GENERAL TECHNICAL REQUIREMENTS FOR MECHANICAL &

PIPING WORKS
Document No: HITPL/146/08/D13

TABLE OF CONTENTS

1.0 General

2.0 Design Standards and Codes

3.0 Design and Construction Requirements

4.0 Materials

5.0 Fabrication and Erection

6.0 Welding

7.0 Pipeline Handling and Cleanliness

8.0 Pipe Supports and Anchors

9.0 Pipe Sleeves and Seals

10.0 Hydrotest – Pipe work

11.0 Painting and Coating

12.0 Safety and Security

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 GENERAL TECHNICAL REQUIREMENTS FOR MECHANICAL & PIPING WORKS

1.0 GENERAL
This section is intended to cover the general technical requirements for the Mechanical &
Piping Works, related to this project.
The Works, all equipment and materials forming part of this Contract shall comply in all
respect with relevant statutory regulations, by laws or orders currently in-force in the
Country of Installation.
2.0 DESIGN STANDARDS AND CODES
2.1 General Compliance with International Standards and Codes
All parts of the Works shall comply with the relevant international standards and
design codes. Where suitable international standards do not exist, internationally
accepted national standards shall apply.
2.2 Standards named in Specification
Although the Works shall generally comply with international standards, any
instruction in this Specification for a particular aspect of the Works shall take
precedence and that particular aspect of the Works shall comply with the named
code or standard.
Where no specific reference is made to any other standard or code of practice,
the Design and Construction of the facility shall be in accordance with the
applicable portions of the following standards, codes and practices:
ANSI B 1.20.1 : Pipe Threads, General Purpose.
ANSI B 16.5 : Steel Pipe Flanges, Flanged Valves and Fittings
ANSI B 16.9 : Factory-made wrought steel butt-welding fittings.
ANSI B 16.10 : Face to Face and End to End Dimensions of Valves
ANSI B 16.11 : Forged fittings, socket welding and threaded.
ANSI B 16.20 : Metallic Gaskets For Pipe Flanges: Ring Joint Spiral
Wound And Jacketed
ANSI B 16.21 : Non-metallic flat gaskets for pipe flanges
ANSI B 16.47 : Large Diameter Steel Flanges
ANSI B 31.3 : Chemical Plant and Petroleum Refinery Piping.
ANSI B 31.4 : Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids.
ANSI B 36.10 : Welded and seamless wrought steel pipe.
ANSI B 36.19 : Welded and Seamless Stainless steel pipe.
API 5L : Specification for Line pipe
API 6FA : Specification for Fire Test of Valves.
API 598 : Valve inspection and testing.
API 600 : Steel gate valves: flanged & butt welding ends.
API 602 : Compact steel gate valves.
API 603 : Stainless Steel Gate, Globe & Check valves.

Technical – Mech & Piping 2 of 18

 API 607 : Fire test of soft seated quarter turn valves.
API RP 1110 : Pressure Testing of Liquid Petroleum Pipelines
ASTM : American Society for Testing and Materials
ASME Sec V : Non-Destructive Examination
ASME Sec IX : Welding and Brazing Qualifications
AWWA C203 : Standard for Coal-Tar Protective Coatings and Linings
for Steel Water Pipelines—Enamel and Tape—Hot
Applied
BS EN ISO 1461: Galvanizing
BS 1868 : Steel check valves flanged, butt welding ends for the
Petrochemical and allied Industries.
BS 4164 : Specification for coal-tar-based hot-applied coating
materials for protecting iron and steel, including a
suitable primer
BS 5146 : Inspection and test of steel valves for the Petroleum,
Petrochemical & allied Industries.
BS 5351 : Steel ball valves for the Petroleum, Petrochemical and
allied Industries.
BS 5352 : Steel gate, globe and check valves 50 mm and smaller
IP Part 19 : Fire precautions at Petroleum Refineries and Bulk
Storage Installations
NFPA 10 : Standard for Portable Fire Extinguishers.
NFPA 11 : Standard for Low Expansion Foam.
NFPA 13 : Standard for the Installation of Sprinkler systems.
NFPA 15 : Standard for Water spray fixed system for fire Protection.
NFPA 24 : Private Service Mains and Their Appurtenances.
NFPA 33 : Spray Application Using Flammable and Combustible
Materials.
SS 055900 : Pictorial surface preparation standard for painting steel
surfaces.
SSPC SP 5 : White metal blast cleaning.
ISO 9000 : Quality systems – Model for quality assurance in Design
/development, Production, installation and servicing.
2.3 Hierarchy of Standards
In the event of any conflict in standards, the hierarchy of standards shall be as
follows:
(i) Statutory regulations of the Country of Installation.
(ii) Standards named in the specification.
(iii) International standards.
(iv) National standards

