Undertaking)

FOR PROGRAMMABLE LOGIC
CONTROLLERS
6-52-0040 Rev. 2
Page 2 of 36
Abbreviations:
Baseefa British Approval Service for Electrical Equipment in Flammable
Atmospheres
CPU Central Processing Unit
CSA Canadian Standards Association
DC Direct Current
DCS Distributed Control System
DMR Dual Modular Redundant
DVD Digital Versatile Disc
EMI Electromagnetic Interference
ESD Emergency Shutdown System
EXIDA Excellence in Dependable Automation
FAT Factory Acceptance Test
FMEDA Failure Modes, Effects and Diagnostic Analysis
HW Hardware
HWC Hardwired Console
IEEE Institute of Electrical and Electronic Engineers
I/O Input / Output
LAN Local Area Network
LCD Liquid Crystal Display
LCIE Laboratorie Central Industries Electriques
MIS Management Information System
MTBF Mean Time Between Failure
MTTR Mean Time to Repair
OPC OLE for Process Control
PC Personal Computer
P&ID Piping and Instrumentation Diagram
PLC Programmable Logic Controller
PTB Physikalisch Technische Bundersanstalt
PLC Programmable Logic Controller
RFI Radio Frequency Interference
SlL Safety Integrity Level
TCP / IP Transmission Control Protocol / Internet Protocol
TMR Triple Modular Redundant
TUV Technische Uberwachungs Vereine
UHF Ultra High Frequency
UPS Uninterrupted Power Supply
VDU Video Display Unit
VHF Very High Frequency
Convener : Mr. Rajiv Gupta
Members : Mr. S Bhowal

Mr. M Nandi
Mr. R K Gupta
Ms. Rima Kundu
Mr. S Mahesh Kumar
Page 795 of 1296

1,39fa_Jei =,) ENGINEERS
fititeg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
1.127t rlecnre oAdods.) (A Govt 01 India Undertalong)
CONTROLLERS Page 3 of 36
CONTENTS
1.0 GENERAL 4
2.0 DEFINITIONS 9
3.0 SPARES PHILOSOPHY 12
5.0 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE 31
7.0 SHIPPING .36
8.0 REJECTION 36
Page 796 of 1296

el ENGINEERS
sige.il 251eg. INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
Govt of Inca Undenaking)
1.0 GENERAL
1.1 Scope
1.1.1 This specification, defines the minimum functional requirements for the design, hardware,
software and firmware specifications, nameplate marking, testing and shipping of
Programmable Logic Controllers (PLC) designed for reliable, effective and optimum control
and monitoring of a process plant (hydrocarbon and non-hydrocarbon) and captive power
plant.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions,
unless otherwise specified: -
RP 552 Transmission Systems
EEMUA Engineering Equipment & Material User Association

191 Alarm System - A Guide to Design, Management and
Procurement
EN 10204 Inspection Document for Metallic Products
IS/IEC Indian Standards / International Electrotechnical Commission
IS/1EC60079 Electrical Apparatus for Explosive atmospheres

IS/1EC60529 Classification of Degree of protection provided by
enclosures (IP Code).
IEC 60584-2 Thermocouples. Part 2: Tolerances
IEC 60617 Graphical Symbols for Diagram
IEC 60751 Industrial platinum resistance thermometers and platinum
temperature sensors
IEC 61000-4-3 Electromagnetic compatibility (EMC) - Part 4-3: Testing
and measurement techniques - Radiated, radio-frequency,
electromagnetic field immunity test.
IEC 61000-4-4 Electromagnetic Compatibility (EMC) —Part 4-4: Testing
and Measurement Techniques — Electrical Fast Transients
/ Burst Immunity Test
IEC 61000-4-5 Electromagnetic Compatibility (EMC) —Part 4-5: Testing
and Measurement Techniques — Surge Immunity Test
IEC 61000-6-2 Electromagnetic Compatibility (EMC) —Part-6-2: Generic

Standards — Immunity for Industrial environments.
IEC 61508 Functional Safety of Electrical / Electronic /

Programmable Electronic Safety-related Systems.
Page 797 of 1296

‘31 rM
a ENGINEERS
0g-a OW-6 11W INDIA LIMITED
1.11Eq, ekTorz aA 340.1) IA Govt o In Underlalang)
CONTROLLERS
6-52-0040 Rev. 2
Page 5 of 36
IEC 61131 Programmable Logic Controllers
IEC 61511 Functional Safety — Safety Instrumented Systems for the

Process Industry Sector
IEC 61643-21 Low voltage surge protective devices - Part 21: Surge
protective devices connected to telecommunications and
signaling networks - Performance requirements and
testing methods
IEC 62561-3 Lightning protection system components (LPSC) - Part 3:

Requirements for isolating spark gaps (ISG)
IEEE 802.3 Telecommunication and Information Exchange between Systems — Local

and Metropolitan Area Networks — Specific Requirements — Part 3: Carrier
Sense Multiple Access with Collisions Detection (CSMA / CD) Access
Method and Physical Layer Specifications
IS Indian Standards
3043 Code of Practice for Earthing
5.1 Instrumentation Symbols and Identification
5.2 Binary Logic Diagrams for Process Operations
5.3 Graphic Symbols for Distributed Control / Shared Display

Instrumentation, Logic and Computer System.
5.4 Instrument Loop Diagrams
5.5 Graphic Symbols for Process Displays
18.1 Annunciator Sequences and Specifications
71.01 Environmental Conditions for Process Management and

Control Systems: Temperature and Humidity
71.04 Environmental Conditions for Process Measurement and

control Systems: Airborne Contaminants
ANSI/ISA American National Standards Institute / International Society of Automation
TR 99.00.01 Security technologies for Industrial Automation and

Control Systems
ISO International Organization of Standardization
216 Writing Paper and Certain Classes of Printed matter-Trimmed

Sizes- A & B Series and indication of machine direction
9241-5 Ergonomic requirements for office work with visual display

terminals (VDTs) -- Part 5: Workstation layout and postural
requirements
Page 798 of 1296

k31 ENGINEERS
oaentapieg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
(A Govt of We Undertsk.0) CONTROLLERS Page 6 of 36
9241-302 Ergonomics of human-system interaction -- Part 302:

Terminology for electronic visual displays
1.1.3 In the event of any conflict between this specification, data sheets, statutory regulations,
related standards, codes etc., the following order of priority shall govern:
b) Job Specifications/ Data Sheets
c) Standard Specifications
1.1.4 In addition to meeting purchaser's specifications in totality, vendor's extent of responsibility

a) Purchaser's data sheets specify the minimum acceptable functional requirements for
the programmable logic controllers. It shall be vendor's responsibility to select proper
hardware, software and firmware to meet the specified functional requirements,
keeping the integrity of functional blocks specified in the configuration diagram
attached with the Requisition.
b) Purchaser's data sheets specify the scan time / cycle time and loading requirements.
Vendor shall be responsible for sizing and selecting their standard product i.e.
hardware, software and firmware to meet the requirements specified in the purchaser's
data sheets.
c) Adequacy of Bill of Material selected to meet purchaser's requirements including

spares. Vendor to note that bill of material shall not be verified by the purchaser
during evaluation stage. Any hardware, software and firmware required to meet the
purchaser's specified requirements shall be provided by the vendor without any
implication.
1.2 Bids
the Requisition. Vendor's quotation shall enumerate and include the detailed specification of
each subsystem and each module of programmable logic controller, detailed system
configuration, hardware and software capabilities, programming aids, display facilities and
other relevant information.
following:
a) Compliance to the specifications.
b) Detailed specification sheet for each sub-system. The specification sheet shall provide
information regarding hardware specifications, software specifications, redundancy
requirements, capacity, power consumption etc. of the programmable logic controllers
and its accessories. The material specifications and unit of measurement for various
items in vendor's specification sheets shall be to the same standards as those indicated
in purchaser's data sheets.
c) System security features and design details.
Page 799 of 1296

ENGINEERS
zlf tlfilegW INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
RIR, 012W WI3VIhA1 IA Govt. India Undertaking)
d) Proven references for each offered model in line with clause 1.2.4 of this specification
whenever specifically indicated in the purchaser's specifications.
e) A copy of approval for flameproof enclosure, intrinsic safety etc whenever specified,
from local statutory authority, as applicable, like Petroleum and Explosives Safety
Organisation (PESO) / Chief Controller of Explosives (CCE), Nagpur or Director
General of Mines Safety (DGMS) in India along with:
i) Test certificate from recognised house CIMFR (Central Institute of Mines & Fuel
Research) / ERTL (Electronics Research and Test Laboratory) etc. for specified
protection class as per relevant Indian Standard for all Indian manufactured
equipments or for equipments requiring DGMS approval.
ii) Certificate of conformity from agencies like LCIE, Baseefa, PTB, CSA, UL etc.,
for compliance to ATEX or other recognised standards for all equipments
manufactured outside India.
f) Deviations on technical requirements shall not be entertained. In case vendor has any
valid technical reason to deviate from the specified requirement, they must include a
list of deviations item wise, summing up all the deviations from the purchaser's data
sheets and other technical specification along with the technical reasons for each of
these deviations.
g) Certificate for specified sm requirement (e.g. SIL-3) from Independent Testing

Agency (e.g. TUV/EXIDA).
h) Catalogues giving detailed technical specifications, model decoding details and other
related information for each item / sub-system covered in the bid.
1.2.3 The equipment being offered / supplied shall be of latest proven version available in the
current manufacturing range.
1.2.4 The system hardware, software and firmware as offered, shall be field proven and should
have been operating satisfactorily for a period of minimum 6 months continuously on the
bid due date in the validly similar size and application specified in the purchaser's data
sheet. Items with prototype design shall not be offered or supplied.
1.2.5 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc.
shall be indicated in the job specifications which shall be part of Requisition
1.2.6 Whenever specified, vendor shall furnish tested values of failure rates, probability of failure
on demand and test intervals for safety integrity level analysis.
installation, operation and maintenance manuals shall be in English language only.
1.2.8 Vendor shall also quote for the following:
a) Two year's operational spares for each sub-system and their accessories which shall
include the following as a minimum:
i) All type of electronic modules e.g. I/O modules, processor modules,

communication modules, power supply modules etc.
ii) All type of auxiliary items e.g. barriers / isolators, hardwired instruments,
annunciator modules, receiver switches, trip amplifiers, temperature element
converters etc.
Page 800 of 1296

ENGINEERS
ogar feta& INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
(artier cleave rt71.3gartrt) (A Goat of India Undertaking)
iii) Switches, lamps, fuses, connectors, terminals, pre-fabricated cables, circuit

breakers, relays etc.
iv) Video display units, keyboards, disc drives, PC's, network items (e.g. switches,
hubs etc.) etc.
b) Any special tools and test equipments needed for the maintenance of PLCs and other
items being offered by vendor. Vendor must confirm in their offer if no special tools
or test equipments are needed for maintenance other than those specifically indicated
in purchaser's data sheet.
1.3.1 Detailed drawings, data, catalogues and manuals required from the vendor are indicated by
the purchaser in vendor data requirement sheets. The required number of prints and soft
copies shall be dispatched to the address mentioned, adhering to the time limits indicated.
1.3.2 Final documentation consisting of design manuals, installation manual, operation and
maintenance manual etc., submitted by the vendor after placement of purchase order shall
include the following, as a minimum:
a) Specification sheet for each sub-system, auxiliary instrument and bought out item.
b) Certified drawings for complete system including the following:
i) System Configuration Diagram
ii) General Arrangement drawings for panels, cabinets, marshalling racks,

hardwired consoles, operator console, programming terminal etc with complete
dimensional details, internal construction and weight in kilograms.
iii) Control room layouts e.g. console room, rack room and engineering room layout
with all dimensions in millimeters.
iv) Channel base frame drawings for console room, rack room and engineering
room.
v) Input/ output assignment.
vi) Logic/ Ladder diagrams.
vii) Loop wiring diagram for all tags.
viii) Power supply distribution diagram.
ix) Memory loading calculations/ Scan time calculations.
x) Modbus address mapping/ Protocol/ Pin Detail wherever required as per

requisition.
xi) Dynamic graphic diagrams.
xii) System grounding drawing.
Design manuals and functional design specifications which shall include hardware
design manual, software design manual and special software specifications.
Page 801 of 1296

ENGINEERS
Oaeir kliaeg WI INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
(A Govt of Ind. Undertaking)
d) Copy of type test certificates.
e) Copy of test certificates for all tests indicated in this specification.
f) Installation manual containing installation procedure for programmable logic

controllers and other items covered in the Requisition.
g) Power-on, start-up and internal testing procedures.
h) Software debugging and system configuration procedures.
i) Calibration and maintenance manual containing maintenance procedures including

replacement of parts, application modification etc.
j) Any other drawings and documents specifically indicated in vendor data requirement
enclosed with the Requisition.
2.0 DEFINITIONS
The various terms used in this specification are defined as follows:
2.1 Programmable Logic Controller
The class of control systems which can be programmed to execute plant shutdown and / or
interlock / sequence logics to the specified safety integrity levels and also regulatory control
functions in specific applications.
2.2 Accessible
A system feature that is viewable by and interactive with the operator and allows the
operator to perform user permissible control action e.g. set point change, auto-manual
transfers or on-off actions.
2.3 Assignable
A system feature that permits an operator to direct a signal from one device to another
without the need for change in wiring, either by means of switches or via other data entry
devices like keyboard commands to the system.
2.4 Configurable
The capability to select and connect standard hardware modules to create a system or the
capability to change functionality or sizing of software functions by changing parameters
without having to modify or regenerate software.
2.5 1/0
Input / Output with respect to process / operator.
2.6 PLC Console (Operator)
PLC console (Operator) is the operator's main plant interface device through which operator
can view, monitor and control the plant and can give instructions to peripherals to execute
commands, and shall have protective access to configure and maintain the system.
Page 802 of 1296

ENGINEERS
Ogeir triitegW INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
elVA,tet.Joto.tt IA Govt of India undertaking)
2.7 PLC Engineering Console (Programming)
PLC Engineering console (Programming) shall be the engineer's main interface device
through which engineer can configure / program and maintain the system, and shall have
protective access to monitor and control the plant, give instructions to peripherals to execute
commands.
2.8 Local Level
All those sub-systems, which directly interface with field devices shall be referred to as
local level.
2.9 Central Level
Operator Console and Programming Terminal, which present data acquired from local level
devices, shall be referred as Central Level.
2.10 Database
Database shall be defined as the information stored temporarily or permanently in the

system which can be accessed by various programs to meet all its functional requirements.
2.11 Loop Integrity
A system shall be said to have loop integrity if the failure of one component in the system/
sub-system does not affect more than one loop.
2.12 System Loading
System loading for a sub-system is defined as the percentage of time a sub-system spends in
carrying out various activities referred to the use of memory, CPU time and communication
capacity in the worst case of high sub-system operation out of the designed / designated
cycle time of the sub-system.
2.13 Redundancy
A system component shall be termed as redundant if it takes over automatically the

operation in the event of the failure of the main component without causing any interruption
in the system and upsetting the process. The repaired or replaced device shall be brought
in-line only through operator action without upsetting system operation.
2.14 Switchover Time
Time required for a back up instrument / system to come on-line automatically in case of the
failure of the main instrument / system.
2.15 Processor Cycle Time (tpc)
Processor cycle time is the measure of the processing speed of a processor. Processor cycle
time for a sub-system of the programmable logic controller shall be defined as follows:-
Processor cycle time for programmable logic controller shall be defined as the total time
taken by the processor to read input supplied by input module, execute all computations
(analog as well as logic as configured) and write the outputs for the output module.
Page 803 of 1296

.31`11Q.Jel. ,,M ENGINEERS FOR PROGRAMMABLE LOGIC
LlI lelf5tegV0 INDIA LIMITED 6-52-0040 Rev. 2
1.1•27, FREW A.JWA) (A Govt of India undertaking) CONTROLLERS Page 11 of 36
2.16 Scan Time (t,)
Scan time of a logic loops is the end-to-end response time of a sub-system and shall be
defined as follows:
The scan time for a logic loop shall be defined as the total time taken by a sub-system e.g.
programmable logic controller to read input from the input terminal, process input, execute
logic, updating logic output and write output at the output terminal for all the logics
configured within the subsystem.
2.17 User's Memory
Free memory space available after utilisation of memory required for system operation,
configuration and implementation of application and other system related functions for
implementation of user defined specific programs such as plant calculations, process
optimization or MIS (like free formatting of certain logs). The programs shall either be
written in high level language or system specific language.
2.18 Event
An event shall be defined as any action taken by the operator via operator keyboard or
switches on hardwired console like change of set point, change of control mode, start/stop of
motor, open/close of shut down valves, alarm acknowledge, etc.
2.19 Sequence of Event (SOE)
Arranging events in the sequence of their occurrence in time with a specified time resolution
by a program is defined as sequence of event.
2.20 Sequence of Event Recorder (SER)
Sequence of event recorder, when specified, shall identify, store and print alarms with the
specified time resolution between two events. SER shall also transfer data to operator sub
system over communication sub system.
2.21 Real Time Trend
Real time trend shall be defined as a continuously progressing graphical record showing
updated parameter with most recent value and a past record of minimum of 10 minutes
without pressing any additional key for moving backward in time.
2.22 Plant Information Network
High-level communication network which serves various users within a plant and transfer
information for the purpose of unit / plant monitoring. This network is different than control
network and is generally realised using open communication protocol network e.g. OPC etc.
2.23 Tag
A Tag is a collection of attributes that specify either a control loop or a process variable, or a
measured input, or a calculated value, or some combination of these, and all associated
control and output algorithms. Each tag is unique.
Page 804 of 1296

ks-afaziei m
s i ENGINEERS FOR PROGRAMMABLE LOGIC
sleji 051eg VIIIIPP INDIA LIMITED 6-52-0040 Rev. 2
(.111712:121MMIJIVAA) (A Govt el We undertakm) CONTROLLERS Page 12 of 36
3.0 SPARES PHILOSOPHY
3.1 The system including sequence of event recorder, hardwired instruments etc. shall meet the
following spare philosophy. This philosophy shall also be applicable for items like barriers,
relays, terminals, lamps, push buttons etc.
3.1.1 Mandatory Spares
Vendor shall include following mandatory spares in their scope of supply:
3.1.1.1 Installed Engineering Spares
Installed engineering spares shall be provided in each sub-system for each type of module to
enhance the specified system functional requirements by 20%. The basis of offering
installed engineering spares shall include:
a) For a system with conventional and / or smart analog input / output, discrete (contact)
input / output, 20% spare input / output of each type shall be considered for
calculating I/O modules and all other related accessories.
b) For all serial input / outputs to the system, 20% spare serial I/O ports of each type of
serial input / output shall be provided.
c) 20% spare accessories like relays, switches, lamps, fuses, circuit breakers, barriers,
isolators, terminals etc.
d) The engineering spares shall be wired up to the field cable interface and shall be in
ready-to-operate condition when field cable is connected to spare assigned terminals.
e) Spare pairs of the incoming cables shall be terminated on spare terminals in the
marshalling / barrier cabinets as applicable.
f) The system shall be fully engineered considering 20% installed engineering spares
including processor loading.
3.1.1.2 Spare Space Requirement
In addition to installed engineering spares specified in Clause 3.1.1.1 of this specification,

the system shall be provided with following spare space:
a) The cabinets of the of the programmable logic controller system shall have 10%
usable spare space for installing additional I/O cards of each type in future and the
PLC processor shall have additional 10% capacity to handle these I/0's. In addition,
provision shall be kept for internal wiring of the same up to the I/O terminals.
b) Processor system of programmable logic controller shall have capability to execute

additional 20% logics.
c) Each operator console shall contain 20% usable spare group and related display
capability in addition to as specified in para 3.1.1.1 of this specification.
d) The system shall have capability to extend its historical trending, logging and user's
memory by 20% to meet future expansion with/without adding additional memory
modules.
e) The communication sub-system shall have sufficient capacity to handle additional

data contributed by addition of 20% I/O over and above installed engineering spares.
Page 805 of 1296

101 ENGINEERS
Ifgar 16101eu INDIA UMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
NIVIT 21221W 01399.1, IA Govt of Me Undeftaloog) CONTROLLERS Page 13 of 36
f) Usable spare space in cabinets to install 10% spare hardwired items like relays,
switches, lamps, fuses, circuit breakers, barriers, isolators, terminals etc. in future.
3.1.1.3 Spare Memory Requirement
a) The system shall be provided with a minimum of 40% spare memory capacity, as
required for application program and data base to meet specified functional
requirements.
b) It shall be possible to extend the memory by at least 20% over and above the actual
requirement at a later date.
3.1.1.4 Spare Software Capability
a) Sufficient additional software capacity shall be available in the system to take care of
spares requirement as specified in para 3.1.1.1 and 3.1.1.2 of this specification to meet
all functional requirements as per para 4.0 of this specification.
b) Unless specifically indicated otherwise, the offered system shall have software
licenses to cover all the tag numbers indicated in the Requisition, including installed
engineering spares and spare space indicated in clause 3.1.1.1 and 3.1.1.2 of this
specification.
3.1.1.5 Predefined Mandatory Spares
a) Mandatory spares shall be ware-house spares and shall be supplied as loose items.
b) Mandatory spare module of 5% or one module of each type, whichever is higher, must
be supplied for each type of modules being used excluding modules used in consoles,
servers, Personal Computers.
c) For items like, Video Display Units, keyboards, disc drives, network components,
hardwired instruments like barriers, lamps, fuses and circuit breakers, complete item
limited to 5% or minimum one of each type shall be supplied as predefined mandatory
spare. But this shall not include hardware like hard discs, terminals.
3.1.1.6 Consumable Spares
Any paper, ribbon, printer heads, toner and ink required for printers, video copier or any
other consumable item shall be supplied along with system required for minimum of six
months duration after system acceptance.
3.1.1.7 Commissioning Spares
Unless otherwise specified, vendor shall be responsible to supply all spares which are found
necessary to replace failed modules, failed sub-systems, or corrupted / faulty software while
performing pre-commissioning and commissioning activities.
3.1.2 Two Years Operational Spares
Two years operational spares shall be as per Clause 1.2.8(a) of this specification and shall be
quoted separately.
Page 806 of 1296

ENGINEERS
51fgar 05i-eg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
(Nrerf rieme dflanddid (A GoN of India Undertaking)
4.1 Design Requirements
4.1.1 Programmable logic controller shall be microprocessor based system which shall be used to
execute all the process and safety shut-down logic of the plant. When specified, it shall also
execute plant interlock logics and sequence operation and analog control. Programmable
logic controller shall be an independent unit and shall not depend on any of its functionality
on any other system including Distributed Control System.
In case of common engineering database for DCS and PLC, engineering data for DCS and
PLC shall be segregated and the data access shall be through respective engineering stations
of DCS and PLC only. Such configuration shall meet the SIL3 compliance by third party
certifying agency like TUV/ EXIDA etc
Moreover, wherever exchange of safety parameters between the different PLC sub-systems
is required for interlock execution, separate communication network shall be provided
between these PLC sub-systems. For SIL certified PLCs, this communication network
between PLC nodes shall also be SIL certified.
4.1.2 The system shall be of modular construction and expandable in future by adding additional
modules which shall be easily accessible for maintenance and repair. The type of modules
shall be kept to the minimum possible in order to have interchangeability and low inventory.
4.1.3 System Availability
a) The system shall be designed 'fault tolerant' as a minimum by selecting high grade
components of proven quality and proper design of system electronics.
Redundancy shall be provided, as a minimum, as per this specification to improve

system availability and reliability. Due considerations shall be given to the
environmental conditions particularly for field mounted sub-system, if specified in job
specifications, during system design.
b) The system shall have a high MTBF value and shall have well proven record of
operating in hydrocarbon plants.
c) The system shall be designed with 99.995% or greater availability. The availability
shall be defined as follows:
Availability = Mean time Between Failure (MTBF)
MTBF + Mean time to repair (MTTR)
For the purpose of calculations, consider mean time to repairs as four (4) hours unless
the manufacturer recommends higher value for MTTR. It is therefore necessary that:
i) Vendor covers all necessary spare parts in 2 years recommended operational

spares which shall be necessary to meet specified MTTR time.
4.1.4 Operating Environmental Conditions
4.1.4.1 Environmentally Controlled Location Installation
a) All subsystem of Programmable Logic Controllers located in Control Room, Local

Control Room or in Satellite Rack Room shall be able to operate satisfactorily from
15°C to 30°C and 20% to 80% non condensing humidity.
Page 807 of 1296

ei 0QA,
41. ENGINEERS
RairduW INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
lailerr ?Vesta allageni) (A Govt of India Undertaking)
b) In addition to above, all such sub-systems shall also be able to operate satisfactorily in
case of air conditioning failure with ambient temperature of 50°C and 90% non-
condensing humidity until the system safe operating limits are exceeded. The
minimum period of continuous operation in such condition shall be 48 hours at least
once in a month without any damage or degradation of system performance. Vendor,
therefore, shall provide continuous temperature monitoring for each cabinet housing
items / equipments generating heat, such as system cabinets, barrier cabinets, relay
cabinets, consoles etc and also provide alarm for operator alert in case the safe
operating temperature limits are exceeded. For marshalling cabinets and Power
distribution cabinets, temperature monitoring through temperature switches is
acceptable.
c) Chemical filters have been provided in the incoming air conditioning air to limit the
concentration of contaminants below following limits:
Contaminants Concentration
(Corrosive Gases)
SOx < 0.01 ppm by volume
NOx < 0.05 ppm by volume
H2 S < 0.003 ppm by volume
C12 < 0.001ppm by volume
All sub-systems and system components shall be suitable for operating continuously
in the above mentioned corrosive environments.
4.1.4.2 Outdoor Installations
a) Sub-systems or system components which are installed outdoor shall be suitable to

continuously operate at ambient temperature and humidity specified under ambient
conditions. The heat generation effect of current carrying for the electronic modules
shall also be considered. For this purpose, the system shall be rated for minimum 5
deg C more than the maximum ambient temperature specified. In case the system is
not suitable for the above conditions, necessary cooling arrangement shall be
provided.
b) Unless otherwise specified, all PLC sub-systems or system components installed

outdoor shall have corrosive environmental protection coating meeting the
environmental classification class G3 as per ISA-S71.04.
4.1.5 Transient, Static and EMI / RFI Protection
4.1.5.1 The system shall be internally protected against system errors and hardware damage
resulting from:
a) Electrical transients on power wiring.
b) Electrical transients on signal wiring.
c) Connecting and disconnecting devices or removing or inserting printed circuit boards

in the Programmable Logic Controller (PLC).
4.1.5.2 All sub-systems and system components shall be capable of accepting various signal inputs
for its direct use while preventing noise errors due to electromagnetic interference (EMI) or
radio frequency interference (RFI) including nearby radio stations, hand held two way
Page 808 of 1296

,531Re_it.-1
ENGINEERS
/INDIA LIMITED
Ogar idiReg 'Voir FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
14iTZA ei7aw7maaarA) f A Govt of India Undertaking) CONTROLLERS Page 16 of 36
radios, solenoids, relays or contactors carrying heavy currents as per levels of

Environmental electromagnetic phenomenon defined in IEC-61000-6-2. The system shall
have total noise immunity from UHF / VHF radio communication equipments, (RFI) and
(EMI) noise generating equipments as per IEC-61000-4.
4.1.5.3 For interplant, inter unit and other system cables routed in the field, the level of surge
immunity required for equipment signal ports shall be increased to level 4 as defined in IEC-
61000-4-5 and the system shall operate according to performance criterion B as defined in
IEC-61000-6-2.
4.1.6 On-line Replacement
4.1.6.1 On-line replacement of any module of programmable logic controller shall be possible in
such a way that removal and addition of the module shall be possible and safe without
de-energising the system. Furthermore, there shall not be any interruption of the system and
process upset while replacing a faulty module in case of TMR, QUAD and dual redundant
PLCs.
4.1.6.2 Apart from system modules, power supply units shall be replaceable on-line without
disrupting the process and without affecting the system redundancies. It shall be possible to
hot swap any faulty system module without degrading the system safety or operation or
freezing the output status. The switchover to the healthy module shall be bumpless. The
swapped module shall take over the function of the failed module without any manual
programming.
4.1.7 Electrical Isolation
Galvanic or optical isolation shall be provided for all field signals. The isolation levels shall
be as follows:
Analog I/O channel to system ground 1500V AC
Discrete I/O channel to system ground 500V AC
External isolator shall be provided, if necessary to meet the above.
Isolation shall also be provided between Engineering / operator console/PLC programming

terminal and related sub-systems connected to it if there is any possibility of high voltage
being transmitted to the sub-systems.
4.1.8 Design Requirements of Equipments in Hazardous Area
4.1.8.1 Unless specifically indicated, the field devices are beyond the scope of this specification.
However vendor shall be fully responsible for integrating these devices with their system
including compiling and maintaining the engineering data base of these devices and
incorporating the data base into the Integrated Asset Management System (whenever
specified in the requisition).
4.1.8.2 General requirements
a) Unless otherwise specified, all instruments in hazardous area shall be intrinsically safe
type. Other concepts shall be used when specified.
b) For conventional instrumentation, entity concept shall be used for selecting proper
barriers / isolators.
Page 809 of 1296

faeieim ENGINEERS FOR PROGRAMMABLE LOGIC
r INDIA LIMITED
ages iiwiv 6-52-0040 Rev. 2
ele.re 0. 3.RM) IA Govt o India Undertaking)
4.1.9 Repeat Signals
4.1.9.1 Unless otherwise specified in the job specifications, following philosophy shall be followed
for repeat signals:
a) Whenever repeat signal/ contact outputs are required as per job specifications
following philosophy shall be followed:
i) For intrinsically safe input, isolating barrier with dual output shall be utilized.
ii) For Non-intrinsically safe input, isolator with dual output shall be utilized.
ii) For other contact inputs, repeat contact shall be provided using electromagnetic
relays.
4.1.10 Surge Protection
4.1.10.1 Surge protection devices (SPD's) shall be provided on the system to limit the surge voltages
reaching beyond the safe limits, under normal, abnormal or lightning strike condition.
Unless otherwise specified, SPD's shall be provided at least at the following locations:
a) All serial signal cables (UTP / STP / coaxial and not fibre optical) going from or to
control system and from one location to another outside the control building at both
control system end.
b) All power incoming cable (110V AC, 110V DC, 240V AC, etc), UPS or non UPS, at
the power supply distribution cabinet.
4.1.10.2 The selection of type and rating of SPD shall be selected such that the introduction of this
device shall not change the characteristics or reliability of an application, whether it is for
the protection of power system, signal such as analog or communication signal, as
applicable. The SPDs shall comply with the requirements of IEC-61643-21.
4.1.11 The system shall be designed fault tolerant and shall utilize high quality components of
proven quality. Any single system fault shall not degrade the system safety or functionality
or affect operation. The system shall have certified Safety Integrity Level as per IEC-61508
/ 61511 as applicable and specified in job specification. Unless otherwise specified, it shall
meet the availability requirement specified in Clause 4.1.3 of this specification.
4.1.12 Unless otherwise specified in the requisition, the scan time of programmable controller shall
be of the order of 250 milliseconds for SIL certified PLCs. The scan time for standard Non-
SIL PLCs shall be of the order of 100 milliseconds. Scan time for a PLC shall be as defined
under para 2.16 of this specification. The PLC processor sizing shall be done considering
the PLC scan time for the units as mentioned in the requisition. Other activities like
diagnostics routines, output / dump of data to peripherals, development of sequence blocks
or any other activity which consume processor time shall also be accounted while
computing scan time. For SIL certified PLCs, this shall also be in line with SIL certification.
4.1.13 Operation of the PLC shall be completely unaffected by a momentary power loss of the
order of 20 milliseconds.
4.1.14 The system shall be programmed in principle as per the logic diagrams.. Owner / Consultant
reserve the right to revise or review the logic diagrams even after acceptance of any offer.
The programming language of offered PLC shall be as per IEC 61131.
4.1.15 Whenever the requirement of SIL is specified for the PLC, it shall meet the requirements of
SIL level specified and shall be certified by an independent body (e.g. TUV/EXIDA) for
complying requirements of 1EC-61508 / 61511 as specified. For shutdown application
requiring SIL certification, PLC shall always meet SIL 3 requirements.
Page 810 of 1296

0 el ENGINEERS
g41 Elt5taG
Cr eknIsRaA3017.11
INDIA LIMITED FOR PROGRAMMABLE LOGIC
IA GON of India Undenak.9)
CONTROLLERS
6-52-0040 Rev. 2
Page 18 of 36
4.1.16 The system shall have extensive set of self diagnostics hardware and software for easy and
fast maintenance of PLC. Routine checks should run automatically at frequent intervals for
identifying any fault in software or hardware. Diagnostics shall be required at local as well
as console level.
4.1.17 Safety barriers shall be provided by the vendor for intrinsically safe input/output circuits
wherever specified. In such cases, the system shall be designed intrinsically safe based on
entity concept. The barriers shall be certified by a statutory authority like Baseefa, LC1E,
CSA, UL, PTB, CIMFR etc., for the use in the area classification as specified elsewhere in
the job specifications. The proper selection of the safety barriers shall be the vendor's total
responsibility. In case of smart transmitter, the entity parameters of the hand held terminals
shall also be considered while selecting proper barriers.
4.1.18 Unless otherwise specified all intrinsically safe barriers shall be 3 port isolating type only
providing isolation between;
i) Input and output (non-hazardous to hazardous side of barriers)
ii) Power supply and input
iii) Power supply and output
The minimum isolation level shall be 250V.

