ECTION V: WORKS REQUIREMENTS (WRQ)

PART A: GENERAL INFORMATION AND REQUIREMENTS

1. GENERAL SCOPE OF WORKS

1.1 Scope of Works
The scope of works includes the following:
1. Design, fabrication, supply, transportation, shifting, handling, aligning and installation, testing and
commissioning of 5 nos. 70 KL Underground Tanks including strip raft, construction of retaining
wall for tanks, beams, steps and other items of work including sand filling, hydrostatic testing as per
specifications, relevant/binding codes and standards.
2. Inside & outside painting with SA 2 ½ Shot Blasting as mentioned in specification.
3. Providing floating suction for 70 KL Tanks as per the specifications/datasheet.
4. Supply, Handling, Aligning, Erecting, Laying, welding and hydrostatic testing of ERW Mild Steel
pipelines of various sizes from tanks to pump house manifold, TLF shed and TT loading and
unloading points including fittings.
5. Supply, handling aligning and installation of product pumps and motor, filters, floating suction or
any other equipments.
6. Making sampling points, drain points, sump etc. of the tanks/pipelines.
7. Supply, Handling, Aligning and Welding of SORF/BLRFs, making joints with supply of all
necessary gaskets, fasteners.
8. Supply, Handling, Aligning and fixing the CS gate valves/ Ball Valves/strainers/filters.
9. Radiography of tanks and pipeline weld joints through approved agency and submission of report.
10. Surface preparation and External Painting of Pipelines as per specified painting scheme.
11. Providing and Construction of Pipelines pedestals/steel structural supports of pipelines or any
other structure works.
12. Various Civil items of works including excavation, PCC, RCC, Reinforcement,
Brick masonry/interlock, Plastering etc.
13. Testing and commissioning of 5 nos. 70 KL Underground tanks.
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14. Testing and commissioning of Pipelines network.
15. Arranging DG Sets as in when required, welding machinery, bending and rolling machines and all other
plants and machineries, tools tackles etc. as required for the successful completion of fabrication work.
16. Providing and taking of radiography films of weld joints of tanks and pipelines.
17. Providing and constructing Earthing pits, laying of GI earth strips for tanks, pipelines, TLF
shed, pump house etc for earthing.
18. Other miscellaneous and associated jobs/works required for successful completion of job.
19. Site clearance after completion of works.
Notes:
a. Entire work is to be carried-out as per the approved scheme and technical specification given in
the tender.
b. In case of any class of work over which there is no specification mentioned, the same shall be carried
out in accordance with the latest edition of IS, EI, API and relevant
codes/standards/specifications/guidelines subject to the approval of NOC.
c. The quantities mentioned in the Bill of Materials, wherever mentioned within this tender, are
tentative. The successful bidder is required to immediately assess the quantities as per the scope of
works aforementioned, the requirement of the site and supply them at site as per the requirement
after approval of Engineer-In-Charge.
d. The contractor shall submit a bar chart detailing the planned execution of work. Such bar charts shall
be approved by NOC before commencement of work. For ready reference these charts shall be
displayed in the site office at all times.

1.2 Design Submission and Completion Period for the Whole Works
The Contractor shall submit the Preliminary Design for approval latest by Twenty One (21) Days from
the Start Date. Upon discussion with the Employer, the Contractor shall submit the Final design for
approval within Thirty (30) Days from the Start Date of the Contract.
The contract completion time shall be Six (6) months from the date of contract agreement. The
following milestones of the contract are set for monitoring the progress of the contract.
Milestone1: completion of survey and submission of design works within One (1) months from
date of signing of Contract Agreement.
Milestone 2: completion of all physical works within 5 months from date of design approval period.
Milestone 3: Completion of whole works within Six (6) months.
Note: For more storage capacity design, the above milestones are to be reviewed and
determined during Contract Agreement.

1.3 Reporting of Works and Mode of Payment

Consultant shall report physical progress of work at 2 (Two) months interval from date of agreement and
payment shall be made based on running bills verified by the client where maximum 3 (Three) running
bills shall be permitted.

1.4 Defect Liability Period

The Defect Liability Period shall be One (1) Years or (365 days) from the issuance of the Final
Completion Certificate by the Project Manager.

1.5 Manpower Deployment at Site by Contractor

The successful tenderer within 10 days of issuance of work order, name an engineer (Bachelor’s Degree
in Mechanical Engineering or equivalent with at least 3 years of general working experience in projects
of similar nature) responsible for the job at site on behalf of the contractor. Bidder should give in writing
to NOC, the name of his authorized and qualified engineer who will supervise the work and shall remain
at the site during execution of the job.

2. Site Assessment before Bidding

The bidder shall be deemed before bidding to have undertaken a thorough study of the proposed work, the job
site(s) involved, the site conditions, soil conditions, the terrain, the climatic conditions, the labor, power,
material and equipment availability and transport and communication facilities, the availability of transport,
the availability of land for right of way and temporary office and accommodations, quarters, and all other
facts and facilities necessary or relevant for the formulation of the tender, supply of materials and the
performance of the work. Without prejudice to the foregoing, the tenderer may be allowed access to any
information regarding the site of the work, the investigations conducted relative thereto, such as soil
investigation etc. But, these shall be only indicative in nature and the tenderer are expected to collect their
own data for preparation and submission of their tender.
Any claim at a later date based on either incorrectness or inadequacy of the information/data made
available by the OWNER/tenderer to a tenderer shall not be entertained. The OWNER/tenderer shall be
fully absolved of any and all liabilities in this regard. Since the location is a licensed premises, handling
with petroleum products, where the safety is of at most importance; the Contractor needs to adhere to the
working hours of the facility. No one from the Contractor’s side will be allowed to stay at the location
beyond working hours unless specific permit/permission is given.
3. Contractor’s Scope of Supply

3.1 Supply of Materials:

All materials including cement, reinforcement, structural steel, steel plates, consumables, testing
appliances, tools and tackles, and all materials necessary for completing the work shall be supplied by the
Contractor at his own cost. No claim/ delay on this account will be entertained by NOC.
NOC reserves the right in selection of best makes of materials to be procured by the contractors &
contractor shall procure the same only up on the approval by site in charge. Make of material to be used
at site should conform to the list of approved makes as per the instructions of Engineer-in-Charge.
3.2 Water Supply:
The contractor shall arrange water/procure water required for the work at his own cost for all leads and
lifts. NOC shall not be responsible for supplying water and Contractor shall ensure timely and adequate
supply of water to meet the schedule.
3.3 Power Supply:
NOC will make arrangements for power required for the work. DG set of suitable capacity may be
installed and operated by the contractor at his cost. NOC shall not be responsible for DG power supply
and contractor shall ensure proper supply of electricity to meet the schedule. The electrical works shall be
carried out through Licensed Electrical personal only.
4. Audits
This project is subjected to inspection by various audit / vigilance agencies of NOC, the Government of
Nepal or any outside agency. If any inspection of works is carried by such agencies, Contractor shall
extend his full co-operation to these agencies in examining records, works etc. On inspection by such
agencies, in their inspection report, if it is pointed out that Contractor has not carried out work according
to guideline laid down in this tender document and also if any recoveries in some items is pointed out
therein, same shall be recovered from Contractor’s RA bills / final bills. The items under dispute shall not
be paid in full till inspection agency gives their No Objection report.
4. Meetings
The partners or Directors of the Contractor shall meet the officers of the NOC at the site of works or
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their respective offices whenever requested to do so. Weekly site co-ordination meetings shall be
attended by the Contractors working on site & proper intimation should be given to NOC in order to
monitor the project more efficient way. The relative decision for the execution of tender items shall
be given in these meetings by NOC by producing working drawings / handmade sketches if any.

6. Removal of Debris and Site Clearing

Contractor shall arrange to dispose of debris, wood shaving and any other waste product created while
carrying out the work, inside/outside NOC’s premises as instructed by NOC. The Contractor shall take
due care while disposing of such waste materials and ensure that any rules / regulations lay down by
Local Authorities, NOC or any other statutory body are not violated. The Contractor shall be responsible
and answerable to any complaint arising out of improper disposal of wastage. Quoted rate shall include
the cost of same and no extra payment shall be made towards this account. The Contractor shall take care
for clearing the working site from time to time for easy access to work site and also from safety point of
view. Working site should be always kept cleared up to the entire satisfaction of the Engineer- in-Charge.
Before handing over any work to owner, the contractor in addition to other formalities to be observed as
detailed in the document shall clear the site to the entire satisfaction of Engineer-in-Charge.
7. Protection of Work Done
During inclement weather the Contractor shall suspend concreting and plastering for such time as NOC may
direct and shall protect from injury all works in the course of erection. Should the work be suspended by
reason of rain, strike, lockouts or other cause the Contractor shall take all precautions necessary for the
protection of the work at his own expense shall make good any damages arising from any of this cause.
8. Work Performed at Contractor’s Risk
The Contractor shall take all precautions necessary and shall be responsible for the safety of the work and
shall maintain all safeguards, including providing for guards, proper lights, signs, temporary passages, or
other protection necessary for the purpose. All work shall be done at the Contractor’s risk, and if any loss
or damage shall result from fire or from other cause, the Contractor shall promptly repair or replace such
loss or damage free from all expenses to the NOC. The Contractor shall be responsible for any loss or
damage to materials, tools or other articles used or held for use in connection with the work. The work
shall be carried on and completed without damage to any work or property of the NOC or of others and
without interference with the operation of existing machinery or equipment, if any.
9. Site Drainage
All water, which may accumulate on the site during the progress of the work or in trenches and
excavations from other than expected risk should be removed from the site to the satisfaction of NOC at
the Contractor’s
expense. All soil, filth or other matter of an offensive nature taken out of any trench, sewer, drain,
cesspool, or other place shall not be deposited on the surface, but shall be at once carried away by the
Contractor disposed of as per the rules and regulations of the Local Authorities concerned.
10. Miscellaneous Requirements
All expenses towards mobilization & demobilization including bringing in equipment, clearing the site
etc. shall be deemed to be included in the prices quoted and no separate payments on account of such
expenses shall be entertained. It shall be entirely Contractor’s responsibility to provide, operate &
maintain necessary construction equipment, scaffoldings and safety gadgets, cranes and other lifting
tackles, tools and appliances to perform the work in a workman like and efficient manner & complete all
jobs as per time schedules.
Preparing approaches and working area for movement and operation of the cranes, leveling the areas for
assembly and erection shall also be the responsibility of the Contractor. The Contractor shall acquaint
himself with access availability, local labor etc. to provide suitable allowances in his quotation. The
Contractor, at his own cost, may have to build temporary access roads to aid his own work that shall also
be taken care while quoting for the work. The procurement and supply in sequence and at the appropriate
time of all materials & consumables shall be entirely the Contractor’s responsibility. Rates for execution
of work will be inclusive of supply of all these items.
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11. Measurements for Works / Record Measurements / Bills

All the payment for quantities certified in the running/final bill shall be as per the details recorded in the
standard measurement book of the Corporation or by a Consultant hired by NOC and jointly signed by
the Contractor/site engineer of NOC. Method of measurement shall be strictly in accordance with the
technical specification/preamble to BOQ for this work.
12. Inspection of Works
The work is subject to inspection at all times by the Site Engineer/ Engineer-in-Charge/ representatives
nominated by NOC. The Contractor shall carry out all instructions given during inspection and shall
ensure that the work is being carried out according to the technical documents and the relevant codes of
practice furnished to him during the performance of the work.
Any work not conforming to the execution drawings, specifications or codes shall be rejected forthwith
and the contractor shall carry out the rectifications at his own cost.
All results of inspection & tests will be recorded in the inspection reports. These reports shall form part
of the completion documents. Inspection & acceptance of works shall not absolve the Contractor from
any of his responsibilities under this Contract.

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13. Quality Assurance/Testing of Materials/Works
The Contractor shall carry out the various tests as enumerated in the technical specifications of this tender
document and the technical documents that will be furnished to him during the performance of the work
and no separate payment shall be made unless otherwise specified in schedule of rates.
All the tests either on the field or at outside laboratories concerning the execution of the work and supply
of materials by the Contractor shall be carried out by Contractor at his own cost through a government-
authorized laboratory as per satisfaction of NOC.
The QAP/Data Sheet of the material shall be approved by TPI. Inspection and testing of major materials to be
supplied viz. pipelines, fittings, valves, strainers, pumps, floating suction, filters etc. shall have to be got
carried through any of TPI agencies as named below or any other agency (proposed by the Contractor and
approved by NOC) based on the approved QAP, PO Specification, Approved Data Sheets:
a. PDIL
b. Mecon
c. EIL
d. Bureau Veritas
e. DNV GL
f. Lloyds Register of Shipping
g. TUV h. Any other on prior approval of NOC
14. General Testing
The Contractor shall provide at site, a necessary testing equipment/gauges, and manpower for carrying
out various tests, including field tests. Any other apparatus deemed necessary by NOC for proper control
shall be provided by the contractor at his own cost.
a. Technician for carrying out above tests and maintaining test records. The Technician shall also
prepare and maintain records of all quality check for verification by NOC Engineers on day-to-
day basis.
b. Apart from the QC checks at site, periodic testing of materials proposed to be used in works shall
also be tested as per IS provisions in government/NOC approved Labs for which no extra
payment shall be made.
15. Warranty Period
The defect liability / warranty period shall be for a period of one year after the successful commissioning
and handing over of the complete system (completion of work at all the locations) by the Contractor. It
may be noted that during the defect liability/warranty period, Contractor will take complete responsibility
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for any defect observed in the system & rectify any defect observed immediately without any extra cost to
NOC. Cost of all spares, equipment, instruments & services, (be preventive & breakdown) to take care of
the above points has to be borne by the Contractor during the warranty period. In case of failure to attend
to these promptly, these will be attended through alternate agency at vendor’s risk and cost.
16. Documentation
LEGEND: I – Information; F – Final delivery of equipment; A – Approval; A3 & A4 represent document
size.
For
Final
Information
SN Description Documentation Remark
Approval In
4 Prints
4 Print
1.0 GENERAL
1.1 Vendor engineering and service I A
personnel organization chart 4
including set up for this project.
1.2 Descriptive catalogue / literature I A