Technical – Mech & Piping 3 of 18

 2.4 Substitution of Standards and Design Code
The Contractor may offer Works that comply with International standards or
internationally recognized National codes or standards but differ from those
specified. However the Contractor may offer Works that comply with the different
standards or codes only if, when requested by the Engineer, he is able to
demonstrate to Engineer's satisfaction that the Works offered are equal to or
superior to that which would have resulted had the specified code or standard
been used. This substitution of codes or standards for those specified in the
specifications, will only be acceptable if the manufacturing organization in
question has extensive experience with the alternative code or standard offered
and approved by the Engineer.
Any Contractor offering Contract Works or part of those Works to standards and
codes, which differ from those specified shall declare the fact to the Engineer. If
requested to do so by the Engineer, the Contractor shall provide to the Engineer,
at his own cost, two copies of the relevant code or standard in English which he
proposes to substitute for that specified.
3.0 DESIGN AND CONSTRUCTION REQUIREMENTS
The Works shall be designed to operate safely, reliably and efficiently in accordance with
the Design and Operating Requirements of the Contract.
No departure from the Specification shall be made subsequent to the Contract without the
written approval of the Engineer.
In the event that the Contractor detects an anomaly, when preparing designs to national
or international standards or codes for Mechanical equipments and Pipe work, that the
specification is in conflict with the standard or code, he shall immediately consult the
Engineer to draw attention to the anomaly and, unless instructed otherwise by the
Engineer within twenty one days, shall proceed with the works on the basis of the
requirements of the national or international standard or code.
Design shall conform to the best current engineering practice. Each of the several
components of the Equipment shall be of manufacturer’s standard design, provided that
this design is in general accordance with Specification, and shall use components proven
to be satisfactory by previous experience.
The design, dimensions and materials of all parts shall be such that they will not suffer
failure/deterioration as a result of stresses under the most severe service conditions. The
materials used in the construction of the Plant shall be of the highest quality and selected
particularly to meet the duties required of them.
All the piping components and other connected fittings shall be selected as stipulated in
the relevant section of the code or as specified in this specification. Structural design and
fabrication shall be in accordance with relevant British Standards or equivalent
international standards.
All piping shall be routed to provide a neat and economical layout requiring minimum
number of fittings. Piping shall be arranged so that full access is available for the
operation and maintenance of the equipment, and the removal or replacement of
equipment can be achieved with the minimum dismantling of piping. Overhead piping,
inclusive of fittings, insulation and support steelwork, shall have a minimum vertical
clearance (headroom) of 2.1 meters above access platform and walkways.
In any one system or pipe service, all the pipe work and fittings shall be of the same
material class or similar unless specified or agreed by the Engineer.
The number of joints shall be kept to the minimum necessary, for efficient maintenance of
the work. Tees and bends shall be of standard dimensions. No crimping or visible

Technical – Mech & Piping 4 of 18

 flattening at the bend will be accepted. Where pipelines are identified for pigging purpose,
the tee's shall be of barred type.
Thrusts at terminal points shall be kept to a minimum and within the tolerance limits
agreed with the supplier for the package items or pipe work to which they connect.
All drain and vent valves shall be located in easily accessible locations. Vents and drains
shall be provided on high point and low points respectively, irrespective of whether shown
in the drawings or not. Drain pipe work shall have a continuous fall to the point of
discharge. All drains and vents shall discharge to safe locations. Drains and vent pipe
work shall be neatly run and shall not interfere with maintenance or operating
requirements.
Where necessary, provision shall be made for the draining and release of air in the
system by the use of valves. In addition plugged drain and air release bosses should be
welded to pipes at appropriate points to facilitate hydrostatic testing of the piping.
Where items of mechanical plant, that are to be mounted on foundations, which are a part
of the civil engineering works, the Contractor shall carry out suitable levelling and
adjustment of the item on the civil foundations, before the item is secured in position by,
suitable non-shrink grouting. The Contractor shall check the alignment, levelling, or
positioning, of the item in question, before and after grouting. The Contractor shall make
records of the alignment, levelling or positional measurement and shall maintain such
records until his activities at site are concluded. Where large and complex item is installed
on extensive foundations, a datum shall be established to check for movement or
settlement of the foundations.
Testing and trial run of the equipment shall be carried out by the Contractor as per the
manufacturer’s recommendations. The relevant procedures for erection and testing of the
items as applicable shall be submitted to the Engineer for approval.
The Contractor shall supply and erect all stairways and platforms as necessary,
irrespective of specified in the drawings or not, for providing safe and easy access to
plant locations for operation and maintenance. The Contractor shall ensure that the
access ways are of uniform design and pattern throughout the Works. The design of all
stairways, access ways etc. shall conform to the requirements of the Specification and
are part of this Contract.
As far as practicable, all main and auxiliary piping, drains etc., shall be arranged so that
they may be run above basement level with adequate headroom and access. Where floor
trenching is unavoidable, pipe work shall be supported above the trench bottom. The use
of buried pipe work other than those shown in the drawing shall be subject to the
Engineer's approval.
For all vendor designed packaged items, all relevant design basis, schemes, drawings,
technical specifications, calculations, testing procedures etc shall be submitted to the
Engineer for approval. Material certificates and records of factory tests shall be submitted
to the Engineer prior to the shipment of the items for verification.
4.0 MATERIALS
4.1 Specification
Piping materials shall be as per the specifications given in the relevant piping
specifications.
4.2 Valves
4.2.1 General
All valves shall be suitable for the service conditions under which they
are required to operate. The design, construction and choice of materials