4.1.19 Alarm By-pass Switches
4.1.19.1 Startup by-pass (SBS) switches for alarms
All SBS's shall be configured in the ESD system (i.e. PLC) and shall be operable from
operator console. All such by-pass switches shall be alarmed and shall have audit trail.
4.1.20 All Emergency (ESD) switches shall he hardwired and shall preferably be pull type with red
coloured knob. Control room mounted ESD switches shall be installed on hardwired
console.
4.1.20.1 The ESD switch contact shall be used in ESD system (PLC etc) for logic implementation
and event history.
4.1.20.2 Additionally, wherever specified in the requisition, ESD switches shall also directly trip the
final ESD element without any intermediate device. Where multiplication of ESD switch
contacts is necessary, fail safe relays shall be utilized.
4.2 System Configuration
4.2.1 General
a) PLC system configuration shall be as specified in the job specification. For

emergency shutdown system application specified with SIL classification, the system
configuration shall be TMR or QUAD or DMR as per the job specification and shall
be certified by independent agency e.g. TUV/ EXIDA.
b) Regardless of the action feature selected (except for single architecture), the failure of
single component shall not result in a failure of correctly executed safety function.
The degradation mode for the selected configuration e.g. 4-2-0 or 3-2-0 or 3-2-1-0,
etc. shall be documented in SIL certification report.
Page 811 of 1296

ENGINEERS
*igenkreg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
IA Govt of India Unden.k..9)
c) In general, the PLC system shall comprise of various sub-systems as described in the
subsequent clauses of 4.2.
4.2.2 Input/Output subsystem
4.2.2.1 Each I/O module shall have its own processor. I/0 modules configured in redundant
configuration, shall have their processors properly synchronised.
4.2.2.2 Unless otherwise specified, system shall accept analog 4 — 20mA inputs and contact inputs.
The maximum number of Input/Output per I/O module shall be limited as per the following
table.
Si. Maximum
Type of Configuration
No. No. of I/Os
1 Single I/O system 8
2 Dual I/O system 16
3 Triple Modular Redundant system (TMR) 32
4 Quadruple Modular redundant System (QUAD) 16
In case of PLC certified for SIL requirements, the maximum number of I/o's shall be
governed by the SIL certification applicable for specified SIL level.
4.2.2.3 Each I/0 shall be galvanically isolated from external control circuit by suitable means. The
minimum isolation level between I/0 and logic circuit shall be 1000 volts AC. External
isolators/ barriers / relays shall be provided for all inputs and outputs of the PLC.
4.2.2.4 Each I/O shall be protected against the reversal of polarity of the power voltage to I/O.
4.2.2.5 Each input shall be provided with filters to filter out any noise in the input line and contact
bouncing noise, as applicable.
4.2.2.6 All the inputs / outputs shall be double ended upto the I/O card i.e. two wires per input /
output and not with common return for all inputs/ outputs.
4.2.2.7 The interrogation voltage to the inputs and power supply for 2-wire instruments shall be
powered from separate redundant power supply / supplies and shall not be a part of PLC,
unless otherwise specified. This power supply shall be supplied at one point and shall be
distributed by the vendor.
4.2.2.8 a) Each I/O module channel status shall be represented on the operator console.
b) When specified, input module shall be capable of monitoring the input contacts for
any wire open fault and short circuit.
4.2.2.9 Analog Input Module
a) Input module shall be able to accept 4-20 mA DC input from smart transmitters (e.g.
4 — 20mA HART).
b) The module shall have 16 bit A/D resolution accuracy of ±0.25% of full scale over the
entire range, unless otherwise specified.
Page 812 of 1296

ENGINEERS
Ogeff teMeg W INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
2i2,15reGA.39111,3) (A Govt. India Undettaking)
4.2.2.10 Output Contact
a) Output contacts from the PLC shall be potential free dry contacts with contact rating as
per para 4.2.2.10 b) of this specification. Vendor must provide arc suppression device
for each output contact.
b) T
' —
VOLTAGE CURRENT
Si. No. APPLICABLE FOR RATING
RATING
All output cards driving solenoid
valve and alarm annunciator system
unless otherwise specified
1. Category - I 110 V AC/ DC 0.5 A
Category - II 24 V DC 2A
All motors/pumps/compressor
output cards unless otherwise
specified.
2 240 V AC 5.0 A
Category - I
Category - II 220 V DC / 0.2 A

110 V DC
c) The category of contacts shall be specified in the Requisition. Each output shall be
short circuit proof and protected by fuse. Visual indication of fuse blown must be
provided for each module.
d) When specified contact output module shall have monitored output features like wire
open and short circuit.
4.2.2.11 Where inputs or outputs have multiple field devices for the same measurement or device,
the corresponding inputs / outputs shall be configured in separate I/O modules.
4.2.2.12 Where single input signal is available for QUAD or TMR configuration, inputs shall be
multiplied to feed inputs to each input modules / channels.
4.2.2.13 PLC shall be provided with Auto I/O testing facility as a standard diagnostics features. PLCs
which do not have auto I/O testing facility, manual testing facility shall be provided to detect
any system fault. For manual testing, manual switches shall be provided to bypass each input
at a time and its effect on the output shall be monitored.
4.2.3 Processor System
4.2.3.1 The processor shall have capability to implement all the control functions required to
implement the logic scheme as logic/ladder diagram.
4.2.3.2 The size of the memory shall be sufficient for storage of the program instructions required
by the logic schemes and other functional requirements. Offer shall indicate the amount of
memory capacity occupied by the actual program and spare capacity available for future
program modifications or additions.
4.2.3.3 Memory shall be non-volatile. However in case volatile memory is provided, battery backup
shall be provided with a minimum of 3 months lifetime to keep the program storage intact.
A battery drain indication shall be provided at least one week before the battery gets drained.
Page 813 of 1296

el ENGINEERS
51ge_al EViegw INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
,..,-e,mm.agt.0 (A Govt of Ind( Undertaking)
4.2.3.4 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in the
processor system, which shall include, CPU, memory, power supply, communication
interface etc. shall cause the watch dog timer to report processor failure.
4.2.3.5 Wherever dual redundant processor is specified, redundancy shall be provided in such a way
that in case of failure of the main processor, the standby shall take over automatically. The
changeover shall be bumpless. Redundancy shall be provided for complete processor system
including processor, power supply and communication sub system.
4.2.3.6 In case of triple modular redundant system all the three processors shall execute the same
instructions/program and check their results and vote to correct any faulty result. The faulty
processor diagnostic shall be made available.
4.2.3.7 In case of Quad system, individual processor shall execute the same instructions/ programs
and check their results within same CPU module and majority vote to correct any faulty
result. The faulty processor diagnostic shall be made available.
4.2.3.8 Failure of a single processor in dual redundant, triple redundant system and two processors
in QUAD system shall not affect the system. In case of failure of complete processor system
i.e. both processors in case of dual configuration, two or more in case of triple redundant
system and more than two in case of QUAD system, outputs shall take failsafe state
automatically unless otherwise specified in the data sheets.
4.2.3.9 In case multiprocessor configuration is offered, the processors must be able to communicate
with each other over the interconnecting data link. Vendor must ensure that system
performance shall not be degraded by any means when such a system is offered.
4.2.3.10 It shall be possible to generate the first out alarm by the PLC in case where a group of
parameters are likely to trip a system.
4.2.4 PLC Console (Engineering / Programming)
4.2.4.1 The PLC console shall be used for programming, program storing, fault diagnostics and
alarm monitoring. Whenever specified, it shall also be possible to use this console for plant
operation. The functionality to operate as engineering / programming terminal or operator
terminal or both shall be as specified in the job specification.
4.2.4.2 It shall consist of at least one coloured 21" active matrix TFT type LCD display unit with
backlit LED and one programming / operating keyboard, mouse and printer. If laptop is
specified in the job specifications, the same shall be of 15" TFT type LCD display.
4.2.4.3 PLC console when used for plant operation shall also meet the functional requirements as
per clause 4.2.5 of this specification.
4.2.4.4 The keyboard shall be easy to operate with each key clearly identified.
4.2.4.5 All illegal entries shall be rejected by the terminal and shall be identified by warning signal
on VDU.
4.2.4.6 Manual forcing of any input or output contact connected to PLC shall be possible from
keyboard. Forced functions shall have an associated audit trail.
4.2.4.7 It shall be possible to modify, add or delete the application program on line without
affecting the outputs.
Page 814 of 1296

0 el ENGINEERS
Ogai fafReg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
( ET, eleave 0,1,39M71) (A Govt of lode Uric/Making)
4.2.4.8 PLC Console shall display logic and/or ladder diagram indicating power flow and shall
show description and status of each contact. It shall also be possible to display process
alarms and diagnostic messages as and when they appear. Further it shall also be able to
display I/O map in a user defined format.
4.2.4.9 It shall be possible to print out the ladder/logic diagram on the dedicated PLC printer. The
printer in addition shall also print out:
a) The diagnostic messages as and when generated and diagnostic reports, when called
for.
b) Process alarms connected to the programmable logic controller as and when they
appear and alarm report whenever initiated. The choice of printing alarms on this
printer shall be operator selectable from a key lock / password protected switch on
PLC console.
c) The I/O maps showing status of all inputs and corresponding outputs in a user defined
format.
4.2.4.10 The PLC console shall be provided with self diagnostics feature which shall display error
messages and initiate an audible alarm if the fault is detected. Wherever specified, a
potential free contact for diagnostic group alarm shall be provided which shall be connected
to the hardwired alarm annunciator system.
4.2.4.11 The system shall be able to identify the failure at least up to the module level including I/O
system and redundant processor and report print out.
4.2.5 PLC Console (Operator)
4.2.5.1 Where dedicated PLC operator console is specified, it shall be used for operation of plant,
fault diagnostics, alarm monitoring and report generation.
4.2.5.2 It shall consist of coloured 21" active matrix TFT type LCD display unit with backlit LED,
operator keyboard and printer unless specified otherwise.
4.2.5.3 At least two number cursor control devices shall be provided in addition to keyboard which
may include touch screen, mouse, track ball etc.
4.2.5.4 PLC operator console shall have complete graphic capability and shall be able to display
process dynamic graphics, overview and group view displays. It shall be possible to operate
the plant i.e. start and stop of rotating machinery, opening and closing of valves, PID
function etc. from dynamic graphics and group displays available on PLC operator console.
4.2.5.5 It shall be possible to monitor, historise and print out all process alarms, diagnostic alarms
and alarm reports.
4.2.5.6 The time stamping of all alarms shall be as per PLC processor time stamping or I/O module
stamping.
4.2.5.7 The system shall be able to store and display stored data wherever required. The minimum
storage capacity shall be for 30 days at 1 minute sample rate for all the inputs specified,
diagnostic alarms, process and first out alarms, manipulation data etc.
4.2.5.8 The system shall be able to generate shiftly, hourly, daily, weekly and monthly reports. The
log format shall be furnished during detailed engineering.
Page 815 of 1296

ENGINEERS
err RA&
I.nen eleaxemr3rram)
INDIA LIMITED
(A Govt of Incite Undertaking)
CONTROLLERS
6-52-0040 Rev. 2
Page 23 of 36
4.2.5.9 The system shall be supplied with first out alarm generation capability. The resolution of
alarm shall be as per processor cycle time, as a minimum.
4.2.6 Communication Subsystem
4.2.6.1 The PLC communication subsystem shall be a digital communication bus that provides a
high speed data transfer rapidly and reliably between the processor, I/O sub-system, PLC
console and other devices connected in the PLC system.
4.2.6.2 Redundancy in PLC communication subsystem shall be provided as follows unless

otherwise specified:
a) For single architecture, the communication subsystem between PLC processor and I/O
subsystem shall be single unless otherwise specified. This shall include single
communication bus and single interfaces/buffers.
b) For dual I/O configuration, each I/O sub set shall have separate communication
interface and bus for connecting to PLC processors.
c) For the triple redundant system, each processor shall have a separate set of PLC
communication subsystem.
d) For the Quad systems each I/O subset shall have redundant communication interface
and bus for connecting to the redundant CPU modules.
e) The communication subsystem between processor subsystem and PLC console shall
be dual redundant, consisting of two separate communication interfaces and two
buses, each one configured in redundant mode, unless this is only used as
programming aid.
4.2.6.3 In case of redundant PLC communication sub system, on the failure of the active device, the
redundant device shall take over automatically without interrupting the system operation.
Information about the failed device shall be displayed at local as well as on PLC console. It
shall be possible to manually switch over the communication from main bus / device to
redundant bus / device without interrupting any system function.
4.2.6.4 The mechanism used by the system for error checks and control shall be transparent to the
application information / program. Error checking shall be done on all data transfers by
suitable codes.
4.2.6.5 In general, PLC shall provide data in a well established protocol format preferably
MODBUS protocol.
Wherever remote I/O is specified in the requisition, it shall be redundant and SIL3 certified
(for SIL3 PLCs).Segregation for the remote I/O shall follow the same philosophy of group
wise PLC segregation specified in the requisition. Moreover, separate PLC in remote I/O
location with peer to peer communication with Host PLC through third party (TUV/ EXIDA
etc.) certified SIL3 redundant network is also acceptable for remote I/O requirement.
However, separate PLC shall be considered for each of the Remote I/O subsystem within
each location.
4.2.7 System Power Supplies
4.2.7.1 Unless specified otherwise, the programmable logic controller shall operate on uninterrupted
power supply (UPS). However the system shall be capable of operating satisfactorily at the
following power supply specifications:
Page 816 of 1296

ENGINEERS
ii aeu INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
INTE'Ff tmecnTedg074,1) IA Govt of India Undertaking)
Voltage 110/ 240 V ±10% (as specified in requisition)

Frequency 50 Hz ±3 Hz
Harmonic contents Less than 5%
Power interruption 10 millisecond
4.2.7.2 The power supply system shall be supplied with dual PLC feeders each capable of handling
100% of the total power supply load requirements. In case of failure of one feeder,
redundant feeder shall supply the total load.
4.2.7.3 Each I/O rack shall be provided with redundant power supply system. The power supply for
the I/O racks shall be sized to take full load of the I/0 racks.
4.2.7.4 The processor rack shall be provided with separate power supply for each processor or
redundant power supply module for the processor rack such that failure of one power supply
does not affect the system operation.
4.2.8 Self Diagnostics
4.2.8.1 The system shall have an extensive set of self diagnostic routines which shall be able to
identify all permanent and transient system faults / failures at least up to module level
including redundant components and power supplies through detailed VDU displays and
report print out.
4.2.8.2 At the local level, failure of a module in any subsystem shall be identified by an individual
LED.
4.2.8.3 Diagnostic software shall have the capability to provide information about the failed
module/system either in the form of a system configuration display or provide information
in the form of a "statement".
4.2.8.4 Self diagnostic software shall have capability to detect faults which make the system
permanently close/open in the I/0 modules or I/0 signal conditioning modules (in case of
triple redundant system). This shall be achieved by automatically running the self diagnostic
software at cyclic intervals. However, system performance shall not be degraded during the
running of this diagnostic software.
4.2.8.5 System for the following functionalities shall be supplied when specified:
a) Long storage historisation
b) Log report generation
c) First out alarm generation
4.2.8.6 System diagnostics shall be capable of identifying, locating and reporting the following
faults, as a minimum:
a) Processor fault
b) Communication fault
c) I/O module fault
d) Power supply fault
e) Over temperature monitoring
Page 817 of 1296

afaeleifr,
idlileg
( ENGINEERS
INDIA
01Rn ertUn 4,1.390,71)
W.
INDIA 1JMITED
(A Gov! Cl India Undenalong)
CONTROLLERS
6-52-0040 Rev. 2
Page 25 of 36
0 Permanently close / open (stuck on or off) fault
g) Memory fault
h) Signal redundancy fault
Any other additional diagnostic alarm if available as a standard shall also be provided by
vendor.
4.2.8.7 Testing software shall be capable of detecting faults in case of normally closed system as
well as in normally open system.
4.2.8.8 Feedback must be provided in case of triple redundant system and QUAD system from the
output voter system to detect any latest faults of the system in addition to other diagnostic
software.
4.2.9 System Software
4.2.9.1 The system software shall include all programs for the PLC and PLC console which are
required to perform all the PLC functions including communication and self-diagnostics.
Whenever PLC is specified for shutdown application with Sit classification, the system
shall be designed and engineered in full compliance with the requirement of IEC-61511.
Whenever different functional logics are combined within a common PLC, the safety related
I/O's of each functionality shall be kept segregated within the system.
4.2.9.2 Logic program shall also be recorded on the external electronic media like DVD which shall
be delivered in duplicate together with the system.
4.2.9.3 The PLC programming language for implementation of logic operations shall be based on
the following representations:
a) Logic diagrams - Binary logic symbols such as AND, OR, NOT Gates, Timers
and Flip-Flops.
b) Ladder diagram - Series / parallel connection of relay contacts.
c) Combination of (a) & (b) above.

4.2.9.4 Diagnostic package and its related equipment and software shall be supplied. A list of
additional diagnostic packages available and the packages provided, including the
description and capabilities, shall be provided with separate quote, wherever asked.
4.2.9.5 It shall be possible to print out the ladder/logic diagram on a dedicated printer. The printer
shall also print out all diagnostic reports. The software package shall enable the owner to
modify/add/delete any part of program both on-line as well off-line and for documentation.
4.2.9.6 Software for the generation of various displays including dynamic graphics wherever
specified to be provided as per given below:
4.2.9.6.1 It shall be possible to display dynamic graphic of plant on the operator console VDU
screens. Graphic displays shall be field configurable only through PLC Console
(Programming terminal) with standard / user defined graphic symbols. Dynamic graphic
displays of different sections of the plant shall be displayed on different pages.
4.2.9.6.2 The system shall have graphic symbol library as per ISA-5.1 and 5.3. In addition standard
industrial symbols like distillation columns, heat exchangers, pumps, compressors, tanks etc.
shall also be provided as a standard.
Page 818 of 1296

101 el fru) ENGINEERS
5lg-ar flf51--eg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
caireR rreant ,751.3.741.1) (A Gout of India Undeftakmg)
4.2.9.6.3 Graphic displays shall be interactive type through which it shall be possible to control the
process. It shall also be possible to send motor start/stop and shutdown valve open/close
commands, as specified in job specifications, from this display
4.2.9.6.4 It shall be possible to view the process variable and alarm points and view and change set
point value, manipulated variable, controller mode etc. from the graphic display. Also
rotating machinery (i.e. compressor / pump) status and valve status shall be displayed on the
graphic display with different colours.
4.2.9.6.5 Various colours used in the generation of graphics like colour of the process lines, utility
lines, Instrument signal lines and event modifier conditions shall be finalised during detailed
engineering. The colours used to identify event modified conditions shall generally be as
follows unless otherwise indicated during detailed engineering.
Red All points alarm
Blue Valve open, pump running.
Green Valve closed, pump stopped.
Flashing green : Shut down valve transition state.
4.2.9.6.6 It shall be possible to go from any graphic page to related graphic pages or any group view
or alarm summary in single key stroke using soft key function.
4.2.9.7 The software for printing alarms, system as well as process, and events on the PLC printer
must be provided. All alarms must be printed as and when they appear.
4.2.9.8 Software package for displaying I/O map showing status of inputs and corresponding output
providing tag numbers as per logic diagram shall be offered. The I/O map format shall be
user definable.
4.2.10 Power Supply Distribution
4.2.10.1 All type of power supplies shall be made available at one point. Further distribution of
power supply shall be in vendor's scope.
4.2.10.2 In general, all output contacts and solenoids shall be powered with 110V±10% DC/
24V±10% DC power supply. However, the actual interrogation voltages shall be as per job
specifications and logic diagrams.
4.2.10.3 The distribution network for interrogation voltage shall be designed such that a single fault
in any branch shall not cause trip of the logic other than where the fault has occurred.
4.2.10.4 Sequential starting of various load centres shall be provided whenever specified.
4.2.10.5 Power distribution network must use bus bars of adequate capacity with DPDT (Double
Pole Double Throw) switches and HRC (High Rupture Capacity) fuses in each branch
network. Vendor may select circuit breaker if short circuit characteristics do not match the
HRC fuse.
4.2.10.6 All cubicles lighting shall be on 240 V, 50 Hz AC normal power supply.
4.2.11 PLC System Cabinets
4.2.11.1 All PLC system cabinets shall be completely wired with all modules in place. Inside cabinet
wiring shall preferably be done using ribbon type pre-fabricated cables.
Page 819 of 1296

ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
OfiljeG INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
Wren rwore =damp) IA Govt of India Undertaking(
4.2.11.2 All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry
of cables. Cabinet structure shall be sound and rigid. Cabinet shall be provided with remova
IS/IEC ble lifting lugs to permit lifting of the cabinets.
4.2.11.3 Cabinets shall be fabricated from cold rolled steel sheet of minimum 1.5 mm thickness for
sides and rear and 2 mm thickness for doors and suitably reinforced to prevent warping and
buckling. The rack/ rail mounting plates inside the cabinets shall be of 3 mm thickness.
Cabinets shall be thoroughly deburred and all sharp edges shall be grounded smooth after
fabrication. Cabinet frame shall be of 9 fold profiled CRCA or of Angle iron frame using
minimum section of 50 x 50 x 4 mm angle.
4.2.11.4 Cabinet painting procedure shall include blast cleaning, grinding, chemical cleaning, surface
finishing by suitable filler and two coats of high grade lacquer with wet blasting wherever
required. Two coats of paint in the panel colour shall be provided for non-glossy high satin
finish. Final coat shall be given after assembly at site. Colour of the panels shall be as per
Requisition.
4.2.11.5 Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base), 800 mm
wide and 800 mm deep, in general. Construction shall be modular preferably to
accommodate 19" standard racks. All cabinets shall be of same height.
4.2.11.6 Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with
lockable handles and concealed hinges with pull pins for easy door removal.
4.2.11.7 In order to effectively remove dissipated heat from the cabinets, ventilation fans along with
vent louvers backed by wire fly screen shall be provided as required. Ventilation fans shall
be provided in all cabinets where the temperature rise with all doors closed and all internal
and external loads energised shall exceed 10° C above the ambient temperature. A
temperature element (resistance temperature detector or semiconductor type sensor) shall be
provided in each System cabinets and temperature switch as a minimum in each
marshalling/ PDB cabinet for temperature measurement. Ventilation fans shall be provided
in dual configuration, as a minimum.
Each fan shall have a separate dedicated assembly and shall be replaceable on-line without
shutting down any equipment/ cabinet/ console in part or in complete.
Ventilation fan assembly shall operate at 240V AC power supply. Each fan shall have its
own dedicated circuit breaker.
Each ventilation fan shall be fitted with a protection type finger guard. Whenever, the
numbers of cabinets are compacted (supplied in mechanical joined conditions), each cabinet
shall be provided with separate ventilation fan assembly.
The maximum noise level with all fans operating and cubicle doors open shall not exceed
85dBA.
Following signals and alarms shall be provided separately as follows:
i) Fan failure alarm for each system cabinet in PLC
ii) Temperature indication of each system cabinet in PLC.
iii) A common high temperature and fan failure alarm in the PLC for each
marshalling / PDB cabinets for a group of maximum 10 cabinets as per the
requisition.
Page 820 of 1296

k-71
Oae.ii faOleg
ED INDIA
ENGINEERS
LIMITED
6-52-0040 Rev. 2
(A Govt of In Undertaking)
4.2.11.8 Internal illumination shall be provided for cabinets to ensure proper illumination level of 250
lux for performing maintenance activities.
Lamps shall be provided in each cabinet which shall be activated individually by door
operated switches. The lamps shall activate when door is opened and deactivate when the
door is closed. The door lock switches selected shall have undergone life cycle cyclic test of
at least 1000000 operations and test certificate for the same shall be provided from the
manufacturer. A manual over-ride switch shall be provided inside the cabinet which shall
keep the lamp (deactivated even when the door is open. Cabinets housing memories, which
are likely to be affected by fluorescent light, shall have incandescent lamps.
The cabinet lighting shall operate on 240V AC Non-UPS power supply.
4.2.11.9 Equipment within the cabinet shall be laid out in an accessible and logically segregated
manner. Cable glands shall be provided and supplied by vendor for incoming and outgoing
cables to prevent excessive stress on the individual terminals. All metal parts of the cabinet
shall be electrically continuous and shall be provided with a common grounding lug.
4.2.12 Control Panel /Hardwired Console
4.2.12.1 Control panels, if required, shall be non-graphic self supporting, free standing cubicle with
back doors made up of sectional steel panels. Each section shall be maximum 2100 mm
high, 1200 mm wide and 1000 mm deep and shall be mounted on 100 mm high channel
base. Care shall be taken to ensure that the face of the panel is truly flat and smooth.
4.2.12.2 Panels / hardwired console shall be fabricated from 3.0 mm thick cold rolled steel sheet.
Angle iron frame shall use a minimum section of 50x50x4mm angle.
4.2.12.3 Front of panel/console instrument nameplates shall be black laminated plastic with white
core. Nameplate shall be provided on the rear of the panel also for each instrument.
4.2.12.4 Document pocket / wallet shall be provided on the inner side of front and rear doors of each
cabinet and on the inner side of the door of each panel. Similar arrangement shall also be
made on the inner side of doors of console.
4.2.13 Wiring Requirements
4.2.13.1 All wiring shall conform to API RP 552- Transmission Systems. Different signal level
cables shall be routed with separation distances as recommended by this code.
4.2.13.2 All wiring inside racks, cabinets, and back of the panels shall be housed in covered, non-
flammable plastic raceways arranged to permit easy assembly to various instruments for
maintenance, adjustments, repair and removal.
4.2.13.3 All wiring in the raceways shall be properly clamped. All incoming cable and outgoing
cables shall be terminated by vendor at marshalling rack. Total wiring cross-sectional area
shall not exceed 50% of the raceway cross sectional area.
4.2.13.4 Separate wiring raceways shall be used for power supply wiring, DC and low level signal
wiring, and intrinsically safe wiring. Parallel runs of AC and DC wiring closer than 300mm
shall be avoided.
4.2.13.5 Vendor can alternately offer prefabricated cables for interconnection between different
cabinets and panels.
Page 821 of 1296

