Technical Documents 8787

PROCESS 32644-11-SE-T1201D/E
DATA SHEET
STORAGE TANK
PAGE 1 OF 1 R2
DESIGN DATA BRANCHES & INTERNALS SKETCH
1. Equipment No.: T-1201D/E No. Of: 2 (TWO) Tag Description Size No
2. Equipment Name: Phosphoric Acid Tanks A1 Inlet nozzle from sump 80 1
3. Type: Fixed Cone Roof (Vertical Cylindrical) A2 Inlet nozzle from ship 500 1 2
4. Material Handled: Phosphoric Acid1 Sp. Grt.: 1.72 A3,7 Inlet nozzle for circulation line 100 3
o
5. Vapor Pressure: negligible at 40 C A4 Inlet nozzle for circulation line 200 1 2
6. Op. / Design Pressure: Atm. / As per code A5,6 Inlet nozzle for circulation line 100 2
o
7. Op. / Design Temp.: 40 / 65 C B1,2 Outlet nozzle 250 2
8. Corrosion Allow. : Nil 2 As per code B3,4 Outlet nozzle 250 2
9. Design Code: API 650 O Overflow nozzle 200 1
10. Inside Dia.: 22,000 mm S1 Spare nozzle 150 1
11. St.Height / Length: 10,500 mm L1 Level indicator (radar) nozzle 100 1
12. MATERIALS L2 Level gauge (float) nozzle 250 3 2
13. Shell : IS 20623 Lining:Rubber Thk:10/5mm5 D1 Drain nozzle 200 1
3
14. Heads: IS 2062 Jacket: V Vent nozzle 200 1
15. Internal: M1-5 Roof Manhole 600 5
16. Nozzles: Carbon Steel with Rubber Lining. M6-7 Shell Manhole (Cleanout Door) 600X600 2
17. Supports: Brackets: INTERNALS & ACCESSORIES
18. Pipes, Internal:SS904L External: 1. Float and scale arrangement for level measurement
19. Painting, Internals: External: 2. Deleted 2
20. Insulation Type & Thk.:NA 2 3. Ship unloading line nozzle A2 shall be provided with dip pipe of 400 NB
21. Gaskets: PTFE size & circulation nozzle A4 shall be provided with dip pipe of 100NB size.
22. Others (List): Both the dip pipes shall extend up to centre line of overflow nozzle. 2 Nominal Capacity: 3480m3(5900MT) 2
23. Breather Valve Flame Arrester Foam Chamber Actual Capacity: 3064m3 2
Project: Construction of
Remarks: Additional Phosphoric
1. Phosphoric acid contains 54% P2O5, 2-4% Sulphuric Acid & 2 Comments Incorporated BV MR KVR 01/07/2020
Acid Storages at Q-10
1-2% Gypsum Solids.
1 Comments Incorporated BV MR KVR 19/06/2020 Berth, WI.
2. Specific gravity varies from 1.63 to 1.7
3. Mild steel as per IS 2062 0 Issued for Comments GKS AT VKS 10/12/2020
4. Nozzles shall be ASTM A 106 Gr.B Client: M/s. FACT-CD
11FT021/15
5. 10 mm for bottom & 5 mm for shell/roof Rev Details By Chkd. Apprd. Date
FACT ENGINEERING AND DESIGN ORGANISATION