Technical – Mech & Piping 5 of 18

 shall take into account all operational deviations including pressure surge
and thermal shock.
The valve bodies shall be of forged or cast steel. Gunmetal or cast iron
valves shall not be used in any fuel or oil system or any similar system
where shock loads could result in sudden fracture.
Bonnets and valve covers shall be bolted in position and not screwed.
Any valve which is designed for unidirectional flow shall have an arrow
embossed or cast on the valve body clearly indicating the required flow
direction.
All valves, unless otherwise approved or specified, shall be of the
external rising spindle type. For valves placed indoors where it is
necessary to protect the spindle against ingress of dirt, or where the
position of the valve may create a hazard to operating personnel when
the spindle is extended, suitable spindle covers shall be provided. The
spindles and operating gear of all valves for use outdoors shall have
weather and dust proof protection.
Unless otherwise stated in the scope of work, valves over ten inch size
shall be with suitable gear mechanism for smooth manual operation. Any
gear or bevel wheels used to transmit motion shall be of cast steel or
approved quality cast iron with machine cut teeth. No thrust from the
valve shall be transmitted to the extension spindles and the valve
pedestals shall not be mounted directly on floor plating.
Any floor steelwork trimmers for supporting pedestals shall be provided
by the Contractor.
Special attention shall be given to positioning of the valves for easy
accessibility for operation and maintenance from permanent floor or
platforms.
Eyebolts or equivalent shall be provided, where necessary, to facilitate
the handling of heavy valves or components.
No valve shall be installed with its operating spindle gland below the
horizontal centre line so as to avoid dirt entering the gland and to ensure
complete drainage.
When valves are required to be locked in position as per operational
requirement, they shall be provided with a chain, padlock with keys or
other secure locking device.
The internal diameter of all valves at the ends adjacent to the pipes shall
be the same as the internal diameter of the pipe to which they are joined.
Valves shall be provided with labels or nameplates. These labels shall
include an inscription of a valve "name" or abbreviated description of the
valve duty, and a unique plant reference number for the valve. Valve
labels shall be circular and fitted under hand wheel captive nut. For
check valves and small valves, the Contractor may provide rectangular
labels fitted to the valve or secured close by the valve.
Valve size and the pressure rating shall be marked on the valve body.
Where direction of flow through a valve or other device is an important
requirement for correct functioning, direction indicators shall be legibly
marked with a cast arrow on the body of the valve or device.
Alternatively, a properly secured arrow made of SS material showing
flow direction shall be used.

Technical – Mech & Piping 6 of 18

 4.2.2 Manual Valve Operation Requirements
All valves with manual operating mechanisms shall be easily operable by
single personnel.
The mechanism shall be such that the total force at the rim of the hand
wheel or other point of application of manual action shall not exceed
400N (normally 200N pull plus 200N push) to operate any valve.
Special attention shall be given to operating mechanism for large sized
valves to ensure that minimum maintenance is required and to facilitate
quick and smooth operation.
All Globe and screw down Non-return valves shall be of the non-rising
hand wheel pattern unless specifically approved by the Engineer. The
valves on fire protection system shall be self-indicating type like rising
stem or other means of indicating the operating condition.
All valves shall be closed by rotating the hand wheels in a clockwise
direction when looking at the face of the hand wheel. In cases where the
hand wheel is not directly attached to the valve spindle suitable bearing
shall be introduced to ensure clockwise closing. The face of each hand
wheel shall be clearly marked "open" and "shut" or "closed" with arrows
indicating the direction of rotation to which they refer .
4.2.3 Pressure / Thermal Relief Valves
Pressure / thermal relief valves shall be of the spring-loaded type unless
otherwise specified, or unless the Engineer has given written permission
for the use of a different type of valve actuation. Unless otherwise
specified all relief valves inlets shall be with flanged ends. Valve size and
the pressure rating shall be marked on the valve body.
4.2.4 Non Return Valves
All non-return valves shall be provided with means of draining the space
between the valve and its adjacent isolating valve.
The design shall preclude the possibility of the valve jamming in the open
position; the effect of solid particles settling out in dead space within the
valve should be recognized in this respect.
4.2.5 Float Valves
Float valves shall be of the equilibrium ball float type. All operating rods,
guides, brackets and covers shall be suitable for product in contact.
4.2.6 Traps, Drains and Vents
The Contractor shall provide all traps, drains and vents which are
necessary for Testing, commissioning, operation etc. Drains and vents
shall be fitted for the pipe work and equipment / plants.
For airlines work, where it is appropriate, condensate traps shall be
provided. The type of trap for each duty shall be carefully selected for the
particular service conditions considering the pressures and
temperatures, maximum condensate flow and range of condensate flows
to be encountered, likely frequency of operation etc.
4.2.7 Control valves - Sizing
Control valves shall be standard size wherever possible and shall be
sized for optimum control. The sizing calculations shall include CV, noise
and cavitation calculations.