4c el ENGINEERS
Ogar faf51-ag
laiRe eRasre enJCmm
INDIA UMITED
Gov. or India Undertaking)
CONTROLLERS
6-52-0040 Rev. 2
Page 29 of 36
4.2.13.6 Wire termination shall be done using self insulating crimping lugs. More than two wires
shall not be terminated on one side of single terminal. The use of shorting links for looping
shall be avoided.
4.2.13.7 Terminal housing shall be strictly sized with considerations for accessibility and
maintenance. Minimum distance required between various components is listed below.
These distances are clear distances and are excluding the width of the raceways or any other
component / item mentioned herein. Following clearances should be considered:
a) Distance between terminal strip and side of the cabinet parallel to the strip, up to 50
terminals, shall be minimum 50 mm.
b) Distance between terminal strip and, top and bottom of the cabinet shall be minimum
75 mm.
c) Distance between two adjacent terminal strips shall be minimum 100 mm.
d) Additional distance for each additional 25 terminals shall be minimum 25 mm.
e) Distance between cable gland plate and the bottom of the strip shall be minimum 300
MM.
4.2.13.8 All terminal / terminal blocks shall be DIN Rail mounted type and shall be easily
removable. The size of the terminal blocks / terminals of different types shall be consistent
and identical. All terminal blocks shall be mounted on suitable anodised metallic or plastic
stand-off.
4.2.13.9 No splicing is allowed in between wire/ cable straight run.
4.2.13.10 Terminal strips shall be arranged group-wise for incoming and outgoing cables separately.
Terminal blocks for intrinsically safe wiring shall be separate. 20% spare terminals shall be
provided, as a minimum, preferably in each terminal strip. Terminals shall be suitable for
wires up to 2.5 sq. mm base solid or stranded conductor in general. For power cables,
higher size terminals shall be used.
4.2.13.11 Cabinet and rack layout shall be made considering proper accessibility and maintenance.
4.3 Earthing
4.3.1 All system equipment such as marshalling cabinets, system cabinets and other powered
equipment shall be provided with following type of grounding system:
a) Protective Earth / Electrical Earth
b) System earth / signal earth
Both system earth and safety earth shall be totally separate from protective earth.
4.3.2 Protective Earth / Electrical Earth

a) Earth metallic enclosure / cabinet / console etc. shall be provided with electrical earth
lug, as a minimum.
b) Unless recommended otherwise by vendor, all earthing lugs of metallic equipment
indicated in Clause 4.3.2(a) above shall be connected individually to electrical
protective earthing system bus-bar / earthing station using a maximum of 10sq mm
solid copper conductor PVC insulated wires.
Page 822 of 1296

ENGINEERS
Ifgar leffWeg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
ofrome Off JOCIf*If
CONTROLLERS
G0v1 of Indio Undetalong)
Page 30 of 36
c) Where multiple cabinets are multiplexed together, earth looping with permanent
shorting link cables shall be acceptable. Earthing connection wires as indicated in
Clause No.4.3.2(b) above shall be used for connecting multiplexed cabinets to
protective earth station / bus-bar.
4.3.3 System Earth

a) System earth shall be totally noise free dedicated earthing system and shall be fully
isolated from electrical protective earth. This earth must be very high integrity system
and shall be used to ground zero volt references and signal cable grounds.
b) System earth shall be less than one (1) ohm grounding system or as per vendor's
recommendation with its own dedicated earth pits. The earth pits shall be suitably
located outside the control room and away from any heavy noise plant equipment.
The earth pit design shall be as per IS-3043 code of practice for earthing. A minimum
of two (2) number of earth pits, in redundant configuration, shall be provided in each
Control room / SRR / Remote I0 cabinet location for System earth. In case number of
pits required to meet system earth resistance are more than one (1) number, the
number of system earth pits shall be two times the actual number of pits required to
meet the redundancy requirement specified above. All these system earth pits shall be
securely connected with each other to form a one homogeneous system earth grid.
c) Each marshalling / system cabinet etc. shall be provided with system earth bus-bar
which shall be insulated from the metallic body frame. This bus-bar shall be used to
earth also signal zero volt references and signal cable screens. Terminals used for
termination of spare conductor pairs / cores of multi-pair signal / control cables shall
be connected to system earth bus-bar. Shorting links shall be used for spare terminal
looping.
d) System bus-bars in the multiplexed cabinets can be joined together by permanent
shorting links. System bus-bars of other cabinets can also be connected together
provided they are permanently joined using 35 sq. mm stranded copper conductor
cable.
c) The redundant System earth pits at each location shall be connected to the Electrical
protective earthing system through suitable surge isolation and protection device for
lightning equipotential bonding. These lightning surge isolation and protection
devices shall comply to the requirements of IEC 62561-3.
4.4 Interface with DCS
The PLC shall be required to be interfaced to the Distributed Control System bus whenever
specified. A suitable interface shall be offered in order to achieve the following functions:
a) Display of all input points under alarm/first out alarm connected to PLC or generated
by PLC, continuous indication for analog signal on the main DCS operator console.
b) Generate shutdown reports on the logging printer of Distributed Control system.
c) To receive certain operational commands from the operator console for the operation
of certain output devices connected to PLC
d) To display diagnostic message of PLC.
In general, PLC shall provide data in a well established MODBUS protocol format.
The interface shall be dual redundant unless otherwise specified.
Page 823 of 1296

ENGINEERS
015reg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
lawn i9CmK 451.370.1) GUN of India Undertaking)
The speed of data transfer shall be such that any change in I/O which is to be updated on the
operator console shall not exceed 3 second from the time event to update on the operator
console screen considering one second standard update rate in DCS operator console.
4.5 Sequence of Event (SOE) Function Requirement
Sequence of Event, whenever specified, for analog and digital inputs shall be generated and
time stamped in PLC. The maximum resolution between two events shall not exceed
specified PLC scan time unless specified otherwise. A separate SOE PC with colour 21"
active matrix TFT type LCD display unit with backlit LED and printer shall be provided for
PLC sub-system unless specified otherwise.
The following signals or changes of state shall also be logged as part of the Sequence of
Event functionality:
For each hard wired analog input:
• Shutdown / trip alarm

• Input Measurement diagnostic status (e.g. input out of range)
• Maintenance override status (wherever provided)
• Input force status.
For each hard wired digital input:
• Shutdown / trip alarm

• Input status (e.g., line breakage)
• Maintenance override status (wherever provided)
• Input force status.
5.0 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE
5.1 General
5.1.1 This specification defines the basic guidelines to vendor for factory testing and acceptance,
installation, commissioning and field acceptance of the complete PLC system. On the basis
of this specification, vendor shall submit their own detailed testing, installation,
commissioning and acceptance procedure. For hardware, the procedure shall include test
name, purpose of test, test equipment / set up, definition of input, test procedure, results
expected and acceptance criteria. Similarly for software, it shall include test name, details of
the method, list of tests, sequence of execution, results expected and acceptance criteria. For
PLC system with SIL 3 requirement, certificate for hardware & software (Like TUV/
EXIDA) shall be verified.
5.1.2 The testing and acceptance of the system shall be carried out on the approved testing
procedures and criteria based on this specification and vendor's standard testing
requirements and procedures.
5.2 Factory Acceptance Tests (FAT)
5.2.1 Vendor shall test and demonstrate the functional integrity of the system hardware and
software. No material or equipment shall be transported until all required tests are
successfully completed and certified "Ready for Shipment" by the owner/consultant.
5.2.2 The purchaser reserves the right to be involved and satisfy himself at each and every stage
of inspection. The purchaser shall be free to request any specific test on any equipment
Page 824 of 1296

ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
fge.fi Elf51-eg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2

I .1127r eleoAeON3Odsa3) f A Govt of India Undertaking)
considered necessary by him although not listed in this specification, as a part of approval of
factory testing procedure. The cost of performing all tests shall be borne by the vendor.
5.2.3 Vendor to note that acceptance of any equipment or the exemption of inspection or testing
shall in no way absolve the vendor of the responsibility for delivering the equipment
meeting all the requirements specified in Requisition.
5.2.4 It shall be vendor's responsibility to modify and/or replace any hardware and modify the
software if the specified functions are not completely achieved satisfactorily during testing
and factory acceptance.
5.2.5 Schedule of FAT shall be included in the Vendor's proposal.
5.2.6 Vendor shall not replace any system component/module/sub-system unless it is failed. A log
of all failed components/modules in a sub- system shall be maintained which shall give
description of the failed component/module, effect of failure on the sub-system, cause of
failure and number of hours of operation before it failed. If malfunction of a
component/module in a sub-system repeats, the test shall terminate and vendor shall replace
the faulty component/module. Thereafter the test shall commence all over again. If even
after this replacement, the sub-system fails to meet the requirements, vendor shall replace
the full sub-system by the one meeting the requirements and the system shall be tested all
over again. If a sub-system fails during the test, which is not repaired and made operational
within four hours of active repair time after the failure, the test shall be suspended and
restarted all over again only after the vendor has replaced the device in the acceptable
operation.
5.2.7 Testing and FAT shall be carried out in two phases. The minimum requirements for testing
during these two phases shall be as follows:
5.2.7.1 Under the first phase, vendor shall perform tests at his works to ensure that all components
function in accordance with the specification for each type of test. A test report shall be
submitted for purchaser review within one week of completion of this test. Phase II testing
(witness inspection) shall start only after this.
All sub-systems shall undergo a minimum of 30 days (720 hours) burn-in period and this
can include FAT duration. Should there be a failure noted during FAT, this duration shall be
extended. It may include any such time for which the system has been kept powered on even
for system generation and Phase-I testing.
Following tests shall be performed by the vendor and reports shall be forwarded to
purchaser:
a) Quality control test which shall be carried out to assure quality of all components
and modules in accordance with vendor's quality control and assurance
procedures.
b) System pre-test which shall be physical check of all modules, racks, cabinets etc.
c) System power-up test which shall test functionally all hardware and software. This
shall include testing of redundancy, System performance on power supply
variations, application software testing and system diagnostic verification.
5.2.7.2 The second phase of testing shall systematically, fully and functionally test all hardware and
software in the presence of purchaser representatives. All subsystems shall be
interconnected to simulate, as close as possible, the total integrated system. Following
minimum tests shall be carried out:-
Page 825 of 1296

ENGINEERS
ligar fat5eg INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
1.1127i vwcnreoodOdvA) Govt of Inda UndOttafongl
a) Visual and mechanical testing, which shall be carried out in principle to assure
correct, proper, good and neat workmanship by the vendor This testing shall include
dimensional verification, Layout verification as per approved GA drawings,
Verification of Sheet thickness / Quality of painting (outer and inner) / Nameplates,
identifiers and tag plates / Adherence to ferruling philosophy / Dressing of wires /
prefabricated cables and clearances / Locks and handles as a minimum.
b) Verification of Bill of Material. The Bill of material verification shall include both
hardware and software.
c) Functional testing:
This shall include the simulation of each input and output to verify proper system response.
The testing as a minimum shall include:
i) Complete system configuration loading.
ii) Demonstration of all PLC system builder functions including addition/deletion of an

input/output, addition/ deletion of a rung or an element in a rung, generation of
dynamic graphics and other views, report generation etc.
iii) 100% checking of logics configured in the PLC by connecting switch/lamp at

input/output, by simulating inputs and verifying outputs preferably using simulator,
other related functions like forcing, first out shall also be verified.
iv) Checking of scan time. Scan time verification shall be carried out during Factory
Acceptance Test based on the specified requirements considering discrete input by
given step change and Step input or slow ramp input (typical frequency of 4 cycles /
second) with amplitude corresponding to 16mA (4mA to 20mA or vice versa) for all
conventional analog and smart (HART) inputs from a signal generator. The scan time
values so observed shall be within 90% confidence level.
The inputs to the system shall be:
Step input i.e. 0 or 1 for all contact inputs. Step input can be generated by
wiring back a digital output configured for the purpose.
Step input or ramp input for all analog inputs. However, for PLC, the scan time
check with analog inputs shall only be for record purposes.
v) Checking of all PLC console displays, keyboard and touch-screen operation
(wherever specified), printer/hard copier functions etc.
vi) System redundancy checks including correct changeover of the back-up unit in case
of failure of main unit.
vii) System diagnostic checking for all subsystems on local level as well as on console,
including checking of the testing software for I/O modules/signal conditioning
modules, when specified.
viii) Checking of output status on processor failure.
ix) Checking of first-out alarm generation.
x) Simulation of power failure and system restart auto boot-up of system configuration
and program after power restoration.
5.2.8 Vendor shall notify the purchaser at least three (3) weeks prior to factory acceptance test. In
the event that representative arrives and the system is not ready for testing, vendor shall be
liable for back charges for any extra time and expenses incurred.
Page 826 of 1296

k.11 ^ ENGINEERS
Ogem EtWeggl'
11, INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
?4,,ff (A Govt me undertaking)
5.3 Installation, Testing and Commissioning
5.3.1 Vendor shall offer the services of an installation team which would install the equipment in
the control room, lay the interconnecting cables inside control room, check-out, test and
commission the system.
All technical personnel assigned to the site by the vendor shall be fully conversant with the
supplied system and software package, and shall have both hardware and software capability
to bring the system on line quickly and efficiently with a minimum of interference with
other concurrent construction and commissioning activities.
5.3.2 Vendor's responsibility at site shall include all activities necessary to be performed to
complete the job as per Requisition including:
a) Receipt of hardware/software and checking for completeness of supplies.
b) Installation of the system including for free supply equipment, if any.
c) Field cable termination and inter-cabinet cabling and termination.
d) Check out equipment installation.
e) Checking of interconnections, hardware and software configuration, overall system
functioning etc.
f) Loop checking.
g) Field tests.
h) Commissioning and on-line debugging of the system.
i) Involvement during plant commissioning and performance of final acceptance test.
j) Co ordination for integration with DCS / other third party system.
5.3.3 Field Inspection
5.3.3.1 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action, in case
unsatisfactory operation of any item is observed, with intimation to Engineer-in-charge.
5.3.3.2 Vendor must document all observations including details of any malfunction observed.
Items/ equipments requiring total replacement must document the reasons for the same.
5.3.4 Loop Checking
5.3.4.1 Loop checking shall be carried out by vendor including checking the interconnections,
configuration and overall system functioning.
5.3.4.2 Vendor's scope of work as a part of system installation and loop checking shall include
termination of field cables in the control room, checking of interconnection between
instrument/equipment, glanding, ferruling/tagging of interconnecting cables in control room,
ferruling of field cables in control room and performing overall loop performance check.
5.3.4.3 Vendor shall coordinate with the field contractor for smooth and proper loop checking. Any
discrepancy found during checking shall be brought to the notice of the Engineer-in-Charge.
Complete loop checking shall be performed in his/her or his/her authorised representative's
presence.
5.3.4.4 The input signals shall be simulated by disconnecting/connecting the field wires for all field
switches connected to PLC. All field transmitters connected to control room shall be loop
checked at 0%, 50% & 100% of full scale (for both increasing and decreasing signals).
Wherever receiver cards are used, the set point shall be generated by giving the input signal
to receiver card. All outputs shall be checked in field, either for actual operation of solenoid
valve or actual pick-up of electrical contactor for rotary equipments. Shutdown schemes
shall be checked for proper functioning, configuration and actuation.
Page 827 of 1296

‘511 Wei&ENGINEERS
sigif fageg WV INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
LIRA 292aAi as IrtClAI (A Govt of India Olden Moog)
5.3.4.5 After loop checking is completed, vendor shall connect back any terminals and connections
removed for loop checking.
5.4 System Acceptance
5.4.1 The owner shall provisionally takeover the system from vendor after System acceptance
test. System acceptance test shall be started only after the satisfactory performance of loop
checking and verification of all loop checking records by Engineer-in-charge.
5.4.2 The system acceptance test shall be carried out in the presence of owner's representative and
Engineer-in-charge or his authorised representative. The tests carried out in System
acceptance test shall be fully recorded and duly signed by all representatives participating in
the System Acceptance Testing.
5.4.3 Vendor shall carry out the following functional tests, as a part of system acceptance test, as a
minimum:-
a) Hardware verification as per final Bill of Material.
b) Visual and mechanical check-up for proper workmanship, identification,
ferruling, nameplates etc.
c) System configuration as per approved configuration diagram.
d) Demonstration of all system function, display and diagnostics.
e) Checking of correct change-over of redundant devices.
f) Checking of various peripheral devices like printers and printing of all reports.
g) Complete checking of logic system, loading of user's program and checkout of
results.
h) Checking of proper functioning of all disc drives, alarm summary, alarm history
etc.
i) Proper information transfer on the information network by verifying system
displays and printout.
5.5 Final Acceptance Test
The owner will take over the system from the vendor after the final acceptance test, which is
defined as successful uninterrupted operation of the integrated system for three weeks.
Vendor's personnel shall be present during the test. Any malfunctioning of the system
components shall be replaced / repaired as required. Once the system failure is detected, the
acceptance test shall start all over again from the beginning. The warranty period
commences from the day owner takes over the system.
6.1 Vendor shall comply fully with the general requirements of PLC system including logistic
support services, documentation, warranty, maintenance contract and shipping instructions.
Post Warranty Maintenance Contract
Vendor shall quote separately for post warranty maintenance contract after warranty period
for five years for the complete system as per commercial terms and condition of the
requisition and the type (i.e. comprehensive or non-comprehensive) of post warranty
maintenance shall be as specified in job specification. The personnel deployed during post-
warranty maintenance shall have thorough knowledge of the system and at least two years
of experience on the maintenance of similar system. Any other conditions of contract
required by vendor shall be explained in the offer.
Page 828 of 1296

16iaziEqA6 ENGINEERS
tifift mwr INDIA LIMITED FOR PROGRAMMABLE LOGIC 6-52-0040 Rev. 2
laiR77 2.12000 0,10,11.1) (A Govt of India Undertaking)
7.0 SHIPPING
7.1 All the materials used for packing, wrapping, sealers, moisture resistant barriers and
corrosion preventers shall be of recognised brands and shall conform to the best standards in
the areas for the articles which are packed.
7.2 Workmanship shall be in accordance with best commercial practices and requirements of
applicable specification. There shall be no defects, imperfections or omissions which would
tend to impair the protection offered by the package as a whole.
7.3 The packing shall be suitable for storing in tropicalised climate, the ambient conditions,
being specified in job specifications.
7.4 Shipment shall be thoroughly checked for completeness before final packing and shipment.
Vendor shall be responsible for any delay in installation or commissioning schedule because
of incomplete supply of equipments.
8.0 REJECTION
8.1 Vendor shall make his offer in detail with respect to every item of the purchaser's
specifications. Any offer not conforming to this shall be summarily rejected.
Page 829 of 1296

15i1P-aeq ENGINEERS STANDARD SPECIFICATION
2f5leg INDIA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 7
1 4.271 4513.713.3) IA Govt of India Undertaking)
Page 1 of 8
Rpm eicei* i(vR 141-1.-W fe-47T

SIGNAL CABLES
7 28.03.17 Revised and Reissued as Standard Specification SMI4 RK
6 15.12.10 Revised and Reissued as Standard Specification RSD RP TGM/JMS
5 03.05.05 Revised and Reissued as Standard Specification NPG AKG PM
4 27.01.98 Revised and Reissued as Standard Specification PM RK BRS
3 10.06.97 Revised and Reissued as Standard Specification PM RK BRS AS

Standards Standards
Committee Bureau
No by by
Approved by
Page 830 of 1296

■_71 ENGINEERS STANDARD SPECIFICATION
INDIA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 7
IA Govt Of NIOta Undertakmq)
Page 2 of 8
Abbreviations:
DC Direct Current
EPR Ethylene-Propylene Rubber
FR Flame Retardant
PE Polyethylene
PETP Polyethylene Terepthalate
PVC Polyvinyl Chloride
XLPE Cross Linked Poly Ethylene

Mr. Sandeep Arora
Mr. A.S.D. Barman
Mr. S. Mahesh Kumar
Page 831 of 1296

1511WIzE? ENGINEERS
Oge..0 2151eg S INDIA LIMITED
(A GM of Inde Undenak.9)
FOR SIGNAL CABLES 6-52-0046 Rev. 7
Page 3 of 8
CONTENTS
1.0 GENERAL 4
3.0 NAMEPLATE 7
5.0 SHIPPING 8
Page 832 of 1296

18110aEg ENGINEERS
Itgar tif5reg
WWI 2.1205r2id Jt4.11
S INDIA LIMITED
(A Govt of IWO Undeffakmg)
Page 4 of 8
1.0 GENERAL
1.1 Scope
1.1.1 This specification, together with the data sheets, covers the requirements for design, materials,
manufacturing, inspection, testing and shipping of signal cables.
1.1.2 Cables shall comply with latest edition of the following standards prior to the date of the
purchaser's enquiry.

D 2843 Standard Test Method for Density of Smoke from the
Burning or Decomposition of Plastics.
D 2863 Test method for measuring the minimum oxygen
concentration to support candle like combustion of
plastics (oxygen index).
BS EN50288-7 Multi-element metallic cables used in and digital

communication and control. Sectional specification
for instrumentation and control cables
IEC International Electro technical Commission
540 & 540A Test methods for insulation and sheaths of electric Cables
60331 Testing of Fire Resistant cables.
60332 Tests on bunched wires and cables.
60092 Electrical Installations of Cables
60754 Test on Gases Evolved during Combustion of materials
from Cables — Part 1, 2.
IS Indian Standards
1554 Part 1 PVC insulated (heavy duty) electric cables-working

Voltage up to and including 1100V.
3975 Mild steel wires, formed wires and tapes for armouring of
Cables.
5831 PVC insulation and sheath of electric cables.
6380 Elastomeric insulation and sheath of electric cables
6474 Polyethylene Insulation and sheath of electric cables
7098 Cross-Linked Polyethylene Insulated PVC sheathed
Cables
10810 Method of test for cables.
Part 40 Method for testing uniformity of Zinc coating on Steel
armour
Part 41 Mass of zinc coating on steel armour
Part 58 Oxygen Index test
Part 59 Determination of the amount of halogen acid gas evolved
during combustion of polymeric material taken from
cables
Part 61 Flame Retardant test
Part 62 Flame Retardance test for bunched cables
Part 63 Smoke densities of electric cables under fire conditions
Part 64 Measurement of Temperature Index
b) Data Sheets
Page 833 of 1296

16dWie? ENGINEERS STANDARD SPECIFICATION
51g-ar iWitu
1.4RA KAecnrennanasA)
INDIA LIMITED
IA Got of India Undertaking)
Page 5 of 8
1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached with the
material requisition.
1.2.2 All documentation submitted by vendor including their quotation, catalogues, drawings and
documents etc. shall be in English language only.
1.2.3 Vendor shall furnish unit price per metre for each type of cable, which shall be used for any
addition or deletion of the quantity.
1.3.1 Detailed drawings, data and catalogues required from the vendor are indicated by the purchaser
in the vendor data requirement sheets. The required number of prints and soft copies should be
dispatched to the address mentioned, adhering to time limits indicated.
1.3.2 Final documentation consisting of design and constructional data submitted by the vendor after
placement of order shall include the following, as a minimum.
a) Specification sheet for each type of cable along with test certificates and test reports.
b) Cable details giving electrical characteristics, overall diameter, diameter under armour
and diameter over armour.
2.1 Constructional Requirements
2.1.1 Cables shall be heavy-duty type, 650/1100V grade.
Primary insulation for PVC insulated cables, shall be 85°C polyvinyl chloride Type C as per IS
5831. Thickness of primary insulation shall be 0.5 mm as a minimum. For PE insulated cables,
primary insulation shall be of 70° C Polyethylene. For XLPE insulated cables, primary
insulation shall withstand maximum conductor temperature of 90° C and shall meet the
requirement specified in IS-7098 (Part-1).
The type of primary insulation shall be as specified in purchasers data sheets.
2.1.2 Inner sheath colour of signal cables shall be black. Outer sheath colour shall also be black
except for cables used in intrinsically safe systems. The outer sheath colour for all such cables
used in intrinsically safe application shall be light blue. The thickness of the sheath shall be as
per IS 1554 part 1.
2.1.3 Inner and outer sheath of cable shall be flame retardant made of extruded PVC Type ST2 (90°C)
as per IS 5831 and shall meet the following requirements:
a) Minimum Oxygen index of PVC shall be 30 at 27 °C ±2°C.
b) Temperature index shall be over 250 °C.
c) Inner and Outer sheath shall meet flame retardant requirements for bunched cables as
per IS 10810 (Part 62) category AF or IEC 60332 category A.
d) A rip cord shall be provided for inner sheath.
e) Outer sheath shall be suitable for protecting the cable against rodent and termite attack.
Page 834 of 1296

afa.z..lelia, ENGINEERS STANDARD SPECIFICATION
faigteg ■ INDIA LIMITED
Govt 1ncla Undettak.g)
Page 6 of 8
2.1.4 Armour over inner sheath shall be of galvanised steel wire/flat. The dimensions of armour shall
be as per IS 1554 (Part 1). Requirement and methods of tests for armour material and uniformity
of galvanisation shall be as per IS 3975 and IS 10810 (Part 40) respectively.
2.1.5 Each pair/triad shall be shielded. Shield shall be of aluminium backed by mylar / polyester tape
bonded together helically applied with metallic side down having 25% overlap on either side
and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall be 0.5 mm 2
multi-srandbe lcoprndut.Theaiwrslbncotu
contact with aluminium side of the shield.
2.1.6 Overall shield shall be of aluminium backed up by mylar/polyester tape helically applied with
the metallic side down with either side having 25% overlap and 100% coverage. Minimum
shield thickness shall be 0.075 mm. Drain wire shall be similar to individual pair/triad drain
wire and shall be over the overall shield.
2.1.7 The cores of a pair triad shall be twisted with a minimum of 10 twists per metre of cable.
2.1.8 Sequential marking of the length of the cable in meters shall be provided on the outer sheath at
every one meter. The embossing /engraving/printing shall be legible and indelible.
2.1.9 Tolerance in overall diameter of cable shall be within ± 2 mm over offered value.
2.1.10 The cables used in installations under the jurisdiction of Director General of Mines and Safety
(DGMS) shall meet all requirements of DGMS. The word "Mining Cable" shall be embossed on
the cable outer sheath as per IS 1554 (Part 1).
2.1.11 Drum length and length tolerance

The length of the cables in each drum (drum length) shall be as specified in the purchaser data
sheets. Where no drum length is indicated in the data sheet /material requisition, the following
shall be apply:
Drum length for single pair/ single triad cable : 500 metres
Drum length for multi-pair/ multitriad cable : 1000 metres
Actual produced drum length shall not vary by more than ± 3% from the length indicated in
purchaser's datasheet or clause 2.1.11.1 of the specification.
2.1.12 Tolerance over the total ordered length shall not vary by more than ± 2% for total length for a
type of cable.
2.1.13 Specific Requirements for fire resistant or fire survival cable.
2.1.13.1 The cables shall have circuit integrity as per IEC 60331.
2.1.13.2 Primary insulation shall be heat resisting elastomeric which can withstand temperature up to
90°C such as silicon rubber/mica glass tape/EPR (medium grade) as per IS 6380. Insulation
thickness shall be 1.0mm minimum (0.44 mm for Silicon rubber) and shall confirm to IEC
60092.
2.1.13.3 Individual pair triad shall be shielded. The shield shall be aluminium backed by mylar/PETP
tape with the metallic side down helically applied with 25% overlap on either side and 100%
coverage. Minimum shield thickness shall be as per IEC 60092. Drain wire shall be 0.5mm 2
(7/0.3mdia)ult-srneb dalcopernut.Daiwshlben
continuous contact with aluminium side of the shield.
2.1.13.4 Inner and outer sheath shall be made of low smoke, heat resistant, oil resistant and flame
retardant material with oxygen index over 30, temperature index shall be over 250°C. Acid
generation shall be maximum 20% by weight as per IEC 60754. Smoke density rating not to
exceed 60% as per ASTM D 2843.
2.1.13.5 The thickness of the sheath shall be as per IEC 60092. Inner and outer sheath colour shall be
orange. A rip cord shall be provided for inner sheath.
Page 835 of 1296

Iii INDIA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 7
212nRe MIJPS1,71) IA Govt of India Undertaking)
Page 7 of 8
2.2 Electrical Characteristics
2.2.1 Maximum DC resistance of the conductor of the finished cable shall not exceed 7.41 n / km at
20°C for cables with 2.5 mm 2 conductors, 12.3 CI / km at 20°C for cables with 1.5 mm 2
2 conductors. condutrsa39.7S2/km0°Cforcableswith.5m
2.2.2 Capacitance
2.2.2.1 Mutual Capacitance for PVC Insulated cables

The mutual capacitance of between pairs/triads or adjacent cores shall not exceed of 250 pF /
metre at a frequency of 1 KHz.
2.2.2.2 Mutual Capacitance for PE/XLPE Insulated cables
The mutual capacitance between the pairs/triads shall not exceed of 100 pF / metre at a
frequency of 1 KHz.
2.2.2.3 Capacitance between any core or screen
The capacitance between any core and screen shall not exceed a maximum of 400 pF / metre
at a frequency of I KHz.
2.2.3 L/R ratio of adjacent core shall not exceed 60 till / S2 for cables with 1.5 mm 2 conductors, 40
/ SI for cables with 1.5 mm 2 conductors and 25 micro h / II for cables with 0.5 mm 2
condutrs.
2.2.4 The drain wire resistance including shield shall not exceed 30 S2 / km.
2.2.5 Electrostatic noise rejection ratio of the finished cable shall be over 76 dB.
2.3 Type I (Single pair/Triad shielded).
2.3.1 Each core shall be 1.5/2.5 mm 2 (as per respective data sheet) made of 7 stranded annealed
electrolytic copper conductor. Each strand shall be 0.53 mm dia.
2.3.2 Colour of core insulation shall be black and blue in pair and black, blue and brown in a triad.
2.3.3 All other specifications shall be as per clauses 2.1. and 2.2 of this specification.
2.4 Type-II (Multi-pair/Multi-triad cable with individual pair/triad shield and overall shield)
2.4.1 Conductor sizes shall be 0.5mm 2 made up of 7 strands of annealed electrolytic copper
conductor. Each strand shall be of 0.3 mm diameter.
2.4.2 Overall twist of all pair/triads shall be as per vendor's standard.
2.4.3 A pair of communication wire shall be provided for multipair / multitriad cables. Each wire
shall be 0.5 mm2 of plain annealed single or multistrand copper conductor with 0.4 mm thick
85°C PVC insulation. Insulation shall be green and red colour coded.
2.4.4 A pair identification shall be with numbers at interval of not more than 250 mm.
2.4.5 All other specifications shall be as per clauses 2.1. and 2.2 of this specification.
2.5 Type-III ((Multi-pair/ Multi-triad cable with individual pair/triad shield and overall shield))
2.5.1 The cable shall be same as type-II cable, except conductor size shall be 2.5 mm 2 made of 7
stranded annealed electrolytic copper conductor. Each strand shall be of 0.53 mm dia.
2.6 Type-IV (Multi-pair /Multi-triad cable with individual pair shield and overall shield)
2.6.1 The cable shall be same as Type II, except conductor size shall be 1.5 mm 2 made of 7 stranded
annealed electrolytic copper conductor. Each strand shall be of 0.53 mm dia.
Page 836 of 1296

∎3I ele ENGINEERS STANDARD SPECIFICATION
$I ii OV.leg INDIA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 7
IA Gov. of India Undertaking)
Page 8 of 8
3.0 NAMEPLATE (Identification on Cable Drums)

Each cable drum shall be marked with the following information at a visible place;
a) Manufacturer's name
b) Type and size of the cable with cable indicated in material requisition.
c) Length of the cable in meters contained in the drum.
d) Gross weight
e) Drum number
f) Direction of rotation of drum for unwinding by means of an arrow.
g) Purchase order number.