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 For
Final
Information
SN Description Documentation Remark
Approval In
4 Prints
4 Print
4
1.3 Progress report I Fortnightly
2.0 ENGINEERING DOCUMENTS
2.1 Detailed list of component A F A4
2.2 Individual data sheet-Valves, Strainers, A F A4
Pumps etc.
2.3 Power Requirement – KVA I F A4
2.4 Heat dissipation – Kcal /H I F A4
2.5 SYSTEM CABINETS A3
a. Arrangement of modules I F
b. Structure, dimension, construction, etc. I F
2.6 AUXILIARY CABINETS A3
a. Arrangement of modules A F
b. Structure, dimension, construction etc. I F
2.7 Electrical power supply distribution A F A3
Diagram
2.8 System drawing (loop diagrams, reports) A F A3
2.9 Wiring diagram A F A3
2.10 Terminal strip diagram A F A3
2.11 Interconnection diagram I F A3
2.12 Cable route, cable schedule, Junction box A F A3
details
& cable trays
2.13 Earthing System I F A4
2.14 As built drawing F A3
3.0 CERTIFICATES A4
3.1 Authority approval for Ex-Proof, IS, IP-65 F
3.2 Vendor’s guarantee /warranty F
3.3 CMRI & CCOE Certificate F A4
4.0 INSPECTION AND TEST A4
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4.1 Inspection and test report from F
Vendor’s quality control department
4.2 Imported shipping documents along with F
test certificate
5.0 MANUALS (BOTH FOR VENDOR’S &
SUB –
VENDORS SUPPLY)
5.1 Vendor’s & Sub-vendor’s test Procedure F A4
5.2 Installation manual F A3
5.3 Operating manual F A4
5.4 Maintenance manual F A4
6.0 QUALITY ASSURANCE PLAN A F

Notes:
a. The above documents cover the minimum requirements and shall be supplemented with other
requirements listed in the specification, if any. Any other documents required to understand and
maintain the system, as felt necessary till handing over of the project, shall be supplied by the vendor.

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b. All documents shall be supplied in English language as per following.
i. - Approval/ Information - 4 sets
ii. - Final -4 sets
c. One set of final detailed termination wiring interconnection diagram shall be kept inside each
cabinet and equipment.
d. Name and address of subsystem vendors with name and telephone no. of contact persons.
e. As built drawings shall be laminated and properly bound with index sheet for preservation and future
reference.
f. All drawing which are submitted for approval, shall be submitted on CD as a final document (after
approval).
g. For diagrams of cable layout, power distribution, earthing etc., the existing diagrams will be provided
to the vendor. The proposed new layout will have to be approved and the final comprehensive
documents have to be submitted.
h. The submission of drawings applies only for the equipment being supplied by the vendor.
17. Safety Precautions & Hot Work
Contractor shall have to take all safety precaution for carrying out hot work in the premises after obtaining
hot work permit from location in charge at his own cost as directed by the Engineer-In-Charge. Necessary
safety equipment such as safety belts, helmets and other equipment are to be positioned by the contractor
and use as per requirement. Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be
maintained strictly. Any casualty or damage caused to property or person by any untoward incidents while
executing this contract will be at the contractor’s risk and cost. The contractor shall also abide by hot
work permits to be taken on day-to-day basis from the location as per policy of the Corporation.

18. DOs and DONTs for Construction Site

18.1 DOs
a. Before commencement of work give sufficient input to the workers on safety requirement of the job.
b. Use personal protective equipment (safety belt, safety shoes, safety helmet etc.) at construction.
Safety belts (ISI approved) must be used when working at heights above 3 m height.
c. Keep the site clean from all unwanted materials and properly store the equipment for easy access.
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d. Keep the visitors away from the construction site.
e. Use safety net whenever required.
f. Keep firefighting equipment handy at site.
g. Keep the escape route clear
h. Provide adequate lighting at site.
i. Use electrical hand tools with double insulation or fitted with ELCB protection.
j. Maintain safe angle of repose while excavating pit exceeding 1.5M depth. (45).
k. Suitable bench of 0.5 M width at every 1.5 M depth of excavation in all soils to be provided expect in
case of hard rock or proper shuttering and shoring.
l. Necessary steps to be provided for escape.
m. Protect the neighboring structure from collapse where excavation is planned.
n. Take adequate precaution for underground utility lines (cables, sewers) before carrying out excavation.

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o. Make necessary arrangement for de-watering of the pit.
p. Ensure Mechanized excavator is operated by well-trained experienced operator.
q. Ensure the wheel / belt of the excavator are suitably jammed to prevent accidental movement.
r. Ensure use of metallic scaffolding designed for their maximum load.
s. Check for any overhead electric wire running over the construction site. If exist, ensure the same is
de-energized.
t. Cordon off the excavated pit with proper red and white band / caution board.
u. Provide suitable rubber mat around electrical panels/switches.
v. Provide First Aid kit with proper medicine at the site.
w. Openings of manholes etc. should be kept in close condition.
x. Cordon off the area where field radiography is carried out.
y. Ensure all electrical connections, water connections etc. have been cut off before start of demolition.
z. Use 24 Volt FLP lamp fitting only for illumination inside confined space.
18.2 DONTs
a. Do not start any work without presence of contractor’s skilled supervisor.
b. Do not wear loose clothing while working near rotating machine or working at height
c. Do not keep inflammable material, waste and debris near the construction site.
d. Do not carry out hot work where inflammable materials are present and also while carrying out
painting job.
e. Do not keep the excavated earth within 1M of the edge of the pit.
f. Do not allow vehicles within 2 M distance from the edge of the pit.
g. Do not allow personnel to come within 1 M of extreme reach of the mechanical shovel.
h. Do not exceed safe working load marked on lifting equipment.
i. Do not use unamored electric cable in construction site.
j. Do not allow electrician without license for carrying out electrical job
k. Do not use bare wire ends in the socket.
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l. Do not use temporary electrical connection.

m. Do not use barrels, boxes, loose bricks etc. as working platform
n. Do not allow welding work if the welder is not in ‘Dry’ condition and not wearing protective
goggles face shield.
o. Do not start the job without proper work permit.
p. Do not keep any load / equipment near the edge of excavated pit.
q. Do not enter the confined space such as empty product tank without proper safety checks and in
absence of competent persons.
r. Do not demolish any structure without initial survey and formulating the method of demolition
s. Do not keep the lighted gas torch left unattended.
t. Do not throw or drop material / equipment from height.

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PART B: TECHNICAL SPECIFICATIONS
I: Introduction
Specifications for piping materials, pumps, floating suction, filter casing with filter elements are provided
in tender document. The technical data sheet, QAP, and relevant document/drawings of the equipment &
major supply items will be submitted for approval of NOC before procurement.
1. Major Equipment and Materials
a. Underground tank assembly
b. Pipelines and fittings`
c. Valves and strainers
d. Pump and motor assembly
e. Float Suction Assembly
f. Installation of Filtration system
2. General Codes of Practice
The fabrication and laying of the tanks shall generally conform to directional enclosed drawings, latest
edition of API-650 and IS:803 (Code of practice for design, fabrication and erection of vertical mild steel
cylindrical welded oil storage tanks).Constructional tolerances, for various items, shall not exceed beyond
permissible limits in the above codes. The fabrication and laying of the tanks shall generally conform to
the binding specification for design, fabrication, testing and installation of ATF underground tanks shall
be: API-650 and IS 10987:1992 (inclusive of all the latest versions of codes mentioned therein).
3. Codes and Standards for Reference
All work under this specification shall, unless specified otherwise, conform to the latest revisions and/or
replacements of the following or any other Indian Standard Specifications and Codes of Practice or any
other equivalent. In case any particular aspect of work is not specifically covered by Indian Standard
Specifications or any other equivalent, any other standard practice, as may be specified by the Engineer-
In-Charge, shall be followed:
1. IS: 73 - Indian Standard Specification for Paving Bitumen
2. IS: 216 -Indian Standard Specification for Coal Tar Pitch
3. IS: 226 -Indian Standard Specification for Structural Steel (Standard quality)
4. IS: 269 -Indian Standard Specification for Ordinary, and Low Heat Portland cement
5. IS: 383 -Indian Standard Specification for Coarse and Fine Aggregates from Natural Sources for
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Concrete
6. IS: 432 -Indian Standard Specification for Mild steel and Medium Tensile Steel Bars and Hard
Drawn Steel Wire for concrete Reinforcement
7. IS: 455 -Indian Standard Specification for Slag Cement
8. IS: 456 -Indian Standard Code of Practice for Plain and Reinforced Concrete.
9. IS: 457 -Indian Standard Code of Practice for General Construction of Plain and Reinforced Concrete
for Dams and other Massive Structures
10. IS: 516 -Indian Standard Specification for Methods of Test for Strength of Concrete
11. IS: 1139-Indian Standard Specification for Hot Rolled Mild Steel and Medium Tensile Steel and High
Yield Strength Steel Deformed Bars for Concrete Reinforcement
12. IS: 1199 -Indian Standard Specification for Methods of Sampling and Analysis of Concrete.
13. IS: 1200 -Part-II-Indian Standard Specification for Method of measurement Cement Concrete Work.
14. IS: 1200 Part-V Indian Standard Specification for Method of Measurement of Formwork

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15. IS: 1322 -Indian Standard Specification for Bitumen Felts for Waterproofing and Damp proofing
16. IS: 1489-Indian Standard Specification for Portland - Pozzolana Cement
17. IS: 1566-Indian Standard Specification for Methods of Sampling and Analysis of Concrete
18. IS: 1609-Code of Practice for Laying Damp-proof Treatment using Bitumen Felts
19. IS: 1786-Indian Standard Specification for Cold-twisted Steel Bars for Concrete Reinforcement
20. IS: 1791-Indian Standard Specification for Batch Type Concrete Mixers
21. IS: 2185-Indian Standard Specification for Hollow Cement Concrete Blocks
22. IS: 2210-Indian Standard Specification for Design of Reinforced Concrete Shell Structures and
Folded Plates
23. IS: 2386-Indian Standard Specification for Methods of Test for Aggregates for Concrete Part-I to VIII
24. IS: 2502-Indian Standard Code of Practice for Bending and Fixing of Bars for Concrete Reinforcement
25. IS: 2505-Indian Standard Specification for Concrete Vibrators Immersion Type
26. IS: 2506-Indian Standard Specification for Screed Board Concrete Vibrators
27. IS: 2514 - Indian Standard Specification for Concrete Vibrating Tables
28. IS: 2654-Integral cement water Proofing compound
29. IS: 2722-Indian Standard Specification for Portable Swing Weigh Batchers for Concrete (Single
and Double Bucket type)
30. IS: 2751-Code of Practice for Welding of Mild Steel Bars used for Reinforced Concrete Construction
31. IS: 2770-Indian Standard Specification for Method of Testing Bond in Reinforced Concrete
32. IS: 3025-Indian Standard Specification for Methods of Sampling and Test (Physical and Chemical)
for Water used in Industry
33. IS: 3201-Indian Standard Specification for Design and Construction of Pre-cast Concrete Trusses
34. IS: 3370-Indian Standard Specification for Code of Practice for Concrete Structures for Storage of
Liquids
35. IS: 3550-Indian Standard Specification for Method of Test for Routine Control for Water used in
Industry
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36. IS: 3558-Code of Practice for use of Immersion Vibrators for Consolidating Concrete
37. IS: 3590-Indian Standard Specification for Load Bearing Light Weight Concrete Blocks
38. IS: 3696-Safety Code for Scaffolding and Ladders
39. IS: 3812-Indian Standard Specification for Fly Ash for use as Admixture for Concrete
40. IS: 4031-Indian Standard Specification for Method of Tests for Hydraulic Cement
41. IS: 4082-Indian Standard Specification for Recommendation on Stacking and Storage of Construction
Materials at site
42. IS: 4090-Indian Standard Specification for Design of Reinforced Concrete Arches
43. IS: 4634-Indian Standard Specification for Method of Testing Performance of Batch-type Concrete
Mixes
44. IS: 4656-Indian Standard Specification for Form Vibrators for Concrete
45. IS: 4925-Indian Standard Specification for Concrete Batching and Mixing Plant

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46. IS: 4926-Indian Standard Specification for Ready Mixed Concrete
47. IS: 4990-Indian Standard Specification for Plywood for Concrete Shuttering work
48. IS: 4991-Indian Standard Specification for Blast Resistant Design of Structure for Explosion above
ground
49. IS: 5512-Indian Standard Specification for Flow Table for use in Tests of Hydraulic Cement and
Pozzolanic Materials
50. IS: 5513-Indian Standard Specification for Vicat Apparatus.
51. IS: 5515-Indian Standard Specification for Compaction Factor Apparatus
52. IS: 5751-Indian Standard Specification for Precuts Concrete Coping Blocks
53. IS: 5816-Indian Standard Specification for Method of Test for Splitting Tensile Strength of Concrete
Cylinders
54. IS: 5891-Indian Standard Specification for Hand Operated Concrete Mixers
55. IS: 6452-Indian Standard Specification for High Alumina Cement for Structural Use
56. IS: 6909-Indian Standard Specification for Super sulphate Cement
57. IS: 6923-Indian Standard Specification for Method of Test for Performance of Screed Board
Concrete Vibrators
58. IS: 6925-Indian Standard Specification for Method of Test for Determination of Water Soluble
chloride in Concrete Admixtures
59. IS: 7242-Indian Standard Specification for Concrete Spreaders
60. IS: 7246-Indian Standard Specification for Table Vibrators for Consolidating Concrete
61. IS: 7251-Indian Standard Specification for Concrete Finishers
62. IS: 7320-Indian Standard Specification for Concrete Slump Test Apparatus
63. IS: 7861- Part-I&II-Indian Standard Specification for Recommended Practice for Extreme
Weather Concreting
64. IS: 7969-Safety Code for Storage and Handling of Building Materials
65. IS: 8041E-Indian Standard Specification for Rapid Hardening Portland Cement
66. IS: 8112-Indian Standard Specification for high strength Ordinary Portland Cement
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67. IS: 8142-Indian Standard Specification for Determining Setting time of Concrete by Penetration
Resistance
68. IS: 8989-Safety Code for Erection of Concrete Framed Structures
69. IS: 9013-Indian Standard Specification for Method of Making, Curing and Determining Compressive
Strength of Accelerated-cured Concrete Test Specimens
70. IS: 9103-Indian Standard Specification for Admixtures for Concrete
71. IS: 10262-Recommended Guidelines for Concrete Mix Design
72. IS: 226: Structural Steel (Standard Quality)
73. IS: 800: Code of Practice for use of structural steel in general building construction
74. IS: 806: Code of practice for use of steel tubes in general building construction.
75. IS: 808: Rolled steel beams, channels and angle sections
76. IS: 813: Scheme of symbols for welding