Technical – Mech & Piping 7 of 18

 Valves bodies shall in all cases match the piping pressure and
temperature rating specifications as a minimum and the operating point
on the valve characteristic i.e. lift / throughput curve should be within the
60- 70% operating range.
4.2.8 Thermal Insulation
The above ground pipe work to be insulated as identified on P&ID’s and /
or Piping Plans shall be insulated using mineral wool. The mineral wool
shall have density of 128 Kg/m3 as blanket and shall be as per ASTM C-
592. Preformed insulation may be used for pipe works smaller than 4”
dia. Insulation shall have suitable weather shield to prevent atmospheric
condensate entrapment in the insulation.
Cladding as per ASTM B 209 using 0.4 mm thick Aluminium sheet for
pipe less than 10” dia and 0.7 mm thick for pipe 10” dia and above with
sealants for the joints shall be used. Insulation thickness shall be 50 mm.
The entire pipe work including valves, flange joints etc. excluding
equipment shall be insulated.
Contractor shall submit design, detailed specification and method
statement for insulation work for Approval.
5.0 FABRICATION AND ERECTION
Fabrication, erection and testing shall be in accordance with this specification and
applicable codes / standards. The fabrication, testing and flushing/cleaning of all pipe
work shall be completed before connecting to any existing pipe network or tanks or
equipment.
Flanged joints should have mating faces parallel and concentric before being bolted up.
Flanges shall be separated by the minimum distance necessary for insertion of the
gasket, which will fit inside the bolt circle. Pipe work will be truly horizontal, vertical or in
accordance with the orientation specified. Where natural drainage is called for, pipe will
be laid to the fall specified in the direction given. Bolt holes in flanges shall straddle the
centreline axis of the pipe.
The Contractor shall ensure that the interior of all pipe work is kept clean during erection
and is free from any spurious matter.
The Contractor shall make necessary adjustments as per site conditions to the pipe
routings and elevations to suit at site, at no extra cost. Vents and drains shall be provided
at all high and low points, irrespective of whether shown in the drawings or not.
Execution of all works included in the Contract shall be supervised by a sufficient number
of qualified representatives of Contractor, and complete facilities and assistance shall be
provided to the Engineer to check the Works.
The contractor shall pressure test the supplied valves without any additional charge, prior
to installing them in the pipeline. Leakage of valves during hydrotest shall not be cited as
a reason for the hydrotest non-compliance. Necessary test bench etc for the testing of
valves shall be in contractor scope of supply. Contractor shall carryout minor adjustments
to arrest the Valve leakage during the testing. If the cause of leakage is beyond his
control, the contractor shall draw the attention of the Engineer to the issue.
The Contractor shall obtain from the Engineer, details of the parts, which he proposes to
inspect but such inspection shall in no way exonerate the Contractor from any of his
obligations under this contract. The Contractor if requested by the Engineer shall open for
inspection before erection, any equipment which has been delivered to the site partly
assembled.

Technical – Mech & Piping 8 of 18

 The Contractor shall keep reasonably clean the site/work front on which he erects or
stores equipment, removing all debris/waste material resulting from the Works as it gets
accumulated and as reasonably directed by the Engineer. On completion of the Works,
the Site shall be left clean and tidy to the satisfaction of the Engineer. Any damage
caused to buildings, structures, plant or property belonging to the Employer shall be
made good at the expense of Contractor.
The contractor shall take adequate precaution for the safe keeping of the materials and
equipments supplied to him under the contract. The contractor shall make good any
damage caused to such materials and equipments at his own expense, till all works under
the contract are handed over after proper commissioning and performance testing.
The Contractor shall ensure the correctness of electrical and mechanical connections to
all equipments supplied under the Contract before such equipment is commissioned.
All tools, tackles, lifting equipments etc engaged by the contractor for the contract shall
have valid licences/clearances from the concerned authority having jurisdiction over the
worksite.
During erection and commissioning, the Contractor shall provide temporary scaffolding,
ladders, platforms with toe boards and hand-rails etc. that are essential for proper access
to workmen and inspectors, cover or rail off dangerous openings or holes in floors, and
ensure adequate protection against materials falling from a higher level onto inspecting
personnel.
The Contractor must take sufficient precaution to ensure adequate protection of all site
personnel from exposure whenever radiographic or X-ray inspection of welding is being
carried out. Warning Boards, Signs & notices must be displayed at all relevant locations
and the radiographic areas cordoned -off so that no personnel shall be subject to any
radiation dosages in excess of the permissible levels quoted for unclassified non-radiation
personnel in published statutory limits.
6.0 WELDING
6.1 General Requirements
This Section defines acceptable practices for fabrication and standard of quality
that relates to all piping constructed and all fabricated pipe work involved in
connection with the Contract.
All welding shall be carried out in accordance with the requirements of ASME
standards.
All welding machines, external and / or internal line-up clamps, bevelling
machines and the welding equipment shall be of a type approved by the
Engineer.
6.2 Welding Procedures
Weld procedure specification (WPS) and Procedure Qualification Record (PQR)
as defined in ASME Section IX shall be prepared and submitted for Engineers’
approval before commencement of welding. The welding technique shall be as
given in this specification, unless otherwise agreed in writing.
All joints to be welded shall be free from rust, scale, oil, grease and such matter
that may affect the quality of welding. The cut edge must be ground, filed or
trimmed back to the tolerance demanded for bevel, root face and gap.
Arc burns, caused by welder striking his arc on the pipe surface, shall not be
allowed to occur. The Contractor must replace any pipe with arc burns with good
pipe to the satisfaction of Engineer.