4.1 Purchaser reserves the right to inspect and witness testing at vendor's works as per Inspection
Test Plan. All these tests shall be completed by the vendor and test reports shall be submitted
to Purchaser for scrutiny.
4.2 Immediately after completion of electrical tests, the ends of the cable shall be sealed to prevent
Ingress of moisture with suitable PVC / rubber caps.
5.0 SHIPPING
Cables shall be dispatched in wooden drums securely battened, with takeoff end fully
protected against damage. Minimum number of eight PVC/rubber end caps shall be shipped
with each drum.
Page 837 of 1296

Ogar0154'dg
.
ala_it4 ENGINEERS
INDIA LIMITED
INSTRUMENTATION OF
PACKAGE UNITS
6-52-0052 Rev. 3
,A Govt of Indla Undertaking) Page 1 of 58
Ada fry
*o-t-§al21mm ITFTW fq fff -kmRT

INSTRUMENTATION OF PACKAGE
UNITS
3 16.03.15 REVISED AND REISSUED
2 29.06.09 REVISED AND REISSUED

RG RP TGM ND
1 25.06.97 REVISED AND REISSUED. RK BRS RB AS
0 30.06.86 ISSUED AS STANDARD SPECIFICATION. RK RB AKV AK

Standards Standards
Committee Bureau
No by by
Approved by
Page 838 of 1296

ENGINEERS INSTRUMENTATION OF
&
$'1gal• faiW
IA Govt of India Undeflaking) PACKAGE UNITS Page 2 of 58
Abbreviations:
AARH •. Arithmetic Average Roughness Height

AC :. Alternating Current
AWG American Wire Gauge
CPU Central Processing Unit
CRCA .: Cold Rolled Cold Annealed
DCS •. Distributed Control System
DPDT :. Double Pole Double Throw
DPST :. Double Pole Single Throw
DTM Device Tool Manager
DVD Digital Versatile Disc
EDDL Electronic Device Description Language
FDT .: Field Device Tool
FF :. Foundation Fieldbus
FISCO :. Fieldbus Intrinsically Safety Concept
FNICO •. Fieldbus Non-Incendive Concept
HART •. Highway Addressable Remote Transducer
HIC Hand Indicating controller
HMI Human Machine Interface
HT .• High Tension
110 •. Input /Output
IP •. Ingress Protection
IU •. Interface Unit
LAS •. Link Activity Scheduler
LT Low Tension
MAWP .• Maximum Allowable Working Pressure
MCB :. Miniature Circuit Breaker
MCC •. Motor Control Center
MR •. Material Requisition
NB -. Nominal Bore
NC Normally Close
NO Normally Open
NPT National Pipe Threads
NPTF •. National Pipe Threads Female
NPTM •. National Pipe Threads Male
P&ID -. Piping and Instrumentation Diagram
PID :. Proportional, Integral and Derivative
PLC •. Programmable Logic Controller
PTC •. Performance Test Code
PTFE :. Poly Tetra Fluoro Ethylene
PVC :. Poly Vinyl Chloride
RAM :. Random Access Memory
RB •. Rockwell Hardness in B Scale
RTD :. Resistance Temperature Detector
Page 839 of 1296

n31 ENGINEERS INSTRUMENTATION OF
Oe.11 tlf5ieg INDIA LIMITED 6-52-0052 Rev. 3
IvIten eivtutzmatmissif Govt of India UrvIertaktng) PACKAGE UNITS Page 3 of 58
RTU Remote Terminal Unit

SOV • Solenoid Valve
SPDT • Single Pole Double Throw
TFT • Thin Film Transistor
TMR Triple Modular Redundant
UPS • Uninterrupted Power Supply
URV Upper Range Value
WC Water Column
Convener : Mr. Rajiv Gupta
Members : Mr S Bhowal
Mr M Nandi
Mr R K Gupta
Ms Rima Kundu
Mr S Mahesh Kumar
Ms. N.P.Guha (Proj.)
Page 840 of 1296

43* ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
sl ar Wes
g
NV, rieaxt
INDIA LIMITED
IA Govt of hrhA Unde,taong) PACKAGE UNITS Page 4 of 58
CONTENTS
PART I GENERAL SPECIFICATION OF INSTRUMENTATION 5
1.0 GENERAL 6
2.0 DESIGN PHILOSOPHY 12
3.0 SPARES PHILOSOPHY 19
4.0 GENERAL SPECIFICATION OF INSTRUMENTS 20
5.0 LIST OF DOCUMENTS ATTACHED 46
PART II SPECIFICATION FOR MATERIAL, INSTALLATION, TESTING AND

COMMISSIONING 47
1.0 INSTALLATION MATERIALS 48

2.0 INSTALLATION 54
3.0 TESTING AND CALIBRATION 56
4.0 COMMISSIONING 58
ANNEXURES:
ANNEXURE — I MATERIAL SELECTION CHART

ANNEXURE — II BLANK FORMATS
Page 841 of 1296

0 e1 ENGINEERS INSTRUMENTATION OF
OQzll taRcg INDIA LIMITED
6-52-0052 Rev. 3
n AVIRot ottratte On avast. Govt Ind. unciertakog) PACKAGE UNITS Page 5 of 58
PART I
GENERAL SPECIFICATION OF
INSTRUMENTATION
Page 842 of 1296

$1g-ar laf5teg INDIA LIMITED 6-52-0052 Rev. 3
r.tea v/vore attow)i) IA GovtofIndia Undertaking) PACKAGE UNITS Page 6 of 58
1.0 GENERAL
1.1 Scope
1.1.1 This specification together with the attachments covers the design and engineering of
instruments, control systems, accessories and materials, along with special test equipments,
where the supply is part of a package being supplied by vendor. This specification is general
and all instruments/systems included may not be required for the proposed package. The
scope shall be as defined in the scope of supply of Instrumentation.
1.1.2 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc.
if any, will be indicated in Scope of Supply of Instrumentation and Job Specification of
Instrumentation included in the material requisition.
1.1.3 This specification provides only the qualitative specifications of commonly used
instruments. Specifications of Instruments not covered in this specification shall be
submitted by vendor for review by Purchaser.
1.1.4 Vendor shall be fully responsible for design, material selection, sizing and selection of the
proper instruments for their system. The compliance to this specification does not absolve
the vendor of the responsibility towards contractual obligations with regards to
completeness, proper selection, satisfactory operation and easy maintenance of the unit.
1.1.5 All items, as offered, shall be field proven and should have completed trouble free
satisfactory operation for a period of minimum 6 months on the bid due date in the similar
application with the process conditions similar to those as specified in the purchaser's data
sheets. Items with proto-type design or items not meeting provenness criteria specified
above shall not be offered
1.1.6 In the event of any conflict between this specifications, data sheets, related standards, codes
etc., the vendor shall refer the matter to the purchaser for clarification and only after
obtaining the same should proceed with the manufacturing/engineering of the item in
question. DCS/ PLC is not included in this specification. Vendor shall refer specifications
attached separately in case DCS/ PLC is included in scope of supply.
1.2 Bids
1.2.1 Vendor shall provide the following information along with their offer:
Compliance to Complete Material Requisition/Tender.
Utility requirements including Power consumption and Instrument air supply

consumption. The offer shall indicate the power requirement for Uninterrupted Power
Supply (UPS), Non-UPS and DC power clearly indicating the locations for each.
Estimated heat load for the equipment located in control room.
Control room size and layout (Tentative)
1.2.2 Vendor shall clearly define the operational philosophy proposed, which shall be in line with
requirements specified in the job specification. Vendor shall also clearly indicate the
provision of control panels and control systems required for the package along with offer.
1.2.3 Documents like Instrument list and typical specifications and any other details if submitted
by vendor in their bid, shall not be reviewed and shall be retained for records only. All such
details shall be submitted by vendor only after the finalisation of P&ID (Piping and
Instrument Diagram) during detail engineering. No implication shall be admissible on the

Format No. 8-00-0001-F1 Rev. 0 Copyright EL — All rights reserved
Page 843 of 1296

Og.r..1101Wteg INDIA LIMITED 6-52-0052 Rev. 3
IA Govt of InOta UndettakIngt PACKAGE UNITS Page 7 of 58
basis of these documents and vendor shall be responsible for completeness and correctness
of the same with respect to Purchase Requisition/Tender.
1.2.4 Vendor's offer, catalogues, drawings, instrument manuals etc. shall be in English.
1.2.5 In addition to mandatory spares, commissioning and consumables indicated elsewhere in

this specification, Vendor shall also quote recommended spares for 2 years normal operation
for the complete instrument and control system for the offered package.
1.3 Applicable National/International Standards:
1.3.1 Design and terminology shall comply, as a minimum, with the latest edition of following
codes, standard practices and publications, unless otherwise specified:
AGA American Gas Association, Gas Measurement Committee
Report No.3 Orifice Metering of Natural Gas and Other Related
Hydrocarbon Fluids — Concentric, Square-Edged Orifice
Meters
Report No.7 - Measurement of Natural Gas by Turbine Meter
AG181 Foundation Fieldbus System Engineering Guidelines

1.20.1 Pipe Threads.
16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24
16.47-B Large diameter Steel Flanges: NPS 26 Through NPS 60
16.20 Ring Joint Gaskets and Grooves for Steel Pipe Flanges.
ANSI/FCI American National Standards Institute/Fluid Controls Institute

70.2 Control valve seat leakage classification.

RP 520 Sizing, Selection and Installation of Pressure Relieving
System in Refineries.
Part-I - Sizing and Selection
Part-II - Installation
RP 521 Guide for Pressure Relieving and Depressurising Systems.
RP 526 Flanged Steel Safety Relief Valves.
RP 527 Seat Tightness of Pressure Relief Valves.
MPMS Manual of Petroleum Measurement Standards.
RP 551 Process Measurement Instrumentation.
Part 1 - Process Control and Instrumentation.
RP 552 Transmission Systems
RP 554 Process Instrumentation and Control
RP 555 Process Analysers
S 2000 Venting Atmospheric and low pressure storage tank.
S 670 Machinery Protection Systems

ASME Boiler and Pressure Vessel Code (BPVC), Section VIII,
Division 1: Rules for Construction of Pressure Vessels.
PTC 19.3 TW :2010 & ERATA 2012
THERMOWELLS Performance Test
MFC-3M Measurement of Fluid Flow in Pipes using Orifice, Nozzle
and Venturi

Page 844 of 1296

tgz1T tte--'
eg INDIA LIMITED 6-52-0052 Rev. 3
1.1¢F, eironeffoJoso•i) (A Go. of WO UndeffOk,o9) PACKAGE UNITS Page 8 of 58
MFC-14M Measurement of Fluid Flow in Pipes using Small Bore

Precision Orifice Meters
ASTM American Society for Tests and Materials

EN 50288-7 Multi Element Metallic Cables used in Analogue and Digital
Communication and Control — Part-7 : Sectional
specification for Instrumentation and Control cables
EN 10204 Inspection Document for Metallic Products
IBR Indian Boiler Regulations.
IEC International Electrotechnical Commission.

60079 Electrical Apparatus for Explosive Gas atmosphere.
60085 Electrical Insulation — Thermal Evaluation and Designation
60332 Tests on electric and optical fibre cables under fire conditions
- Part 1-1: Test for vertical flame propagation for a single
insulated wire or cable - Apparatus
Parts and Sections
60529 Classification of degree of protection provided by enclosures.
60534-2 Industrial Process Control Valves-Flow capacity.
60584-2 Thermocouples — Tolerances
60751 Industrial Platinum Resistance Thermometer and Platinum
Resistance Sensors
61285 Industrial Process Control Safety of Analyser Houses
61000-4 Electromagnetic compatibility for Industrial Process
measurement and Control equipment
61158 Foundation Fieldbus Specifications
61804-3 Functional blocks for process control — part 3 Electronic
Device Description Language (EDDL)

IS Indian
Standard
5 Colours for ready mixed paints.
319 Specification for free cutting Brass bars, rods and sections
1239 Mild steel tubes, tubulars and other wrought steel fittings
1271 Specification of Thermal Evaluation and Classification of
Electrical Insulation
1554 PVC insulated (heavy duty) electric cables-working
Part I voltage upto and including 1100V
2074 Ready mixed paints, air drying, red oxide- zinc chrome.
3624 Specification for pressure and vacuum gauges
5831 PVC insulation and sheath of electric cables
7358 Specifications for Thermocouples
8784 Thermocouple compensating cables

S-5.2 Binary logic diagrams for process operations.
S 7.0.01 Quality standard for Instrument Air
S-75.xx Standards related to Control Valves
ISO 5167 Measurement of fluid flow by means of orifice plates, nozzles and venturi
tubes inserted in circular cross-section conduits
ITK Interoperability Test Kit (latest version)

Page 845 of 1296

1
k3 ENGINEERS INSTRUMENTATION OF
tif5lreg INDIA LIMITED 6-52-0052 Rev. 3
.W1 03/1 (A Gov/ of India Untlertakolg) PACKAGE UNITS Page 9 of 58
NEC National Electric Code
NEMA National Electrical Manufacturer's Association
NFPA-496 National Fire Protection Association - Purged and pressurised enclosures for
electrical equipment
OSHA Occupational Safety and Health Authorit.
SAMA Scientific Apparatus Maker's Association

1.4.1 Detailed drawings, data and catalogues required from the vendor shall be as per Vendor
Data Requirement attached elsewhere in the Material Requisition / Tender.
1.4.2 The minimum requirements expected from the various documents listed in Vendor Data
Requirement shall be as follows:
1.4.2.1 Document Control Index (DCI)
This document lists out all drawings and documents prepared and/or submitted by vendor to
purchaser after placement of order through vendor portal. Following information shall be
available in this document:
Name and number of each drawing and document listed.
Expected and Actual date of submission to purchaser.
c) Review category of the documents
1.4.2.2 Instrument Index
Instrument Index lists out all instruments appearing on the P&ID without any exception. It
is a basic instrument document which is necessary for the smooth execution of a job and is
also a reference document after the completion of job. Instrument Index shall be prepared in
EIL Format. In case, any other format is used, it must contain all information as listed in
this format as a minimum.
1.4.2.3 Sub Vendor List (for Instruments and Accessories)
This document shall list out all instrument items and accessories including control system
along with the name of the sub-vendors from whom vendor is likely to procure these items.
Instrument Sub-vendor shall meet the enlistment conditions of Ell, approval at the time of
placing the order on sub-vendor for the Project Approved Vendor List. The EIL approval
conditions are available with the Sub-Vendors. Vendor shall follow the approval
requirement.
For Instruments / items not covered in the vendor list, Vendor shall get approval from
purchaser/ owner for the vendors proposed, prior to the placement of order. In such cases the
sub-vendors suggested shall be manufacturer of repute and it shall meet the provenness
criteria specified in this document.
1.4.2.4 Instrument Sizing Calculations
Instrument sizing calculations provide information regarding sizing (as per standards
specified else-where in this document), type, selection and other related information.

Page 846 of 1296

51:4231a5teg
1.1771 rirc.t .,,J,12M11 IAGoNatIWOUndfr,dkiO, PACKAGE UNITS Page 10 of 58
Following sizing calculations shall be applicable, in general, duly approved by the authority
indicated in Vendor's Standard Quality Plan;
Control valve including noise and velocity.

Pressure relief valves/pilot operated pressure relief valves/rupture disc/breather
valve/flame arrester.
Flow element including orifice plates, averaging pitot tubes, venturi, flow nozzle etc.
Utility consumption calculation including power supply (UPS/Non UPS), Instrument
air, steam for tracing, cooling water, nitrogen etc.
Cable sizing calculations for power cables.
Intrinsically safe loop calculation for proper selection of cables considering various
entity parameters.
Segment loading calculations.
Thermowell wake frequency calculations as pe ASME PTC 19.3 TW-2010
1.4.2.5 Utility Requirements
This document lists out the following information regarding utilities required by the vendor;
List of utilities required i.e. Power (UPS, Non UPS), Instrument air, Cooling water,
steam for tracing, Nitrogen etc.
Location and estimated/actual requirement at each location. The requirement shall be
listed as minimum/normal/maximum.
Incase of AC power, the In-rush current with duration and power factor shall also be
indicated for each location.
In case of cooling requirement of any instrument/equipment, vendor shall provide the
detail of pressure/flow requirement with location.
1.4.2.6 Nozzle Elevation for Level Instruments
Nozzle elevation for level Instruments represent the nozzle elevation, nozzle sizes and
rating, requirement of stand-pipes, type of level instrument etc. for all the vessels, columns,
exchangers and tanks.
1.4.2.7 Purchase Requisition (PR)
Purchase Requisition shall contain following information as a minimum but updated in line
with the finally accepted offer of the successful vendor including:-
Instrument specifications including detailed instrument data sheet and special

requirements, if any
Testing and Inspection requirements
Vendor data requirements
Other related documents like Standard Specifications, Quality Assurance requirements etc.
1.4.2.8 Functional Schematics
Functional Schematics details out the functionality of all the loops shown on the P&ID
including their correlation. The schematic shows all the hardware necessary to configure a
loop including their physical location, their interconnection and important software blocks as
applicable to make a loop complete. Similar loops may be combined under the same
functional schematic.

Page 847 of 1296

tg‘-ar Oa& INDIA LIMITED 6-52-0052 Rev. 3
erraretraJwom, IA Gort of intha Under/along) PACKAGE UNITS Page 11 of 58
1.4.2.9 Logic Diagrams
Logic diagram is a logic representation of process interlock and shutdown system and details
out the functionality, in a schematic form, as either process cause and effect table shown on
the P&ID or in a separate write-up. The schematic shall be prepared based on ISA S5.2 — A
Binary Logic Diagrams for Process Operations and shall show the physical location of
Input/output devices, their interconnection with functional blocks, bench status of all
electrical devices etc. The schematic shall also be supplemented with operational
requirements like startup and process bypasses, reset and shut down push buttons, selector
switches, status lamp etc.
1.4.2.10 Segment Drawing
The FF segment drawing provides the complete segment design details indicating all the
devices of a segment, the Tag names, device control/monitoring functional requirements,
spur length, FF Junction box barriers connectivity, termination details, location of JB etc.
1.4.2.11 Instrument Loop drawings
Each loop shall have a separate Instrument Loop drawing which shall show each component
from field device to final receiver including physical location; initiating device, its terminal
number; junction box with its terminal number; cable number with pair number/polarity;
receiver instrument terminals/cabinet terminals; system functional blocks of loop in
simplified manner (without configuration details).
1.4.2.12 Control Room Layout
Control room layout drawing shall show the location of control panels, system cabinets,
marshalling racks and other auxiliary cabinets, consoles with monitors, hard wired consoles,
printers, non-system panels/cabinets including panels/cabinets for packages, LEL panel, fire
alarms panels or any other equipment required to be installed in control room. The layout
shall be prepared on control room architectural drawing and shall also show layout of
equipment in engineering room/computer room etc.
1.4.2.13 Panel Front Arrangement
This drawing shall show the arrangement of panel mounted instruments like indicating
instruments, alarm annunicator, indicating lamps, push buttons/switches etc. including their
approximate sizes and their mounting locations.
1.4.2.14 Configuration Diagram
This drawing is a graphical representation of all major hardwares required in a configurable

control system which are necessary to meet all the expected functional requirements.
1.4.2.15 Dynamic Graphic Display Drawings
These drawings provide a graphic representation of P&ID's arranged in a sequence which

when displayed on the HMI, shall provide easy and logical operational views.
1.4.2.16 Input/ Output Assignment
This document indicates the physical assignment of various I/O modules and their respective
channels to various physical inputs and outputs.
1.4.2.17 Instrument Duct/ Tray/ Trench Layout
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Ogar
g tif5te INDIA LIMITED 6-52-0052 Rev. 3
t412,, ,-trotte ott3O0A1 Govt 0 Indo Uncle„a„n, PACKAGE UNITS Page 12 of 58
Instrument duct/tray trench drawing shows the routing of main instrument duct/tray trench in
the unit/plant. The drawing shall be prepared on plot-plan/ Equipment layout and shall show
the size, cross-section at various locations, general notes, symbols, reference drawings and
the control room entry.
1.4.2.18 Instrument Location Plans
Instrument Location Plans shall show the location of instruments, location of tapping points,
location of local panels, junction boxes, main cable trenches, instrument air distribution
scheme etc. These drawings are prepared on equipment layout drawings in 1:50 or 1:100
scale depending on density of instruments.
1.4.2.19 Instrument Cable Schedule
The instrument cable schedule shall show all instrument and power cables required for
complete instrumentation. The document shall show tag number, cable number, type, length
and size of cables, type of junction box, identity of local panel, control room panel/cabinet
location etc. The document shall also show the size of terminals considered for power
junction boxes and the dimensions of cable considered by the contractor.
The cable schedule document shall include all single & multi pair cables indicating
terminations of instruments, field junction boxes and respective termination in satellite rack
room cabinets. The instrument cable schedule shall be prepared on ElL format.
1.4.2.20 3D Modelling:
Whenever 3D modeling is included in package vendor's scope, it shall include the following
instrumentation items as a minimum:
Instrument Cable Duct.

Analyser shelter/ cabinet.
Local Control Panels.
Prefabricated Hook-ups
Gas Detectors
CCTV
Instrument Junction Boxes
Instrument Stanchions and Canopy
2.0 DESIGN PHILOSOPHY
2.1 Instrumentation shall be complete in every respect in accordance with latest approved
P&IDs for the safe, efficient and easy operation, start up and shut down of the plant.
2.2 All instruments and equipments shall be suitable for use in a hot, humid and tropical
industrial climate in which corrosive gases and/or chemicals may be present. As a
minimum, all instruments and enclosures in field shall be metallic construction, dust proof
and weatherproof to IP-65 as per IS/IEC-60529 and secure against the ingress of fumes,
dampness, insects and vermin. All external surfaces shall be suitably treated to provide
protection against corrosive plant atmosphere.
2.3 The design of electronic instruments shall be in compliance with the electromagnetic
compatibility requirements as per IEC 61000-4 'Electromagnetic compatibility for Industrial
Process measurement and Control equipment.

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n31 ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
Ifgar idtareg INDIA LIMITED
PACKAGE UNITS
1.1E'A 292tATUOT.AVA/ IA Govt of InOta Undertak.ng) Page 13 of 58
2.4 Instrument Requirements for Classified Area:
Certified Intrinsically Safe (IS) equipment as per IEC-60079-11 shall be used, in

general, in hazardous area, for conventional loops.
Field instruments in fieldbus loops shall be designed and certified as per the hazardous
area protection specified in Job Specification.
In case intrinsically safe equipment is not available, flameproof enclosures as per IEC-
60079-01 may be considered.
Junction boxes, cable glands and accessories required for flameproof instruments shall
also be certified flameproof.
All non flameproof panels and cabinets installed in classified area shall be purged as per
requirements specified in NFPA-496, as a minimum.
Other type of protection specified in IEC-60079 shall not be used.
2.5 Statutory Approvals
Contractor shall be responsible for obtaining all statutory approvals, as applicable, for
all instruments and control systems.
In addition, equipments/instruments/systems located in the hazardous area shall be

certified by the local statutory authorities for their use in the area of their installation. In
general following certification shall be given:
For all intrinsically safe/ FISCO/FINICO/ explosion proof/flameproof equipments/

instruments/systems or equipments with any other type of protection allowable as
per this package which are manufactured abroad and certified by any statutory
authority like Laboratorie Central Des Industries Electriques (LCIE), British
Approval Service for Electrical Equipment in Flammable Atmospheres (Baseefa),
Canadian Standards Association (CSA), Factory Mutual(FM), Underwriters
laboratories(UL) etc. for compliance to ATEX directives or other equivalent
standards. All these equipments/ instruments/systems shall additionally have the
approval of Petroleum and Explosives Safety Organisation (PESO)/ Chief
Controller of Explosives (CCE), Nagpur, if installed in INDIA and the same is
mandatory.
For all flame proof equipments manufactured locally (indigenously), the testing
shall be carried out by any of the approved test house like Central Institute of
Mining & Fuel research (CIMFR)/ Electronics Regional Testing Laboratory
(ERTL) etc. The equipment shall in addition bear the valid approval from
Petroleum and Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur and a valid BIS license.
iii) For all intrinsically safe equipment manufactured locally (indigenously), the
testing shall be carried out by any of the approved test house like Central Institute
of Mining & Fuel research(CIMFR)/ Electronics Regional Testing
Laboratory(ERTL) etc. The equipment shall in addition bear the valid approval
from Petroleum and Explosives Safety Organisation (PESO)/ Chief Controller of
Explosives (CCE), Nagpur.
c) Approvals other than above shall neither be offered nor will these be acceptable.
2.6 Following units of measurement shall be applicable, unless indicated specifically otherwise:

Flow Liquid M3/11

Steam kg/h

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50Z:Eq ENGINEERS INSTRUMENTATION OF
51gaf Weg INDIA LIMITED 6-52-0052 Rev. 3
n oqR ,Neant CIA ,141,0, A GoK otino undertak.9) PACKAGE UNITS Page 14 of 58
Gas & Vapour Nm3/h

PressureNacuum Gauge kg/cm2g
mm of H2O
Vacuum kg/cm2
mm of H2O
Temperature °C
Level
Analysis
ppm
Conductivity micro siemens
Viscosity mPa.s (cP)
2.7 Local control loops shall be avoided. In case these are unavoidable, these shall be electronic
field mounted manual loading station only.
2.8 Ranges for instruments shall be selected in general, such that in normal process operation
the indication is between 35% to 65% of the range i.e. middle 30% of the full working
range.
2.9 Field mounted direct actuated Flow and Temperature switches shall not be used. Instead,
transmitters shall be used along with flow element/temperature element. Process switches
shall not be considered unless its use is unavoidable and the same shall be subject to
purchaser's approval. In case switch has been considered, same shall be provided with
sealed micro switch contacts rated for the specified application. Also contacts shall be SPDT
type unless otherwise specified. Contacts used in intrinsically safe applications shall be
suitable for the application.
2.10 Intrinsically Safe System Requirements (for Non Fieldbus Instruments)
Following points must be considered while designing an intrinsically safe system;
All intrinsic safety barriers shall be active type isolating barriers only, with three port
isolation.
Barriers must be selected based on entity concept. Cable parameters shall also be
considered while matching entity parameters.
Each instrument in the hazardous area and the intrinsic safe barrier shall be certified for
intrinsic safety by any statutory authority.
Each input and output in a loop shall have separate barrier. No barrier shall be shared
between two loops or input/outputs.
Any device required to be connected to any intrinsically safe loop in the hazardous side
permanently or temporarily shall also be certified intrinsically safe.
Configuration tools whenever required for any intrinsically safe item, which forms part
of the intrinsically safe item, shall also be certified intrinsically safe.
2.11 Power Supplies and their Distribution
a) Power supply shall be made available at the following voltage levels, unless otherwise
specified:
0 For Instruments, Control Systems, 240V AC/110V AC
Analyzers

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n31 ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
Igar OIRT ,12,V77 aRJQCITA)
INDIA LIMITED
IA Govt of India Undertaking) PACKAGE UNITS Page 15 of 58

Solenoid Valves, Relays, lamps 24V DC/110V DC ±10%/
240 AC/ 110 V AC UPS

Input interrogation voltage 24V DC/110V DC ±10%
0
Panel/cabinets lighting 240V AC Non-UPS ± 10%
In case 24 V DC is required for Input interrogation, relays and lamps, any other vendor
supplied instruments/ electronics), same shall be considered by the vendor using dual
redundant power packs (110 V AC to 24 V DC converter). 24 V DC feeders shall not be
provided by Purchaser unless indicated specifically in the job specifications.
All instruments, control systems (PLC and DCS) and analyser system shall be able to
operate at the following UPS specification:
Voltage level 240V AC/110V AC ± 10%

Frequency 50 Hz ±3 Hz
Switch over time : 5 milli seconds.
Power feeders shall be supplied to the vendor at only one location. All further
distribution within the package shall be taken care of by the vendor. Number and size of
power feeders shall be informed during detail engineering. Vendor shall provide
adequate number and size of terminals and cable glands required.
d) Instrument power circuits shall be individually protected and isolated from fault with
the help of fuses and DPST switches. Power supply to the individual instrument shall
be disconnected with the help of DPST switch and protected with the help of fuses.
Miniature circuit breakers (MCB's) may be selected in place of switch fuse unit in case
protection is provided for overload protection.
2.12 Alarm Philosophy
Alarms shall be provided to give audible and visual warning of any process and
machine malfunction in the package.
All trips shall have a pre-trip warning alarm in addition to alarm at the trip condition.
Package alarms including pre-trip warning alarms and trip alarms (shutdown alarms)
shall be annunciated on the local panel as per approved P&ID.
Rotating equipments shall have the status indication provided on the local panel as per
approved P&ID.
e) 'Fail-safe' type with normally closed alarm contacts shall be used.
2.13 All line or equipment mounted instruments like control valves, pressure relief valves,
thermo-wells, orifice flanges, level instruments etc., installed on pipes and vessels under
IBR shall be certified by IBR or their authorized representative.
2.14 Location of process connections shall be from the side or from the top of the process
equipment but not from the bottom. This requirement is applicable to both pipes and vessels.
The location of lower side connection for level measurement when necessary shall be
extended inside the equipment with the approval of purchaser to prevent plugging due to dirt
or other suspended solids. In addition, the connections shall be short, vertical or horizontal
and without any pockets.
2.15 Material of construction of instruments shall be as per the material selection chart, attached
as Annexure I of this specification, as a minimum. However vendor is responsible to ensure
that the selected material is consistent with temperature, pressure, corrosion conditions and
other process requirements.