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77. IS: 814: Covered electrodes for metal arc welding of structural steel
78. IS: 815: Classification and coding of covered electrodes for metal arc welding of mild steel and
low alloy high tensile steel
79. IS: 816: Code of practice for use of metal arc welding for general construction in mild steel
80. IS: 817: Code of practice for training and testing metal arc welders
81. IS: 818: Code of practice for safety and health requirements in electric and gas welding and cutting
operations
82. IS: 822: Code of practice for inspection of welds
83. IS: 9595: Recommendations for metal arc welding of carbon and carbon manganese steels.
84. IS: 919: Recommendations for limits and fits for Engineering
85. IS: 961: Structural Steel (High Tensile)
86. IS: 1148: Rivet bars for structural purposes
87. IS: 114: High tensile rivet bars for structural purposes
88. IS: 1161: Steel Tubes for structural purposes
89. IS: 1200: Method of measurement of steel work and ironwork (Part 8)
90. IS: 1239: Mild Steel Tubes
91. IS: 1363: Black hexagon bolts, nuts and lock nuts (dia. 6 to 30 mm) and black hexagon screws (Dia
6 to 24 mm)
92. IS: 1364: Precision and semi-precision hexagon bolts, screws, nuts and lock nuts/dia. range 6 to 39
mm).
93. IS: 1367: Technical supply conditions for threaded fasteners
94. IS: 1442: Covered electrodes for the metal arc welding of high tensile structural steel
95. IS: 1608: Method for tensile testing of steel products other than sheet strip, wire and tube.
96. IS: 1730: Dimensions for steel plate, sheet and strip for structural and General Engineering purposes.
97. IS: 1731: Dimensions for steel flats for structural and general engineering purposes
98. IS: 1852: Rolling and cutting tolerances for hot-rolled steel products
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99. IS: 1977: Structural steel (Ordinary quality) St-42-0
100. IS: 2062: Structural steel (fusion welding quality)
101. IS: 2074: Ready mixed paint, red oxide zinc chromate priming
102. IS: 2629: Recommended practice for Hot-Dip Galvanizing of Iron and Steel
103. IS: 2633: Method for testing uniformity of coating on Zinc coated Articles
104. IS: 3757: High Tensile Friction Grip bolts
IS: 4759: Specifications for Hot-Dip Zinc Coatings on Structural Steel and other
Allied products
105. IS: 7215: Tolerances for fabrication of steel structures

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II: Specifications for General Civil Works

1. Applicable Codes and Specifications - General

The specifications, standards and codes in the sections that follow, including all official amendments/
revisions and other specifications & codes referred to therein, should be considered a part of this
specification. In all cases the latest issue/ edition/ revision shall apply. In case of discrepancy between the
specifications referred to herein below or other specifications forming a part of this bid document, this
specification shall govern. The binding specification for general civil works shall be: “Standard
Specifications for Road and Bridge Works, 2073”, issued by the Department of Roads, Government of
Nepal.

2. Materials
a. IS: 269 - Specification for 33 Grade Ordinary Portland Cement (If Specially Intended To Be Used
As Per Drawings/Specifications)
b. IS:455 - Specification for Portland slag cement.
c. IS:1489 - Specification for Portland-Pozzolana cement.
d. IS:8112 - Specification for 43 grade ordinary Portland cement.
e. IS:12330- Specification for Sulfate resisting Portland Cement
f. IS:383 - Specification for coarse and fine aggregates from natural sources for concrete.
g. IS:432(Parts I & II) - Specification for mild steel and medium tensile steel bars and hard- drawn
steel wires for concrete reinforcement.
h. IS:1786 - Specification for high strength deformed steel bars and wires for concrete reinforcement.
i. IS:1566 - Specification for hard-drawn steel wire fabric for concrete reinforcement.
j. IS: 2062 – Steel for general structural purposes.
k. IS:9103 - Specification for admixtures for concrete.
l. IS:2645 - Specification for integral cement water proofing compounds.
m. IS:4990 - Specification for plywood for concrete shuttering work.
2. Material Testing
82
a. IS:4031(Part 1 to 13) - Methods of physical tests for hydraulic cement.
b. IS:4032 - Method of chemical analysis of hydraulic cement
c. IS:650 - Specification for standard sand for testing of cement.
d. IS:2430 - Methods for sampling of aggregates for concrete.
e. IS:2386(Part 1 to 8) - Methods of test for aggregates for concrete.
f. IS:3025 - Methods of sampling and test (physical and chemical) water used in industry.
g. IS:6925 - Methods of test for determination of water soluble chlorides in concrete, admixtures.
4. Material Storage
a. IS: 4082 - Recommendations On Stacking And Storing Of Construction Materials At Site.
5. Concrete Mix Design
a. IS:10262 - Recommended guidelines for concrete mix design.
b. SP:23(S&T) - Handbook on Concrete Mixes.

86
6. Concrete Testing
a. IS:1199 - Method of sampling and analysis of concrete.
b. IS:516 - Method of test for strength of concrete
c. IS:9013 - Method of making, curing and determining compressive strength of accelerated cured
concrete test specimens.
d. IS:8142 - Method of test for determining setting time of concrete by Penetration resistance.
e. IS:9284 - Method of test for abrasion resistance of concrete
f. IS:2770 - Methods of testing bond in reinforced concrete.
7. Equipment
a. IS:1791 - Specification for batch type concrete mixers.
b. IS:2438 - Specification for roller pan mixer.
c. IS:4925 - Specification for concrete batching and mixing plant.
d. IS:5892 - Specification for concrete transit mixer and agitator.
e. IS:7242 - Specification for concrete spreaders.
f. IS:2505 - General Requirements for concrete vibrators: Immersion type.
g. IS: 2506 - General Requirements for sereed board concrete vibrators.
h. IS:2514 - Specification for concrete vibrating tables.
i. IS:3366 - Specification or pan vibrators.
j. IS:4656 - Specification for form vibrators for concrete.
k. IS:11993- Code of practice for use of screed board concrete vibrators
l. IS:7251 - Specification for concrete finishers.
m. IS:2750 - Specification for steel scaffolding.
8. Codes of Practice
a. IS:456 - Code of practice for plain and reinforced concrete.
b. IS:3370(Parts I TO IV) - Code of practice for concrete structures for storage of Liquids.
c. IS:3935 - Code of practice for composite construction.
82

d. IS:2502 - Code of practice for bending and fixing of bars for concrete reinforcement.
e. IS:5525 - Recommendation for detailing of reinforcement in reinforced concrete works.
f. IS:2751 - Code of practice for welding of mild steel plain and deformed bars used for reinforced
concrete construction.
g. IS:9417 - Specification for welding cold worked bars for reinforced concrete construction.
h. IS:3558 - Code of practice for use of immersion vibrators for consolidating concrete.
i. IS:3414 - Code of practice for design and installation of joints in Buildings.
j. IS:4326 - Code of practice for earthquake resistant construction of building.
k. IS: 13920 – Code of Practice for ductile detailing of reinforced concrete structures subjected to
seismic forces.
l. IS:4014(Parts I & II) - Code of practice for steel tubular scaffolding.
m. IS:2571 - Code of practice for laying in-situ cement concrete flooring.

87
 n. IS:7861 - Code of practice for extreme weather concreting.
o. Part-I Recommended practice for hot weather concreting. Part-II Recommended practice for cold
weather concreting.
9. Construction Safety
a. IS:3696(Parts I & II) - Safety code for scaffolds and ladders.
b. IS:7969 - Safety code for handling and storage of building materials.
c. IS:8989 - Safety code for erection of concrete framed structures.
10. Measurements
a. IS:1200 (Part 2, 5 & 23) - Method of measurement of building and engineering works

III: Specifications for Piping System and Related Items

1. General
This specification covers design, manufacture, testing and supply of forged carbon steel seamless welded
pipe fittings like LR bends, concentric/ eccentric reducers, equal/unequal tees and cross bar tee suitable
for use in Petroleum Product service. The type, size, working pressure and quantity of fittings required as
per Schedule of Rates of Tender Document. The following temperatures shall form the basis of design of
these fittings.
a. Maximum temperature : +55°C
b. Minimum temperature : +5°C
Fittings shall be designed and manufacturing tolerances shall be as ANSI31.4.
2. Product Piping
SIZE
DESCRIPTION RANGE SPECIFICATION
NB(MM)
Pipes 15-20 SCH 160 Ι Seamless Ι ASTM 106 Gr.B Ι ASME B36.10
25-50 SCH 80 Ι Seamless Ι ASTM 106 Gr.B Ι ASME B36.10
82
80-100 4.78 THK Ι ERW Ι API 5L Ι ASME B36.10
Fittings 15-20 6000# Ι Socket Weld Ι ASTM A105 Ι ASME B16.11
(R=1.5Dfor 25-40 3000# Ι Socket Weld Ι ASTM A105 Ι ASME B16.11
Elbows)
50 SCH 80 Ι Butt Weld Ι ASTM A234 Gr. WPB Ι Seamless Ι
ASME B16.9
80-150 4.78 (80 & 100 mm) /6.35 (150 mm) THK Ι Butt Weld Ι
ASTM A234 Gr. WPB Ι Seamless Ι ASME B16.9
200-450 6.35 THK Ι Butt Weld Ι ASTM A234 Gr. WPB-W Ι ASME
B16.9
500-600 7.14 THK Ι Butt Weld Ι ASTM A234 Gr. WPB-W Ι ASME
B16.9

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 SIZE
DESCRIPTION RANGE SPECIFICATION
NB(MM)
Flanges 15-600 150# Ι Weld Neck Ι Raised Face Ι 125 AARH Ι ASTM A105 Ι
ASME B16.5 Ι Bore to suit pipes, which are as follows:
15-20 NB : ASTM A106 Gr.B SCH 160
25-50 NB : ASTM A106 Gr.B SCH 80
80-100 NB : API 5L Gr BX 4.78 THK
150-450 NB : API 5L Gr BX 6.35 THK
500-600 NB : API 5L Gr B X 7.14 THK
Blinds 15-600 150# Ι Raised Face Ι 125 AARH Ι ASTM A105 Ι ASME
B16.5
Flanges 100 150# Ι Raised Face Ι 125 AARH Ι ASTM A105 Ι ASME
B16.48
Gaskets All sizes 150# Ι Spiral Wound SS316 + Grafoil Ι ASME B16.20/ASME
B16.5 (Glass Filled Teflon For Ethanol Service)
Note: Thickness of Gasket shall be 2mm upto 300NB and
3mm for sizes above 300NB.
Studs/Nuts/ All Studs and Nuts shall conform to ASTM A193 Gr. B7 and
ASTM A194 Gr. 2h respectively.
Washers
Washers shall conform to IS 2016 (Punched washers ‘A’
with 2mm minimum thickness)

Gate Valves 20-25 800# Ι Rising Stem Ι Outside Screw & Yoke Ι Bolted Bonnet
Ι Solid Wedge Ι Renewable Seat Ring Ι Hand Wheel
Operated Ι Body & Bonnet ASTM A105 Ι Trim Stellited Ι
Stem 13 Cr Steel Ι Mfg. Std. API 602 Ι Testing Std. API 598
Note: To be supplied with 100mm long ASTM A 106 Gr.B
Sch 80 seamless pipes with ASME B16.5 Weld neck Flanged
at one end and welded to each end of the valve.
50 150# Ι Rising Stem Ι Outside Screw & Yoke Ι Bolted
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Bonnet Ι Solid Wedge Ι Renewable Seat Ring Ι Body &
Bonnet ASTM A216 Gr.WCB Ι Trim Stellited Ι Stem 13 Cr
Steel Ι Raised Face Flanged Ι Mfg. Std. API 600 Ι Testing
Std. API 598
Ball Valves 15- 50 150# Ι Single Piece Ι Full Bore Ι Fire Safe to API 607 Ι Anti
Static Ι Anti Blow Out Stem Ι Lever Operated Body ASTM
A216 Gr.WCB Ι Ball & Stem SS316L Ι Seat RPTFE Ι Raised
Face Flanged Ι Mfg. Std. BS 5351 Ι Testing Std. BS 6577
NonReturn 50- 250 150# Ι Swing Type Ι Body & Cover ASTM A216 Gr.WCB Ι
Valves Disc ASTM A216 Gr.WCB With 13% Cr SS Facing Ι Raised
Face Flanged Ι Mfg. Std. BS 1868 Ι Testing Std. BS 5146
89
 3. Structural Sections