Technical – Mech & Piping 9 of 18

 The deposit weld metal shall be thoroughly fused with the parent metal, particular
care being taken with root runs.
All fillet welds shall be of such a form that the minimum throat thickness is always
obtained, and these welds shall be free from under cut, porosity, cracking and
other defects.
Weld joints shall not be disturbed until thoroughly cooled.
6.3 Welding Electrodes
The electrodes shall be supplied by the Contractor and shall be in accordance
with the latest edition of AWS A5.1 issued by the American Welding Society and
the approved welding procedures. Electrodes shall be from a recognized
manufacturer and Engineer’s approval shall be taken for its usage. Electrodes
shall be baked as per the manufacturer’s recommendation prior to usage.
6.4 Qualification of Welders
Contractor shall ensure qualifying of welders to meet requirements of ASME
Section IX. Welder qualification shall be done for this project regardless of their
previous qualification for earlier projects and their validity of certification.
6.5 Welding Inspection and Testing
Each weld shall be subjected to a stringent visual inspection and shall be free
from undercut, excessive spatter, craters, cracks, porosity and other surface
imperfections. Welds shall be of regular contour, even weld ripple and indicative
of good workmanship.
During inspection and testing of fillet weld, the weld shall be checked for
dimensional tolerance by using a fillet weld gauge. Fillet welds shall be slightly
concave in form and each leg of the weld shall have equal length.
The Contractor shall provide radiographs of welds as per ASME Section V to
Engineer’s representative. The sensitivity of the radiograph films shall be 2% or
better.
All Non-Destructive examinations shall be supervised by a fully qualified and
experienced Inspector appointed by the Contractor. Following NDE activities are
to be carried out by the Contractor.
1) Butt weld – 20% radiography
2) Underground Piping – 100% radiography
3) Fillet weld – 100 % MPI.
4) Tie-in welds – 100% radiography
Welds shall meet acceptance standards per ANSI B 31.3. Weld repair and quality
assurance shall be per ANSI B31.3. All NDE requirements shall be done for the
repaired joint as per the specification.
At the commencement of pipe work, the Contractor shall produce pipeline
welding record schedule and shall maintain it up to date throughout the
construction period. The schedule shall record all necessary details of each weld
made, including location, type, date, welder etc. and shall be submitted to the
Engineer for information. Contractor shall maintain a copy and update on daily
basis.
The Contractor shall carry out hardness testing as required by the standards /
specification / where instructed for by the Engineer. Acceptable hardness values
shall be BHN 220 for weld metal and 260 for base material.

Technical – Mech & Piping 10 of 18

7.0 PIPELINE HANDLING AND CLEANLINESS
7.1 Handling of Pipelines
The Contractor shall transport the pipes and pipe fittings, accessories, valves,
flowmeters etc from the storage point to the work front. Contactor will be
responsible for the safe keeping of the line pipe and accessories and shall make
good any subsequent damage to them. Contractor shall arrange all manpower,
tools, tackles and lifting equipments required for the job.
During the operations of handling, hauling, stringing and storing, the coated /
wrapped pipes shall not be allowed to drop or strike objects which will damage
the pipe or coating. Pipes shall be lifted or lowered from one level to another by
suitable equipment. When lifting pipes fitted with protective end caps, special
lifting hooks equipped with a plate curved to fit the outside of the pipe shall be
used. Pipes not fitted with end caps may be lifted by hooks equipped with plates
curved to fit the inside curvature of the pipe.
While loading coated pipes on trucks for transportation to site, each length shall
be carefully lowered into position without dropping and each succeeding length
shall rest evenly with other lengths on the truck after loading. Suitable chains
shall be used to tie the load securely to each bolster. Due care shall be exercised
to prevent damage to coated pipes during the securing of the pipes using chains
/ other suitable method or transportation.
Protective barriers/pads shall be installed between each layer of pipes to prevent
them coming into contact with each other and the body of the trailer. Care shall
be exercised in handling or storing pipe in order to avoid distortion, flattening,
denting, scouring or other damage.
Pipe shall be transported from the storage location to the site of the Works and
the Contractor shall be liable for any damage to roads, bridges, culverts, etc. In
stringing the pipe along the route, gaps must be left at access roads to allow the
free passage of pedestrians, vehicles, etc., during the interval of the time
between stringing and the finalization of the works.
The unloading of pipe from stringing trucks and lowering to the ground shall be
carried out by suitable equipment. Special care shall be exercised to see that the
pipe is not dropped on rocks or allowed to rest on sharp or jagged surfaces.
Dragging and skidding of pipe will not be permitted after the pipe has been laid
and inspection carried out by the Engineer or his representative. The cost of
repair / replacement of any damaged pipe shall be borne by the Contractor.
7.2 Pipe Cleanliness
During the construction work, every precaution must be taken to keep the
pipeline internally clean. Each pipe joint shall be cleaned internally to the
satisfaction of Engineer to remove dirt, loose mill scale, etc., before placing in
alignment for welding. No tools or other constructional materials are to be left in
pipes and all apertures shall be closed by suitable wooden plugs, having an air
release hole towards the top and fitting the aperture/opening and entering the
pipe for at least six inches (150 mm). These wooden plugs shall be kept in place
overnight and at all times except when work is in progress. Any obstruction
remaining in the pipe after the completion of the line shall be removed at the
expense of the Contractor. Particular care shall be taken to see that valves are
left properly closed and free from all matter likely to impede their operation.
The Contractor shall ensure that the interior of all pipe work is kept clean during
erection, and shall demonstrate to the satisfaction of Engineer that the pipelines
are clean and clear before plant commissioning.