Page 852 of 1296

'
a ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
$T4Zif laWeg
INDIA LIMITED
my', twaxt ...5,... IA Govt 07 Groba Undenak,r,g ) PACKAGE UNITS Page 16 of 58
2.16 Field Transmitters
2.16.1 SMART Field Transmitters:
2.16.1.1 The field transmitters in all conventional loops shall be smart type only unless specified
otherwise. Field transmitters for flow, pressure, temperature, differential pressure and level
applications shall be yoke mounted type unless specified otherwise. Meter electronics used
for flow measurement etc. shall include all the associated items like pre-amplifier, converter,
transmitter, integrator, integral output meter etc.
2.16.1.2 Field transmitter shall be intrinsically safe and meter electronics shall be intrinsically safe, in
general. In case, intrinsically safe is not available from the approved vendor list enclosed
with this MR/tender, flameproof enclosure is acceptable. In case sensor/ pick up coil is
intrinsically safe, suitable barrier shall be provided and installed in flameproof enclosure.
2.16.1.3 These transmitters shall be 2 wire systems having 4 - 20 mA DC output with superimposed
digital signal having simultaneous analog and digital communication with HART
communication protocol, unless otherwise specified.
2.16.1.4 The transmitter shall be microprocessor based and it shall incorporate a non-volatile memory
which shall store complete configuration data of transmitter and sensor characterization. All
necessary signal conversions, including conversion to produce output with the required
protocol shall be carried out in the transmitter electronics. The configuration data of the
instruments shall be stored in a non-volatile memory such that this remains unchanged
because of power fluctuations or power off condition. In case vendor standard instrument
has battery backed RAM, vendor to ensure that battery drain alarm is provided as diagnostic
maintenance message.
2.16.1.5 Transmitter shall also run complete diagnostic subroutines and shall provide diagnostic
alarm messages for sensor as well as transmitter healthiness. In the event of detection
failure, the output shall be driven to a predefined value, which shall be field configurable.
2.16.1.6 Universal hand held configurator / terminal for the configuration and maintenance of
instruments with HART output shall be provided for all HART based smart instruments.
2.16.2 Fieldbus Field Transmitter and devices:
2.16.2.1 Fieldbus transmitters/ devices shall be provided, if specified, in fieldbus loops.
2.16.2.2 Field bus based transmitter/ devices shall meet the following requirements;
All instruments must satisfy the requirements of the fieldbus registration laboratory
with applicable checkmark like foundation field bus, profibus etc as specified in Job
Specification.
All instruments shall be polarity in-sensitive. Also transmitter shall be LAS capability.
Line plugging detection facility shall be provided, whenever specified in data sheet.
All instruments shall have Analog Input (AI) block and Proportional, Integration and
Differential (PID) control block, as a minimum.
All instruments must be interoperable and shall have valid interoperability test
clearance like ITK latest version for foundation field bus or equivalent for profibus PA,
as applicable.
The field bus instruments shall support peer to peer communication with two wire
communication and bus powered supply.
All instruments shall support EDDL or FDT/DTM requirements.

Page 853 of 1296


Og en ttliteg INDIA LIMITED
6-52-0052 Rev. 3
.AF,,,,AIA' AAJAA,A) IA Govt Ind Undertaking) PACKAGE UNITS Page 17 of 58
Internal software shall be configured by the vendor including the following information
such as serial number, Device Tag (Tag Number) and Process description
All instruments shall be capable of supporting incremental Device descriptor (DD) for
extra functionality and for software revisions in device memory.
Soft copy of the Device Descriptor (DD) files for configuring the FF device parameters
and common file format (CFF) files for integrating the device into the system shall be
provided by the bidder for offline configuration by System vendor immediately after
despatch.
Fieldbus based field indicator shall be able to indicate all signals available in the
fieldbus segment, selectively.
2.16.2.3 The fieldbus / devices provided shall be able to communicate with latest universal fieldbus
communicator.
2.16.3 Accuracy of transmitters (Pressure & Differential pressure), smart as well as fieldbus based
shall be as follows:
Type of Transmitter Range of Transmitter Accuracy for the rangeability of 1:10
Direct 760 mm WC and above Equal to or better than ±0.075%
Direct Less than 760 mm WC Equal to or better than ±0.15%
Diaphragm seal 500 mm WC and above Equal to or better than ±0.25%
Diaphragm seal Less than 500 mm WC Equal to or better than ±0.5%
The accuracy is defined as the combined effect of repeatability, linearity and hysteresis.
2.16.4 Transmitter shall update the output at least 8 times a second unless otherwise specified.
Unless specified otherwise in purchaser's specification, transmitter response time shall be as

follows:
For transmitter range of 760 mm WC and above, the response time shall be equal to or
better than 500 milliseconds.
For transmitter range below 760mm WC, the response shall be equal to or better than 1
second.
The response time of the transmitter shall be considered as the sum of dead time and 63.2%
step response time of the transmitter.
2.16.5 Unless specified otherwise, the over-range/static pressure protection of the transmitter shall
be as follows;
Over range/ static pressure <N1>

Range of Transmitter Pressure
Pressure Transmitter Differential
(kg/cm2) Transmitter (kg/cm2)
0 < (V < 250 mm WC 20 20
250 < ®< 1000 mm WC 45 52
1000 < ®< 5000 mm WC 45 70

Page 854 of 1296

5/gZif 2151eg w INDIA LIMITED 6-52-0052 Rev. 3
(A Govt of India Unclenaking) PACKAGE UNITS Page 18 of 58
5000 < ®< 10000 mm WC 45 160
1 < ®< 10 kg/cm2 52 160
10 < 0 < 100 kg/cm2 160 210
> 100 kg/cm2 210 210
<N1> However if the Over range/ static pressure value specified above is less than the
maximum/ design pressure of service conditions, offered instrument shall be suitable for the
maximum/ design pressure.
2.16.6 Diaphragm seal DP transmitters in flow measurement with a DP of less than 250 mmWC
shall be avoided and alternate type of flow meters shall be provided for such cases suitable to
the process condition.
2.16.7 All transmitters shall have vent and drain facility and the same shall be provided with metallic
plugs. All the cable entries shall also be provided with metallic plugs.
2.17 Instrument Connections
2.17.1 The connections of instruments installed on vessels, tanks, standpipes and piping shall be as
per following EIL Standards.
7-52-0001 Instrument Connections on Vessels and tanks.

7-52-0002 Instrument connection on Piping.
2.17.2 Pneumatic instrument connections for signal and air supply shall be 1/4" NPT (F).
2.17.3 Electrical cable entry connection shall be 1/2" NPT (F)/ 3/4"NPT (F) as per the cable size.
Suitable cable gland shall be used.
2.17.4 End connections shall meet the following, unless, otherwise specified:
Threaded end connection shall be NPT as per ASME B1.20.1.

Flanged end connection shall be as per ASME B16.5 or ASME B16.47B or AWWA
C207 Cl D as per related Piping Specification.
When Flanges are Raised Face (RF) type, the face finish shall be as per ASME B 16.5
and shall be as follows:
125 AARH : 125 to 250 microinch AARH
Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20 and
groove finish shall be as follows:
2.18 Instrument Air Supply
2.18.1 Air supply at pressure specified elsewhere shall be made available to the vendor at the
battery limit for distribution to the instruments.
2.18.2 Pneumatic Instruments shall operate on air supply of 1.4 kg/cm2g and shall have
transmission and output signal of 0.2 to 1.0 kg/cm2g.

Page 855 of 1296


15iF4TE? ENGINEERS INSTRUMENTATION OF
Vligieg INDIA LIMITED 6-52-0052 Rev. 3
Govt of India Undertaking) PACKAGE UNITS Page 19 of 58
2.18.3 Instrument air quality shall be as per ISA- S 7.0.01and free from corrosive, hazardous and
toxic contaminants.
2.19 Interface with Main Control Room
2.19.1 Wherever applicable, instrument junction boxes shall be provided as interface between
purchaser and vendor. Marshalling details between purchaser-vendor cabling shall be shown
with corresponding junction box termination number allocated against appropriate
purchaser's/vendor's instrument tag number in the format provided by purchaser.
2.19.2 Direct signals from package/package skid
All signals from package skid/battery limit to purchaser's control room shall be terminated
in the junctions boxes located at the battery limit. Separate junction boxes shall be used for
the following type of signals:
Fieldbus based Signals

Intrinsically Safe Analog Inputs/Outputs (4-20mA)
Non -intrinsically Safe Analog Inputs/Outputs (4-20mA)
Intrinsically Safe Thermocouple Inputs
Intrinsically Safe RTD Inputs
Intrinsically Safe contact Inputs
Non-Intrinsically Safe contact Inputs
Intrinsically safe contact Outputs
Non-Intrinsically Safe contact Outputs
DCS and PLC signals shall be further segregated and shall in no case be mixed up.
2.19.3 Repeat Signals from Package Local Panel
Where signals as indicated in Clause 2.19.2 is less in number and do not justify
separate junction boxes, all such signals may be routed via local control panel.
All such signals shall be terminated on separate terminal strips in the local control
panel. The terminal strips shall be segregated as per Clause 2.19.2.
c) Intrinsically safe barriers for all such signals, wherever required, shall be provided.
The above shall only be considered with prior approval from purchaser.
3.0 SPARES PHILOSOPHY
3.1 Mandatory Spares
Unless specified otherwise, the following mandatory spares shall be provided by vendor.
3.1.1 Predefined Mandatory Spares
Mandatory spares shall be ware-house spares and shall be supplied as loose items.
3.1.1.1 Higher of 10% or minimum one of each type (range, type, material and rating ) of complete
instruments for commonly used instruments such as transmitter, gauges, temperature
elements, switches, probes.

Page 856 of 1296

Ifgzrr tlf5t-eg INDIA LIMITED 6-52-0052 Rev. 3
1.1,1 evecnre aA,NmN, (A Govt of Me Unde,fakng) PACKAGE UNITS Page 20 of 58
3.1.1.2 For Control valve one set of packing and bonnet gasket with tag, one set of stem seal o-ring
for each actuator and piston o-ring additionally for each piston actuated valve, line bolting
(set of studs and nut) and set of gasket with each tag no.
3.1.2 Commissioning Spares
Vendor shall be responsible to supply all spares which are found necessary to replace while
performing pre-commissioning and commissioning activities and this includes system
oriented items (hardware / software).
3.1.3 Consumable spares
Vendor shall supply consumable spares for six months of normal operation.
3.1.4 Engineering Spares
3.1.4.1 For Control system, installed spare module of higher of 10% or minimum one of
input/output modules (including termination panels, if applicable) to enhance the system
functional requirements of control system.
3.1.4.2 For Hardwired console / Local control panel:
A minimum of 20% spare windows with alarm modules shall be provided in alarm
annunciator.
A minimum of 20% spare status lamps / switches / pushbuttons / terminals or one no of
each type, whichever is higher, shall be provided.
For pneumatic panels, 10% spare instrument air header branch lines and 15% spare
bulkheads and tapping points shall be provided in each panel.
Control panels shall have additional spare-space as per clause 4.2.8 of this specification.
3.2 Spares for 2 years normal operation
Vendor shall supply a list of recommended spare parts for each instrument and system
required for two (2) years of normal operation. These spares shall be quoted separately.
4.0 GENERAL SPECIFICATION OF INSTRUMENTS
4.1 Panel Board Instruments
4.1.1 Alarm Annunciator shall either be solid state type or microprocessor based programmable
type with plug in modules and integral power supply. Window display shall be back lighted
incandescent lamps or cluster LED type integral power supply. For window display with
back lighted incandescent lamps two numbers of incandescent lamps of minimum 5 watt
each shall be provided for each window. For cluster type LED display, the number of
LED's in the cluster matrix windows shall be sufficient to provide illumination level of at
least 150 lumens. The circuit shall be designed in such a way that removal/failure of one
lamp or LED from a window/ cluster shall not hamper functioning of that particular
window/display. The annunciator lamps shall be replaceable from the front of the enclosure
panel. In general, dedicated alarm logic module shall be used for each alarm input.
However, when micro processor based alarm Annunciator is offered failure of one
microprocessor shall not affect more than four alarm windows.
Intrinsically safe annunciator circuit, when used, shall have power supply unit in a safe area.
Annunciator alarm sequence shall be as per F3A of ISA.
Page 857 of 1296

$fgaf tiaeg
lanTer 212a7 CANTRI IA Govt 01 India Undertaking) PACKAGE UNITS Page 21 of 58
The design of the alarm annunciator system shall be such that transient alarms of less than
330 milliseconds duration shall be automatically rejected.
4.2 Panel Design
4.2.1 All panels shall be supplied in pre-tubed/pre-wired condition and shall be completely tested
at manufacturer's works prior to dispatch.
4.2.2 Panels shall be free standing type. Panels with instruments mounted on the front shall be
fabricated from 3 mm thick cold rolled steel sheet. If the same is not available, 4 mm thick
hot rolled steel sheet shall be used. All other panels shall be fabricated from 2mm thick cold
rolled steel sheet. Angle iron framework shall use a minimum section of 50 x 50 x 4 mm
angle. Panel painting procedure shall include blast cleaning, grinding, chemical cleaning,
surface finishing by suitable filler and two coats of high grade lacquer with wet blasting
wherever required. Two coats of paint in the panel colour shall be provided for non-glossy
high satin finish. Final coat shall be given after assembly at site.
Unless otherwise specified, exterior/interior portion of all panels and closed cabinets shall
have a colour as per RAL-7035. Channel base shall be of black colour.
4.2.3 Panel shall be enclosed cubicle type with each section of typically 2100 mm high, 1200 mm
wide and 800 mm deep mounted on 100 mm channel base.
4.2.4 Enclosed cubicle panels shall have removable hinged doors for easy maintenance and
accessibility of the instruments. Doors shall be double leaved type with handle and shall be
provided with lock and key. Adequate illumination shall be provided inside the panel. All
light fittings shall be suitable for 240 V, 50 Hz AC. Power supply greater than 240 V shall
also not enter the control panel.
4.2.5 All cable entries to the panel shall be from panel bottom only using cable glands of adequate
size. Cable gland plate thickness shall be a minimum of 3 mm cold rolled cold annealed
(CRCA) as a minimum. All unused cable entries must be plugged.
4.2.6 Space heater shall be provided where condensation is expected. The space heater provided
shall be with temperature cut off and manual control.
4.2.7 The design of panel shall incorporate provision for expansion by installing adequate spare
capacity. Each panel shall be designed to accommodate the following additional equipment,
as a minimum:
20% of panel front/inside mounted instruments including lamps, push buttons,

switches, relays etc.
20% additional power feeders each provided with switch fuse assembly.
20% additional spare windows in alarm annunciators.
20% spare cable entry points.
4.2.8 Panel layout shall be designed considering ease of operation. No push button or hand switch
shall be located below 600 mm. Instrument mounting heights, in general, shall be as follows:
Electronic Instruments Bottom row 1100 mm

Middle row 1350 mm
Top row 1600 mm
Annunciators 1950 mm
c) Electric push buttons/ 700 mm
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,r_Jt4 ENGINEERS INSTRUMENTATION OF
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1.12M c'crg, ern ,1-45411 A Govt of inda Undenaking) PACKAGE UNITS Page 22 of 58
switches, lamps etc.

4.2.9 The internal panel layout shall be designed considering proper approach for instruments,
terminals and other accessories for maintenance, easy removal and online calibration. No
instrument, terminals, power distribution box etc shall be mounted on the panel side plates
inside the panel.
4.2.10 All lamps, status as well as alarm, shall be provided with lamp test facility. One single lamp
test push button shall be used for each panel. Logic for lamp test shall not be implemented
through relay logic in the panel.
4.2.11 Colour Scheme
Status Lamps
On/Open/Permissive Green
Off/Close/Emergency Red
Alarms
Normal/Pre-trip alarms Amber
Shutdown alarms Red
e) Push/Pull buttons
On/Open Green
Off/Close Red
Emergency shut-down (ESD) Red
(Push-button with cover/
Mushroom push button)
4.2.12 Panel Piping and Tubing
4.2.12.1 The instrument air header shall be adequately sized with 1/2" branches, SS packless isolation
valves and shall be complete with suitable dual filter-cum-air reducing station.
4.2.12.2 Panel tubing from the bulk head to the panel instruments and instrument air supply to the
panel instruments shall be of 6 mm x lmm thick SS 316L tubing.
4.2.12.3 The tubing shall be laid in plastic slotted ducts. Panel air header and tube fittings shall be of
SS 316.
4.2.12.4 Each tube shall be identified at both the terminating ends.
4.2.13 Panel Wiring
4.2.13.1 Open terminals shall generally be avoided. Terminal strips shall preferably be mounted in an
enclosure. Fused terminal may be used wherever necessary. All terminals shall be of
mechanical screw clamp/screwless type with pressure plates as per the job specification.
Self-insulating crimping wire lugs shall be used for all terminations on terminal blocks,
whereas forked tongue type or lug with eyehole type shall be used for termination on
screwed terminals such as on relays, push buttons, lamp etc. Terminal blocks shall be rated
for 600 V.
4.2.13.2 A minimum of 1 mm multi stranded PVC insulated copper conductor shall be used in
2
general. All wiring shall be laid in the PVC troughs. No trough shall be more than 70%
full.

Page 859 of 1296

zroaretraarasso (A Govt ol India Undedaking) PACKAGE UNITS Page 23 of 58
4.2.13.3 Wires carrying measurement signals associated with thermocouples, resistance

thermometers and other low level signals shall be routed in separate troughs/wire ways and
not alongwith power cables. Power wiring and control wiring shall be separated by not less
than 150 mm. The crossing, if unavoidable, shall be as close to right angles as possible.
4.2.13.4 Extension cables/wires shall be used for all thermocouple inputs. These wires shall be
routed in separate troughs/wire-ways.
4.2.13.5 All intrinsically safe wires shall be routed in separate wire ways from non-intrinsically safe
and power wiring. Intrinsically safe wiring and terminals shall be light blue in colour and
shall be separated from non-intrinsically safe terminals atleast by 50 mm.
4.2.13.6 All incoming power feeders shall be terminated on separate terminals suitable for the
incoming feeder size. These shall be located at the bottom of the panel and shall be suitably
covered for protection against accidental shorting and for human safety.
4.2.13.7 Power supply shall be made available at one point. Further power distribution network shall
be designed such that a single power fault in any instrument branch system shall not cause a
trip of the entire system. Each consumer shall be provided with a separate switch and fuse
for isolation and protection of the system.
4.2.14 Electrical Wiring
All the cabinets, consoles and panels shall be completely wired. Interconnections shall
preferably be done with the help of pre-tracked cables. Vendor may follow their standard
wiring practices, however the requirements specified herein must be complied.
All wiring shall conform to API RP 552- Transmission Systems. Different signal level
cables shall be routed with separation distances as recommended by code.
All wiring inside racks, cabinets, and back of the panels shall be housed in covered,
non-flammable plastic raceways arranged to permit easy assembly to various
instruments for maintenance, adjustments, repair and removal.
All wiring in the raceways shall be properly clamped. All incoming cable shall be
terminated by vendor at marshalling rack with cable glanding including supply of
cable glands. Total wiring cross-sectional area shall not exceed 50% of the raceway
cross sectional area.
Separate wiring raceways shall be used for power supply wiring, DC and low level
signal wiring, and intrinsically safe wiring. Parallel runs of AC and DC wiring closer
than 300mm shall be avoided.
Vendor can alternately offer prefabricated cables for interconnection between
different cabinets and panels.
Wire termination shall be done using self-insulating crimping lugs. More than two
wires shall not be terminated on one side of single terminal. The use of shorting links
for looping shall not be done.

g) No splicing is allowed in between wire / cable straight run.
4.2.15 Terminals and Terminal Blocks
Terminals shall be non-hygroscopic type made up of unbreakable, fire-retardant, safe

extinguishable, halogen free polyamide compound.
Terminals shall be suitable for wires up to 2.5 sq. mm base solid or stranded
conductor in general. For power cables, higher size terminals shall be used.
c) The metal parts of terminals shall be of high quality (pure electrolytic) copper and
shall be tin or nickel plated (of thickness up to 15 micron).
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Ogar Weg INDIA LIMITED 6-52-0052 Rev. 3
(A Govt of Indo Undertaking) PACKAGE UNITS Page 24 of 58
The spring material for all terminals shall be chrome nickel spring steel of high tensile
strength and of excellent corrosion resistance. All terminal / terminal blocks shall be
DIN Rail mounted type and shall be easily removable. The size of the terminal blocks
/ terminals of different types shall be consistent and identical.
All terminal blocks shall be mounted on suitable anodised metallic or plastic stand-
off.
f) Terminal strips shall be arranged group-wise for incoming and outgoing cables
separately. Terminal blocks for intrinsically safe wiring shall be separate. 20% spare
terminals shall be provided, as a minimum, preferably in each terminal strip.
4.2.16 Following design philosophy shall be followed while deciding the internal layout of panels,
as a minimum;
Distance between terminal strip and 100 mm (min.)+ trough

side of the panel upto 50 terminals width
Distance between two adjacent terminal : 100mm (min.)+trough
strips width
Distance between gland plate and 300mm (min.)
bottom of the strip
Distance of terminal strip 100mm (min.)
from instrument/trough/panel top
4.3 Local Control Panel (LCP)
4.3.1 Local control panel for the package units shall be installed within the battery limit of the
package considering operational and maintenance requirements and accessibility. In case of
skid mounted packages, panel shall be located away from the skid.
In case local control panel is housed outdoor i.e. not in a local control room, it shall be
designed to meet IP-55 requirements. In addition, panel must be provided with a rain cum
sun shade/canopy.
4.3.2 Local control panel/panels shall be totally enclosed cubicles. Panel sizing shall be carried
out based on equipment being installed keeping in view the maintenance clearances and
easiness of operation. Although the panel dimensions shall be guided by the actual
requirements, typical dimensions shall be 2100 mm height x 1200 mm width x 1000 mm
depth. In any case, vendor shall not proceed with panel manufacturing before getting prior
approval from the purchaser.
4.3.3 Local control panels located in the hazardous area shall either be purged type or flame proof
Ex'd' or weather proof with Ex'd' components such as lamps, push buttons, switches etc. as
specified in job specification. In case pressurized panels are specified the same shall be
purged and pressurized as per NFPA 496 requirements to render space within the panel non
hazardous. For panels located in IEC Zone 2, hazardous area type Z purging shall be used
with a purge fail alarm in main control room. In case, panels are located in Zone 1, the
power shall be cut off on perssurisation failure as per x-purge requirements of NFPA-496.
An alarm shall be provided on local panel and a contact shall be provided for remote
annunciation, whenever the panel pressurization falls below 2.5 mm of H2O. A protective
device to protect the panel from over pressure must be provided.

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Lrr faiteg INDIA LIMITED 6-52-0052 Rev. 3
.1771 eletnfr IN OW, IA Govt of India undeoalong) PACKAGE UNITS Page 25 of 58
4.3.4 Panel pressurisation with start-up panel purging scheme shall be fully automatic however it
shall be started manually from a push button. Solenoid valves and differential pressure
switch required for panel purging shall be flameproof, however other items like relays,
switches/pushbuttons, timers etc. shall be located in a flameproof housing. Other items like
valves, restriction orifice plates, dual filter regulators, pressure gauges, rotameters etc
required for pressurization shall also be located in the non-pressurized section of the panel.
4.3.5 It shall be possible to switch off incoming power to panel from panel front. All such power
on/off switches shall be flameproof type.
In addition, all those devices and terminals, which cannot be powered off from on/off
switches shall also be located inside flameproof enclosures.
4.3.6 All hinges, screws and other non-painted metallic parts shall be of stainless steel material.
4.3.7 All other requirements as specified in clause 4.2 of this specification shall also be applicable
for local control panels.
4.3.8 Whenever weatherproof local panel is provided by vendor for classified area, the Alarm
Annunciator shall be intrinsically safe and push button, lamps; selector switches shall be
flame-proof "Exd" type mounted on LCP. IS Barriers/ relays for IS alarm annunciator shall
be supplied by vendor along with IS annunciator and potential free non-flameproof contact
for the same shall be considered from the PLC / DCS/ control systems. The IS power supply
module for alarm annunciator shall be installed in a flameproof box in local panel by bidder.
For Lamps, wet contact shall be considered from the PLC/ control system and the lamp test
logic shall be realised in PLC/ control system. The Power supply distribution box inside the
Local Panel shall also be flame-proof "Exd'. IS PCs for display of loop powered indicators
shall be used in weather-proof local panels in case no. of tag local display more than Five
tags. The same IS PC can also be used for local display of vibration and temperature
monitoring system parameters at field instead of separate display unit at field. For 5 or less
number of tags for local indication, normal IS loop powered indicators shall be provided on
weather proof local panel.
Intrinsically Safe (IS) type with minimum 15" Display (Remote interactive PC terminal) unit
certified suitable for the hazardous area shall be mounted on the panel front of local control
panel of the package, wherever IS PC is considered. All local control panel mounted field
remote output indicators, wherever required as per approved P&IDs, shall be displayed in
this remote PC. Single serial interface (RS 485 with Modbus RTU protocol) corresponding
to these signals from control system shall be considered and vendor's scope shall include all
necessary converters, power supply module, connectors at both ends along with serial
communication cables for connecting to serial interface cards.
The PC terminal shall be equipped with necessary keyboard suitable for specified hazardous
area.
4.4 Local Gauge Board
4.4.1 Local gauge board shall be used to install skid-mounted instruments like pressure gauges,
temperature gauges and transmitters.
4.4.2 Location of local gauge boards, when provided, shall be decided to allow easy access at the
rear and front for all instruments and accessories for maintenance and operation.
4.4.3 Gauge board shall be constructed from 3 mm stainless steel sheet with other necessary SS
supporting structure.