3.1 Structural Steel Works and Materials

Structural steel work shall conform to IS: 808 – latest Edition. Structural steel materials shall be of
approved make and shall be conforming to IS-2062 GrA. Sectional weight as per IS standard will be
considered for payment purposes.
3.2 Steel Plates
Plates shall conform to IS: 2062 GR. B Fully Killed subject to stipulations provided in IS: 803.
4. Welding in Tank and Pipeline Fabrication
4.1 Welding Requirements
4.1.1 Welding
Welding of steel plates and related accessories shall be carried out conforming to the requirements
of various paragraph in this chapter.
4.1.2 Welding Responsibility
The contractor is responsible for the welding done by welders employed by him. Engineer- In-Charge
shall conduct the tests required to qualify welding procedures, and to qualify the welders and welding
operators.
4.1.3 Qualification Requirements
Qualification of the welding procedures to be used and of the performance of welders and
welding operators shall conform to the requirements of the ASME Section IX.
4.2 Welding Materials
4.2.1 Welding Electrodes
a. Welding electrodes shall conform to IS: 814 - Covered electrodes for manual metal arc welding of
carbon and carbon manganese steel/American Welding Society, AWS - A5.1 - “Carbon Steel
covered Arc Welding Electrodes” - AWS classification Nos. E6010 / E6011 / E6013 / E7015 /
E7016 /E7018.
b. Product piping : Root run: E 6010; Fill Up: E6018
c. High Cellulose/ Rutile type electrodes namely E-60 series as per latest addition of AWS A 5.1
(Carbon Steel Covered Arc Welding Electrodes) specifications wherever applicable for covered
electrodes for metal arc welding of mild steel.
d. Electrodes shall be stored in dry places in their original packets or cartons. Pre-heating of
electrodes shall be provided as per AWS requirements.
e. Tack welds used in the assembly of circumferential and vertical joints of tank shells, and those used
for assembling the shell to the bottom shall be removed and surface grinded properly and
82
gaps filled with weld metal.
f. Welder performance qualification shall be carried out as per API-650 Section 7 Welding
Procedure and Welder Qualification’ or ASME Boiler & pressure Vessels Code Sec. IX. Welders
shall be qualified in the approved procedure as per the code requirements. The qualification test
shall be arranged by contractor at his cost and witnessed by Site Engineer/ Engineer-In-Charge /
inspection agency. IS:823 should also be referred in the matter.
4.2.2 Filler Material
a. Filler metal shall conform to the requirements of ASME Section IX.
b. A filler metal, not yet incorporated in ASME Section IX may be used with NOC approval, if a
procedure qualification test is first successfully made.
4.3. Preparation for Welding
4.3.1 Cleaning
a. Internal and external surfaces to be thermally cut or welded shall be clean.
b. They will be free from paint oil rust scale and other material that would be detrimental to either
the weld or the base metal when heat is applied.

90
4.3.2 End Preparation
a. End preparation is acceptable only if the surface is reasonably smooth and true, and slag
from oxygen or arc cutting is cleaned from thermally cut surfaces.
b. Dis-coloration remaining on a thermally cut surface is not considered detrimental oxidation.
c. End preparation, for groove welds specified in ASME or as specified, which meets the WPS
is acceptable.
4.4 Welding Alignment
4.4.1 Circumferential Welds
a. Inside surface of steel plate ends to be joined shall be aligned within the dimensional limits in the
WPS and the engineering design.
b. If the external surfaces of the steel plates are not aligned, the weld shall be tapered between them.
4.4.2 Tack Welds
a. Tack welds at the root of the joint shall be made with filler equivalent to that to be used in the root
pass.
b. Tack welds shall be made by a qualified welder or welding operator.
c. Tack welds shall be fused with the root pass weld, except that those which have cracked shall be
removed. Bridge tacks (above the weld) shall be removed.
4.4.3 Fillet and Socket Welds
a. Fillet welds, including socket welds, may vary from convex to concave.
b. The size of a fillet weld shall be as per engineering design.
4.4.4 Seal Welds
a. Seal welding shall be done by a qualified welder. Seal welds shall cover all exposed threads.

IV: Specifications for Pipeline Works

1. General
For payment purpose against items, of supply fabrication and erection of steel of all types, the weight
shall be calculated based on section given in the standard steel tables and physical verification
whichever is less. The net fabricated dimensions edge to edge shall be taken into account. The
measurement shall exclude any allowance for wastage and weld metal etc.
Measurement of pipeline shall be taken for actual pipeline laid at site. The rate for laying & welding 82
includes provision of saddle plates beneath the pipelines. Gate valves, flanges, strainers, filters etc.

would not be included for measurement in pipeline.Maximum wastage of 1.5% shall be allowed in
pipeline fabrication for all diameters of pipes.
2. Scope
This specification covers the minimum requirements for erection, flushing, pressure testing, draining,
drying and reinstatement of piping systems.
3. Requirement of Drawings
General Layout accompanying the tender document are indicative of scope of work and issued for
tendering purpose only. Detail piping drawings, P & IDs diagram, will be submitted by successful
bidder for carrying out the work.
The contractor shall prepare the isometric drawings for product piping and calculate the actual
requirement of various items/fittings like bends, flanges etc. The complete set of drawings shall be
submitted for approval before commencement of the work. No fabrication will start without the
approval of NOC. The construction drawings shall include:
a. Location of all weld seams, weld sizes and details of weld etc.
b. Material to be used.

91
 c. Welding procedures and radiographic inspection.
d. Edge preparation and method employed.
e. Tolerances
f. Quality, brand and gauge of electrodes to be used.
g. Details of welding reinforcement
h. Details of brackets for supporting pipes, platforms, etc.
i. Complete bill of materials with item wise quantities for materials to be supplied by NOC and the
contractor.
j. Any correction or modifications suggested by NOC while approving the drawings.
The drawings shall be prepared on computer and one USB Flask disk of as built drawings shall be
submitted after completion of work. All drawings are to be prepared on Auto-CAD.
4. Inspection
Engineer-in-Charge or his authorized representative or third party appointed by NOC shall have free
access at all reasonable time to inspect those parts at the manufacturer's works which are connected
with the fabrication of the steel work and shall be provided with all reasonable facilities for satisfying
himself that the fabrication is being undertaken in accordance with the provision of this contract.
Inspection shall be made at site/ at the place of manufacture prior to dispatch of the fittings. The
inspection shall be conducted so as not to interfere unnecessarily with the operation of work.
Should any structure or part of a structure be found not to comply with any of the drawings and
specifications, it shall be rejected. No structure or part of the structure once rejected shall be re-
submitted for test except in case where the corporation considers the defects as rectifiable.
Defects which may appear during fabrication shall be made good by the contractor.
The suitability and capacity of all plants &equipment used for erection shall be to the satisfaction of
the engineer.

5. Fabrication
Fabrication, installation/erection and assembly shall be done as indicated in P & IDs and piping layout
drawings. Contractor shall promptly notify Engineer-in-charge of any defective or damaged material,
materials that are not as per specification and materials that differ in any manner from the
designations in the drawings.
82
Pipe to pipe jointing for CS & SS materials

50 NB and above : Butt welding

Below50 NB : Socket weld Coupling
Pipe to pipe jointing for Galvanized materials
All sizes for Instrument Air : Grooved fittings
All sizes for Service Water : Screwed Coupling

Bends, reducers, expanders, tees and end blinds provided shall be factory made forged irrespective of
diameter of pipeline .Such fittings shall have approximately the similar material composition as that
of pipeline under fabrication. Use of miter bends/reducers are not permitted.
Carbon steel pipes shall be cut by mechanical or thermal cutting depending upon thickness and size.
Thermal cutting shall not be employed for stainless steel. Internal burrs shall be removed by suitable
grinding.
Section of pipes shall not be welded together to form a random length shorter than3m.
Contractor shall provide facility to fabricate reinforcement pads.
Allweldingendsshallbebeveledwithanangleof300+/-50, and a root pass of 1.5mm. The bevels shall be

92
 machine-cut bevels or smooth, clean, slage-free flame-cut.
All pipe branches shall be at 900 unless otherwise indicated in the drawing.
6. Codes to be followed
API - 1104 : Welding of Pipelines and Related Facilities
ANSI B 31.3 : Code for petroleum Refinery Piping
IS823 : Code of procedure of manual Arc welding of mild steel.
IS814 : Metal arc welding for mild steel.
IS817 : Welder qualification tests.
7. Erection
Cleaning - Before erection all pre-fabricated spool pieces, pipe fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of foreign matter such as scale,
sand, weld spatter, cutting chips etc. by wire brushes cleaning tools etc., and blowing out with
compressed air and/or flushing out with water.
Flange Connections - While fitting up matching 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 equipment nozzles.
Valves - Valves shall be installed with spindle/ actuators orientation / position as shown in the layout
drawings. Line mounted equipment/ items - installation for line mounted items like filters, strainers,
sight glasses etc., including their supporting arrangements shall from part of piping erection work and
no separate payment shall be made for this work.
8. Pipe Supports
Pipe supports are designed 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 as per the following table
or as given by site engineer:
Nominal pipe size in MM. Maximum span in M.
20/25mm 2.10 m
050 mm 3.05m
080 mm 3.60m
100 mm 4.25m
150 mm 5.15m
200 mm 5.75m
250 mm 6.70m
300 mm 7.00m
350 mm& above 7.60 m
The above spacing are indicative and will be kept as per site req uirements (min. above). The minimum
82 clearance of 300 mm has to be maintained between the ground and the bottom surface of pipeline. All
pipeline supports will be numbered serially for identification.
8.1 Temporary Supports
During erection, piping shall be adequately temporary supported until the final supports are installed.
Temporary supports shall rest on paving, or direct indirect on concrete or structural beam. Piping
shall not be temporarily supported from platform grating or from scaffolding. Temporary supports
shall consist of wooden blocks and /or steel hoisting ropes. Synthetic ropes or strings are not
acceptable as temporary supports. Steel temporary supporting material for stainless steel materials
shall preferably be stainless steel.
8.2 General
Pipe supports shall be fabricated and installed according to the standard and special pipe support drawings
and the piping drawings on which the location are indicated. Construction contractor shall adjust the pipe
support to overcome construction measure deviations. Shims used to achieve full bearing between a pipe
and / or a pipe attachment and main support member must have sufficient area to carry the load. After
erection shims must be preferably welded to the main steel to prevent slippage when the pipe moves during
operation. Shims which are to be welded to the pipe shoe must extend full length and width of the shoe.
Alternative support shall only be installed after approval by construction supervision contractor only. Pipe
support construction contractor shall remove fireproofing locally from

93
 steel columns and beams for a proper installation of pipe support according to the pipe support
drawings. Fireproofing shall be repaired on the main structure and need not to be installed on the
additional pipe support, unless otherwise shown. Fireproofing around directional anchors from pipes
which are free to move in transverse direction shall be kept free minimum 50 mm from pipe anchor
parts. Where expansion bolts have to be applied in concrete members, care shall be taken not to
undercut retaining bars in the concrete. Pipe supports shall be adjusted to suit the final location of the
expansion bolts.
8.3 Expansion Joints
Expansion joints shall be installed following thoroughly the instructions of the manufacturer
regarding removing of shipping supports and attachments, adjusting tie-rod nuts, recompressing
bellows, the directional orientation if an internal sleeve is include etc. If the joints have welding ends,
protection shall be given to the bellows to prevent any injurious effects during welding.
8.4 Final Corrections
If correction is required after fabrication, they may be carried out a method approved by construction
supervision contractor.
9. Testing of Piping System
Testing of piping after erection shall be done as per API-1104 and as specified in price bid. With the
exclusion of instrumentation, piping systems fabricated or assembled in the shop/factories shall be
tested at the site, irrespective of whether or not they have been pressure tested prior to site welding or
fabrication. A test pressure of 10.5 kg/sq.cm shall be maintained for minimum 4hours. All tests shall
be completed to the satisfaction of site engineer including retesting if any leakage is noticed during
testing. The site engineer shall be notified in advance by the contractor of testing sequence/ program,
to enable him to be present for witnessing the test. All equipment, materials, consumables and
services required for carrying out the pressure testing of piping system shall be provided by the
contractor at his own cost. Water for testing shall be arranged by contractor at his own cost. Test
records in triplicate shall be prepared and submitted by the contractor for each piping system line wise
for the pressure test done in the pro forma as approved by site engineer.
10. Documents to be submitted by Contractor
Welder’s qualification test report as perIS-817.
Electrode and material test certificates from the manufacturer.
Complete record of the Hydrostatic testing carried out on each section of the pipeline including
test certificates for the same for submission to CCOE authorities.
Flushing reports.
Pipeline quantity certificates for product piping system as per the pipe lines laid. On completion of
work, as built drawings of complete piping system are to be prepared and furnished by the contractor
82 as required by NOC. All drawings are to be prepared on Auto-Cad (on PC). The contractor shall submit

two CDs containing all drawings, one set of tracing and 3 sets of drawings/printouts. Pipeline elevation
profile for the entire route of pipeline. Any other records as required by the site engineer.