Technical – Mech & Piping 11 of 18

 The contractor shall also ensure that at the completion of each days work, the
exposed end of the pipeline is suitably capped to prevent any entry of foreign
material in the pipeline overnight. Everyday before commencing work, the
contractor shall check the end caps and if the cap has been removed or
damaged, the contractor shall remove any foreign matter that has entered the
pipeline overnight.
Where pipes are installed at the road crossings in advance, prior to the
installation of the connecting pipeline, the Contractor shall on completion of the
work ensure that interior of the pipe crossing is clean and they are suitably
capped to prevent the ingress of dirt or foreign matter in the period up to its
connection to the pipeline.
7.3 Defective or Damaged Pipe
All pipes shall be visually examined for laminations internally and externally and
for split ends after the pipe has been strung and prior to welding.
Should laminations or split ends be discovered in the pipe before or during the
process of welding, the full joint containing such a defect shall be removed from
the pipeline and shall not again be used in the pipeline construction.
If the ends of the pipes are damaged to such an extent that satisfactory welding
joint cannot be obtained or if the misalignment or indentation is greater than the
tolerances allowed in API Specification 5L, then the defective pipe end shall be
cut and bevelled to the standard angle with an approved type of bevelling
machine.
In accordance with the requirements of ANSI B31.3 and / or ANSI B3l.4, dents of
unacceptable size and injurious gauges or grooves, shall be removed and
replaced by sound pipe. This shall be carried out by the Contractor at no extra
charge for the items covered by the Contractor's scope of supply.
8.0 PIPE SUPPORTS AND ANCHORS
Pipe work shall be supported and anchored in an appropriate manner. Supports shall be
positioned before the pipe has been erected and near to valves wherever possible.
Supporting straps shall not be provided around flanges or welded joints.
Where required, supports shall be provided with means of adjusting the height of
supports and the length of rods or straps. All such adjusting devices shall be capable of
being securely locked. The supporting arrangements of all pipe work systems shall be
designed with due regard to any additional loads imposed during hydraulic or hydrostatic
leak testing and cleaning.
Outdoor piping support systems shall be designed to withstand the environmental
conditions. All the pipe supports shall be hot dip galvanized and painted to the
Specification. Where supports are extended from concrete foundations all necessary
grouting, studs, bolts etc. shall be supplied and installed by the Contractor.
Similarly, in case of supports extended from the steel structures, all painting or
galvanizing or coating damage shall be rectified by the Contractor to Engineer's
satisfaction.
9.0 PIPE SLEEVES AND SEALS
Where the pipeline crosses through the bund wall or RCC wall, for the product retaining
purposes, carbon steel sleeve with insulators and end seals shall be installed. Seal shall
be link seal with Zipper end.
The insulator and seals shall be designed for a long life leak proof service and the
materials shall be selected with due consideration given to products which it may come in

Technical – Mech & Piping 12 of 18

 contact. The seals and insulators shall be fire and oil resistive and to the Engineer's
approval.
10.0 HYDROTEST – PIPE WORK
Notwithstanding the requirements of the approved Standards, the Contractor shall submit
the hydrotest procedure for Engineer’s approval and conduct testing of all his work in the
presence of the Engineer.
Testing of the terminal pipe work shall comply with ANSI B31.3. On completion of the
pipeline erection and prior to the final hydrostatic test of the pipeline, the Contractor shall
clean the line by flushing with fresh water and the pipeline gauged. Water for testing shall
be potable water and shall be supplied and disposed off by the Contractor.
The hydrotesting shall be done with chart recorders and the pressure holding time for the
above ground lines shall be 2 hours and underground lines shall be 24 hrs.
Contractor shall submit a test pack with the portion or the piping system to be tested
along with all relevant documents to Engineer at least 7 days in advance of the testing.
The Contractor shall submit his hydrostatic test procedure to Engineer for approval at
least one month prior to the commencement of the hydrostatic test.
The pipeline shall comply fully with the test requirements and should it fail to meet the
test requirements, then the Contractor shall take all necessary steps to locate the cause
of Non-compliance and make necessary repairs without charge -till the entire pipeline
complies with the requirements on retesting.
Equipments like pumps etc shall be isolated from the piping by suitable method to
prevent pressurisation during the pipeline hydrotesting.
Leaks found in any weld or joint shall not be repaired by mechanical caulking. All
necessary connections, test pumps, gauges, vents, drains, etc. required for carrying out
these test shall be included in the Contractor’s supply.
On successful completion of hydrotest, the water shall be drained and pipes dried by a
method approved by the Engineer. Prior approval of Local Authority shall be obtained by
the Contractor for disposing the test water. Necessary arrangements to take water away
to an approved disposal site shall be arranged by the Contractor, at no additional cost, if
directed by the authorities.
11.0 PAINTING AND COATING
11.1 General Requirement
The Contractor shall prepare and submit a detailed painting / coating schedule
and procedure for the complete works together with a quality assurance program
for Engineer’s approval. The Contractor’s proposed painting / coating systems
must be suitable for the product to be stored and climatic conditions of the area.
All paint material shall be procured from a single Manufacturer and shall be
manufactured in the same country to ensure compatibility. The painting shall be
carried out after a successful hydrotest, in accordance with the appropriate
schedules as per the Painting Specification. Painting shall include all Carbon &
Stainless steel above ground pipe work, valves and other pipe fittings, structures
etc. Buried pipe work shall be coated and wrapped in accordance with
specifications.
The paints shall be standard proprietary products manufactured by an approved
manufacturer. The application of paint shall be in complete conformity to
manufacturer’s recommendations. The Contractor shall submit a joint
performance guarantee by the Contractor and manufacturer for the paint material
and application for a period of 5 years according to level Re3 of European rusting
scale grade from date of final acceptance of works. Contractor shall take