PROCESS 32644-11-SE-P3202A/B
DATA SHEET
PUMP
PAGE 1 OF 1 R2
Equipment No. P-3202A/B
Equipment Name Phosphoric Acid Transfer Pumps
No. Of 1 Working 1 Standby & 0 Warehouse Standby
Type of Equipment Centrifugal Reciprocating ……….
Operating Conditions
Fluid Handled Phosphoric acid
Analysis 54% P2O5, 2-4%H2SO4, 1-2% Gypsum solids.
Pumping Temperature, oC 400C
Density &Viscosity at Pumping Temperature 1630 to 1700kg/m3 , 65 cP
Vapor Pressure at P.T & pH value Negligible
Operating Level Units Min / Normal / Maximum
Capacity m3/h / 175 / 175
Suction Pressure kg/cm2G 0.07 / 0.07 /
o
Suction Temperature C 40 2 / 40 / 40
Discharge Pressure kg/cm2G / 4.0 / 4.0
Differential Pressure kg/cm2 / 3.93 / 3.93
Priming
Net Positive Suction Head MLC Available:6.511 MLC Required (From Mfr.) …….
Duty Continuous / Intermittent
Drive Electric Motor Turbine Using ……….. ………………….
Capacity Control Local / Remote / Auto 2
Location Indoor / Outdoor
Area Hazardous / Non Hazardous
Necessity to start against system pressure Yes No
Material of Construction
Casing / Cylinders CD4MCu
Impeller / Pistons CD4MCu
Shaft CD4MCu
Drive Turbine Steam Details Normal Minimum Maximum
Inlet / Outlet Pressure, kg/cm2G / / /
Inlet / Outlet Temperature, oC / / /
Packing/Mechanical Seal Mechanical Seal 2
Flashing Arrangements (From Mfr) Self Flushing As per API Plan No. ……………………
Using …………………… at …… kg/cm2G & …..oC
Minimum Flow Requirements, m3/h (From Mfr.)
Shut-off Head (From Mfr.)
Remarks:
1. NPSH indicated is minimum considering Tank Pad Elevation as 1m,LLLL as 1.1m& Pump suction nozzle CL elevation as
0.8 m.
Additional Phosphoric
2 Issued for Comments BV MR KVR 01.07.2020
Acid Storage Tanks at
1 Issued for Comments BV MR KVR 19.06.2020 Q-10 Berth, WI
0 Issue for Comments BV MR KVR 08.06.2020
Client: M/s. FACT-CD
11FT028/15
Rev Details By Chkd. Apprd. Date

PROCESS 32644-11-SN-L001
DATA SHEET
LEVEL INSTRUMENTS
PAGE 1 OF 1 R1
Sl. No. 1
Tag No. LI-101/2
P&ID No. 32644-11-PD-001
Service / Location Storage Tank, T-1201D/E
Type Radar
Mounting (L/P) L (Note:2)& P
Fluid Phosphoric Acid (54% Conc.)
Min. & Max. Level, mm 1,100 & 9,160 1

Pressure, kg/cm2G Atmospheric
Temperature, oC Ambient
Density, kg/m3 1630 - 1700
Range, mm 0 – 10,500
Material Of Construction SS
Nozzle Size & Spec. 100 NB & ASTM A 106 Gr.B with Rubber Lining 1
Remarks
Notes:
1. Level Instrument shall Indicate, Transmit & Alarm.
2. Local indication shall be available at the ground level.
Additional Phosphoric Acid
Storage Tanks at Q-10
1 Issued for Comments BV MR KVR 01/07/2020 Berth, WI.
0 Issued for Comments BV MR KVR 08/06/2020
Client: M/s. FACT – CD
11FT005/15

PROCESS 32644-11-SE-P3203
DATA SHEET
PUMP
PAGE 1 OF 1 R1
Equipment No. P-3203A/B 1
Equipment Name Phosphoric Acid Sump Pump
No. Of 1 Working 1 1 Standby & 0 Warehouse Standby
Fluid Handled Phosphoric acid
Analysis 54% P2O5, 2-4%H2SO4, 1-2% Gypsum solids.
Density &Viscosity at Pumping Temperature 1630 to 1700 kg/m3 , 65 cP
Vapor Pressure at P.T & pH value Negligible
Suction Pressure kg/cm2G 0.034 / /
o
Suction Temperature C 40 / 40 / 40
2
Discharge Pressure kg/cm G / 4.4 / 4.4
Differential Pressure kg/cm2 / / 4.36
Priming
Capacity Control Local / Remote / Auto
Shaft CD4MCu
Packing/Mechanical Seal Mechanical Seal
Using …………………… at …… kg/cm2G & …..oC
Remarks:
1. NPSH indicated considering minimum submergence level as 200 mm
Acid Storage Tanks at
1 Issue for Comments BV MR KVR 01/07/2020 Q-10 Berth, WI.
0 Issue for Comments BV MR KVR 19/06/2020
11FT028/15