11. Installation
Construction contractor is responsible for installation of all piping spools, all piping components, such as
bolting, gaskets, flanged valves and fittings, blind flanges, etc. and all other items such as flow meters,
control valves, orifice plates and similar items necessary to complete final piping erection with all lines
cleaned , supported, pressure tested and ready for plant operation. Alignment of piping to equipment
(machinery, vessels, exchangers, etc.) shall be permit fit up with bending or springing of the pipe in any
circumstances. Alignment should be checked and approved by construction supervisor prior to bolting up.
Where a discrepancy between drawing dimension and field dimension exists, sufficient modification
should be made so that unintended cold springing and cold forcing is avoided, and also the discrepancy in
dimension should be duly approved by the construction supervisor. Deviation from arrangement shown in
drawings shall be made after consulting construction supervision contractor. Construction contractor shall
submit alternative routing for review and approval by the construction supervision contractor. Alternative
routing shall keep clear all access ways and equipment openings and shall maintain accessibility of valves
and instruments. Cutting, welding and making attachments to

94
 structural members, vessels, heat exchangers, and other equipment not detailed in the piping and
piping support drawing, shall not be permitted without prior approval of construction supervision
contractor. Vents, drains, condensate drip legs, pressure instrument and other connection shall be
installed where indicated on isometric drawings, in accordance with engineering standards included in
“Piping Design Basis”. Protective devices on pipe ends, flanges and equipment opening remain in
place until the piping connection is ready to be made.
12. Flanges
In making of flanged joints, gaskets and flange faces shall be cleaned and free of weld spatters, burrs
etc. Gasket should be properly centered and bolting shall be well lubricated. All flanged joints shall be
brought up flush until the entire flange face or groove bears on the gasket and then made up with
uniform bolt tension. Bolting shall be tightened in a sequence assuring equal distribution of bolt
loading. Torque wrenches are recommended to achieve this uniform bolt loading. The bolting
procedure shall be checked by measuring the space between flanges during and after completion of
tensioning. Steel to cast iron flanged joints shall be made up with extreme care. In order to avoid
breaking of cast iron equipment flanges, piping flanges shall be brought up flush with gasket and
equipment flanges in to close parallel and lateral alignment, before uniformly tightening the bolts.
Hydraulic bolt tensioning equipment shall be applied when indicated in the piping class. Bolting is
supplied with one diameter extra length for mounting the tensioning device. Do not cut off this extra
length. Tensioning shall be executed in accordance with the requirements described in supplier’s
manual of tensioning device. Calculation for determining the minimum required bolt load shall be
executed by construction contractor and submitted to construction supervision contractor for approval.
13. Threaded Connections
All threaded connections shall be seal welded, except the following:
a. Connections in galvanized piping.
b. Screwed plugs in valve drains and vents.
c. Screwed thermos-wells and instruments connections.
d. Screwed control valves and safety / relief valves.
Screwed plugs in hydrostatic test vents and drains without valves shall be seal welded after
completion of testing.
Use sealing compound or Teflon tape for all connections not to be seal welded. Teflon tape is only
allowed in utility services, up to and including 200°C.
14. Inspection and Testing
14.1 General
82 Test and measuring equipment used shall be calibrated shall be calibrated six (6) months. All inspection

and testing is responsibility of construction contractor. Construction supervision contractor’s

representatives shall always have the right to witness inspection. Any defects revealed by any of the
examination performed shall be reworked and retested. All assemblies indicating irremediable
defects, excessive repairs, improper fabrication or not being in accordance with the requirement of
this specification shall be subject to rejection, even if the condition are discovered after acceptance at
the construction contractor shop or revealed during field testing .All costs related to repairs and or
re-fabrication shall be for construction contractor’s account.

14.2 Pressure Testing & Flushing

Except when specifically noted on the drawings, spools shall not require shop hydrostatic testing. This
shall not, however, relieve construction contractor of the responsibility for any defects in materials
and/or fabrication that may be revealed during field hydrostatic testing.
15. Cleaning
15.1 Weld Ends
During weld preparation, ends of all components shall be freed from any trace of oil, grease, paint, rust,
scales etc. over a distance of 50 mm minimum from the weld edge. Cleaning agents and solvents used

95
 for degreasing shall not have any properties causing corrosion of the piping.
15.2 Piping
15.2.1 Internal
During fabrication and installation, construction contractor shall prevent foreign material such as oil,
grease, sand, loose particles from cutting and grinding etc. from entering in to pipe component. If
foreign materials have entered the pipe component, they shall immediately be removed before
assembly of the parts by a suitable cleaning method, such as blowing through with air or degreasing
with suitable cleaning agent or solvent. Cleaning agent and solvents used for degreasing shall not
have any properties causing corrosion of the piping.
15.2.2 External
Piping to be painted shall be cleaned in accordance with the requirements in specification” Surface
Preparation and Painting of Piping which needs to be painted shall be cleaned by a suitable cleaning
method to remove scale excessive rust, or grease only. Cleaning agents and solvents used for
degreasing shall not have any properties causing corrosion of piping.
15.2.3 Complete Piping System
Unless otherwise indicated in the pipe class or on piping drawings or P & ID s only flushing as
described in this specification shall be followed.
15.3 Degreasing
For certain services, lines need to be degreased to prevent operation problems. This requirement is
indicated in the pipe class or on the piping drawings or P& ID s and shall be executed in accordance
with additional specification supplied by construction supervision contractor. Cleaning agents and
solvents used for degreasing shall not have any properties causing corrosion of the piping.
15.4 Chemical Cleaning
Requirements for chemical cleaning of lines are indicated on the piping drawing and or P & ID and
shall be executed in accordance with requirements of the specification “Chemical Cleaning of Carbon
steel pipes. Construction contractor responsible for chemical cleaning shall check whether all
materials include in the piping systems are compatible with intended cleaning liquid.
16. Documentation
Both shop & field fabrication include administrative of material certificates, welding operation, and
non-destructive examination and all testing operations as required by the applicable specification and
codes.
Construction contract or is responsible for planning and documentation all activities and controls
which include, but are not necessarily limited to, the following operations:
a. Material receiving (including administration/filing of certificates)
b. Cutting
82
c. Bending (on site and at construction contractors for induction bending)
d. Welding
e. Heat treatment
f. Destructive and non-destructive testing
g. Hydraulic bolt tensioning
h. Hydro testing
i. Flushing
j. Cleaning/chemical cleaning, Painting.
Construction contractor shall provide construction supervision contractor with two (2) copies of
material test certificates for all materials purchased by construction contractor. Documents relating to
assemblies to be shipped shall be submitted to construction supervision contractor. Documents shall
be available to construction supervision at all times. For each piping system (defined as piping items
welded together of same material and same design pressure/temperature e.g. line from a pump to a

96
 vessel) construction supervision contractor shall provide a fabrication book containing documents
showing all above listed operations.
17. Pressure Testing Scope
Piping systems subject to pressure testing shall be indicated on test diagrams which shall be prepared
by the construction contractor under the super vision of the construction supervision contractor using
P&ID as the basis Prior to testing, construction contractor shall provide documentation (test packages)
in which the test system limits, type of testing and the test pressure are defined. Test systems shall be
divided into systems which require hydro-testing, pneumatic testing or only a service test. Pneumatic
testing always needs approval from customer and construction supervision contractor and shall be
limited to:
a. Instrument airlines
b. Plant airlines.
c. Nitrogen lines
d. Lines where introduction of water damages piping systems or product to be conveyed after
Start-up.
e. Service testing shall be limited to piping systems as defined in ASMEB31.1/B31.3.
All testing forpipingsubjecttoauthorityapprovalasidentifiedin"testpackages"shallbein accordance with
authority rules Piping not subject to authority approval shall be tested in accordance with this
specification and ASME B31.1/B31.3 (depending on selected design code) as a minimum. Test
pressures listed in test packages shall be determined in accordance with one of the above-mentioned
codes.
Following systems are excluded from pressure testing.
a. Complete package units delivered by suppliers shall not be flushed and pressure tested unless
specifically designated by construction supervision contractor, since this has already been
performed during fabrication in supplier's shop.
b. Lines and systems open to the atmosphere, except buried systems, which may contain
contaminating substances.
c. Equipment, with the exception of cases where simultaneous testing of equipment and piping
is more practical or economical. In all cases testing of equipment simultaneous with piping
systems is subject to approval of construction supervision contractor.
Although some test systems may be tested in combination with systems installed by other construction
contractors, each construction contractor shall remain responsible for the part installed by him, unless
82 agreed otherwise.
18. General Requirements
Prior to testing, construction supervision contractor must have inspected the piping system for
completeness and conformity to piping drawings, specifications and P &ID.
Test packages for piping systems are to be released by construction supervision contractor prior to
flushing and pressure testing.
All welds shall be free of painting, coating or insulation to enable visual inspection of all welds.
For stainless-steel piping, the duration of the flushing, hydro testing and draining/drying sequence
shall be kept as short as possible, in order to reduce the possibility of chloride attack.
Testing against a closed valve is not permitted, unless specifically approved by construction
supervisioncontractorandundertheconditionthatthetestpressureisnothigherthan1.1times the maximum
allowable pressure at ambient temperature of subject valve as indicated in ASME B16.34.
Test systems with equipment or closed valves may be combined when specifically approved by
construction supervision contractor.

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 19. Safety and Environmental Control
Before starting any pressure test or flushing operation, the adequate measures for safety and
environmental control shall be established. All local regulations and all recommendations from
customer and construction supervision contractor shall be complied with.

19.1 Safety
No unauthorized person shall be allowed to enter the testing area. Piping systems subject to extended
hydrostatic test periods shall be provided with a protective device to relieve excess pressure due to
thermal expansion of the test fluid. Care shall be taken that flushing and testing water, shall not
freeze, either in the storage tanks or in the piping systems. Construction contractor is to provide
heating or insulation, in case a freezing risk exists. Proposed measures shall be agreed upon with
construction supervision contractor (antifreeze or steam heating). Test pressure shall not be applied
until the piping system and its contents are at approximately the same temperature. Pressure test shall
not be conducted when the metal temperature and/or test liquid is below10°C. Care shall be taken that
as little water as possible is spilled over the paving to prevent muddy and/or icy roads, or damage to
equipment, instrumentation or insulation. As pneumatic testing presents special risks, utmost care
shall be taken during pressurization and inspection of the systems to prevent any danger to personnel
or equipment. After completion of the pressure test, the pressure shall be released so as not to
endanger personnel or damage equipment.
19.2 Environmental Control
The use of chemical additives, i.e. wetting agents, biocides, inhibitors, etc. shall only be allowed when
an environmentally acceptable disposal has been agreed with construction supervision contractor and
local authorities. A wastewater disposal plan, which will specify the handling of the water used for
flushing and pressure testing, shall be prepared and agreed upon between customer, construction
supervision contractor and construction contractor. Disposal off lushand test water via the plant sewer
system shall only be allowed after written approval from construction supervision contractor at
specified flow rates. Construction contractor shall estimate the expected quantities, flow rate and
composition of the wastewater.
20. Test Equipment
Equipment used for testing shall be approved by construction supervision contractor and authority
inspectors prior to use. Hydrostatic testing equipment, including filters, fill pump, pressurizing pump,
dully calibrated test gauges, relief devices, storage tanks, test and flushing medium, shall be supplied
by construction contractor.
For pneumatic testing, an air compressor suitable to supply dry, clean air at the pneumatic test pressure
shall be supplied by construction contractor. The test pressure shall be checked by mean so gauge’s having
a range from zero up to a minimum of 1.5 and a maximum of 4 times the required maximum
82
test pressure. All test pressure gauges shall be calibrated prior to testing. Calibration certificates shall be
available at the work site and all gauges shall be properly identified to enable traceability to the calibration
certificates. Calibration of gauges shall be repeated every 6 month or whenever requested by the inspection
team (representatives from the authorities, customer, construction supervision contractor and construction
contractor). Test blanks shall be supplied by construction contractor. Design and dimensions shall be in
accordance with construction contractor’s standard. Construction contractor shall prove by means of
calculations that supplied test blanks are suitable for the intended test pressure.
21. Test Medium
The test medium for hydrostatic testing shall be clean water (maximum chloride content 50 ppm
without foreign matter such as sand, rust or other particles. D.M. water shall be used for S.S.
line/equipment for test a filter shall be provided in the fill line when dirt is present in the water
proposed to be used. Prior to use the water shall be analyzed and the results shall be reported to the
construction supervision contractor. Testing of the water quality shall be repeated once every week.
Where the test packages indicate that a pneumatic test must be performed, air shall be used for
pressure testing. Service tests shall be performed with the intended service medium.

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 22. Test Procedure
22.1 Preparations for Pressure Testing
Blind flanges, blanks, caps or plugs with adequate pressure rating shall be installed to isolate piping
systems and equipment as indicated on the test diagrams. All temporarily installed items (blanks,
gaskets, spools, strainers, etc.)Shall be adequately marked using paint or tags for easy trace ability.
Items not to be subjected to the pressure test shall be removed. Items to be removed or blanked off
prior to testing/ flushing shall include, but shall not be limited to:

a. Equipment not included in the test system.

b. Relief valves and rupture discs.
c. Orifice plates, flow nozzles or other similar restrictions.
d. Venturi type flow meters (flanged).
e. Internals of equipment (trays, demisters, level instrument floats, float cages, etc.), if
included in the test system.
f. Flanged control valves (for welded-in type control valve internals shall be removed).
g. Flanged check valves unless internals are removed (for butt-weld or socket weld check
valves internals shall be removed).
h. All instruments (unless otherwise approved by construction supervision contractor).
i. Any items not designed to withstand the test pressure (e.g. pressure gauges).
j. Internals of strainers and filters.
Instrument piping shall be tested together with the piping system up to the piping block valve nearest
to the instrument. When a union is provided downstream of an instrument block valve, it shall be
broken to prevent dirt or foreign matter from being introduced into the instrument.
If the test pressure on both sides of flanged control valves is equal and when block valves and bypass
are installed, the block and bypass valves shall be left open with the control valve removed and with
blinds or a spool piece installed.
If test pressures up and own stream of a control valve are not equal, the spool piece between the
control valve and the downstream block valve shall be tested in combination with the upstream part.
Piping supported by counter weight or spring without" down travel stop "shall be temporarily
supported prior to filling of the line with water. A spring with "down travel stop" shall have the "stop"
(wedges or block) I inserted prior to filling of the line with water.
82 Piping designed for vapor or gas shall (when necessary) be provided with additional temporary supports
to support the additional weight of the test liquid.All open valves in the test system, which have a
back seat (gate and globe valves) shall be fully opened until the stem seat contacts the back seat and
then the hand wheel shall be turned twice in the direction of closing to assure that gland packing is
subjected to full line test pressure.
Open ends of atmospheric lines to be "full of liquid" tested shall be left open during testing. For
pneumatic testing or service testing with air or nitrogen, screwed and flanged joints shall be prepared
for soap testing by taping with masking tape and punching a 3 mm diameter hole through the tape.
When electronic leak testing will be applied, taping with masking tape will not be required. The
system shall be pressurized with air up to the system operating pressure with a maximum of 6
2
kg/cm g and expanded abruptly to atmospheric pressure in order to clean the pipes before hydro
testing. Cardboards may be used for this test. Cleaning of pipes using cardboard breaking method will
be part of hydro testing for which no extra payment will be made.
22.2 Pressure Testing
After acceptance of the preparations for pressure testing by construction supervision contractor, the
piping system will be released for pressure testing.
All systems shall be properly vented (at the high points) while filling. Special attention shall be paid
to the direction of filling when check valves are installed in the system.