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INDIA LIMITED 6 - 52 -0052 Rev. 3
1.117,enflz751..07-415.3, IA Go, 01 Indo undertakng) PACKAGE UNITS Page 26 of 58
4.4.4 Local gauge board shall be supplied with all instruments installed and completely in
tubed/wired condition before shipment.
4.4.5 All pressure transmitters and gauges shall be provided with block and bleed valves securely
fastened. Identification tags shall be securely fastened for easy identification. Wherever local
temperature indicator is required with temperature transmitter, Loop powered indicator shall
be provided.
4.5 Temperature Instruments
4.5.1 Thermowells
All temperature elements shall be provided with thermowells fabricated out of bar stock
of minimum SS 316 material as per EIL Standard 7-52-0035. The base of the
thermowells shall be chosen to fit the instrument without air gap for minimizing
measurement lag.
Built-up thermowells shall be used in low pressure and low velocity services like in
fired heaters and also where thermowell immersion lengths greater than 500 mm are
required.
Immersion length of thermowells shall be as follows:
Line Size Immersion length

From 4" to 6" 280 mm
From 8" to 20" 320 mm
>20" and Vessels / columns 400 mm
In special applications, not covered above, vendor shall decide the immersion length
based on actual requirements. Immersion length is based on 200 mm length between
flange face and outer wall of pipe and 200 mm length between flange face and outer
wall of the vessel.
Any pipe line less than 4" nominal bore shall be blown to 4" size to install thermowell.
e) Thermowell flange and well material shall be as per material selection chart.
0 The vibration analysis shall be carried out as per PTC 19.3 TW:2010 (latest version)
and corrective measures shall be taken as necessary.
4.5.2 Temperature Gauges
Local temperature gauges shall be in general bimetallic type. The temperature bulb
shall be of stainless steel construction. The gauge connection shall be all angles
adjustable. Gas filled type shall be used when measuring range is beyond the limits of
Bimetallic gauge or thermowell length exceeds 550 mm or in applications involving
excessive vibrations. Mercury filled type temperature gauge shall not be used.
All local temperature gauges shall have 150 mm dial size. The bulb size shall be
selected to suit the thermowell.
Cases shall be minimum 304 SS and weatherproof to IP-65 as per IS/IEC-60529.
Temperature gauges shall have accuracy of ±1% URV (upper range value).
e) Bimetallic type dial thermometers shall be avoided where excessive vibrations are
enoniinterett, clich ac reriprnrating rnmpreccor clicrharr Only filled type with
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Igar INDIA LIMITED 6-52-0052 Rev. 3
0171, rirove JOOf
AI IA Govt of lode Unoertakng) PACKAGE UNITS Page 27 of 58
capillary extension shall be used in such cases. Capillary tubing shall be a minimum of
304 SS with stainless steel flexible armouring, and PVC covering over armour. Filled
type gauges shall be manufactured as per relevant SAMA class.
f) Thermometer stem adjustable gland with union connection and bushing shall be
suitable for 1/2" NPTF connection.
4.5.3 Temperature Elements
a) For remote temperature indication/recording/control/switch etc., resistance temperature

detector (RTD) shall be used upto 400 deg C (operating) and above 400 deg C
(operating) thermocouples shall be used. Elements shall be spring loaded, mineral
insulated and shall have stainless steel sheath as a minimum.
Thermocouple assemblies shall be furnished with weatherproof screw type heads as per
EIL Standard 7-52-0036.
Thermocouples shall be as per IEC-60584-2 and shall have a wire size of 18 AWG for
single and 20 AWG for duplex thermocouples. These shall be magnesium oxide (MgO)
filled grounded type, unless necessary otherwise. The type of thermocouple shall be
selected based on temperature. The selection of type shall be as per following
guidelines:
Copper-Constantan (ISA-Type-T) (-) 200 to 200°C

Chromel-Constantan (ISA-Type-E) (-) 200 to 600°C
lion- Constantan (ISA-Type-J) 0 to 600°C
Chromel-Alumel (ISA-Type-K) 600 to 1200°C
Platinum Rhodium-Platinum (ISA Type-S) 600 to 1600°C
The design of thermocouple assemblies shall be such that replacement on line is
possible.
RTD (Resistance Temperature Detecter) shall be platinum element 3 wire type with
100 ohms resistance at 0°C calibrated as per 1EC 60751. RTD shall be used within a
temperature range of -200 to 650°C. Three-wire system shall be adopted in connecting
the element.
0 RTD shall be used where accuracies of the order of 0.25% or better and smaller
measuring spans are required.
g) Duplex element sensors shall be supplied. Two separate cable entries shall be provided
with plugs.
4.5.4 Temperature Transmitter
Temperature transmitters shall have a built-in linearising function to produce an output

linear to temperature range.
The Temperature transmitters with RTD shall have an accuracy of 0.075% of URV as a
minimum for range above 350° C, 0.15% of URV for temperature range 350° C to 150°
C and 0.25% for calibrated range below 150° C.
The Temperature transmitters with cold junction compensation for thermocouple shall
have an accuracy of 0.25% of URV as a minimum for range above 350° C, 0.5% of
URV for temperature range between 350° C to 150° C and 0.75% for calibrated range
below 150° C.
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0 el ENGINEERS INSTRUMENTATION OF
$fgar 0151-'eg INDIA LIMITED 6-52-0052 Rev. 3
.
71/FR c 1,4,n 1 ,1,1 070519 (A Govt of (Ado U n dertAk(A9t PACKAGE UNITS Page 28 of 58
c) Transmitters shall be provided with dual compartment.
4.5.5 Burn out protection must be provided with temperature transmitters. Upscale or downscale
protection shall be decided based on its application to ensure fail-safe operation.
4.6 Pressure Instruments
4.6.1 Pressure Gauges
Pressure gauge dial shall be white with black figures. The dial face shall be marked
with pressure element material. Pointers shall have micrometer adjustment.
Pressure gauges shall be weatherproof with dial size of 150 mm and shall have features
like over range protection (at least 130% of max. operating pressure) and blowout
discs. Glass shall be shatter proof. Pressure gauge sensing element shall be of SS 316
and movement of SS 304, as a minimum.
Pressure gauges shall have an accuracy of ±1% of URV as a minimum. Differential

pressures gauges, diaphragm seal pressure gauges and draft gauges may have an
accuracy of ±2% of URV.
Over range protector and pulsation dampener, whenever used, shall be of SS 304, as a
minimum. Pulsation damepner shall be used for all pulsating services. It shall be
floating pin type, externally mounted and externally adjustable.
Pressure gauges with range 0-100 kg/cm 2g and more shall have safety type solid front
case.
Connection shall normally be 1/2" NPTM bottom.
Cases shall be minimum 304 SS and weatherproof to IP-65 as per IS/IEC-60529.
Ranges shall be so specified that the gauge normally operates in the middle third of the
scale and shall conform to IS-3624 standard dials, wherever possible.
Diaphragm seals shall be furnished where plugging of the element may occur or where
suitable material is not available in highly corrosive services. When chemical seals are
required, they shall be of the clean out type with flushing connection.
Where vibrations and pressure fluctuations are expected, glycerin filled type and
snubber shall be used.
k) Receiver pressure gauges for local transmitter output indication shall have 100 mm dial
with stainless steel element and 1/4" NPTM connection.
1) The pressure element shall be bourdon, diaphragm or bellows depending upon process
condition. Single diaphragm type Differential pressure gauges shall not be considered,
Instead double diaphragm type or bellows shall be considered.
4.6.2 Pressure/Differential Pressure Transmitters
Pressure/differential pressure transmitter shall have electronic state-of-art capacitance

or any other type of sensor meeting all functional specifications as per clause 2.16.
Element material for transmitters shall be 316 SS, as a minimum.
All transmitters shall have an integral output meter. Remote mounted meters may be
provided if required in addition.
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1
t_7 7- •) ENGINEERS INSTRUMENTATION OF
Of5teS' v INDIA LIMITED 6-52-0052 Rev. 3
Govt of India Undenakno PACKAGE UNITS Page 29 of 58
c) Diaphragm seal element with capillary shall be used for congealing, corrosive and
highly viscous services.
4.6.3 Pressure Switches
Process switches shall not be considered unless its use is unavoidable and the same
shall be subject to purchaser's approval
Pressure switches shall have either diaphragm or bellow type of process element with
SS 316 material of construction as a minimum. Switch type shall be sealed micro-type
with contact rating suitable for specific application. Also contacts shall be SPDT type
unless otherwise specified. Contacts used in intrinsically safe applications shall be
suitable as per the process condition.
Pressure switches shall be blind type with 1/2 NPTF process connection and shall be
operative in full-specified range. The switch differential shall be selected as per
operating conditions.
Pressure switches shall have repeatability of ±0.5% of URV, as a minimum. Pressure

switch shall have over range protection of at least 130% of maximum working pressure.
The set pressure shall fall in the middle third (between 35% to 65%) of the adjustable
range in general. Set point shall be field adjustable.
4.7 Level Instruments
4.7.1 Level gauges
All gauge glasses shall be steel armoured reflex or transparent type with body and cover
material of forged carbon steel as a minimum and shall have tempered borosilicate glass
with asbestos or other suitable gasket. Transparent type of gauges shall be provided
with integral illuminators operating at 240 V 50 H z supply and shall be suitable for
electrical area classification specified. All gauge glasses must have a rating equal to or
more than the vessel design pressure and temperature.
Reflex type will be used for clean and colourless liquids, except liquids level interface.
For low temperature, low boiling point service, large chamber type will be used.
Transparent type will be used on acid, caustic, dirty or viscous, coloured liquids and
liquid interface. Transparent type with Mica or Kel-F shields shall be used for treated
water, boiler and condensate services, and for corrosive liquids, which will attack glass.
Tubular gauge glasses shall, in general, not be used in Hydrocarbon/hazardous services.
They may be used for non-hazardous services at ambient temperature and low pressures
(less than 10 kg/cm2g operating).
Large chamber gauges with frost shields shall be provided for cold services below 0° C.
Heating jacket shall be provided for viscous liquids with 1/2" flanged connection.
All gauges shall have top and bottom chamber connections, unless otherwise specified.
However side-side chamber connection is acceptable where nozzle installation is a
constraint. In addition each gauge shall be provided with ball check valves and pipe
union.
e) The visible range of level gauge shall be selected to cover the complete operating level
as well as measuring range of the other level instruments provided for the same
purpose. In general, the visible length and C to C distance of the top and bottom level
gauges shall be selected from the following:
Visible length Centre to Centre Length

Copyright EIL -All rights reserved
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n31 ENGINEERS INSTRUMENTATION OF
idigte'g INDIA LIMITED 6-52-0052 Rev. 3
IA Govt of India OnctertaAng) PACKAGE UNITS Page 30 of 58
220 470
470 720
720 970
980 1230
1230 1480
1490 1740
For side-side level gauge C to C distance shall be 10 mm less than visible length.
0 For level gauging in very viscous, corrosive liquids, liquids with crystals and high
pressure service, float operated magnetic gauges with 2" (50 mm) flanged end
connections, shall be used. C to C length of single magnetic level gauge shall not be
more than 2500mm.
4.7.2 Level Transmitter
Guided Wave Radar type instruments with external cage and side-side connections
shall normally be used for level and for interface level measurement upto 2400 mm.
Guided wave radar inst shall have ±3mm accuracy.
Differential pressure transmitter shall be used for level measurement above 2400 mm,
for services requiring purge or where liquid might boil in external portion.
Differential Pressure transmitters for use on corrosive or fouling service shall generally
be diaphragm wafer with extended filled capillary type. Flush or extended diaphragm
type differential pressure transmitter shall be considered for special applications only.
Diaphragm material shall normally be stainless steel or any other special alloy.
e) For sump levels, Guided wave radar or non- contact type radar level instrument shall be
used depending on the application within accuracy ± 3mm.
0 Generally for top mounted level transmitters, internal guided wave radar type
instruments shall be used for level measurement upto 3000mm. Above that non-contact
type radar shall be used.
g) Level transmitters shall meet all requirements specified in clause 2.16.
4.7.3 Other Special types of level instruments like ultrasonic, hydrostatic, nucleonic, capacitance,
conductivity type shall be used as necessitated by application requirements.
4.7.4 For high pressure steam drum application at least one number conductivity type (Hydrastep
or equivalent) level instrument shall be provided. Also level gauges shall be of bi-color type
for such application.
4.7.5 For solid level measurement, type of instrument shall be ultrasonic/

electromechanical/capacitance/nucleonic/non-contact type radar as per the process
condition. The actual type selection shall be carried out based on the provenness of the
selected type for similar type of application.
4.8 Tank Level Instruments
a) Each tank shall be provided with minimum 2 types of tank level instruments operating
on different principles like one servo and other one radar (Antenna) type.

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.111 ENGINEERS INSTRUMENTATION OF
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0 11277 29226,2 JP41.71, A Govt of Indld uneenaw.ng ) PACKAGE UNITS Page 31 of 58
Radar type transmitter shall be provided with ±3 mm accuracy for storage tanks and ±1
mm for custody transfer. Whenever ±3.0 mm accuracy is required, process connection
on vessel/ tank/ equipment for non-contact radar gauge can be 4" with 4" Carbon Steel
/ Stainless Steel (depending on the pipe schedule requirement) still well. However
wherever ±1.0 mm accuracy is required (e.g. in custody application), process
connection on vessel/ tank/ equipment for non-contact radar gauge shall be 8" with 8"
Carbon Steel / Stainless Steel (depending on the pipe schedule requirement) still well.
For viscous service, nozzle connection shall be 24".
Servo type instruments shall have 6" process connection with 6" diameter still well,
with accuracy ±3 mm for storage tanks and ±1 mm for custody transfer. Raising or
lowering of displacer for calibration shall be possible on-line with the design of still-
well.
The wetted material like float, displacer, tape, wire etc. shall generally be 316 SS.
The accessories for servo-controlled level gauge shall include isolation ball valves for
pressurized tanks and calibration/maintenance chamber for all tanks. Each calibration
chamber shall be provided with a viewable window of blast proof glass. The
calibration chamber can be either integral to the instrument or separate. Whenever
calibration chamber is separate i.e. not integral to the tank level instrument, the material
of construction of calibration chamber shall be stainless steel. The calibration chamber
shall also permit insertion / removal of displacer for maintenance without removing the
instruments.
f) Servo and Radar type instruments shall be capable of providing serial output as per
vendor standard protocol or field bus protocol as per IEC-61158 in addition to analog
4-20 mA DC current output. These instruments shall also be capable of accepting input
from multi element tank temperature sensors (thermocouple/ RTD), water cut probes
and transmit the same as a part of serial signal from the transmitter. Multi-element tank
temperature sensors when used shall be provided with 3" stillwell and 3" process
connection.
4.9 Flow Instruments
The selection of flow measurement instruments shall be based on the requirement of

accuracy, repeatability, location, physical properties of the flowing fluids handled, pressure
drop and ease of maintenance.
In-line flow instruments shall have a direction of flow indication clearly marked and easily
visible in the final installed position.
Flow switches shall not be used without prior approval from the purchaser.
4.9.1 Orifice Plates
a) Flow measurement shall normally be carried out by using thin square edged concentric
orifice plate mounted between a pair of weld neck flanges of minimum 300 pounds
ANSI rating for line size 2" and above. Flange taps shall be used for line sizes upto 14"
while D-D/2 taps shall be used for line sizes more than 14". The material of the orifice
plates shall be normally 316 SS, as a minimum.
Quadrant edge or quarter circle orifice plates shall be used for highly viscous liquids
and for pipe Reynold number below 10,000.

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af-aeltii ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
fg-ar eleage0,01-
jEtoteg INDIA LIMITED
0.1, AGoo 0 Indo Unelettak.g) PACKAGE UNITS Page 32 of 58
Conical entrance type of orifice plates shall preferably be used for very highly viscous
liquids upto throat Reynolds number of 250. These plates shall be fabricated as per
Flow Measurement Hand Book by RW Miller.
Vent and Drain holes shall be provided for bore dia above 25.4 mm.
b) Sizing of orifice plate shall be carried out in accordance with ISO-5167 (Latest
Edition). For orifice plates not covered in ISO 5167, sizing methods shall be ASME
MFC-14M (latest Edition) or AGA Report No. 3 or 'Flow measurement-Engineering
Handbook' by RW Miller.
Honed metering runs or integral orifice type transmitter shall be used in line size with
1.5" (40 mm) nominal diameter or below.
Upstream and downstream straight length shall be provided based on maximum d/D
ratio of 0.75, in general. Where it is difficult to meet this requirement, the actual d/D
ratio can be considered for reducing the straight length as permitted by the codes. Flow
straighteners are to be considered, where straight runs are difficult to achieve otherwise.
f) Meter taps shall be horizontal for liquids, condensible vapours and steam. The taps
shall be on top for gas, non-condensible vapour, or liquids which boil at or below the
maximum design ambient temperature at operating pressure. Where piping clearances
are a factor, taps may be located upto 45 degree below the horizontal center line for
condensible vapour and liquid. The taps may be located upto 60 degree from vertical
for gas, non-condensible vapour and steam.
4.9.2 Venturi Flowmeters
Venturi shall be designed and constructed as per ISO 5167-4 (Latest Edition) or ASME
MFC-3M.
The Venturi Flow element shall be classical, machined, non truncated type.
c) Impulse piping connection for venturi tubes shall be provided with 1/2" NPTF
connection, unless otherwise specified in the data sheet.
Venturi tube shall be forged/cast construction in general. However fabricated

construction shall also be acceptable, wherever allowed as per ISO-5167.
Venturi tube shall be provided with Annular chamber / Piezo-metric Ring. Material of
construction of Annular chamber / Piezo-metric Ring shall be same as material of
Venturi tube.
Material of construction of Venturi tube shall be SS316 as a minimum. Material of

construction for Throat, Divergent section and Convergent section shall also be SS316
as a minimum. Flanges shall be provided as per the material specified in the datasheet.
Flow calibration for those Venturi tubes, which are necessitated due to their installations
outside the limits as defined in ISO 5167 for D (Pipe Inside Diameter), beta and
Reynolds numbers shall be considered in the base quote
4.9.3 Averaging Pitot Tube
Averaging pitot tube in general shall not be considered unless specifically required by the
purchaser. Averaging pitot tube shall meet the following requirements:
a) The flow sensor shall be continuous averaging velocity head producing type of pitot
tube with four or more equal averaging pitot tube sensing ports or continuous slots to

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t31 ENGINEERS INSTRUMENTATION OF
2151-eg INDIA LIMITED 6-52-0052 Rev. 3
WIRT FREW OA JG53,711 IA Govt of India Undertaing) PACKAGE UNITS Page 33 of 58
suit line velocity profile. The sensor shall also incorporate a rear port for the
measurement of line static pressure.
Averaging pitot tube shall be of 3" flanged connection with isolation ball valve.
The insert retract mechanism shall be provided to allow on line removal and insertion
of the average Pitot tube under maximum pressure and flow condition.
Vibration analysis for each averaging pitot tube element shall be done for the indicated
flow condition to ensure that the averaging pitot tube is of sufficient thickness and
strength to withstand the vibration effects created due to Karman vortex shedding in the
fluid stream.
The free end of the averaging Pitot tube shall be pressure supported at the pipe wall.
However, for the large pipe sizes and where vibration analysis recommends the
requirement of end support, the end support/weld cap support shall be provided.
f) The offered averaging pitot tubes shall have ±1% accuracy of actual value and
repeatability of ±0.1% of actual value.
4.9.4 Variable area Flow Meters
Variable area flow meters or rotameters shall be provided as per the P&ID or where
rangeability in flow precludes the use of an orifice. Variable area flow meters shall be as per
ISA-RP 16.1, 16.2, 16.3, 16.4, 16.5 and 16.6. Metal tube rotameters shall be used for all
fluids. External devices for indicating or transmitting shall be magnetically coupled to the
float or extension.
Glass tube rotameters shall not be used unless it is necessitated for low range or for low
pressure utility services for local indication and where line size is 1-1/2" (40mm) or less
with the approval of purchaser.
Reducer shall be considered, in case the size of the flowmeter is less than the line size.
4.9.5 Mass Flow Meters
The mass flow meters shall meet the following requirement:
Flow meter shall be of in-line mounting design and shall be of flanged body
construction with stainless steel as minimum material of construction.
The mass flow meter shall be provided with the external flow tube housing. In all
such cases, the flow tube housing shall have provision to monitor housing pressure
continuously.
The mass flow meter shall have high vibration immunity.
The meter electronics shall be protected against transients induced by lighting and
power supply surges. Transient protection electronics shall preferably be provided in
the terminal block.
e) Flow meter electronics shall be microprocessor based and shall include pre-amplifier,
converter, transmitter electronics and integral output meter. The indication on the
output meter shall be digital with engineering units.
0 The mass flow meter shall be capable of computing field density and shall incorporate
temperature sensor flow fluid temperature measurement. Whenever required, the flow
meter electronics shall have capabi lity to compute vnliimPtri, flow rates.
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ENGINEERS
'e--1 INSTRUMENTATION OF
$'1g-af f
aWeg INDIA LIMITED 6-52-0052 Rev. 3
>men etro,te =Jot:ow Govt of India Uottertok n og) PACKAGE UNITS Page 34 of 58
The meter electronics shall be protected against transients induced by lightning and
power supply surges. Transient protection electronics shall preferably be provided in
the terminal block. The transient protection shall meet the requirements specified in
IEC-60587.
Unless specified otherwise in the job specification, the performance requirements for
the mass flow meter shall be as follows:
Flow meter accuracy: + 0.2% of mass flow rate for liquid service.
± 0.5% of mass flow rate for gas / vapour
service.
Flow meter repeatability: ± 0.1% of mass flow rate for liquid service.
± 0.25% of mass flow rate for gas / vapour
service.
The performance requirements specified above excludes the effect of zero stability of
the flow meter on these parameters.
Flow accuracy shall be maintained between the minimum and maximum flow. Where
only normal flow is specified, the maximum and minimum flows considered for the
purpose of sizing shall be:
Maximum flow = 1.4 times the normal flow
Minimum flow = 0.4 times the normal flow
When only maximum flow is specified minimum flow shall be considered as 0.2
times the maximum flow for sizing the meter.
The maximum pressure drop at meter maximum shall not exceed the allowable
pressure drop across the meter specified in the data sheet.
The meter shall be selected such that both accuracy and allowable pressure differential
across the meter are complied.
4.9.6 Ultrasonic flowmeter
Ultrasonic flow measurement shall be considered where non-intrusive flow measuring is

required.
The Ultrasonic flow meter shall be based on transit time technology.

The design used shall provide maximum reliability, maximum on-line performance and
minimum maintenance. It shall be immune to other impurities in the fluid stream.
Ultrasonic flow meters and the meter runs/flow conditioners shall be rated for the maximum
design pressure.
Spool piece type Ultrasonic flow meters shall have flanged end connections. Weld joints, if
any, shall be of radiographic quality.
Meter Sizing:
Selected meter size shall ensure that flow meter operates within 85% of their standard range
considering density and viscosity of the fluid. Extended range shall not be referred for the
meter selection.
Vendor to ensure the velocity in the Ultrasonic flow meter and meter run shall not exceed
maximum permissible velocity.
4.9.7 Target meters shall be considered for highly viscous hydrocarbon streams such as asphalt,
tar, polymers etc.

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4.9.8 Vortex meter shall be considered where high rangeability is the prime requirement.
4.9.9 Differential Pressure type flow transmitter shall meet all the requirements specified in clause
2.16.
4.9.10 Wedge flow meter shall be considered in slurry services or where powder deposits may form.
However, Diaphragm seal type DP transmitter shall be provided along with wedge flow
meter duly calibrated with both sensor and the transmitter.
4.10 Control Valves
4.10.1 Control valves shall normally be globe type. Other valve types like butterfly, ball, rotary
plug, angle or 3way etc., shall be selected as per service and process requirements.
4.10.2 Control valve sizing shall be carried out as per ISA S75-01. The valve shall permit upto
150% of normal flow or 110% of maximum flow, whichever is higher. In general, control
valves shall be sized so that the valve opening is as noted below:
At max. flow about 90% open

At normal flow about 75% open
At minimum flow about 20% open.
4.10.3 Flanged control valves shall be used. Body material, body rating and flange rating shall be
as per piping specifications. However body and flange rating shall be minimum 300#.
4.10.4 Minimum control valve body size shall be 1" in general. Reduced trims can also be
considered.
4.10.5 For globe valves trim characteristics shall be equal percentage type unless required
otherwise. Control valve plugs shall be heavy top guided for single seated valves. Cage
guiding may be used in clean applications.
4.10.6 Anti-cavitation trim shall be selected wherever cavitation is expected in the valve. For
flashing services and hardened trim shall be used and anti-cavitation trim shall not be
provided.
4.10.7 Noise from control valve during operation shall be limited to OSHA specified level or
better. The maximum allowable noise is 85 dBA SPL (Sound Pressure Level). Source
treatment for noise may be performed by using special trims like low noise trims, in case
noise exceeds the specified level. Other methods based on merit are also permissible.
4.10.8 Valve seat leakage shall be minimum class IV as per ANSI/FCI 70.2 unless tight shutoff
requirement is required as per the P&ID.
4.10.9 Flanged bolted type gland packing boxes shall be used. Packing shall normally be PTFE on
liquid and gas service up to 200°C (design). Graphite/grafoil shall be used above
200°C(design) temperature. Asbestos based packing material shall not be used.
4.10.10 Bellows seal shall be used where it is required to isolate the packing from the process fluid
or where no leakage to atmosphere can be tolerated like toxic, explosive and precious fluids.
4.10.11 Material used for trim shall be minimum SS 316, with guide bushing of hardened stainless
steel like 440 C, 17-4 PH. For higher pressure drops (more than 10 kg/cm 2) or erosive and
slurry services and in general for all steam services, flashing and cavitating services, plug
and seat shall be stellited.

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ligfa0
71
6 11 ENGINEERS
INDIA LIMITED
INSTRUMENTATION OF 6-52-0052 Rev. 3
vilrvvt rirove on,tootto IA Govt Of Ind. Undettekvt9) PACKAGE UNITS Page 36 of 58
Special cases may require 17-4 PH seat ring and 440 C solid plugs or other materials like
Hastelloy, Monel etc.
4.10.12 Valve actuator shall be pneumatic spring opposed diaphragm type, in general. Piston type
actuators may be used for very high shut off pressure requirements. Additional equipment
including volume bottle necessary to meet fail safe condition shall also be included in case
double acting piston type actuator is selected. In either case, actuator shall be able to
withstand maximum shut-off pressure (1.5 times of design pressure) with the minimum
instrument air pressure specified.
4.10.13 Whenever limit switches are specified as inductive proximity type, these shall meet
NAMUR (DIN-19234) requirements.
4.10.14 Solenoid valves, wherever used, shall be universal and continuous rated type with class H
coil insulation. These shall be SS body as a minimum.
4.10.15 Self-actuating regulators for flow, pressure and temperature shall be used where loads are
constant and requirements of precision and accurate controls are not stringent.
Direct action (open on air failure) valves - Green
Reverse acting (close on air failure) valve - Yellow
Actuator for shutdown valves - Red
4.11 ON-OFF VALVE

4.11.1 On-off valves shall have flanged end connections integral to the valve body. Top entry valve
design shall not be offered unless specifically indicated. Body rating of valve shall be
minimum 300g.
Whenever flangeless on-off valve body design is specified, following shall apply:
Wafer type or lug type body design for butterfly type on-off valves body size up to
6 inches.
Lug type body design for butterfly type of on-off valve body size more than 6
inches.
4.11.2 For on-off valves with fire safe design, flanged body construction shall only be acceptable.
4.11.3 For all services where full port valves are specified, following shall apply:
Port size shall be equal to line size for rating up to ASME Class 1500.
Port size shall not be less than one size than the line size for rating ASME Class
2500 and above.
4.11.4 For steam jacketed valves, the body and port size shall be one size lower than the on-off
valve end connections.
4.11.5 On-off valve body, bonnet, bottom flange, line flanges and other pressure containing
assemblies shall be of the same material of construction as specified for valve body.
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4.11.6 In case of ball-type of on-off valves;
The valve design shall ensure valve seat and body protection against thermal expansion
of the entrapped fluid when the on-off valve is fully close.
For size up to 4" and rating up to ASME Class 300, the on-off valve shall have floating
ball design. For ratings ASME Class 600 and above, floating ball is acceptable for
sizes less than 2". For higher sizes trunion mounted ball design shall be provided.
4.11.7 Rotary type on-off valves like Ball valves, butterfly valves etc. shall have blow out proof
shaft guiding design.
4.11.8 Guide bushing shall be of a sufficiently hard material to resist side thrust on the plug or
shaft.
4.11.9 Vendor shall be responsible for trim design and selection of the on-off valve. However, it
must meet the following minimum requirements:
The valve characteristics shall be quick-opening (on-off) type.
Vendor shall select proper material pairs, surface finish, hardness and clearances to
avoid galling.
Valves operating under extreme temperature conditions, vendor shall consider

increased clearances at room temperature and seal welding of threaded seat rings
etc whenever required. Hard facing of trim including guide bushing shall be
considered for all valves operating at high temperatures (i.e. temperature more than
200°C). For very low temperature application, material used shall have adequate
cold impact strength.
For all on-off valves including 3-way type of valves, stem and plug shall be
detachable and shall be attached together by suitable threaded design secured with
a pin to avoid plug rotation during operation.
4.11.10 Trim material and actuator colour shall be as specified for the control valve.
4.11.11 Leakage class of on-off valves shall be as specified in data sheet, where no class is
specified it shall be Class IV.
4.11.12 For on-off valves specified with Class VI / bubble tight (as per API) leakage class,
vendor shall select the soft seat (elastomer) material suitable for the process conditions
i.e., shut off pressure, maximum temperature and process fluid. Metal seated on-off
valves meeting the leakage class shall also be acceptable.
4.11.13 For application in vacuum service, vendor to provide inverted packing design suitable for
vacuum service. For pressure-cum-vacuum service, the on-off valve shall have dual
packing design suitable for the application. Dual packing design shall also be provided
for on-off valves in toxic service, with a facility to connect inert fluid between the
packings.
4.11.14 Valve actuator shall be designed to move the valve to the failure position as specified.
For failure position specified as 'fail-locked', vendor shall provide air reservoir with all
required accessories to meet the fail lock position of the valve.
4.11.15 Whenever double acting springless type of actuator is unavoidable, all accessories like
pilot valves, booster relays, non-return valve, pressure gauge, volume tank etc. shall be
provided to ensure desired action on air failure.
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fel5reg INDIA LIMITED 6-52-0052 Rev. 3
1.1,11 eiverenv,gdoei IA Govt of India Undertaking) PACKAGE UNITS Page 38 of 58
4.11.16 The volume tank shall be of carbon steel construction and sized as per ASME Section
VIII with design pressure of 10kg/cm2g as a minimum. Each volume bottle shall be sized
for a minimum of 3 valve strokes
4.11.17 The actuator casings and diaphragms shall be designed for minimum twice the maximum
pneumatic operating pressure of the on-off valve.
4.11.18 Vendor shall be fully responsible for sizing and selection of correct actuator, while sizing
the actuator vendor shall consider minimum actuator thrust equal to two times (2) the
total force induced by shut off condition and the force required to overcome packing
friction.
4.11.19 Wherever the valves are indicated as fire safe, they shall be tested for fire safe as per BS
6755 (Part-2) when the valves are supplied with metal-to-metal seats and shall be tested
as per API 607 latest edition when the valves are provided with soft seats.
4.11.20 Wherever fire safe actuator and controls have been asked for, actuators and all
accessories such as solenoid valves, air volume bottles etc. shall meet the fire proof
requirement to ensure normal valve operation even during and after exposure to fire.
Vendor shall clearly define the schemes they propose to achieve the above requirements
and ensure that the proposed schemes shall meet the requirement in terms of type of
exposure and exposure time of the testing procedure given in BS 6755/API 607.
4.11.21 Vendor shall furnish type test certificate duly witnessed by third party inspection agency
like M/S LRIS,BV,DNV,TUV etc. for fire safe testing of valve, actuator and controls for
the offered models.
4.12 Smart Type and Field Bus Type Positioners
Digital smart positioners or field bus type of positioners with diagnostic capabilities shall be
provided as per job specific requirement. These shall meet the following minimum
requirements:
The positioner sensor and sensing mechanism shall be rugged and shall not be affected
by the line/valve vibration. The performance of the positioners shall be immune to
above vibration.
The positioner's output and input range shall be field adjustable without any hardware
modification. The output from the positioners shall be available for both single acting
as well as double acting actuator.
Each positioner shall be operable, configurable and accessible through HART

compatible hand held configurator/field bus configurator as applicable. Smart
positioners shall also have dedicated buttons for the above functions.
Control valve's operating signatures in the form of hard copy and soft copy for each
control valve provided with smart positioners shall be supplied. The necessary software
for advanced control valve diagnostics like seat ring condition, gland packing condition,
actuator leakage etc. shall also be included.
Fieldbus positioner shall have the capability to perform functions like PID etc.
All positioners shall have metallic casing and cover.
4.13 Pressure Relief Valves and Rupture Discs

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e IA Govt of India Undertaking)
deter ?Wag ‘151 Wadi, PACKAGE UNITS Page 39 of 58
4.13.1 Pressure Relief Valves
4.13.1.1 All pressure relieving devices shall be designed in accordance with ASME code for 'Boilers
and Pressure Vessels', API-521 and Indian Boiler Regulations. The pressure relief valve
sizing shall be as per API 520. For mixed phase fluids, sizing shall be as per Leung-Omega
method (or Diers) sizing shall be followed. The orifice sizing, area and designation, valve
size and rating shall be as per API RP 526.
4.13.1.2 Pressure relief valves shall be full nozzle full lift type except for thermal relief valves.
4.13.1.3 Conventional valves shall be specified for constant back pressure while bellows seal type
valves shall be specified for variable back pressure. Pilot operated pressure relief valves
shall be used when Back pressure is greater than 50% of set pressure or when the difference
between operating pressure and set pressure is within 10% of the set pressure.
4.13.1.4 Lifting lever shall be specified for steam, air or water above 65 degree service. Open bonnet
shall be used for steam service.
4.13.1.5 The percentage accumulation in case of pressure relief valves/safety valves shall be as
follows:
Steam Service
- ASME SEC I(steam generation/consumption) 3%
- IBR (Before steam let-down station) 5%
- IBR (Distribution & utilities) and 10%
ASME Section VIII
Gas, Vapour or liquid for process service 10%
Liquid for thermal Relief 25/ 10% (as per Process requirement)
Fire exposure on unfired vessels 21%
4.13.1.6 3/4" x 1" threaded (NPT) modified nozzle type valves with typically 0.38 cm 2 orifice size
shall be specified for thermal relief. However, if discharge is connected to flare or with
variable back pressure more than 10% of set pressure, 1D2 flanged valves as per API-526
as a minimum to be provided.
4.13.1.7 The body material shall, as a minimum, be as per piping specifications. Nozzle and disc
material shall be SS 316 as a minimum with machined stainless steel guide and spindle.
Whenever semi nozzle designs are unavoidable, body material shall be atleast same as
nozzle and disc material.
4.13.1.8 The spring material of pressure relief valves shall be as follows unless otherwise necessary
because of process conditions;
(-)29° C to 230° C Carbon steel with weather protective coating.

above 230°C Tungsten alloy steel.
Below (—)29° C 316 Stainless Steel
4.13.1.9 Flanged connection shall be for standard sizes 1" or larger.
4.13.1.10 Where permissible, screwed connections shall be used on sizes 3/4" and below.