DATA SHEET
LEVEL INSTRUMENTS PAGE 1 OF 1 R1
1Si. No. 1
Tag No. LS-103
P&ID No. 32644-11-PD-001
Service / Location Phosphoric Acid/Sump Pit (S-1201)
Type Float type
Mounting (L/P) P
Fluid Phosphoric Acid (54% Conc.)
Minimum Level, mm NA 1
Density, kg/m3 1630 – 1700
Set point 350 mm1 from bottom
Material Of Construction PVC/Equivalent 1
Remarks
Notes:
1. Set point indicated is assuming pump minimum submergence level as 200 mm 1
Acid Storage Tanks at Q-
1 Issued for Comments BV MR KVR 01/07/2020 10 Berth, WI.
11FT005/15

PROCESS 32644-11-SN-P001
DATA SHEET
PRESSURE INSTRUMENTS
PAGE 1 OF 1 R1
Operating
Sl. Mounting Pressure Range Nozzle/Line
Tag No. P&ID No. Service/Location Type Temperature Remarks
No. (L/P) kg/cm2G o kg/cm2G Size & Spec.
C
1. PG-101 32644-11-PD-001 Liquid/200-PA-013A-1G10-NI Diaphragm L 4.0 40 0 - 10 50 NB & 1G10
2. PG-102 32644-11-PD-001 Liquid/200-PA-014A-1G10-NI Diaphragm L 4.0 40 0 - 10 50 NB & 1G10
3. PG-103 32644-11-PD-001 Liquid/80-PA-018C-1G10-NI Diaphragm L 4.4 40 0-10 50NB & 1G10
4. PG-104 32644-11-PD-001 Liquid/80-PA-018D-1G10-NI Diaphragm L 4.4 40 0-10 50NB & 1G10
5. PG-105 32644-11-PD-002 Liquid/80-WR-038-1G10-NI Diaphragm L 1 40 0-5 50NB & 1G10
Remarks: Project: Construction of

1. For Sl No.1 to 4, Liquid is 54% Phosphoric acid. Additional Phosphoric
2. For Sl No:5 Liquid is water. Acid Storage Tanks at
1 Issued for comments BV MR KVR 01/07/2020 Q-10 Berth, WI
0 First Issue BV MR KVR 30/06/2020
11FT003/15

PROCESS 32644-11-SP-001
DATA SHEET
PIPING SPECIFICATION
PAGE 1 OF 1 R0
Stream / Fluid Phosphoric Acid 54% Piping Class

Corrosion
Allowance Design
10.0 Rating 1G1O
Pressure, kg/cm2(G)
Design
1.5 mm 55 150#
Temperature, OC
Nominal Pipe Size, NB 50 80 100 150 200 250 300
Wall thickness Pipe Sch.40 Sch.40 Sch.40 Sch.40 Sch.20 Sch.20 Sch.20
mm/Schedule/Class Fittings Sch.40 Sch.40 Sch.40 Sch.40 Sch.20 Sch.20 Sch.20
Part Standard Specification