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 adequate precaution to contain over spray (zero over spray) to adjacent facilities
and personnel working near by, during the blasting and painting.
Steel sections and plates shall be free from surface flaws and laminations prior to
blast cleaning and shall not be in worse condition than Pictorial Standard A, and
shall be cleaned to Swedish Standard SIS 055900 (SA 2½).
The whole of the steel work shall be prepared for painting by an approved blast
cleaning method using clean and dust free abrasive grit. The grit used shall be
copper or iron slag of medium grade to Engineer’s approval. The surface profile
produced shall be to SIS 055900 pictorial standard “A”.
All paints shall be applied by airless spray method in accordance with the
specification. The applicator shall demonstrate that the spray technique
employed does not produce paint films containing vacuoles.
All polished and bright parts shall be coated with other approved rust preventives
before despatch and during erection. This coating shall be cleaned off and the
parts polished before being handed over.
Where lapped or butted joints form part of an assembly which is assembled or
part assembled prior to final painting, the jointed surfaces shall be cleaned free
from the scales, loose rust, dirt and grease and given one brush applied coat of
the zinc epoxy primer before assembly.
Paint shall not be applied to surfaces which are superficially or structurally damp
and condensation must be absent before the application of each coat.
Blast cleaning and painting shall not be conducted when steel surface
temperatures are minimum below 3 Deg. C above dew point and when relative
humidity is more than 85% so as to avoid the risk of condensation during
painting.
Blast cleaning shall be carried out in a covered area to avoid spreading of blast
material.
Priming coats of paint should not be applied until the surfaces have been
inspected and preparatory work has been approved. The time period between
blast cleaning and priming shall not be more than 4 hours. The Contractor shall
provide proper and recently calibrated equipment to inspect the surface profile
and paint thickness.
No consecutive coats of paint, except in the case of white, should be of the same
shade. The final shade of the painted surface shall be confirmed by Engineer
upon award of Contract.
On sheltered or unventilated horizontal surfaces on which dew may linger and
more protection is needed, additional top coat of paint shall be applied to achieve
this.
All paint film thickness values given are minimum and refer to the dry film
condition. All thickness shall be measured by an Elcometer (DFT paint gauge).
The Contractor shall ensure that precautions are taken in packing and crating to
avoid damage to the protective treatment applied before shipment during
transport to the site.
For internal coating and in confined area, the painter shall wear a personal
explosive meter to monitor the lower exposure limits (LEL). It should not exceed
10% LEL
Product data sheets with manufacturer’s recommended application procedures
shall be submitted for approval before the procurement of the materials.

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 Nameplates of Equipment, Valves, Motors, Pumps etc shall not be painted during
the painting process.
11.2 Schedules for Painting and Coating
A. Non Galvanized Steel surfaces
The following paint system shall be applied to the external carbon steel
surfaces of the piping, all fittings, accessories, valves, mountings,
equipment etc.
(a) Treatment before installation
- Blast clean to SA 2½ finish using clean abrasive grit.
- One coat of 2 components inorganic zinc silicate primer, with
75% solids minimum - 75 microns DFT minimum.
- Two coats of 2 component polyamide cured Hi-build epoxy
coating containing MIO all together 125 microns DFT
minimum.
(b) Treatment at site after installation
- Clean damaged and uncoated areas to SA 2½ finish using
power brush.
- Coat the patches with the treatment as at works
- Two coats of 2 component Polyurethane paint of specific shade
all together 100 microns DFT minimum
Total 300 microns DFT minimum
The following paint system shall be applied to the external stainless steel
surfaces of the piping, all fittings, accessories, valves, mountings,
equipment etc.
- Sweep blast the surface.
- One coat of etch primer.
- One coat of 2 component Polyurethane paint of specific shade
50 micron DFT minimum
B Steel surfaces requiring lagging
1. Lagged with Mineral Wool
Piping Surfaces, to be insulated with a mineral wool layer shall
be prepared as per the schedule below;
a) Treatment at manufacturer’s works
- Blast clean to SA 2½ finish using clean abrasive grit.
- One coat of 2 components inorganic zinc silicate primer
with 75% solids minimum - 75 microns DFT minimum.
b) Treatment at site before lagging
- Clean damage and uncoated areas to SA 2½ finish
using power brush.
- Coat patches with the primer as at Manufacturer’s
works.
2. Lagged with Polyurethane Foam

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 Piping surfaces to be insulated with polyurethane foam shall be
prepared as per schedule below;
a) Treatment at manufacturer’s works
- Blast clean to SA 2½ finish using clean abrasive grit
- One coat of coal tar epoxy to a minimum thickness of
300 microns DFT.
C. Galvanized Steel Surfaces
All steel structures like pipe supports, pipe rack, gratings, walkways,
ladders, stairs, platforms, handrails etc shall be hot dip galvanized and
painted as per the schedule below:
(a) Treatment before installation
- Hot dip galvanizing shall be done in accordance to BS EN
ISO 1461 to minimum thickness of 85 microns DFT
- 1 coat etch primer
- 1 coat 2 component polyurethane paint of specific shade 50
micron DFT minimum
(b) Treatment at site after installation
- Clean damaged and uncoated areas thoroughly to remove
oil, grease and dirt. Damage to galvanized surface shall be
made good by thorough cleaning and application of cold zinc
spray to a thickness of 85 microns DFT. Coat the patches
with etch primer and coat 2 component polyurethane paint of
specific shade 50 micron DFT minimum
- 1 final coat 2 component polyurethane paint of specific
shade 50 micron DFT minimum
- Total coating thickness – 100 microns DFT minimum
D. Stainless Steel Surface:
The atmosphere being corrosive, the Stainless Steel Surfaces shall be
sweep blast, etch primed and applied with one coat of 50 DFT thick
Polyurethane epoxy paint.
11.3 Hot Dip Galvanizing
All galvanized work shall be carried out by the hot dip process and shall comply
in all respects with BS EN ISO 1461. All surface defects in the steel including
cracks, surface laminations and folds shall be removed. All drilling, cutting,
welding forming and final fabrications of unit members and assemblies shall be
completed before the structures are galvanized.
The surface of the steelwork to be galvanized shall be free from welding slag,
paint, oil, grease and similar contamination.
The minimum average coating weight shall be as specified in Table 1 of BS 722.
Structural steel items shall be initially blasted to BS EN ISO 12944, second
quality, or SIS 055900 pictorial standards and the minimum average coating
weight on steel sections of 5 mm thickness and over shall be 915 g/M2.
On removal from the galvanizing bath the resultant coating shall be smooth
continuous, free from gross surface imperfections such as bare spots, lumps,
blisters and inclusions of flux, ash or dross.