Page 876 of 1296

ligodaalez ENGINEERS
INDIA LIMITED
1.111,1 IA Govt of India Undertaking) PACKAGE UNITS Page 40 of 58
4.13.2 Rupture Disc
4.13.2.1 Rupture discs shall be reverse buckling type, in general and shall be supplied in pre-torqued
holder assembly, which shall fit inside the inner diameter of the bolt circle of standard
flanges. Disc material shall be compatible with the vessel contents and shall be consistent
with the bursting requirements. Inconel discs shall be used above 100°C if compatible with
the process fluid.
4.13.2.2 When rupture disc is used upstream of a pressure relief valve, a pressure gauge shall be
provided on the downstream of the disc to indicate any rupture of the disc in addition to an
excess flow check valve. In addition combination capacity factor of 0.9 shall be used for
sizing unless the combination has been tested and approved for any other combination
capacity factor.
4.13.2.3 The bursting tolerance of the rupture disc shall be 5% of the specified bursting pressure or
less, unless otherwise specified.
4.13.2.4 Vendor shall consider 5 nos. rupture discs (1 for testing + 1 for installation + 3 nos. spare) of
the same specifications.
4.14 Interlock and Shutdown System
4.14.1 Interlock and Shutdown System shall be an independent system with its own dedicated
primary element except for orifice flow measurement. For orifice flow element, separate set
of tapping for each flow transmitter for shut down / interlock shall be considered.
4.14.2 The system shall be designed fail safe and shall meet the following requirements, as a
minimum:
All initiating contacts shall be close (except limit switches for which contact shall close
when the limit reaches) under normal conditions and shall open under abnormal
conditions.
All relays and solenoid valves shall be energised under normal conditions and shall de-
energize under abnormal conditions.
c) If desired, because of operational or maintenance requirements, adequate trip by-pass
facilities are to be provided with warning lights to indicate that the trip has been
bypassed. Trip bypass alarms shall be provided in local as well as in remote location.
All such by-pass switches shall be key-operated type.
4.14.3 Each shutdown circuit and solenoid valve shall be provided with a switch-fuse unit
separately.
4.15 Instrumentation for Rotating Equipments
Rotating Equipment vendor shall be completely responsible for providing adequate

instrumentation for safe and efficient operation of the machine. The commonly used
instruments are being detailed out in the following clauses, however this does not absolve
the vendor of providing additional instrumentation, if required.
4.15.1 Anti surge and performance control system (ASC)
a) Vendor shall be fully responsible for the complete design of Anti surge/performance
control system (ASC) including selection of type of flow element, controller Algorithm,
type of explosion protection, type and operating timings of final control element. Vendor
shall guarantee the performance of machine with the offered ASC system. Wherever
required, ASC system shall be designed in such a way that it is capable of correcting the

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Ogar tlf5leg INDIA LIMITED 6-52-0052 Rev. 3
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compressor operating point so as to avoid surge in order to protect machine from possible
damage, to minimize process upsets and to minimize recirculation.
ASC system shall typically consist of but not limited to flow element, flow transmitter,
differential pressure transmitter, ASC controller, control valve and other accessories as
felt necessary by the vendor.
Vendor shall supply all the hardware and software related to the operation and safety of
the equipment. This shall include but not limited to the following;
Design and operation of surge control loop scheme based on offered equipment
performance.
Supply of all hardwares in antisurge control loop including dedicated controller,

transmitters, measuring elements, final control element etc.
Fast response transmitter and control valve etc. as required.
Algorithm required for antisurge/ Performance control application.
The ASC shall be a dedicated single loop controller on proprietary Hardware Platform or
single/multi loop controllers of common hardware platform such as PLC. The single loop
controller shall be dedicated controller for each Anti-surge or Performance control
application/Tag. Dedicated panel mounted facia shall be provided. The ASC system
when provided on common hardware platform shall be with redundant configuration as
minimum viz-dual processor, dual input/output, redundant communication & dual power
supply system. The multiloop controller/system shall be dedicated for Anti-
surge/Performance applications/Tags of each machine/each machine tag. Unless specified
otherwise dedicated panel facia for each application shall be provided to mount on
hardwired console in control room
It should be able to accept 4-20 mA signal from field or from HIC at purchaser DCS or
at LCP as a manual override to anti-surge control system with bump less transfer.

0 Auto-manual operation with bump less transfer shall be provided.
The controller response time (total time to read input, processing time and output) shall
be as per the machine dynamics and safety and shall be of the order of max. 40-milisec.
Any faster response required based on machine dynamics shall be considered by
vendor. The input sampling interval shall be as per machine dynamics within the
controller response time as above. The processor cycle time shall be considered to meet
the overall response time.
The ASC shall be field proven, specific to the make of machine and for the similar
application in hydrocarbon industries. Vendor shall provide the proven track record for
the offered ASC meeting the above.
The anti surge/performance control algorithm shall be implemented using standard

firmware in the controller/processor system.
The algorithm developed by vendor shall be specific for given application, surge
control, performance, load sharing etc. and shall be field proven for the compressor
make.
k) The algorithm implemented in the system shall be protected against any

modifications/changes.

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The configuration shall be stored in non-volatile memory or battery back-up for

configuration shall be provided (minimum 48 hours) in case of volatile memory along
with battery drain indication.
In case of ASC on common hardwired platform separate configurator with necessary

hard ware/ soft ware shall be provided for application programming.
Anti surge controller shall not be used for performing any other machine related inter
locks/logics.
All the instruments (transmitters, Positioner and temperature elements and / or

transmitters) connected with anti-surge control loop shall be flame proof "EExd" type
suitable for the area as specified. The suitability of smart transmitter/ Positioner shall be
confirmed by vendor and to be provided accordingly.
p) The ASC system vendor shall be fully responsible for the sizing and selection of the anti-
surge valve. Vendor to provide the sizing calculations duly vetted by ASC system
manufacturer.
4.15.2 Machine Monitoring System (MMS)
Machine Monitoring system shall be provided for continuous monitoring and indication of
machine parameters like vibration & axial displacement, bearing and winding temperature,
key-phasor etc.
4.15.2.1 Vibration and displacement monitoring system shall be as per API-670. The extent and type
of monitoring shall be as defined elsewhere. However, vendor shall furnish any additional
requirements for monitoring deemed essential by them with reasons. Two probes at 90
degree apart for each location shall be provided and connected to same dual channel monitor
for vibration monitoring.
4.15.2.2 The machine monitoring system shall be provided with preferably built in intrinsically safe
barrier and shall be duly mounted in separate panel. However, separate terminal blocks shall
be provided for terminating the field cables for maintenance purpose. Direct cable
termination on modules shall not be considered.
4.15.2.3 For MMS the display unit shall be provided at local control panel with necessary statutory
certification. Alternatively purged enclosure is also acceptable with necessary certification.
4.15.2.4 The sensing probe shall be accessible for adjustment, repair and replacement without
dismantling the machine.
4.15.2.5 Vendor shall provide hardwired Voted contact output of each parameter for Pre trip and trip
alarms for alarms/ interlock in purchaser's control system. The alarms/trips of the channels
within each monitor/ Module can be grouped together and common pre-trip alarm and
common trip contact for each monitor/ Module shall be provided. 4-20 mA signals from
Vibration & Temperature Monitoring System racks to DCS system are not required
separately, unless specified and vendor to ensure that all the parameters are available
through serial interface. For multi racks, vendor shall provide common serial interface
through multi drop link.
4.15.2.6 In addition to this, it shall be provided with necessary hardware (communication gateway
module) including the cable for serial data communication from monitoring system to
purchaser's DCS for machine monitoring through purchaser's DCS via redundant serial
data interface. This serial link shall be RS 422 / RS 485 with MODBUS RTU protocol.
Vendor shall furnish all details like pin configuration and tag number wise MODBUS
address mapping list etc. for smooth interfacing of this communication link with DCS.

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Vendor shall also provide necessary hardware and software for providing raw data to
conditioning monitoring system for each rack.
4.15.2.7 Vendor shall also supply one common laptop based configuration unit for the package unit
with required configuration software (refer clause 4.17) and hardware for configuration of
MMS system including the serial communication cable required between configuration unit
(laptop) & MMS monitors.
4.15.2.8 Key Phasor
Key phasor system shall be provided by vendor for performing analysis of vibration signals
to determine machine malfunctions. It shall consist of a proximity probe and transmitter,
extension cable etc. and other accessories to make the system complete. Vendor shall
provide necessary reference on the shaft to determine one-per-turn occurrence.
4.15.2.9 Vibration and Axial Displacement Monitoring
Monitors shall be four channel types and shall meet the following specifications as a
minimum:
Continuous channel monitoring with each channel input from one probe. Readout
scale shall read higher of the sensors.
Each channel shall have two independent alarm levels one for pre trip alarm and one
for each trip and that can be set continuously over measurement range. Two relay
contacts for each pre-trip alarm and trip alarm per channel shall be provided.
Broken sensor failure detection without causing shut down.
LED lamps on monitor front for each channel to indicate pre-trip alarm, trip-alarm and
circuit fault conditions.
e) Selector switches on monitor front to read vibration/ displacement pre-trip alarm and
trip set points for each channel shall be provided.
4.15.2.10 Bearing & Winding Temperature Monitoring
a) Sensor shall be three wires RTD element of platinum having 100 ohms resistance at
0°C.
The temperature sensor, cables, terminal heads, junction boxes etc. shall be capable of
withstanding the mechanical vibration and environment of a rotating machinery
atmosphere.
c) Bearing and Winding temperature shall be monitored by means of a temperature

monitor. It shall meet following requirements:
Accept RTD inputs (platinum, I 00ohm at 0°C).
Continuous six channel monitoring with each channel input from each RTD.
Read out scale shall read higher of the six temperatures.
Each channel shall have two independent alarm levels one for pre-trip alarm and
one for trip alarm and that can be set continuously over measurement range.
Broken sensor failure detection without causing shut down.

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k3u ENGINEERS INSTRUMENTATION OF
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101FR etormt J4317.. ∎ (A Govt n
of n 000 U cWntak.9) PACKAGE UNITS Page 44 of 58
Selector switches on monitor front, to read temperature, pre-trip alarm and trip set
points for each channel shall be provided.
Analog output 4-20 mA DC isolated signals shall be provided for each channel
for remote indication, if specified.
4.15.2.11 Wherever MMS is not specified, vendor shall provide suitable transmitter for all the
vibration and axial displacement, temperature, key phasor to provide 4-20mA signal to
purchaser's control system.
4.15.3 Speed Governor System
4.15.3.1 Digital microprocessor based system mounted in standalone cabinet and located in rack room
shall be provided. Fault tolerant triple modular redundant (TMR) system shall be supplied
unless otherwise specified in Job Specification.
4.15.3.2 HMI for operator interface shall be supplied loose with all mounting accessories for mounting
this HMI in purchaser's hardwired console in general. This shall include all basic features of
governor to enable operator to do all control and monitoring operations from console itself
4.15.3.3 This shall include features like assignable speed range, adjustable speed set point, remote
speed set point input, digital speed indication, adjustable speed ramp, override for testing the
external over speed trip system etc.
4.15.3.4 It should be able to accept 4-20 mA signal from HIC at purchaser's DCS or LCP as a manual
override to governor and pass on the same, after a bump less auto / manual selection and
local / remote selector switches configured in speed governor (shall be possible through
HMI) to governor valve as manual control.
4.15.3.5 Vendor shall provide all hardware & software in the system (including the cable for serial
data communication from system to purchaser's DCS) for serial communication link for all
data transfer from governor to purchaser's DCS. This serial link shall be RS 422 / RS 485
with MODBUS RTU protocol, vendor shall furnish all details like pin configuration and tag
number wise MODBUS address mapping list etc. For smooth interfacing of this
communication link with DCS.
4.15.4 Accumulator of Lube Oil System
4.15.4.1 If accumulators are used with nitrogen for lube oil dampening at the desired pressure to meet
the system requirement the following instrumentation with the accumulator to be provided
by vendor:
Accumulator shall have charge kit with isolation valves and connection hoses.
Standard nitrogen cylinders available in India are at pressure of 140 kg/cm 2g with
standard connection sizes. Vendor shall provide the complete regulator system with
protection for charging nitrogen from nitrogen cylinder to accumulator at the desired
pressure. Regulator shall be suitable for the inlet pressure variation of 140 to 150
kg/cm2g while charging with suitable inlet connection to match the Nitrogen cylinder
connection. Regulator system shall have pressure indicator, regulator, relief valve,
needle valve etc. as a minimum. Material of construction shall be stainless steel.
4.15.5 The compressor loading-unloading scheme for reciprocating compressors shall be provided
as per the minimum requirements specified in the job specifications. Manual as well as
automatic schemes shall be provided.

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k31 ENGINEERS INSTRUMENTATION OF
lig-aria51-eg INDIA LIMITED 6-52-0052 Rev. 3
1.112n 22nTre Tl JWISIC IA Govt O, India tinee11ak.9) PACKAGE UNITS Page 45 of 58
4.15.6 Emergency switch shall be provided in the local panel/local. All such switches shall have a
protective cover to avoid inadvertent shutdown.
4.15.7 Vendor shall provide the following common alarms for purchaser:
Common machine pre-trip alarms.

Common machine trip alarm.
4.16 System Cabinets, Racks and Consoles
4.16.1 All system cabinets, marshalling racks and hardwired consoles shall be free standing and
enclosed cubicles type. All these items shall have bottom cable entry.
4.16.2 Cabinets shall be fabricated from cold rolled steel sheet (CRCA) of minimum 2.0mm
thickness suitably reinforced to prevent warping and buckling. Doors shall be fabricated out
of 1.6 mm thick CRCA sheet. Cabinets having modular construction and with basic frame
structure of heavy duty aluminium shall also be acceptable.
4.16.3 Cabinet/Console finish shall include sand blasting, grinding, chemical cleaning, surface
finishing by suitable filler and two coats of high-grade lacquer with sanding between coats.
Two coats of paint in the cabinet colour and a final coat after assembly at site, shall be given
for non-glossy high satin finish.
4.16.4 In order to remove dissipated heat effectively vent louvers backed by wire fly screen shall be
provided. Further, ventilation fans shall be provided wherever required. High temperature
annunciation shall be provided on operator console.
4.16.5 Illumination shall be provided for all cabinets by fluorescent lamps, which shall be operated
by door switch.
4.16.6 All cabinets/racks/consoles shall be adequately sized to avoid any congestion. Wiring shall
be done as per guidelines provided in clause 4.2.14 of this specification.
4.16.7 The height and colour of the cabinets shall be inline with other equipments being installed in
the control room.
4.17 System software / License

Systems (like PLC, ASC, Speed Governor etc.) software shall include the operating system
and application program. The application program shall include software for performing
functions like interlock and shutdown logic, programming/program modification,
documentation etc. Two copies of application program and two sets of licensed system
software shall be supplied. The program language shall be English.
The licenses and application program shall allow:
Monitoring of system program for troubleshooting purpose.
Carrying out any modifications to the PLC/system program if need arises (engineering
license with proper validity)
Troubleshooting of any system related failures.
Monitoring of the system healthiness
The system shall be supplied with programming tools and related accessories.
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$fg-af fafgrdg INDIA LIMITED 6-52-0052 Rev. 3
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5.0 LIST OF DOCUMENTS ATTACHED
7-52-0001 Instrument connections on vessels, standpipes and tanks

7-52-0002 Instrument connections on piping.
7-52-0035 Thermowell
7-52-0041 Orifice Plates and Flanges -Dimensional details.
7-52-0254 Duct Fabrication — Bolted Construction Details
Page 883 of 1296

oi el ENGINEERS INSTRUMENTATION OF 6-52-0052 Rev. 3
51gar015ieg
Wan
INDIA LIMITED
PACKAGE UNITS
IA Govt 01 Ind. Undenakmg)
Page 47 of 58
PART II
SPECIFICATION FOR MATERIAL, INSTALLATION,

TESTING AND COMMISSIONING
Page 884 of 1296


ENGINEERS
Oar 1#112,1 eiecnte ,,o++1,
INDIA LIMITED
A Go„ of India Undellaktng) PACKAGE UNITS Page 48 of 58
1.0 INSTALLATION MATERIALS

1.1 Vendor shall ensure and supply all erection hardware required for the installation of
complete instrumentation which form a part of the package unit. This includes items like
cables, cable glands, junction boxes, instrument valves and manifolds, mounting accessories,
impulse piping/tubing, pipe/tube fittings, pneumatic signal tubes, air line pipes and fittings,
filter regulators, steam/electrical tracing, insulation materials, cable duct and trays, conduits,
prefabricated canopies for instruments, identification tags, structural material required for
instrument supports and trays etc.
1.2 Clause 1.1 above broadly covers the items required for any typical plant, however vendor
shall supply all necessary items to make the installation and commissioning work complete
in all respect, irrespective of whether these have been explicitly included in their scope or
not.
1.3 Salient feature and minimum requirement for some of the main installation materials is
being described in the following paragraphs. For items for which no specification has been
provided, vendor may follow their own specifications and prevailing international standards.
1.4 Cables
1.4.1 All cables shall have PVC insulated primary insulation of cable shall be 85°C Polyvinyle
Chloride type as per IS-5831 and inner and outer sheath of cable shall be flame retardant
made of extruded PVC Type ST-2 at 90°C as per IS-5831. Oxygen index of PVC shall be
over 30% at 27 °C+2 °C and temperature index shall be over 250°C. However, Polyethylene
(PE) insulation shall be provided in IIC area classification.
1.4.2 In general cables shall be flame retardant as per standard IEC 60332 Part 3 Cat.A. However,
cables with fire-safe valves shall be fire resistant also as per the following.
1.4.2.1 The insulation grade shall be 650 V/1100 V as a minimum and shall meet insulation
resistance, voltage and spark test requirements as per BS-5308 Part-II.
1.4.2.2 All cables shall be twisted and armoured. Armour over inner jacket shall be of galvanised
steel wire/flat as per IS-1554 part I.
1.4.3 For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall be
light blue for intrinsically safe application and black for others. For thermocouple extension
cables the inner and outer jacket colour shall be as per IEC.
1.4.4 Maximum DC resistance of the conductor of the completed cable shall not exceed the
following:
12.3 ohms/km at 20°C for cables with 1.5 mm2 conductor.

39.7 ohms/km at 20°C for cables with 0.5 mm2 conductor.
1.4.5 The mutual capacitance of the pair or adjacent cores shall not exceed 250 pF/m at a
frequency of 1 kHz whereas the same shall not exceed 100 pF/m for PE insulated cables.
The capacitance between any core and screen shall not exceed 400 pF/ m at a frequency of 1
kHz.
1.4.6 L/R ratio of adjacent cores shall not exceed 40 [tH/Q for cables with 1.5 mm 2 conductor and
25 p,H / Q for cables with 0.5 mm 2 conductor.
1.4.7 The drain wire resistance including shield shall not exceed 30 ohms/km.
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1.4.8 A pair of communication wire shall be provided for multipair/multitraid cables. Each wire
shall be 0.5 mm2 of plain annealed single or multi-strand copper conductor with 0.4 mm
thick 85°C PVC insulation. Insulation shall be green and red colour coded.
1.4.9 Each multipair cables shall have 20% pairs as spare.
1.4.10 Running length of the cable shall be printed on the outer sheath at least at every 5 metre
interval.
1.4.11 Signal Cables
Single pair shielded signal/alarm cables shall be used between field instruments and
junction boxes/local control panels.
Multipair individually and overall shielded signal/alarm cables shall be used between
junction boxes/local control panels and control room, in general.
The single pair and triad cables shall be of 1 5 mm 2 conductor size made of electrolytic
copper conductor of 7 strands with each strand of 0.53 mm diameter, multipair cables
with 0.5 mm2 conductor size shall have 16 strands of annealed electrolytic grade copper
conductor with each strand of 0.2 mm diameter, multi triad cable or multi pair cable
with 1 5 mm2 conductor shall have 7 strands with each strand of 0.53 mm diameter, as
per the job specification.
Shield shall be aluminium backed mylar/polyester tape bonded together with the
metallic side down helically applied with either side having 25% overlap and 100%
coverage. The minimum shield thickness shall be 0.05 mm in case of single pair/traid
and 0.075 mm incase of multipair/triad cable.
Drain wire shall be provided for individual pair and overall shield which shall be 0.5
mm2 multi stranded bare tinned annealed copper conductor. The drain wire shall be in
continuous contact with aluminium side of the shield.
All multi pair cables shall have 6 pair/12 pairs only while multitriad cable shall have 6
triads/8 triads only.
1.4.12 Control Cables
Single pair control cables shall be used between field mounted solenoid valves and
junction boxes/local control panels and shall meet the requirements specified in para
1.4.11 above.
Multipair control cables shall be used between junction boxes/local control panel and
control room mounted devices in general. These cables shall have only overall
shielding.
c) These control cables shall have 1.5 sq mm conductor size with 7 stranded conductors of
annealed electrolytic grade copper, with each strand of 0.53 mm diameter.
1.4.13 Fieldbus Cables
Fieldbus cables shall be 16AWG (1.31 mm 2) for trunk and 18 AWG (0.82mm 2 ) for
spur twisted in pair individually and overall shielded with aluminium mylar tape with
drain wire and armoured. Other parameters shall be as per Type A defined in IEC-
61158-2.
Fieldbus cables shall be single pair or two pairs.
Field bus cable shall be field proven for FF applications.
Fieldbus cable shall comply with H1 cable test specification FF 844.
e) Outer jacket color shall be orange with 3 longitudinal blue stripes for spur cables and
black stripes for trunk cables.
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1.4.14 Thermocouple Extension Cables
Single pair shielded thermocouple extension cables shall be used between

thermocouple head and junction boxes/ transmitters/local control panel mounted
instruments.
Multipair individually and overall shielded thermocouple extension cables shall be used
between junction boxes and control room mounted devices.
The type of thermocouple extension cables shall be compatible with thermocouple
used. In addition the colour coding of the primary insulation shall be as per IS-8784-
1987 (R2004).
The cable shall have 16 AWG and 20AWG solid conductors for single and multipairs
respectively.
All thermocouple extension cable shall be matched and calibrated in accordance with
IEC-60584-2.
Shield shall be aluminium backed by mylar/polyester tape bonded together helically
applied with the metallic side down with either side having 25% overlap and 100%
coverage. Minimum shield thickness shall be 0.05 mm for single pair and 0.075 mm for
multipair cable. Drain wire shall be similar to individual pair and shall be in continuous
contact with the aluminium side of the overall shield.
Inductance shall not exceed 4mH/Km. However for J-type thermocouple inductance
could be 8 mH/km.
Electrostatic noise rejection ratio shall be over 76dB.
i) All multi-pair cables shall have 6 pairs/12 pairs only.
1.4.17 Power Supply and Other Cables
a) All power supply cables shall be as per IS-1554 Part I and shall have copper/aluminium
conductors depending on conductor size. Minimum conductor size shall be 2.5 mm2 of
copper conductor. For higher sizes (above 16 mm2), aluminium conductor can be
considered. All these cables shall be PVC insulated and armoured.
1.4.18 Any other special cable required for instruments shall also be supplied as per the
requirement. Vendor shall ensure that these cables are armoured type and shall meet all other
requirements specified in para 1.4.1 through 1.4.10, as applicable.
1.5 Cable Glands
Vendor shall supply all cable glands required for glanding the above mentioned cables
at field instrument side, local control panel side, junction boxes side and at control room
side.
All cables glands shall be of nickel-plated brass and shall be double compression type
suitable for armoured cables.
Flame proof glands wherever required shall be supplied with Ex (d) certification.
PVC Cable shrouds shall be provided with all the cable glands.
1.6 Junction Boxes (Non-Fieldbus loops)
Vendor shall supply junction boxes as per the cables selected, wherever required. These
shall be of die cast aluminium alloy (min. LM-6) body and shall be weather proof to
IP65 as a minimum.
These boxes shall have terminals suitable for minimum 4.0 mm 2 cable termination
mounted on rails. 20% spare terminals shall be supplied in each junction box.

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g
I NIR71 2.12M2 JP415.1, IA Govf of lixha Undertaking, PACKAGE UNITS Page 51 of 58
Telephone sockets and plugs shall be provided in junction boxes.
Flame proof junction boxes shall be used in explosion proof/ flame-proof instruments
circuits and supplied with Ex (d) certification. All such boxes shall be weatherproof
also.
e) Each junction box shall have a minimum 12 numbers of entries with 20% or 2 Nos. as
spare entries for branch cable and minimum 2 numbers of entries for multipair cable
with 1 No. spare. All entries shall be provided with suitable plugs.
0 Suitable 3-way power junction box shall be considered for higher size of incomer
power cable, which is not matching with the terminals provided in the control panel.
1.7 Junction Boxes for Fieldbus Loops
1.7.1 For Fieldbus segment, junction box shall be used for mounting the wiring/ terminal blocks to
terminate the trunk and spurs in the fieldbus networks.
Unless otherwise specified, vendor must use the following type of terminal blocks:
For all FISCO signals Weatherproof terminal blocks

For all safe signals Weather proof terminal blocks
For all Explosion proof signals Explosion proof/Flameproof terminal blocks
1.7.2 Junction box for Fieldbus field barrier concept:
Fiedbus junction boxes with field barrier assembly/ assemblies shall be provided. Not more
than 12 spurs shall be considered in one junction box. Each junction shall not have more
than two segments and no. of field barrier assemblies shall be considered accordingly. Field
barrier assemblies in a segment shall be multidropped (shall not be daisy chained in a trunk).
Only one closed loop can be considered per segment. Remaining spur connections in the
segment can be used for open loop. For multi field barrier assembly in a junction box, Field
barrier assemblies shall be DIN rail mounted. Vendor shall terminate the spare pair of trunk
cable in DIN rail mounted terminal in junction box. One field barrier assembly shall contain:
Isolation facilities (EEx de) for isolating the field barrier assembly from fieldbus
trunk.
Not more than 6 spur / barriers connections and Not more than one field device in
each spur connection.
Internal short circuit protection for each spur (short circuit current <= 45 mA)
LED indicator for each spur short circuit.
Each spur shall be galvanically isolated from trunk.
Fieldbus terminator for each segment shall be inside junction box.
1.7.3 Housing of the fieldbus junction boxes shall be electropolished type SS 316.
1.7.4 Surge protectors on the field side shall be provided whenever specifically mentioned in job
specification either within the FFJB or along with the instrument.
1.7.5 Sufficient spacing shall be provided inside the Junction Boxes for mounting of field barrier
assemblies, termination and routing of Trunk/ Spur cables to the barrier/Megablocks,
sufficient space shall be provided for installing terminator etc. inside the Junction Box.
1.7.6 For spur and trunk cables, 20 % addition cable entries must be provided. Unused entries
shall be plugged.

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$2-41- tif5ilegt INDIA LIMITED 6-52-0052 Rev. 3
Riven riecat AA saa dr (A Govt 0 India Undertaking) PACKAGE UNITS Page 52 of 58
1.7.7 Each junction box shall be provided with sufficient entries with weatherproof, flameproof
plugs, as required. Trunk and spur entries shall be from the bottom.
1.8 Instrument Valves and Manifolds
Vendor shall supply instrument valves (miniature type) and valve manifolds wherever
required.
The hydrostatic test pressure for instrument miniature valves shall be 153 Kg/cm2g for
pipe class upto 600 and whereas for Instrument air lines, it shall be 41 Kg/cm2g. All
valves and manifolds shall be forged type only.
c) Valve body and trim material shall be 316 SS unless otherwise specified. Superior trim
material shall be selected as required by process conditions. Packing material in general
shall be of PTFE.
1.9 Impulse Piping/Tubing
Vendor shall supply 1/2" OD x 0.065" thick ASTM A 269 TP 316 L stainless steel
seamless tubes as a minimum for impulse lines.
Where the pressure (operating) exceeds 70kg/cm2g or if piping is specified as impulse
line, seamless pipes of size '/2" NB of required thickness shall be supplied with material
as per piping class.
Seamless tubes shall have a hardness of max 80 RB as typical.
Steam tracing shall be 10 mm OD copper tubes of electrolytic grade copper.
e) Instrument air tubing shall be 6 mm SS316L.
1.10 Pipes and Tube Fittings
Vendor shall supply flareless compression type of tube fitting and of three piece
construction.
The fitting/ferrule hardness shall not be less than RB 90 so as to ensure a minimum
hardness difference of 5 to 10 between tube and fittings. The fitting/ferrule shall be of
SS316 material.
Socket-weld type forged pipe fittings of suitable material and rating shall be supplied
for pipe fittings as per Piping Material Specification. The minimum rating shall be 3000
Lbs. Weld neck fittings shall be used where socket weld type are not allowed by piping
class.
Brass fittings, wherever used as per job specification, shall be suitable for use on
copper tubes conforming to ASTM B68 /B68M hardness not exceeding RB 50. All
fitting parts shall be manufactured from Brass as per IS-319 bar stock or equivalent and
shall be nickel plated.
e) All threaded fittings shall have NPT threads as per ANSI/ASME B 1.20.1 only.
1.11 Pneumatic Signal Tubes
Vendor shall supply 6mm OD x 1mm thick SS316L tube for pneumatic signal tubes.
Vendor shall avoid use of intermediate connections and shall estimate single length for
each instrument location.