Pipe ANSI B 36.10 API 5L Gr.B SMLS for 50 NB to 200 NB, ERW for 250 NB & above.
Elbow R=1.5D ANSI B16. 9 ASTM A 234 WPB 50 NB to 200 NB, 3 weld mitre for 250NB & above.
Tee ANSI B16. 9 ASTM A 234 WPB 50 NB to 200 NB. Fabricated for 250NB & above.
Reducer ANSI B16. 9 ASTM A 234 WPB 50 NB to 200 NB. Fabricated for 250NB & above.
Cap
Saddle
Blind ANSI B 16.5 ASTM A 105, FF. Lined with 4mm thk Butyl rubber.
Flange SW
Slip-on ANSI B 16.5 ASTM A 105, FF, 50 NB AND ABOVE
Bolts&Nuts IS 1364/4218 STUD BOLT & HEX. NUTS, ASTM A 193 Gr B7/ A 194 Gr.2H
Gasket ANSI B 16.21 EPDM, FF, 5 mm thk
Gate Valve SW
FLGD
Check Valve SW
FLGD
Ball Valve FLGD BS 5351 Short pattern, Reduced bore, FF, Body & ball- A 351 Gr.CN7M
Diaphragm
FLGD BS 5156 Weir type, FF, Body-IS 210 Gr. FG 200, Lining &Diaphragm-Butyl rubber (Tag No: DV 110)
Valve
Remarks:
1. All pipes and fittings shall have flanged ends.
2. Maximum length of flanged pipe shall be 5500mm.
3. Internal surface and face of flange of each section shall be lined with 5 mm thk. Natural rubber.
4. Rubber lining and testing shall conform to IS 4682 (Part 1)
Acid Storages at Q-10
Berth, WI.
0 For Comments BV MR KVR 19/06/2020
Process Piping Process Piping Process Piping
Rev Details Date Client: M/s. FACT-CD
By Chkd. Apprd.

PROCESS 32644-11-PC-001
DATA SHEET
PIPING MATERIAL CLASSIFICATION
PAGE 1 OF 2 R0
Designation used for Piping material classification will consists of a four letter code “RBMS” as detailed below:
R B M S
Code for Rating Code for Base Material Code forMaterial Standards Code forSpecial Requirements
(See table 1 below) (See table 2 below) (See table 2 below) (See table 1 below)
Table1
Code for Rating Code for Special requirements
Code “R” Rating Code “S” Special requirements
0 125 # O No. special requirements
1 150 # S Seamless
3 300 # J Jacketed
6 600 # B IBR
T Tubing
-- --
-- --
X Unclassified (Duct) X Special service (Brick Lining)
Table 2
Code for Base Material Code for Material Standards
Code “B” Base Material Code “B” Material Standards
1 ASTM A106 GR.B
2 ASTM A53 GR.B
3 ASTM A333 GR.1
4 IS 226
A Carbon Steel
5 IS 1239
6 IS 2002
7 ASTM A516 GR.70
8
1 ATSM A204 GR.B
2 ASTM A387 GR.2
3 ASTM A335 GR.P11
4 ASTM A335 GR.P22
5
B Low Alloy Steel
6
7
8
9
10
1 ASTM A312 TP304
2 ASTM A312 TP304L
3 ASTM A312 TP316
C Stainless steel 4 ASTM A312 TP316L
5 ASTM A312 TP321
6 ASTM A312 TP321H
7 ASTM A240 TP304
10 Berth, WI
0 Issued For Comments BV MR KVR 19/06/2019
Client: M/S. FACT – CD
11FT038//15

PROCESS 32644-11-PC-001
DATA SHEET
PIPING MATERIAL CLASSIFICATION
PAGE 2 OF 2 R0
D Cast iron 1 CHROMIUM C. I.
E Galvanised iron 1 IS 1239 GALV.
1 HDPE
2 PVC
3 FRP
F Plastics
4
5
6
1 RUBBER
2 PTFE
3 GLASS
G Lined (Base Material A1O)
4 LEAD
5
6
H Non-ferrous metals 1 COPPER
I Graphite 1 IMPERVIOUS GRAPHITE
J Glass 1 BOROSILICATE GLASS
Remarks
10 Berth, WI
0 Issued For Comments BV MR KVR 19/06/2019
Client: M/S. FACT – CD
11FT038//15