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 Galvanized contact surfaces to be joined by high strength friction grip bolts shall
be roughened before assembly so that the required slip factor as defined in BS
4604, Part 1 is achieved. Care shall be taken to ensure that the roughening is
confined to the net area of the spraying surface.
Bolts, nuts and washers, including general grade high strength friction grip bolts
referred to in BS 4395 Part 1 shall be hot dip galvanized and subsequently
centrifuged according to BS 729. Nuts shall be tapped up to 0.4 mm oversize
after galvanizing and the threads oiled to permit the nuts to be finger turned on
the bolt for the full depth of the nut.
No lubricant, applied to the projecting threads of a galvanized high strength
friction-grip bolt after the bolt has been inserted through the steelwork, shall be
allowed to come into contact with the spraying surfaces.
During unloading and erection nylon slings shall be used. Galvanized work, to be
stored in works or on site shall be stacked so as to provide adequate ventilation
to all surfaces to avoid wet storage staining (white rust).
Small areas of the galvanized coating damaged in any way shall be restored by
a) Cleaning, the area of any welding slag and thoroughly wire brushing to
give a clean surface.
b) The application of two coats of cold galvanizing spray or zinc rich paint.
After fixing, bolt heads, washers and nuts shall receive the paint system as for
adjacent steelwork.
Connections between galvanized surfaces and copper, copper alloy or aluminium
surfaces shall be protected by suitable inert tape wrapping to the Engineer's
approval.
11.4 Field wrapping buried pipelines
Non-lagged (uninsulated) buried (underground) metallic pipe work shall be
prepared as per the schedule below:
a) Treatment at manufacturer’s works
- Blast clean to SA 2½ finishing using clean abrasive grit.
- Apply the dry, clean, prepared surface with one coat of
recommended primer.
- Wrap the coated surface with an approved Self-adhesive
Anticorrosion Bituminous Rubber compound tape with 50%
overlap, SERVIWRAP or approved equivalent.
b) Treatment at site
- Clean weld and damaged areas using power brush.
- Apply one coat of recommended primer.
- Wrap the surface with Self Adhesive Anti-Corrosion Bituminous
Rubber compound tape, with PVC out Wrap, SERVIWRAP or
approved equivalent.
The buried flange joints shall be avoided. The field wrapping shall be tested to
prove the integrity of coating using holiday detector. The operating voltage range
shall be as per coating materials manufacturers’ recommendations.

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 11.6 General Schedule for Final Coat Colour
ƒ Air piping - Sky Blue
ƒ Fire water piping - Red
ƒ Foam piping - Orange Yellow
ƒ Products - White
ƒ Slop Line for White Product - White
ƒ Slop Line for Black Product - Black
ƒ Water piping - Green
ƒ Product Pumps - Dark Blue
The above colour codes shades shall be reconfirmed with the Owner by the
Contractor
11.7 Pipe / Equipment Service Identification
Colour bands shall be painted on each side of all valves and equipments in the
piping systems. The use of adhesive-backed colour bands is not permitted.
Valve labels shall be circular and fitted under the hand wheel captive nut. For
check valves and small valves, the Contractor may provide rectangular labels
fitted to the valve or secured close by the valve.
Where the direction of flow through a valve or other device is an important
requirement for correct functioning, the body of the valve or device shall be
legibly marked with a cast on or alternatively, a properly secured arrow, showing
the direction of flow.
Pipe work shall be provided with plentiful large painted arrows or other secure
and durable arrow markings to allow the flows of fluids around the plant to be
readily understood.
In addition to the colour band coding, pipe work and vessels shall be liberally
labelled, in large painted letters on exterior of the insulation cladding, stating the
fluid conveyed or contained and the destination to which it is conveyed.
The identification pattern (Colour bands, Direction Indicator & Product/Fluid
Name) shall be repeated every 100 metres of piping length, at every turn of
piping and at every take off from the parent piping.
12.0 SAFETY AND SECURITY
The Plant and equipments shall meet the sound/noise level requirements for general
work area limits. Measured noise levels or Noise calculated from measurements after
application of allowances for background and other corrections and consideration of any
appropriate tolerances that are allowed in accordance with the given standards must not
exceed 80 dB.
All moving parts, shafts, couplings, flywheels, bare conductors and hot or cold surfaces
shall be adequately and securely guarded in accordance with the prescribed legislation
and to the Engineer’s approval so as to afford complete safety to all personnel.

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