99
 2
Test pressure of 10.5kg/cm shall be applied by means of a suitable test pump or other pressure source
for minimum 4 hrs. This pump shall be positively isolated from the system except when being used
to pressurize the system. At least two (2) pressure gauges per test system shall be installed. One at the
test pump discharge and one (1) at or near the highest point of the test system. For large systems,
more pressure gauges shall be installed at suitable locations, in coordination with construction
supervision contractor.
The test pump shall be constantly attended during the test by an authorized person. Before the pump is
left unattended, it shall be positively disconnected from the system, while the pressure gauge remains
connected to the test system. The test pressure shall be as indicated in the test index as provided by
construction supervision contractor. Retesting of a system (when required) shall be performed at the
same pressure as originally specified for the test.
The pressures hall be increased gradually. For test pressures over100kg/cm2, the pressure shall be
increased in steps of 25 kg/cm2, providing sufficient time to check for leaks and to allow the piping to
equalize strains during the test. The outside surface of the test system shall be clean and dry before
and during testing
The test pressure shall be maintained for at least half an hour prior to start of inspection and long
enough to enable a visible inspection of the complete test system by the inspection team. A pressure
recorder may be installed. Atmospheric lines to be" full of liquid" tested shall be filled with water for
at least 24hours before visible inspection of the complete test system by the inspection team. In case
hydro testing through equipment is required, construction supervision contractor will provide special
instructions {e.g. maximum differential pressures on shell and tube side of heat exchangers) where
applicable.
22.3 Additional Requirements for Service Tests
A service test shall be performed with the line in service i.e. with the service medium and at service
pressure.
A visual inspection and/or (in case of air or nitrogen lines) soap leakage tests shall be carried out.
22.4 Additional Requirements for Pneumatic Tests
For systems being pneumatically tested, a preliminary check of the test system shall be made at a
pressure not exceeding 1.7 kg/cm2g (25psig). A visual inspection, and soap leakage tests shall be
carried out. Care shall be taken to avoid a temperature drop which could cause failure of metal
and thermoplastics due to embrittlement. The metal temperature during testing shall not be below
the minimum allowable temperature indicated in the "test package".
22.5 Flushing
Afteracceptanceoftestingreportsbyconstructionsupervisioncontractor, the piping system will be
released for flushing.
Flushing will be carried out in order to remove all waste material and construction debris from the 82
piping systems.
Flushing through equipment is not allowed unless specifically approved by construction supervision
contractor.
During flushing of pump suction/discharge lines, the elbow close to the pump shall be turned away
and the pump inlet shall be adequately covered to prevent contamination of pumps. This applies also
for equipment nozzles, which shall be blinded off during the flushing operation. Water jetting can be
applied for cleaning the inside of storage tanks.
Commissioning team representatives from construction supervision contractor shall witness each
flushing operation.
Flushingshallbeperformedagainstopenpipeends.Flushingviasmallopeningslikevents, drains, etc., is
regarded as insufficient.
Stainless-steel lines shall be flushed with D.M. water or clean condensate to prevent chloride stress
corrosion cracking.
After completion of the flushing operation, equipment which is welded in-line and included in the test
system, shall be inspected internally for cleanliness.
Waste material and construction debris in air or nitrogen systems, which will not be hydro- tested,
shall be removed from the piping systems by air blowing.

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 22.6 Draining &Drying
Immediately after flushing, all lines and systems shall be completely drained. After draining, all test
systems not subject to chemical cleaning shall be dried with air. Special measures shall be taken to
prevent freezing in winter. Construction contractor shall provide a suitable air compressor with drier.
After dry out, the systems shall be presented to construction supervision contractor for acceptance.
22.7 Reinstatement
After completion of testing, chemical cleaning (where applicable) and drying, all systems shall
be reinstated as per drawings and specifications.
This also includes but shall not be limited to:
a. Removal of all temporary materials such as spades, blinds, gaskets, and pipe spools, temporary
supports, etc.
b. Replacement of all damaged gaskets and all test gaskets.
c. Positioning of spectacle blinds to the correct position.
d. Reinstallation of all items removed for hydro-testing.
e. Reinstallation of unions downstream of instrument blocks valves.
f. Inspection of the completed system for correct flow direction of instruments, check and control
valves, etc.
During the activities described above, measures shall be taken to avoid dirt, debris, etc., entering the piping
system. Each pipe spool shall be inspected for cleanliness prior to reinstallation. This inspection shall be
witnessed by customer, construction supervision contractor and construction contractor.
After inspection and acceptance by construction supervision contractor, the system shall be released
for further activities, e.g. steam tracing, painting, insulation, etc.
The “stop” of pipe support springs with “down travel stop” placed prior to flushing, shall be removed
at request of customer during pre-commissioning or commissioning stage. Notes:

a. Before installation of NOC valves (under any circumstances) contractor should carry out
visual inspection fall the valves and may carry out test to ensure no leakages from the valves at
their own cost.
b. Contractor should ensure proper cleaning of pipes so that foreign material should not damage the
valves or other equipment. In case of damage or malfunction of valve/equipment due to improper
cleaning of pipes, contractor should be responsible for the maintenance of that equipment otherwise
cost of replacement of that equipment/part/valve etc. will be recovered from the contractor

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23. Inspection and Reporting
Construction contractor shall prepare a final report, giving positive documented evidence that subject
systems are pressure tested in accordance with the requirements. Documentation shall be maintained
in accordance with the authority requirements for piping systems. The report will at least include but
not limited to the following:
a. Reference to documents and specifications.
b. Hydro test diagrams.
c. P&ID's.
d. Isometrics.
e. Agreed punch lists.
f. Authority approvals.
g. All required certificates.
h. A continuous log of operation, if applicable.
i. Test results and duration.

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 j. Signature of local authority (when applicable), customer, construction supervision contractor
and construction contractor.
24. Erection of Equipment (Pumps and Motors)
24.1 Drawings
The following drawings will be provided by the corporation, which are to be followed for erection of
each equipment:
a. General arrangement drawing without line dimensions.
b. Foundation detail drawings.
24.2 Erection of the equipment
All equipment erection shall be done by experienced fitters. For this purpose, the contractor shall
employ an able erection supervisor and crew who have done similar jobs. Erection shall be carried out
as per instructions of the equipment manufacturers and direction of site engineer.
All the instruments of hydrant engine such as pressure gauges, Composite gauges etc., including
instrument panels, shall be installed by the contractor as part of equipment erection and no
separate gemn will be made.
After piping has been connected, the alignment shall be checked by the contractor again, to ensure the
piping connections do not induce any undue stresses on the equipment.
Pumps will be supplied for erection either completely assembled, couple to the drive and both
mounted on a common base plate or in 3 individual parts as pump assembly, motor and base plate or
as pump assembly and motor mounted on separate base plate. The pumps shall be erected on
foundations and leveled with shims and wedges with help of precision levels and other instruments.
The pump and the driver shall then be coupled and aligned. Final alignment shall be done after all
piping connections are made. Shims and wedges where required will be arranged by the contractor.
Trial runs of equipment - unless indicated otherwise, all equipment shall be subjected to trial runs up
to the satisfaction of the site engineer on load and without load condition. This also includes
coordination with the supplier of equipment to commission the same.
25. Piping Works
25.1 Working Drawings
Drawings accompanying the tender document are indicative of scope of work and issued for tendering
purpose only.
The contractor is required to prepare the drawings for the complete piping work with its isometric view etc.
to calculate the actual requirement of various items / fittings like bends, flanges etc. The piping layout
must show the expansion loops as per the requirement. The complete set of drawings shall be submitted for
approval, before commencement of the work. No fabrication will start without the
82 approval of NOC. The construction drawings shall include:

a. General arrangement drawings.

b. Location of all weld seams, weld sizes and details of weld etc.
c. Material to be used.
d. Welding procedures and radiographic inspection.
e. Edge preparation and method employed.
f. Tolerances
g. Quality, brand and gauge of electrodes to be used.
h. Details of welding reinforcement
i. Details of brackets for supporting pipes, platforms, etc.
j. Complete bill of materials with item wise quantities for materials to be supplied by NOC and
the contractor.
k. Any correction or modifications suggested by NOC while approving the drawings.

102
 The drawings shall be prepared on computer and one floppy of as built drawings shall
be submitted after completion of work. All drawings are to be prepared on Auto-CAD.

25.2 Codes/Standards to be followed:

API - 1104 : Radiography of weld joints
ANSI B31.3 : Code for petroleum Refinery Piping
IS823 : Code of procedure of manual Arc welding of mild steel.
IS814 : Metal arc welding for mild steel.
IS817 : Welder qualification tests.

25.2.1 Fabrications
Bends, reducers, expanders, tees and end blinds provided shall be factory made forged
irrespective of diameter of pipeline .Such fittings shall have approximately the similar material
composition as that of pipeline under fabrication.
25.2.2 Erection
a. Cleaning - Before erection all pre-fabricated spool pieces, pipe fittings etc. shall be cleaned
inside and outside by suitable means. The cleaning process shall include removal of foreign
matter such as scale, sand, weld spatter, cutting chips etc. by wire brushes cleaning tools etc.,
and blowing out with compressed air and/or flushing out with water.
b. Flange Connections - While fitting up matching 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 equipment nozzles.
c. Valves-Valvesshallbeinstalledwithspindle/actuatorsorientation/positionasshowninthe layout
drawings.
d. Line mounted equipment / items - installation for line mounted items like filters, strainers,
sight glasses etc., including their supporting arrangements shall from part of piping erection
work and no separate payment shall be made for this work.
26. Testing of Piping System
Testing of piping after erection shall be done as per API-1104. With the exclusion of instrumentation,
piping systems fabricated or assembled in the shop/factories shall be tested at the site, irrespective of
whether or not they have been pressure tested prior to site welding or fabrication. A test pressure of 10.5
kg/sq.cm shall be maintained for minimum 4hours. All tests shall be completed to the satisfaction of site
engineer including retesting if any leakage is noticed during testing. The site engineer shall be notified in
advance by the contractor of testing sequence/program, to enable him to be present for
82 witnessing the test. All equipment, materials, consumables and services required for carrying out the
pressure testing of piping system shall be provided by the contractor at his own cost. Water for testing
shall be arranged by contractor at his own cost.
Test records in triplicate shall be prepared and submitted by the contractor for each piping system line
wise for the pressure test done in the preform as approved by site engineer. Documents to be
submitted by contractor: (four copies each)
a. Welder’s qualification test report as per IS-817.
b. Electrode and material test certificates from the manufacturer.
c. Complete record of the Hydrostatic testing carried out on each section of the pipeline including
test certificates for the same for submission to CCOE authorities.
d. Flushing reports.
e. Pipeline quantity certificates for product piping system as per the pipelines laid.
On completion of work, as built drawings of complete piping system are to be prepared and furnished
by the contractor as required by NOC. All drawings are to be prepared on Auto-Cad. The contractor
shall submit two CDs containing all drawings, one set of tracing and 3 sets of drawings/ printouts.

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 Pipeline elevation profile for the entire route of pipeline. Any other records as required by the site
engineer.
27. Hot Work Permit
No hot work is permitted without issuance of hot work permit by location in-charge at existing
locations. After completion of work the site should be cleared of all scrap, contractor’s equipment and
machinery used in fabrication.

V: Specifications for Steel Structural Works

1. General
The work covered consists of supply, fabrication & erection of structural steel, pipe supports and
cable trays in strict accordance with this specification and applicable drawings. Structural steel
shall conform to IS 2062.
2. Codes
All structural steel work shall be in accordance with IS: 800 Code of practice for the use of structural
steel in General Building Construction and the other Indian Standards referred to therein. Indian
Standards referred to in these specifications shall be the latest published by Indian Standard Institute.
Welding shall be in accordance with Indian Standard IS: 823, IS: 800, IS: 816 and IS: 808 including
other relevant I.S. Specification on welding.
3. Materials
All materials used in fabrication shall conform to the requirements as mentioned in the
following codes:
a. Steel for General Structural Purposes: IS: 2062 Gr A
b. Covered Electrodes for Manual Arc Welding: IS: 814
Grating shall be done out of electro forged construction as per the specifications given in tender
to match the required. Grating shall be galvanized as per requirements specified.
4. Fabrication
All fabrication work shall be in accordance with IS: 800 Section V.
All fabrication shall be carried out as per the drawings approved by NOC.
Platform and ladders shall be shop assembled in the largest unit suitable for handling,
transportation and erection.
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5. Straightening
All material shall be clean and straight. If straightening or flattening is necessary, it shall be done by
a process approved by Engineer-in-Charge / NOC and in a manner that will not damage the material.
6. Gas Cutting
The use of a hand cutting torch is permissible if the metal being cut is not subject to substantial stress
during the operation. Gas cut edges subject to substantial tensile stress shall be cut by a mechanically
guided torch, or if hand cut, shall be carefully examined and any nicks removed by grinding.
Shearing, cropping and gas cutting shall be clean, reasonably square and free from any distortion and
should the inspector find it necessary, the edges shall be subsequently ground.
7. Welding
Surface to be welded shall be free from loose scale, slag, rust, grease, paint and other foreign material,
and shall be wire brushed and cleaned prior to welding. Parts to be fillet welded shall be brought into
as close contact as practicable and in no event shall be separated more than 5mm. If the separation is
5mm or greater, the size of the fillet welds shall be increased by the amount of the separation.
Abutting parts to be butt-welded shall be carefully aligned together within 3mm gap. Welding
sequence shall be followed to avoid needless distortion, and minimize shrinkage stresses.