PROCESS 32644-11-SE-P3204
DATA SHEET
PUMP
PAGE 1 OF 1 R0
Equipment No. P3204
Equipment Name Rain Water Pit Pump
No. Of 1 Working 0Standby & 0 Warehouse Standby
Fluid Handled Water
Analysis Water
Density &Viscosity at Pumping Temperature 1000 Kg/m3
Vapor Pressure at P.T & pH value 0.074Kg/cm2
Suction Pressure kg/cm2G -0.308 / /
o
Suction Temperature C 40 / 40 / 40
2
Discharge Pressure kg/cm G / 1 / 1
Differential Pressure kg/cm2 / / 1.308
Priming
Capacity Control Local / Remote / Auto
Shaft CD4MCu
Packing/Mechanical Seal Packing
Using …………………… at …… kg/cm2G & …..oC
Remarks:
1. Maximum elevation for discharge head is assumed as 5 meters.
Project: : Construction of
10 Berth, WI.
0 Issue for Comments BV MR KVR 30/06/2020
11FT028/15

DATA SHEET
LEVEL INSTRUMENTS PAGE 1 OF 1 R0
Si. No. 1
Tag No. LS-104
P&ID No. 32644-11-PD-002
Service / Location Rain Water Sump Pit (S-1202)
Type Float type
Mounting (L/P) P
Fluid Water
Minimum Level, mm NA
Density, kg/m3 1000
Set point 350 mm1 from bottom
Material Of Construction PVC Equivalent
Remarks
Notes:
1. Set point indicated is assuming pump minimum submergence level as 200 mm.
Project: : Construction of
10 Berth, WI.
11FT005/15

TECHNICAL
PROCUREMENT
32644-02-PS-001AT
ATTACHMENTS
SPECIFICATION PAGE 1 OF 1 R4
No. of Rev. No. with Issue
S.No. Doc. No. Description
pages 1 2 3 4 5 6
1 32644-02-PS-001 SW Scope of Work - Storage Tanks 2 A 0 0 0 0 0
2 32644-01-PS-001 SW Scope of Work - Pumps 2 - 0 0 0 0 0
3 32644-02-PS-001 SPL Special Requirement of the Project - Storage Tanks 5 A 0 0 1 1 1
4 32644-01-PS-001 SPL Special Requirement of the Project - Pumps 5 - 0 0 0 0 1
5 32644-02-PS-001 VDR Vendor Data Requirements - Storage Tanks 1 A 0 0 0 0 0
6 32644-01-PS-001 VDR Vendor Data Requirements - Pumps 1 A 0 0 0 0 0
7 32644-01-PS-001 INS Scope of Inspection and Tests - Pumps 1 A 0 0 0 0 0
8 32644-02-PS-001 VDI Vendor Data Index 1 A 0 0 0 0 0
9 32644-02-PS-001 SPR Spares - Storage Tanks 1 A 0 0 0 0 0
10 32644-01-PS-001 SPR Spares - Pumps 1 A 0 0 0 0 1
11 32644-01-PS-001 LD Equipment Lubrication data sheet 1 A 0 0 0 0 0
12 32644-01-PS-001 SV Sub Vendor List 1 A 0 0 0 0 0
DATA SHEET & DRAWINGS
13 32644-01-DA-001 Data Sheet Phosphoric Acid Transfer Pumps 3 - 0 0 1 1 2
14 32644-01-DA-002 Data Sheet Phosphoric Acid Sump Pumps 5 - A A 0 0 1
15 32644-01-DA-003 Data Sheet Rain Water Pit Pump 3 0
Dwg. for Phosphoric Acid Storage Tank
16 32644-02-DG-10618 1 A 0 1 2 2 3
(T-1201 D / E)
ENGINEERING SPECIFICATIONS
17 02 ES 001 / 2010 Vendor Data Submission Procedure 4 - - - - - -
18 02 ES 032 / 2010 Storage Tank 11 - - - - - -
19 02 ES 023 / 2010 Painting 13 - - - - - -
20 02 ES 030 / 2010 Rubber Lining 9 - - - - - -
21 02 ES 041 / 2010 Anchor Bolt 2 - - - - - -
22 01ES 010 / 94 Centrifugal Pump for General Purpose 7 - - - - - -
23 01ES067 / 19 Centrifugal Pump for Heavy Duty Service 5 - - - - - -
DESIGN STANDARDS
24 02 DS 002 / 2010 Anchor Bolt 3 - - - - - -
25 02 DS 006 / 2010 Earthing Boss 1 - - - - - -
26 02 DS 020 / 2010 Name Plate 3 - - - - - -
27 02 DS 022 / 2010 Platforms 1 0 0 0 0 0 0
28 02 DS 027 / 2010 Spiral Stairway 2 0 0 0 0 0 0
29 02 DS 029 / 2010 Storage Tanks Accessories 5 - - - - - -
30 02 DS 007 / 2010 Float Level Indicator 2 1 1 1 1 1 1
PRICE BID
31 32644-02-PS-001 SIW Schedule of Items of Work - Mechanical 1 A 0 1 1 2 3
32 32644-02-PS-001 RN Rate of Addition/Deletion of Nozzles 1 A 0 0 1 1 1