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=
Ogar Rift
ENGINEERS
INDIA LIMITED
INSTRUMENTATION OF
6-52-0052 Rev. 3
PACKAGE UNITS Page 53 of 58
1.12 Instrument Air Lines Fittings and Valves
Seamless galvanised, inside and outside, carbon steel pipes used for instrument air
distribution shall be as per IS 1239 class Heavy. In view of difficulty in bending such
pipes, elbows shall be used wherever bending is expected or A106 Gr B pipe shall be
supplied.
Galvanised forged screwed carbon steel screwed fittings of 2000 lbs rating fittings shall
be used.
c) Isolation valves on instrument air service shall be packless gland type full bore ball
valves. .
1.13 Air Filter Regulators
Instrument air filter regulator of suitable size, range and capacity shall be supplied for
each pneumatic instrument.
The body of the filter shall be anodised aluminium.
c) The filter shall have 5 micron sintered bronze filter element and shall be provided with
manual drain and 2" nominal size pressure gauge.
1.14 Cable Trays and Cable Ducts
All cables on the main pipe rack shall be laid in cable duct. Cable ducts shall be of
galvanised mild steel with SS bolts and shall be fabricated as per 'Duct Fabrication-
bolted Construction Details' standard No. 7-52-0254.
All branch cables/tubes shall run on cable trays.
These cable trays shall be made out of galvanised mild steel sheets of 2.5 mm
thickness. Ladder trays shall be of galvanised mild steel. 50 mm x 50 mm x 6mm thick
angle shall be used as a minimum.
The width shall be so selected that 50% of tray space is available for future use.
Suitable SS wire cable clamps shall be supplied for binding the cables/tubes at every
500 mm. Nuts/Bolts used for cable trays fixing shall be SS.
FRP cable trays shall be provided when specified.
1.15 Instrument Support/Structural Steel
a) Vendor shall supply instrument stands, stanchions and other structural steel material
required for supporting the cable trays, impulse lines and instruments.
1.16 Heat Tracing and Insulation

Heat tracing and insulation of line mounted instrument impulse lines shall be carried
out as per line specifications. Similar philosophy shall also be followed for equipment
mounted instruments. However, impulse lines for instruments/level instrument in
congealing, viscous services shall also be stream traced even though the
pipe/equipment not traced.
Instruments mounted on jacketed lines and jacketed equipments shall be jacketed only.
In case the jacketing of any particular instrument item is not possible, heat tracing may
be selected after intimation to Owner/ Owner Representative before proceeding ahead.
c) For all steam traced lines and steam jackets, a suitable type of steam trap must be
provided for proper and efficient tracing. Separate dedicated steam trap shall be used
for each instrument. Steam trap shall preferably be located on ground level with its

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Ogal" fa5reg INDIA LIMITED 6-52-0052 Rev. 3
lama viva, ,t
451 07-0 1, A Govt of India Undettakogl PACKAGE UNITS Page 54 of 58
outlet connected to drain funnel or as advised elsewhere in the package. Each

instrument to be traced shall be provided with steam isolation valve.
Wherever electric tracing is shown in the approved P&ID and selected for instruments
and instrument lines, this must be suitable for the line temperature rating.
Steam tracing shall be avoided inside any room/ or shelter. The heat tracing required
for analyzers shall be carried out by electrical tracing using prefabricated tube tracers.
0 Insulation of all in-line instruments like control valves, safety valves etc. shall be done
as per the line requirements. Also all direct equipment mounted instruments like level
gauge, displacer/float type instruments etc. shall be properly insulated as per insulation
requirements of the equipment on which these are installed.
The insulation with 25 mm dia. Sodium silicate inhibited ceramic fiber rope (fiber glass
/ SS wire braided) by spiral winding in position, wrapping the rope around piping so as
to cover the piping completely without leaving any gap, application of two layers of
self adhesive aluminum foil tape (min 0.1 mm thick) spirally wound over the rope
surface with the joints in two layers staggered. Ceramic fibre rope shall be of minimum
density 250 kg/m3 shall be made up of ceramic fibre insulation with other properties of
ceramic fibre rope confirming to 3.2.3 (1) of specification "6-44-0002 for hot
insulation" work.
Steam tracing shall be considered for instrument impulse line for cryogenic services
(i.e. operating temperature is less than 0° C).
2.0 INSTALLATION
2.1 Vendor shall be completely responsible for installation of all instruments within their battery
limit, in line with the installation standards (typical) furnished alongwith package
specification.
2.2 Whenever installation is beyond the scope of vendor/contractor, purchaser shall install the
instruments as per the details/documents/drawings provided by the vendor/contractor.
However, in such a case it must be ensured that complete installation materials shall be
supplied.
2.3 All direct mounted instruments like thermocouples, thermowells, temperature gauges,
pressure gauges, pressure switches etc. shall be installed in such a way that they have good
readability and accessibility.
2.4 The capillary of all capillary type instruments shall be supported properly and shall be
protected against mechanical damage.
2.5 All pressure/differential pressure instruments shall be provided with block and bleed/ by-
pass, drain/vent valves etc as per the installation standards, and shall have accessibility.
2.6 All primary piping/tubing (impulse lines) shall have a slope of 1 in 12 on the horizontal run.
2.7 All welding shall be carried out as per the relevant codes with proper electrodes. Any testing
(non destructive) like DP test and radiography on root weld and final weld shall be carried
out as applicable. All consumables shall be part of vendor's scope of supply. Any pre/post
weld treatment as required by the relevant codes shall be carried out.
2.8 All threaded joints shall be joined by PTFE tapes only.
2.9 All impulse lines shall be supported at regular intervals.
2.10 Instrument drain/vent connections shall be piped to safe area like oily water sewer or above
pipe racks to avoid accumulation of hazardous fluid in the plant atmosphere.
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Igar la leg INDIA LIMITED 6-52-0052 Rev. 3
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29-075,2 .770.1) PACKAGE UNITS
IA GoA of Incha Undeffak,N)
Page 55 of 58
2.11 Steam tracing wherever required shall be carried out by 10 mm OD x 1 mm thick coper
tubes and condensate traps shall be provided to collect all the condensate and shall be piped
to the nearest pipe drain funnels.
2.12 All tubes/cables shall be properly laid on cable trays, which shall be supported at regular
intervals.
2.13 Separate routing or physical separation shall be maintained between signal, shut down and
power cables.
2.14 Wherever intrinsically safe system cabling is employed, the minimum separation of 150 mm
shall be adhered between IS (intrinsically safe) and non- IS signal cables.
2.15 The cases of instruments shall be earthed by earthing wire to the nearest earth bus bar for
safety reasons.
2.16 In case the cables are to be buried or laid in concrete trench the same shall be carried out by
vendor. In case civil work is carried out by purchaser, requirement of trenches shall be
provided with prior intimation to client.
2.17 Painting of angle trays, instrument supports and all structural supports shall be painted as
under :-
a) The surface to be painted shall be thoroughly cleaned with brush and sand paper to
remove all scales. After cleaning, one coat of red oxide zinc chromate primer shall be
given conforming to IS-2074 and allowed to dry. One coat of final paint shall be
applied.
Second and final coats of paint of final colour shall be given before handing over the
plant/ commissioning.
2.18 Installation of Systems ( MMS, Analysers etc.)
2.18.1 The system as applicable shall be installed by the system vendor who would be responsible
for installation and termination of interconnecting cables in the system racks/cabinets. All
interconnecting cables shall be identified and the individual cores/wires shall be properly
identified using ferrules. Direct-cross ferruling method shall be used for identification.
2.18.2 All system communication cables shall be laid in covered GI (galvanised iron) trays away
from power cables. Prefabricated cables shall be avoided for interconnection if these are to
be routed out side the cabinets. If unavoidable these should be laid in covered GI trays.
2.18.3 All panels/cabinets shall be properly leveled and secured firmly with the base supporting
structure. However, the consoles and printer stands need not be secured to base structure.
2.18.4 Grounding
Each cabinet, console and other equipment supplied as a part of system shall have
earthling lugs which shall be secured to the 'AC mains earthing bus'.
All circuit grounds, shields and drain wires shall be connected to the 'system ground'
bus which is isolated from 'AC mains earth'. This bus shall typically be 25 mm wide
and 6 mm thick of copper.
The total resistance of system ground shall be less than 5 ohms unless otherwise
recommended by system manufacturer.
c) Safety barriers, if used, shall be secured to 'Safety ground' which shall have typically
ground resistance of less than 1 ohm. The bus shall be designed considering a fault level
of 0.5 A at 250V r.m.s. per barrier.
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2.18.5 All other installation guidelines as recommended by system manufacturer shall be followed.
3.0 TESTING AND CALIBRATION
3.1 All impulse lines shall be tested hydrostatically at 1.5 times the design pressure / maximum
operating pressure. Ensure that instrument and vessel/piping is isolated during this test.
3.2 In case of special instruments/items where hydrotesting is not permitted due to service
conditions, the impulse lines testing shall be carried out by using air or nitrogen.
3.3 After pressure testing, all these impulse lines shall be drained and dried with dry air for 15
minutes to remove any traces of moisture, oil and dust.
3.4 Instrument air lines shall be duly tested for any leak after pressurising and isolating the main
root valve by soap solution and bubbler unit. After isolation, the rate of fall in pressure shall
be less than 1 kPa for every 4.4 metre (1 psi for each 100 feet) of tubing for a test period of 2
minutes.
3.5 All instrument cables shall be tested for continuity and insulation. While meggering the
cables for insulation testing, ensure that all instruments and barriers are isolated at both ends.
The megger testing at site is not required to be carried out for the field bus cables and
thermocouple extension cables. However, for field bus cables and thermocouple extension
cables, the loop resistance and capacitance shall be checked by the contractor before and
after the completion of cable laying.
3.6 All instruments supplied by the vendor shall be calibrated using proper test equipment.
3.7 All instruments shall be calibrated for 0%, 25%, 50%, 75%, 100% and vice versa.
3.8 All temperature gauges shall be calibrated using temperature baths.
3.9 All thermocouple activated instruments shall be calibrated by generating millivolts by a

potentiometer.
3.10 All transmitters shall be calibrated as per instrument ranges.
3.11 All displacer type level transmitters shall be calibrated with water or suitable fluids and
corrected for specific gravity.
3.12 All alarm and trip switches shall be calibrated over the entire range, finally set and checked
for alarm/trip points and reset points as per the alarm/trip set point schedule. After setting,
these shall be sealed.
3.13 All control valves, prior to stroke checking, shall be externally cleaned thoroughly. The full
stroke of valve shall be checked for opening and closing. Any adjustment required for
obtaining full stroke and reducing hysteresis shall be carried out. The hysteresis shall not be
more than 1% URV (upper range value) with positioners and 5% URV without positioners.
3.14 Solenoid valve shall be checked functionally for its operation and also compatibility with
respect to barrier.
3.15 Safety valves and relief valves shall be set/ tested by using dry air/nitrogen. Leakage if any
shall be removed by proper lapping of seat and disc.
3.16 All electronic/pneumatic receiver instruments shall be calibrated as per the manufacturer's
instructions. Controllers shall be aligned properly.

Page 893 of 1296

elf ttai
eg INDIA LIMITED 6-52-0052 Rev. 3
141FR ,I,CP1149,710.0 (A Govt India UnOettak nngt PACKAGE UNITS Page 57 of 58
3.17 All special instruments like analyzer shall be checked and calibrated as per manufacturer's
instructions. Prior to testing, all analyzer sample lines shall be thoroughly cleaned by carbon
tetra chloride or any other cleaning liquid. After cleaning, these lines shall be thoroughly
purged with dry nitrogen.
3.18 No oil should be used in oxygen and chlorine service lines.
3.19 The accuracy of overall loop shall be within 1% for electronic and 1.5% for pneumatic
loops.
3.20 After performing the calibration of all instruments, the entire loop shall be checked for
proper operation.
3.21 The entire shutdown scheme shall be simulated from the process trip switches/ control
system and the scheme shall be tested for its proper operation prior to start up of the unit.
3.22 If no instrument air is available vendor shall provide necessary nitrogen cylinders with
suitable regulators to carry out the above activity.
3.23 Testing Of Systems
3.23.1 All the system functions shall be checked thoroughly for proper functioning. These shall
include but not limited to the following tests:
Visual and mechanical.

Complete system configuration loading.
Demonstration of all system functions.
Checking of all systems displays.
Checking of correct functioning of all keyboards.
Demonstration of all system diagnostics.
Checking of proper functioning of all printers, hardcopy unit, and printing of all reports.
Checking of all disc drives.
Complete checking of logic system, loading of user's program and checkout of results.
Checking of correct changeover of the back-up/redundant units in case of failure of
main units.
Vendor shall also carryout the system checks as per respective items specifications wherever
provided along with package.
3.23.2 The input signals shall be simulated by disconnecting the field wires for all inputs. Wherever
control room mounted Transmitters/Converters/Receiver switches are used, the functioning
of same shall also be checked.
3.24 Loop Checking
3.24.1 Loop checking shall be carried out by vendor, which shall include proper functioning and
interconnection of all items in the loop.
3.24.2 All input signals shall be generated in the field and corresponding reading shall be checked
at all corresponding displays.
All the outputs shall be checked in the field, by physical verification of valve stroke or
operation of solenoid valve/pick-up of electrical contactor.

Page 894 of 1296

Ogar faajeg INDIA LIMITED 6-52-0052 Rev. 3
,A Govt of Indo Unclertakow PACKAGE UNITS Page 58 of 58
3.24.3 After loop checking is completed, vendor shall connect back any terminals and connections
removed during loop checking.
3.24.4 For fieldbus loops the segment verification shall be carried out by DCS vendor. Any field
side modifications required shall be carried out by vendor.
4.0 COMMISSIONING
4.1 This activity shall be carried out in a systematic manner so as to avoid any accident to plant
and operating personnel.
4.2 During the plant start up all the instruments calibration, controller alignment, trip point
settings shall be trimmed so as to meet the operation requirements.
4.3 Prior to guarantee run of any package unit, the vital instruments as required by vendor have
to be recalibrated and the results recorded.

Page 895 of 1296

ENGINEERS MATERIAL SELECTION CHART Annexure Ito

Ogar faiRegWf INDIA LIMITED STANDARD SPECIFICATION NO.
AMA' WORM) IA Go. of Indus Und.slung)
6-52-0052 Rev. 3
Page 1 of 5
1.0 GENERAL

1.1 Material selection chart defines the base material requirements for major instrument
items. The materials have been specified as per 'piping class' in which these
instruments are installed. Additional requirements like stelliting etc. shall be selected
based on process conditions.
1.2 Although materials as specified in Material Selection Chart shall be acceptable, in

general, this does not absolve vendor of the responsibility of proper selection of
material as per the fluid being handled and process conditions.
1.3 For all instruments in sour service requiring NACE as per Piping class, all materials
of construction shall meet the requirements specified in NACE MR 01-03 latest
edition. In addition, any other requirements if specified in respective piping class,
shall also be complied.
1.4 Impulse pipe material shall be as per the corresponding piping class. However, for
Impulse tubing material shall be 316L SS, as a minimum. Better material shall be
selected wherever required.
1.5 This gives details of selection criteria for most of the common EIL Piping Classes.
However, variations may exist from these in jobs and also new piping classes may
arise. In those circumstances, the material selection shall be based on the relevant job
piping classes and evaluation of actual requirements.
1.6 For testing requirement like Radiography, IBR, NACE, Hydrogen testing, Post weld
heat treatment, etc shall be followed as per piping material specification for the
respective piping class.
Page 896 of 1296

fiPzrekgi:—
:h ENGINEERS Annexure I to
iaReg INDIA LIMI1B D MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
14917A 2120,1,61JAMI, una,isonsi
in Govt Of InOta
6 -52 -0052 Rev3
Page 2 of 5
CONTROL VALVE PRESSURE RELIEF VALVE

SL.
PIPING CLASS
NO Body / Nozzle /
Body Trim Bellow
Bonnet disc
1. A1A,A3A,A5A, A6A, A8A, A9A, A216 SS316 A216 SS316 SS316L

AI OA, A14A, A19A, A22A, A28A, Gr. WCB Gr. WCB
B IA, B5A, B6A, B9A, B I3A,
B19A, B28A
2. A16A, A23A, A26A, A68A, B16A, A216 SS 316L* A216 Gr. SS 316L Inconnel
B23A, B24A, B26A, B68A • Gr. WCB * WCB * * *
3. D23A, D26A A216 SS 316L A216 Gr. SS 316L Inconnel
Gr. WCB * Stellited* WCB * * *
4. A2A, B2A, B21A, DI A, D9A, A216 SS 316 A216 SS 316 SS 316L
D19A, D2A, D5A, ElA, E2A, FIA, Gr. WCB Stellited Gr. WCB
F2A, F5A
A4A, B4A, D4A A352 SS 316 A352 SS 316 SS 3I6L
Gr. LCB Gr. LCB
AlB, BIB, D1B, D2B A217 SS316 A217 SS316 SS316L
Gr. WC1 Stellited Gr. WC1 stellited
7. AID, BID, B5D, D1D, D2D, F2D A217 SS316 A217 SS316 SS316L
Gr. WC6 Stellited Gr. WC6 stellited
8. A4F, B3F, B4F A217 SS 321 A217 SS 321 SS321
Gr. C5 Gr. C5
9. A4G, B4G A217 Gr. C12 SS321 A217Gr. SS321 SS321
C12
10. D4G A217 Gr. C12 SS321 A217Gr. SS321 SS321
Stellited C12
A1H, BIH, DIH A352 SS 316 A352 SS 316 SS 316L
Gr. LC3 Stellited Gr. LC3 stellited
AIK, A2K,A3K, A22K, BIK, B2K, A351 SS 316 A351 SS 316 SS 316L
D2K Gr. CF8 Gr. CF8
D2K A351 SS 316 A351 SS 316 SS 3I6L
Gr. CF8 Stellited Gr. CF8
B25K A351 SS 316L A351 SS 316L SS 316L
Gr. CF3 Stellited Gr. CF3 stellited
15. B18K, D18K A351 SS316 A351 SS316 SS 316L
Gr. CF8 Gr.CF8
16, AIM, BIM A351 SS 316 A351 SS 316 SS 316L
Gr. CF8M Gr. CF8M
AIN, BIN, B6N A351 SS 316L A351 SS 316L SS 316L
Gr. CF3M GrCF3M
A26N A351 SS 3I6L* A351 SS 3I6L* Inconnel
Gr. CF3M* GrCF3M* *
D26N A351 SS 316L A351 SS 316L* Inconnel
Gr. CF3M* Stellited* GrCF3M* *
B4K, B5K A351 SS 304H A351 Gr. SS 316 SS 316L
Gr. CF1OM Stellited CFIOM
21. A70M, A74M, B70M, B74M A351Gr. SS 321 A351Gr. SS 321 SS 321
CF8C CF8C
22 D25M A351Gr. SS 347 A351Gr. SS 347 SS 347
CF8C Stellited CF8C Stellited
23. AllK, B11K A351Gr. CF3 SS316L A351Gr SS316L SS 316L
CF3

Page 897 of 1296

latitzieift ENGINEERS Annexure Ito
itaieg W INDIA LIMITED MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
MOM evim2fenaae1oo IA Goa of Inclo Undeotalang)
6-52-0052 Rev3
Page 3 of 5
ORIFICE/SENIOR ORIFICE FIELD TRANSMITTER

S.
PIPING CLASS
NO
Flange/Body Plate Body Sensor
AlA, A3A, A6A, A8A, A9A, A10A, A105 SS 316 SS 316 SS 316L
A14A, A19A, A22A, B1A, B21A, B6A,
B9A, B13A, B19A, D1A, D9A, D19A,
E1A, F1A,
A16A, A23A, A26A, A68A, B16A, B23A, A105 * SS 316L* SS 316* SS 316L*
B24A, B26A, B68A, D23A, D26A
A2A, B2A, D2A, E2A, F2A, A105 SS 316 SS 316 SS 316L
A4A, B4A, D4A A350 GrLF2 SS 316 SS 316 SS 316L
AlB, B1B, D1B, D2B A182 SS316 SS316 SS316L

GrF1
AID, BID, B5D, DID, A182 SS316 SS316 SS316L
D2D, F2D GrF11
A4F, B3F, B4F A182 SS 321 SS316 SS321 or
GrF5 Hastelloy-C
A4G, B4G, D4G A182 SS 321 SS316 SS321 or
GrF9 Hastelloy-C
AlH, B1H, D1H A350 SS316 SS316 SS316L
GrLF3
A1K, A2K, A3K, A22K, B1K, B2K, D2K A182 SS 316 SS 316 SS 316L
GrF304
B25K A182 SS 316L SS 316 SS 3I6L
GrF304L
B18K, D18K A182 SS316 SS316 SS316L
GrF304
AIM, BIM A182 SS 316 SS 316 SS321 or
GrF316 Hastelloy-C
AIN, A26N*, B1N, B6N, D26N* A182 SS 316L SS 316 SS 316L
GrF316L
A5A, B5A, D5A, F5A, F25A A105 SS316 SS 316 SS316L with
Note-1 gold plated
B4K, B5K A182 SS 316 SS 316 SS 316L
GrF304H
A70M, A74M, B70M, B74M A182GrF321 SS321 SS316 SS321 or
Hastelloy- C
D25M A 1 82GrF347 SS347 SS316 SS316L with
gold plated
19. AllK, B11K A182GrF304L SS316L SS316 SS316L

Page 898 of 1296

101
ifft ENGINEERS Annexure I to
Itgar ial5tegW INDIA LIMITED MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
1.27121OMOOnaOarfl, IA Govl ol Inda Undertalorg)
6-52-0052 Rev3
Page 4 of 5
THERMOWELL LEVEL INSTRUMENT

S.
PIPING CLASS
NO
Flange Well Cage/ Chamber
A1A, A3A, A6A, A8A, Al OA, A14A, A105 SS 316 A106
A19A, A22A, B1A, B21A, B6A, B9A, Gr. B
B13A, B19A, D1A, E1A, F1A, A5A,
B5A, D5A, D9A, D19A, F5A
A16A, A23A, A26A, A68A, B16A, A105 * SS 316L A106 GrB*
B23A, B24A, B26A, B68A, D23A,
D26A
A2A, B2A, D2A, E2A, F2A A105 SS 316 A106 GrB
A4A, B4A, D4A A350 GrLF2 SS 316 A333 Gr6
A1B, B1B, D1B, D2B A182 GrF1 SS 316 A335 GrP1
AID, B1D, B5D, D1D, A182 GrF11 SS 316 A335 GrP11

D2D, F2D
A4F, B3F, B4F, A182 GrF5 SS 321 A335 GrP5
A4G, B4G, D4G A182 GrF9 SS 321 A335 GrP59
A1H, B1H, D1H A350 GrLF3 SS 316 A333, Gr3
A1K, A2K, A22K, A3K, B 1K, B2K, A182 GrF304 SS 316 A312 GrTP304
D2K
B25K A182 GrF304L SS 316L A312 GrTP304L
B18K,D18K A182 GrF304 SS 316 A312 GrTP304
AIM, BIM A182 GrF316 SS 316 A312 GrTP316
AIN, BIN, B6N, A26N*, D26N* A182 GrF316L SS 316L A312 GrTP316L
15. B4K, B5K A182 GrF304H SS 304H A312 GrTP304H
16 A70M, A74M, B70M, B74M A182 GrF321 SS321 A312 GrTP321
D25M A182 GrF347 SS347 A312 GrTP347
AUK, B11K A182 GrF304L SS316L A312 GrTP304L

Page 899 of 1296

laffkle/ ift ENGINEERS Annexure Ito
Ogeil Eifilegyr
INDIA LIMITED
Govt ol India U.d.ak.n9)
MATERIAL SELECTION CHART STANDARD SPECIFICATION NO.
6-52-0052 Rev3
Page 5 of 5
PRESSURE, DIFFERENTIAL
LEVEL GAUGE PRESSURE AND VACUUM
SL. GAUGE
PIPING CLASS
NO Sensing
Cock Cock Diaphragm
Chamber Element
Body Trim
/ Socket
Al A, A3A , A6A, A8A,A10A, A105 A105 SS 316 SS 316 SS 316
A14A, A19A, A22A, B IA, B6A,
B9A, B13A, B19A, B21A, D1A,
D9A, D19A, E1A, F1A,A5A,
BSA, D5A, F5A
Al 6A, A23A, A26A, A68A, A105* A105* SS SS 316* SS 316L*
B16A, B23A, B24A, B26A, 316L*
B68A, D23A, D26A
A2A, B2A, D2A, E2A, F2A A105 A105 SS 316 SS 316 SS 316
A4A, B4A, D4A A350 A350 SS 316 SS 316 SS 316

GrLF2 GrLF2
AlB, B1B, D1B, D2B A182 A182 SS316 SS316 SS316
GrF1 GrF1
AID, BID, B5D, DID, A182 A182 SS316 SS316 SS316
D2D, F2D GrF11 GrF11
A4F, B3F, B4F A182 A182 SS 321 SS 316 SS 321 or Hastelloy
GrF5 GrF5 or Inconel
A4G, B4G, D4G A182 A182 SS 321 SS 316 SS 321 or Hastelloy
AlH, B1H, DIH A350 A350 SS 316 SS 316 SS 316
GrLF3 GrLF3
A1K,A2K, A22K,A3K, B1K, A182 A182 SS 316 SS 316 SS 316
B2K, D2K GrF304 GrF304
B25K A182 A182 SS 3I6L SS 316 SS 316
GrF304L GrF304L
B18K, D18K A182 A182 SS 316 SS 316 SS 316
GrF304 GrF304
AIM, BIM A182 A182 SS 316 SS 316 SS 321 or Hastelloy
AIN, BIN, B6N, A26N*, D26N* A182 A182 SS 316L SS 316 SS 316L
GrF316L GrF316L
B4K, B5K A182 A182 SS 304H SS 316 SS 316
Gr. F304H GrF304
H
A70M,A74M, B70M, B74M, A182Gr. A182Gr SS321 SS 316 SS 321 or Hastelloy
F321 F321 or Inconel
D25M A182Gr. Al 82Gr SS347 SS 316 SS 347 or Hastelloy
F347 F347 or Inconel
AUK, BlIK A182Gr. A182Gr SS316L SS 316 SS 316L
F304L F304L
Notes:
* Material shall be hardness controlled and shall comply with NACE MR-0103 latest edition.
For Hydrogen service wetted part material for switches, transmitters shall be SS 316L gold
plated, base material Hastelloy shall be avoided
SS 316L, SS 316Ti are also acceptable in place of SS316.

Page 900 of 1296

ANNEXURE4I TO STANDARD
15IPZEC(ft
-- ENGINEERS STANDARD SPECIFICATION FOR SPECIFICATION No.
$ fliAegW7- INDIA LIMITED
IA Govt al India UncleMO.9)
PACKAGE UNITS 6-52-0052 Rev. 3
Page 1 of 9
ANNEXURE-Il
Format of Instrumentation Index
Format of Point Data Base
Format for Functional Schematics
Format For cable Schedule (Non-FF)
Format For cable Schedule (FF)
Format for Logic Diagram
Format for Electrical/Instrumentation interface
Format for FF instrument details
Page 901 of 1296

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SHEET 1 OF 1
Page 904 of 1296

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Page 905 of 1296

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Page 377 of 1296

Page 378 of 1296

JOB SPECIFICATION FOR

PROJECT- SRU REVAMPING AT ONGC HAZIRA PLANT

JOB NO. - B115

LOCATION - HAZIRA, GUJARAT

A 08.11.2017 ISSUED AS JOB SPECIFICATION AN SSP SKG

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 402 of 1296

DP/LP : Dye/Liquid Penetrant

ASTM : American Society for Testing & Materials

ASME : American Society of Mechanical Engineers

IBR : Indian Boiler Regulations

PMS: Piping Material Specification

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 403 of 1296

S.NO TITLE PAGE NO.

3. NON DESTRUCTIVE EXAMINATION 6

4. TABLE-1 (With applicable Notes to Table-1) 7

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 404 of 1296

1.2 RELATED CODES & ENGINEERING STANDARDS

e) Piping Material Specification, B115-6-44-0005

f) Welding Specification Charts for Piping Classes, 6-77-0005.

g) Standard Specification for Fabrication & Erection of Piping 6-44-0012.

i) Welding specification for fabrication of piping, 6-77-0001.

j) Design Guide for Radiography Requirements, 8-77-0010

k) Indian Boiler Regulations (IBR)

a) Internal misalignment 1.5 mm or less

b) Cracks or lack of fusion Not permitted

d) Surface porosity and Not permitted

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 405 of 1296

f) Weld ripples irregularities 2.5 mm or less.

g) Lack of uniformity in bead 2.5 mm or less.

h) Lack of uniformity of leg 2.5 mm or less.

i) Unevenness of bead 2.0 mm or less.

j) Weld undercutting 0.8 mm or 1/4 thickness of thinner components

k) Overlap 1.5 mm or less

l) Bead deflection 2.5 mm or less

Wall thickness of thinner Weld reinforcement or internal weld protrusion

6.4 and under 1.6

n) Throat thickness of fillet welds:

Nominal thickness of the thinner component x 0.7 or more.

Flattening of a bend, as measured by difference between the nominal outside

p) Reduction of wall thickness

Reduction of wall thickness of a bend, as measured by difference between the

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 406 of 1296

3. NON DESTRUCTIVE EXAMINATION

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 407 of 1296

4. TABLE-1 (With applicable notes)

TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION

I CATEGORY 'D' CARBON 1 0 A3A, J2A

REMARKS FOR ABOVE TABLE:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 408 of 1296

TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)

REMARKS FOR ABOVE TABLE:

(i) NOTE-7 FOR HARDNESS IS VALID FOR P.NO. 8

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 409 of 1296