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 8. Connections
Connections shall be as shown on the drawings. Where details are not given, standard beam
connections shall be followed. In any case connections shall be strong enough to develop the full
strength of the member and shall be approved by Engineer-in-Charge / NOC. One sided, or eccentric
connections will not be permitted, unless they are shown in detail on the drawing and are approved by
Engineer-in-Charge /NOC. All shop connections shall be bolted or welded as approved by Engineer-
in-Charge /NOC.Welded connections shall be made only where indicated on the drawings or
approved by Engineer-in- Charge / NOC. Holes shall not be made or enlarged by flame, nor will
flame cut of unfair holes in the shop or in the field be acceptable. Grout holes shall be provided in the
steel members as shown in the drawings and holes shall be provided in members to permit
connections of supported items.
9. Inspection
The contractor shall arrange for inspection of the fabrication of items as and when directed by NOC.
However, suchinspectionshallnotrelievethecontractorofhisresponsibilitiestofurnish satisfactory work.
Materials of workmanship not conforming to provisions of the specifications may be rejected at any
time defects are found during the progress of the work. The Site Engineer shall have free access to the
Contractor shop for periodical inspection and all arrangement/facilities for the inspection shall be
provided by the Contractor at his cost.
10. Erection
The positioning, levelling, alignment, plumbing of the structures shall be in accordance with the
relevant drawings. Maximum tolerance for line and level of the steel work shall be ± 3mm for any
part of the structure. The structure shall not be out of plumb by more than 3.5mm on each 10 meter
section of height as well as not more than 7mm per 30 meter length. Wherever so provided in the
respective drawings or otherwise as instructed by the Engineer-in- Charge/NOC, the Contractor shall
so arrange that the structural support is mounted and grouted on concrete foundation.
11. Ladders and Rungs (As Applicable)
Contractor shall provide and install all iron ladders and rungs where indicated and as detailed on the
drawings. He shall also include base plates, fastenings, anchor bolts, guard rails/rings, safety chains,
etc.

12. Painting (Shop and Site Coat)

For painting requirements, minimum one coat of primer painting shall be applied after proper surface
preparation as per painting manual for supply of readymade fabricated items to the site.

82
13. Measurements
All structural steel work shall measure by weight, weights being calculated on the basis of standard
weights of sections used. No allowances shall be made for welding or for bolts, rivets etc. The rates
hall include painting of the structural steel work wherever required including shop coat and site coat
of primer as per painting specification.

VI: Radiographic Inspection Procedure (Pipelines)

1. Radiographic Inspection – General

Radiographic inspection of weld joints shall be conducted as per latest API 1104.
The radiographic requirement shall be as given below:
a. First weld of each welder is to be radio graphed except that for pipe 100 mm and lower in
nominal size, where the first two welds of each welder are to be completely radiographed.

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 b. The radiographic procedure shall be approved by the Owner’s Inspector, the procedure and
quality of radiographic examination, limits of acceptability, repair and removal of defects
shall be as per API code 1104, ASTM E-94 and ASTME-142.
c. The contractor shall be responsible for carrying out radiography, rectification of defects and
re-radiography of welds repaired and rectified. He shall make necessary arrangements for
providing the equipment as well as radiographic film for the satisfactory and timely
completion of the job.
d. Radiographic inspection of the welds shall be preferably made with X rays. Iridium 192
isotope or any other source may be used with the approval of the site engineer.
e. The contractor shall fulfill all the statutory safety requirements in handling the X ray
or gamma ray equipment.
f. The details of the radiography shall be duly entered and signed by him in a register and shall
be submitted to the Owner’s Inspector for approval.
g. The contractor shall afford all necessary facilities to the inspector at site such as darkroom
with controlled temperature, viewer etc. for the examination of the radiographic film.
h. Interpretation of radiographs shall be done as per acceptable standards.
i. When the entire joint is unacceptable, the weld shall be cut completely and the pipe ends shall
be restored for re-welding. After re-weld the joint shall be again checked.
j. No repair of welds shall be done without prior permission of the site engineer.
k. For each weld found unacceptable due to welder’s fault such as lack of fusion and
penetration, two additional checks should be carried out on welds performed by the same
welder whose joint was judged unacceptable originally. The operation is progressive and the
procedure of radiographing two additional welds for each weld deemed unsatisfactory shall
be followed till such time two consecutive satisfactory welds are obtained.
l. The contractor shall carry out these additional radiographs at his own expense.
m. To avoid the possibility of too many defective welds by as single welder going undetected
over a period of time, the contractor shall arrange to radiography promptly so that there is no
backing in radiography.
n. Repairs and / or work of defective welds shall be done in time to avoid delays in the
construction program.
82
2. Examination of Radiographs
The radiographic examination method employed shall be in accordance with the ASME Boiler and
Pressure Vessel Code Section V “Non Destructive Examination” Article2. The requirements of
Article 2, Section V of ASME code are to be used only as a guide. However, final acceptance of
radiographs shall be based on the ability to see the prescribed penetrometer image and the specified
hole. Contractor will engage minimum one L-2 inspector at site for interpretation of radiographs
which in-turn will be submitted to NOC for final interpretation.

3. Determination of Limits of Defective Welding

When a section of weld is shown by radiograph to be unacceptable under provisions of 10.1 or limits
of the deficient welding are not defined by the radiograph, two adjacent spots shall be examined by
radiography.
However, if the original radiograph shows at least 75 MM of acceptable weld between the defect and
any one edge of the film, an additional radiograph need not be taken of the weld on that side of the
defect. If the weld at either side of two adjacent sections fails to comply with the requirements of 10.1
additional nearby spots shall be examined until the limits of acceptable welding are determined or the

106
 fabricator may replace all the welding performed by the welder on that joint. If the welding is
replaced one radiograph should be taken at any selected location on any other joint on which the same
welder has welded. If any of these additional spots fails to comply with the requirements of 10.1the
limit so fun acceptable welding shall be determined as specified for the initial section.

4. Repair of Defective Welds

The defective weld shall be removed by chipping or melting out by thermal gouging process from
both sides of joint and re-welding. Only sufficient cutting out of the defective joints, as is necessary to
correct the defect, is required. All repaired weld in joints shall be checked by repeating the original
inspection procedure and by repeating the hydrostatic testing / vacuum box testing method.
5. Record of Radiographic Examination
The fabricator shall make a record consisting of all films with their identification marks and
submit the same on completion of work.
6. Radiographic Interpretation of Weld Joints as Per API 1104
Standard for Welding Pipelines and Related Facilities for Pipe 2-3/8” O.D. and Above
Acceptance
SN Observation Criteria
1 CRACK Not acceptable
2 LACK OF ROOT PENETRATION Individual defect shall not exceed FUSION-1” in 12” weld
length
a. Shall not exceed2”.
3 LACK OF SIDE WALL FUSION
b. Total
length shall not exceed 3” in weld length
4 INTERNAL CONCAVITY Not acceptable
a. Max. dimension shall not exceed ½” in 12”weldlength
5 POROSITY
b. Distribution of gas pockets as per porosity chart given
in code
Individual defect shall not exceed
6 BURN THROUGH ¼”
a. Any elongated slag shall not exceed 2” in length or
1/16” in width.
b. Total length of such defect shall not exceed 2” in 12”
weld length.
c. Parallel slag lines shall be considered as separate
conditions if width of either exceeds1/32”.
82 d. Isolated slag inclusion width shall not exceeds1/8”.

7 SLAG INCLUSION e. Total length of any isolated inclusion shall not exceed
½” in 12” length of weld nor shall there be four isolated
inclusion of width greater than 1/8” in this length.
Undercutting shall not exceed 1/32” in depth and 2” length
8 UNDER CUTTING under
cutting adjacent to the root bead shall not exceed 2” in
length

VII: Pressure Testing of Tanks

1. General
Soundness of the welds shall be tested by means of hydrostatic tests. The test shall be conducted only
after fulfilling the requirements of visual inspection, radiography etc. and when the entire work is

107
 certified by the site engineer for the performance of such tests. This recommended practice covers the
hydrostatic testing of new and existing petroleum guidelines. It recommends minimum procedures to
be followed, equipment to be used and conditions to be considered during the hydrostatic and
dynamic testing of pipelines. Nothing in this recommended practice should be considered as a fixed
rule for application without regard to sound engineering judgment. Certain Governmental
requirements may differ from the criteria set forth in this recommended practice, and its issuance is
not intended to supersede or override such requirements.
2. Test Medium
The hydrostatic test should be conducted with potable water.

3. Equipment for a Hydrostatic Test

Equipment for the hydrostatic test should be properly selected and in good working order. Equipment
affecting the accuracy of the measurements used to validate the specified test pressure should be
designed to measure the pressures to be encountered during the hydrostatic test. Water should be
completely drained off. This can be accomplished with spheres, squeegees and/ or other pigging
devices wherever practical. Water should be disposed of at approved locations in a manner that will
cause minimal environmental effects.

VIII: Specification for Blast Cleaning & Painting of Mild Steel

Pipelines/Allied Structural Work/Doping for Underground Pipelines

1. General
These specifications define basic requirements for painting of mild steel pipelines and allied structural
work. It is deemed that the work shall be carried out by the contractor with the best quality of
specified material and workmanship at his own cost. Adequate numbers of required tools, brushes,
blast material, scaffolding, shot/sand blasting equipment, air compressors etc. shall be arranged by the
contractor at site. During storage and application of paints, the paint manufacturer’s instructions shall
be strictly followed. Particular attention shall be paid to the following:
a. Proper storage avoiding exposure and extreme temperature.
b. Specified surface preparation.
c. Mixing and thinning.
d. Application of paints and the recommended time intervals between consecutive paint coats.

82 Two pack paint system will be mixed by mechanical means. The Engineer-In-Charge may allow hand
mixing of small quantities at his discretion. Painting shall be done only after the mechanical
completion and testing on systems are completed. The` Post Office Red’/approved color paints hall be
used for painting fire water network, hydrants monitors, hose boxes etc.
2. Scope of Painting
Scope of pipeline painting work covered in the specification shall include:
a. Structural steel work, walk ways, pipes supports, ladders etc.
b. All above ground piping and fittings including identification marks).
c. Painting of valves/ strainers/ check valves and fitting of pipeline
d. Identification color bands and directions on all piping as required.
e. Supply of all primers, paints and all other material required for painting.
f. Coating and wrapping of underground pipelines.

108
 3. Surface Preparation
In order to achieve the maximum durability, one or more of following methods of
surface preparation shall be followed before blast cleaning.
3.1 Manual or Hand Tool Cleaning
This normally consists of hand de-scaling and/or hammering, hand scrapping and hand wire brushing.
Rust, mill scales, weld spatters, old coatings and other foreign matter shall be removed by hammering,
scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On
completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be brushed swept, re-dusted and blown off with compressed air to remove all loose
matter. For repainting of existing tanks, Non-ferrous tools should be used for cleaning.
3.2 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 brushing 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.

3.3 Blast Cleaning

The sand/shots used for blasting shall be free from moisture, salt. Sand/shot size should be 16 mesh to
30 mesh in order to have surface profile range 55-65 microns. Size of abrasive: 16 - 30 mesh. The
particle should pass through 100 % when sieved with 16 mesh and nothing to pass through when
sieved with 30 mesh i.e. size below 16 & above 30 mesh are not recommended. Shape of abrasive:
Sharp, semi-sharp, spherical or near spherical. Semi-sharp means, some sharp as well as round edge in
one particle grit. The total surface shall then be blast cleaned to Swedish Standard SA 2-1/2. The
blasting has to be carried out at a pressure of 7 kg/sq.cm.at the nozzle tip. Compressed air is to be free
from moisture and oil. On completion of blasting operation, the blasted surface shall be made clean
and free from any dust and scale or rust and must show a grey white metallic luster as demonstrated in
SA2 1/2. Blast cleaning shall not be done in bad weather without adequate protection or when there is
dew on the metal which is to be cleaned or humidity exceeding 85%. Surface profile shall be uniform
to provide good key to the paint. Primer or first coat of paint shall be applied within 4 hours of sand
blasting or as directed by Engineer-In- Charge depending on weather conditions.

3.4 Application of Primer and Paint

Before application of primer, thesurfaceshallbecleanedofdustetc.Allpaintsshallbethoroughlystirred up
prior to and during their application. Application of coats shall not be carried out if the atmospheric
temperature is less than 5ºC or if the temperature exceeds 40ºC in the shadow, 50ºC due to the influence
82 of sun or if relative humidity exceeds 85% or in case of adverse weather conditions like rain, fog, dust
storm etc. Coating media shall be applied in uniform thickness. All slots, recesses, grooves, corners,
angles and interstices shall be covered by paint. Sag and runs shall be distributed or removed and new
paint shall be applied uniformly.
Paint containers shall be opened only prior to utilization and shall be carefully closed immediately
after withdrawal of paint. Expiry date of the paint should be checked before opening the container.
Paint, which have become unserviceable during storage, shall not be applied. All painting material
shall be kept in weather proof barracks and shall be kept cool and dry Irrespective of the method of
surface preparation, the first coat of primer must be applied on dry surface. This should be done
immediately and in any case within 4 hours of cleaning of surface. Sweet blasting of the blasted
surface should be carried out in case of more than 4 hours delay in painting. The brushes will
conform to IS: 384. The width of the brushes shall not be more than 15 cm.
Paint shall be applied by brush/conventional spray/ airless spray. During spraying the paint shall be
maintained thoroughly mixed in the spray gun. Contractor shall obtain approval for specification for
spraying installation concerned, the type of equipment, nozzle diameter, pressu re setting etc. The paint
shall be sprayed uniformly. Surfaces impossible to be coated by spraying must be painted by brush.
Painting work shall be done in day time only preferably between 9AM to 5PM. Successive coats in paint
system shall be slightly different in shade for easy identification. Shade of each coat shall be

109
 decided by Engineer-In-Charge. Lettering, painting directional signs and relevant data shall be painted
in suitable size as directed by Engineer in Charge.
4. Inspection and Testing
Required painting materials for application shall be procured directly from manufacturers as per
specification. Manufacturer’s test certificates for every batch should be submitted to Engineer-in-
Charge without which paints will not be accepted. Engineer-in-Charge at his discretion may call for
tests for paint formulations. Contractor shall arrange to have tests performed including batch wise test
of wet paints for physical and chemical analysis at no extra costs to the Corporation.
The painting work shall be subject to inspection by Engineer-in-Charge at all times. Following aspects
will be considered during inspection and contractor shall offer the work for inspection and approval of
Site Engineer before proceeding with the next stage. The record of inspection shall be maintained in
the registers. Stages of inspection are as follows.
a. Surface preparation
b. Primer Application
c. Each coat of paint
Any defect noticed during the inspection is to be rectified by the contractor to the satisfaction of
Engineer-in-Charge 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
the 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 the NOC. The
contractor has to position an ELCOMETER at site for checking the paint thickness by the site
engineer. The contractor shall arrange and keep Holiday Detector at site.