Note : 1. The receipt of all attachments shall be checked and asertained.
2. All attachments of this TPS shall be retained since only revised sheets, if any, shall be issued.
4 06.07.20 Revised as marked GPG SK AAN
0 10.06.20 Tank capacity revised GPG SK AAN
A 05.05.20 For Review GPG SK AAN
REV.NO. DATE DESCRIPTION PREPD CHKD APPRD

TECHNICAL SCOPE OF WORK 32644-02-PS-001 SW
PROCUREMENT
SPECIFICATION STORAGE TANK PAGE 1 OF 2 R0
ITEM: PHOSPHORIC ACID STORAGE TANKS (2 nos.) (space for vendor’s name, signature & seal)
EQPT. Nos.:
1 T - 1201 D/E
The scope of work for the equipment listed above shall include design, manufacture, supply of material and engineering work as tick
marked below. Vendor shall fill in the column marked as “offer from vendor” and return the same along with the offer, without which the
offer will be considered as incomplete.
Sl. Sl. Offer from

Description Reqd. Offer from vendor Description Reqd.
No No vendor
1 Detailed design YES 23 Inspection YES

2 Drawing Preparation YES 24 Third party inspection NO
Submission of Drawings for CCE
3 YES 25 NO
documents as per VDR Approval
Procurement of
4 YES 26 Calibration YES
materials
5 Fabrication YES
6 Testing and Inspection YES Equipment components
7 Shop assembly NO 27 Shell YES
8 Site assembly YES 28 Shell stiffeners YES

9 Equipment erection YES 29 Roof YES
External surface Roof Stiffeners / Curb
10 YES 30 YES
preparation angle.
11 Painting (CS) YES 31 Roof support structure YES
12 Internal Rubber Lining YES 32 Bottom plate YES
Corrosion inhibitor for
13 NO 33 Nozzles YES
internal surface
Corrosion inhibitor for
14 NO 34 Flanges YES
external surface
Companion flanges / bolts
/ nuts / gaskets for
15 Pickling NO 35 YES
nozzles (for Manway &
spare nozzles only)
16 Passivation NO 36 Bolts, nuts & gaskets YES
17 Hydrotest at shop NO 37 Wind girder, if required YES
18 Hydrotest at site YES 38 Agitator supports NO
19 Pneumatic test at shop NO 39 Platform & Handrails YES
20 Pneumatic test at site YES 40 Ladder NO
Packing, marking and
21 NO 41 Spiral Stairway YES
forwarding
Supply of spares as
22 YES 42 Gauge Hatch NO
per spare part list

00FT013/94

00FT013/94
REV. NO. DATE DESCRIPTION PRPD CHKD APPRD

TECHNICAL 32644-02-PS-001-SW
SCOPE OF WORK
PROCUREMENT
Sl. Offer from Sl. Offer from