5. Painting for Civil Defense Requirements

Two coats of selected finishing paint as per defense requirements shall be applied wherever specified in a
camouflaging pattern and as per instructions of Engineer-in-Charge. Disruptive painting for camouflaging
shall be done in three colors in the ratio of 5:3:2 (all Matt finish). The patches should be asymmetrical and
irregular. The patches should be inclined at specified angle to horizontal. The patches should be continuous
where two surfaces meet at an angle. The patches should not coincide with corners. Slits and holes are to
be painted in dark shades. Width of the patches should be 1 to 2meters.
6. Painting Specifications
In the case of surface preparation, wherever blasting to SA 2 ½ is recommended, maximum peak of surface
profile should be less by 5-10 micron from the primer DFT. Material specification are given in
82 the following heads.
6.1 Sand/Grit
The sand/grit used for Blasting shall be free from moisture, impurities salt and shall have a maximum
particle size of not more than passing through a 500 micron mesh (IS.)
6.2 Brushes
The brushes used in painting shall conform to IS: 384
6.3 Primer Coat
The primer used must provide good protection against corrosion and shall leave a tough adherent film
which will form a suitable base for the following coats. It shall conform to given specifications.
6.4 Finish Coat
The finish coats shall conform to given specifications.
6.5 Fire Red Paint
The fire red paint shall be used for painting over surface of fire water pipelines. Only superior grade
paints of approved make and quality and conforming to given specification shall be used. Contractor
shall obtain approval from site engineer in writing before procurement of primer/paint etc. and shall
obtain approval from site in sealed and unopened condition for inspection and approval of engineer-
in-charge.

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 IX: Specification for Blast Cleaning & Painting of Mild Steel Tank
1. General
These specifications define basic requirements for painting of mild steel shell, end plates and allied
structural work. It is deemed that the work shall be carried out by the contract or with the best quality
of specified material and workmanship at his own cost. Adequate numbers of required tools, brushes,
blast material, scaffolding, shot/sand blasting equipment, air compressors etc. shall be arranged by the
contractor at site. During storage and application of paints, the paint manufacturer’s instructions shall
be strictly followed. Particular attention shall be paid to the following:
a. Proper storage avoiding exposure and extreme temperature.
b. Specified surface preparation.
c. Mixing and thinning.
d. Application of paints and the recommended time intervals between consecutive paint coats.
Two pack paint system will be mixed by mechanical means. The Engineer-In-Charge may allow
hand mixing of small quantities at his discretion. Painting shall be done only after the mechanical
completion and testing on systems are completed.
2. Surface Preparation
In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed before blast cleaning.
3. Blast Cleaning
The shots used for blasting shall be free from moisture, salt. Shot size should be 16 mesh to 30
mesh in order to have surface profile range 55-65microns. Size of abrasive: 16 - 30 mesh. The
particle should pass through 100 % when sieved with 16 mesh and nothing to pass through when
sieved with 30 mesh i.e. size below 16 & above 30 mesh are not recommended. Shape of abrasive:
Sharp, semi-sharp, spherical or near spherical. Semi-sharp means, some sharp as well as round
edge in one particle grit.
The total surface shall then be blast cleaned to Swedish Standard SA 21/2.
The blasting has to be carried out at a pressure of 7 kg / sq. cm. at the nozzle tip. Compressed air is to be
free from moisture and oil. On completion of blasting operation, the blasted surface shall be made clean
and free from any dust and scale or rust and must show a grey white metallic luster as demonstrated in
SA2 1/2. Blast cleaning shall not be done in bad weather without adequate protection or when there is
dew on the metal which is to be cleaned or humidity exceeding 85%. Surface profile shall be uniform to
provide good key to the paint. Primer or first coat of paint shall be applied within 4 hours of sand
blasting or as directed by Engineer-In-Charge depending on weather conditions.
82
4. Application of Primer and Pain
Before application of primer, the surface shall be cleaned of dust etc. All paints shall be thoroughly
stirred up prior to and during their application. Application of coats shall not be carried out if the
atmospheric temperature is less than 5ºC or if the temperature exceeds 40ºC in the shadow, 50ºC
due to the influence of sun or if relative humidity exceeds 85% or in case of adverse weather
conditions like rain, fog, dust storm etc. Coating media shall be applied in uniform thickness. All
slots, recesses, grooves, corners, angles and interstices shall be covered by paint. Sag and runs shall
be distributed or removed and new paint shall be applied uniformly.
Paint containers shall be opened only prior to utilization and shall be carefully closed immediately
after withdrawal of paint. Expiry date of the paint should be checked before opening the container.
Paint, which have become unserviceable during storage, shall not be applied. All painting material
shall be kept in weather proof barracks and shall be kept cool and dry.
Irrespective of the method of surface preparation, the first coat of primer must be applied on dry
surface. This should be done immediately and in any case within 4 hours of cleaning of surface. Sweet
blasting of the blasted surface should be carried out in case of more than 4 hours delay in painting. The
brushes will conform to IS: 384. The width of the brushes shall not be more than 15cm. Paint shall be
applied by brush/conventional spray/ airless spray. During spraying the paint shall be

111
 maintained thoroughly mixed in the spray gun. Contractor shall obtain approval for specification
for spraying installation concerned, the type of equipment, nozzle diameter, pressure setting etc.
The paint shall be sprayed uniformly. Surfaces impossible to be coated by spraying must be
painted by brush. Painting work shall be done in day time only preferably between 9AM to5PM.
Successive coats in paint system shall be slightly different in shade for easy identification. Shade
of each coat shall be decided by Engineer-In-Charge.
5. Lettering
Lettering and painting directional signs and relevant data shall be painted in suitable size as
directed by Engineer in Charge.
6. Inspection and Testing
Required painting materials for application shall be procured directly from manufacturers as per
specification. Manufacturer’s test certificates for every batch should be submitted to Engineer-in-
Charge without which paints will not be accepted. Engineer-in-Charge at his discretion may call
for tests for paint formulations. Contractor shall arrange to have tests performed including batch
wise test of wet paints for physical and chemical analysis at no extra costs to NOC.
The painting work shall be subject to inspection by Engineer-in-Charge at all times. Following
aspects will be considered during inspection and contractor shall offer the work for inspection and
approval of Site Engineer before proceeding with the next stage. The record of inspection shall be
maintained in the registers. Stages of inspection are as follows:
a. Surface preparation
b. Primer Application
c. Each coat of paint
Any defect noticed during the inspection is to be rectified by the contractor to the satisfaction of
Engineer-in-Charge 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 the 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 the
Corporation. The contractor has to position an ELCOMETER at site for checking the paint
thickness by the site engineer.
The contractor shall arrange and keep Holiday Detector at site. Irrespective of the inspection,
repair and approval at intermediate stages of work, contractor shall be responsible for making good
any defects found during the 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
82
without any extra cost to the Corporation. The contractor has to position an ELCOMETER at site
for checking the paint thickness by the site engineer. The contractor shall arrange and keep
Holiday Detector at site.

X: Specifications of Wrapping/Coating of Underground Pipelines

(Coal Tar Type Application)

1. General
This specification lays down the requirements for selection, application and protective coatings on
exposed metal surface of underground piping.
Vendor to supply all the material required for pipe coating and wrapping, including supply of
primer, coating and wrapping material and other accessories required for the purpose. The scope
should also include application of primer and providing pipe coating / wrapping as per the
specifications given below or as per the instructions of Engineer – in-charge.
It consists of a cold applied liquid primer and heated coal tar base tape used in conjunction with coal

112
 tar and other type of coatings. Primer and tape shall be either shop or field applied to the exterior
surfaces or steel pipes. Primer and tape shall be furnished by the same manufacturers.
The coating materials shall consist of cold applied liquid primer and tape meeting the following
requirements:
a. Primer shall be cold applied liquid that shall comply with pollution control requirements in
effect at the location of use. Primer shall not settle in the container to form a cake that
cannot be mixed easily by hand stirring. Primer shall have satisfactory brushing or
spraying properties and a minimum tendency to produce bubbles during application.
b. Tapes shall be composed on coal tar base coating material supported on a fabric of organic
or inorganic fibers. The tape shall comply with the physical properties listed in table
below. The fabric shall be covered on both sides by the coating material. Tape shall be
furnished in standard widths as recommended by the manufacturer. Rolls shall be wound
on hollow cores having a minimum inside diameter of 37.5 mm. Tape shall have sufficient
pliability at a temperature of 25 degree Celsius to unwind from the roll without disbanding
the coating from the fabric.
c. Coal tar tapes are available in roll of 9 M, 15 M, 23 M length and 30 CM width. The
thickness of coal tar tape at the minimum is 1.27 mm.
d. The tape application should be done as per recommendation of manufacturer. The tape should
be wrapped over the pipe with minimum of 12.5 mm overlap per single wrap. Manufacturer
may specify either single or double wrap. In application care should be taken that there are no
air pockets and bubbles beneath the tape. The tape should remain in intimate contact of
primed pipe.
e. Theelectricalinspectionofcoaltartapecoatingshouldbedonebyrunningtheholidaydetectoroncoal
tar tape coating for any voids /holidays.
2. Physical Properties of Coal Tar Tape
Property ASTM Requirement
method Minimum Maximum
Tape thickness (microns coal tar component 1270 -
Softening point (0C) D36 65 121
Penetration of 25 deg.c./100 gm 3 20
Filter % D2415 20 30
Film separator (if used and if of the type that is not 6.4 12.7
removed prior to primer application) microns.

82
3. Inspection Format during Paint Application
Surface preparation adopted
Type of primer used
Method of application
Date and time of application
Whether condition prevailing on the day of application (temp.)
humidity, rainy, sunshine)
DFT measured (24 hour later)
Method of application
Date of time of application
Whether condition on the day of application
DFT measured
Type of subsequent paint
Method of application
Date and time of application
Whether condition on the day providing and fixing application.

113
 4. Technical specifications for floating suction assembly

i. Distinctive Specifications

Size and Type of Assembly : 150 mm NB Articulated Type,

Single Arm with 1 Swivel
Type of tank : 200 kl Underground , horizontal tank
Dimension of Tank : Tank length - 16.2
meter; Tank diameter –
4.00 meter
Max. Flow rate through Floating Suction: 150 kl/hr
Angle of movement of Arm : 0 to 45° max upward with respect to
Horizontal line

ii. Common Specifications

Operating Conditions:
Liquid : Aviation Turbine Fuel (ATF) - Jet
A-I Operating Temperature (C) : Normal - 5-45; Maximum - 50
Maximum working pr : 20 MLC
Design Pressure : 2.0 kg/cm² (g)
Hydro Test Pressure : 3.0 kg/cm² (g)
Specific gravity of liquid@ PT : 0.775 - 0.830
Viscosity of liquid @ PT : 1.5 - 3.4 Centi Stokes
Service : Intermittent
Design & Construction:
Floating Suction Type : Articulated, Single Arm with one
Swivel Max. Allowable pressure drop : 0.14 kg/cm through the Unit

5. Material of Construction:
Swing Joints : Aluminium
Pipe Assembly : Aluminium
82 Float : Aluminium /SS
Cable System : Stainless Steel
Antistatic bonding connection : Stainless Steel
Nuts and Bolts : Stainless Steel
Gaskets : SS

However for Panagarh AFS, material of construction for all the afore-mentioned parts has to
be Stainless Steel only.
All metal parts coming in contact with fuel must be free of Zinc,
Copper, Cadmium, and their alloys

General requirements:-
1. Cable System - Against hitting of Floating Suction on to the roof

2. Bonding - Antistatic bonding connection

3. Lifting lug :One Lifting Lug near the Suction End of the Floating Suction to be

114
 provided
4. Swing Joints: Aluminum, steel, or special alloys for chemical and
other applications; flanged dual ball bearing – suitable for submerged
liquid ATF application.
5. Pipe or Tubing: Aluminum, lengths and sizes suitable for
installation in the tank (tank size)
6. Bell mouth: Low velocity conical configuration with baffle plate
and anti-vortex plate.
7. Floats: Stainless steel or aluminum and pressure tested; the floats
provided shall have 100% redundancy for buoyancy.
8. Baffle and Stop Leg: Aluminum, steel, or special alloys for chemical
and other applications; designed to break suction 9 inches above tank
bottom (or as specified)
9. Inspection Cable: stainless steel SS 316
10. The floating suction assembly shall be checked for its functional test,
hydro test and visual examination and shall be released after TPIA
witness at the factory before dispatch of material to the location.
6. Strainer

Strainers:
a) Manufacturers Standards for body materials of strainers can be
accepted with due approval of NOC.
b) Internal Screen & Mesh - shall be in S.S AISI 304.

c) Allowable pressure drop shall be 0.5 kg./cm2 (max.) under clean condition
& 0.8 KSC (max) under clogged condition and also shall be certified by
the vendor. Pressure drop calculations shall be furnished as required by
Engineer-in-charge / NOC.

d) All 2” and higher sized bucket type strainers shall be provided with
¾“threaded tap and solid threaded plug as drain connection. For less than
2”, this shall be ½“size.

e) Strainers for water service for all sizes shall be fabricated Y type to
suit a design pressure of 15 KSC.

82
f) All strainers shall be supplied with spare basket complete with straining element.
g) All strainers for ATF service shall have SS304 internals. Also entire
internals of strainer which will come into contact with ATF to be
handled shall be epicoated.

h) All the strainers shall be hydrostatically tested at 15.0 Kg/cm2

pressure.