Description Reqd. Description Reqd.
No vendor No vendor
42 Supporting leg/bracket NO
43 Anchor frame NO
44 Anchor bolts/nuts NO
45 Template for base ring NO
Supporting frame for
46 NO
connected equipments.
Internals:
47 Wire mesh NO
48 Demister & supports NO
Internal pipes, flanges,
49 supports, bolts, nuts & NO
gaskets
50 Baffles NO
51 Internal ladder rungs NO
Internal clips / anchors etc.
52 NO
for lining
53 Refractory / castable lining NO
External attachments:
54 Insulation clips NO
55 Fire proofing clips NO
Platform & ladder clips YES
56 Pipe support clips YES
Support clips & brackets for
57 NO
other eqpt.
Manhole/hand hole
58 YES
davit/hinge
59 Name plate YES
60 Earthing boss YES
62 Tank bottom/drain noz. YES
Relief valve / Breather valve
63 NO
with sight glass
64 Wind analysis YES
65 Seismic analysis YES
66 Overflow nozzles (As Rqd) YES
67 Flame Arrestor NO
68 Foam Chamber NO
69 Safety Plug NO
70 Float Level Indicator YES

TECHNICAL
SCOPE OF WORK 32644-01-PS-001 SW
PROCUREMENT
SPECIFICATION (Phosphoric Acid Pump) PAGE 1 OF 2
TPS NO. 32644-
ITEM : CENTRIFUGAL PUMP
EQPT. NO.
The scope of work for the equipments listed above shall include design,manufacture ,supply of materials
and engineering work as detailed below.
Sl.
Description Reqd. Remarks
No
1.0 Pump X
2.0 Auxiliary piping within the confines of the baseplate
Casing drain and vent piping with valve & flanged connection X
Cooling water piping inlet & outlet valves with flanged connection X IF APPLICABLE
Self or external flushing piping with flanged connection X IF APPLICABLE
Quench water or steam piping with flanged connection & traps X For jacketed pumps
3.0 Coupling with nonspark coupling guard
Between pump and driver X
Between pump and gear
Between gear and driver
4.0 Base
4.1 Common baseplate
For pump & driver X MOC: SS 316 L
For pump & gear
For pump, gear & driver
4.2 Separate baseplate
4.3 Mounting flange for pump
5.0 Lube oil system X
5.1 Common oil system for pump and gear / driver
5.2 Oil system for pump only
5.3 Complete lube oil system including X As applicable
Shaft driven main pump
Motor driven standby pump
5.4 Interconnecting lube oil piping X
Between oil console and pump
6.0 Gear unit
7.0 Inspection and testing X
0 09-06-2020 FOR ENQUIRY LA SK AAN

01FT010/94-R1
REV.NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

TECHNICAL
SCOPE OF WORK 32644-01-PS-001 SW
PROCUREMENT
SPECIFICATION (Phosphoric Acid Pump) PAGE 2 OF 2 R0
Sl.
Description Reqd. Remarks
No
8.0 Painting
Prime coating only
Prime coating and finish paint X
9.0 Packing
Domestic packing X
Export packing X IF APPLICABLE
Rust prevention for long term storage X 6 months
10.0 Special tools X IF ANY
11.0 Spare parts
Construction and commissioning X
Mandatory Spares X
Two years operation - ( Purchaser reserves full right to (Shall not be considered for
purchase or not to purchase the item fully or partially as per X
price bid evaluation)
rate quoted by the vendor.)
12.0 Foundation bolts and nuts X MoC - SS 316L
13.0 Driver
Main electric motor for pump X
14.0 Mounting driver
Mounting driver on baseplate X
Mounting driver half coupling X
Provide shim plates and set bolts for mounting driver X
15.0 Miscellaneous
Noise attenuation cover * * (If required)
Level switch for sump pump
Strainer for sump pump suction
Minimum flow recirculation valve
Mechanical Seal X
16.0 Erection X
17.0 Commissioning X
18.0 Drawings & documents X As per VDR
01FT010/94-R1

TECHNICAL 32644–02–PS–001-SPL
SPECIAL REQUIREMENTS OF THE PROJECT
PROCUREMENT
PHOSPHORIC ACID STORAGE TANKS Page 1 of 5 R1
SPECIFICATION
TPS NO. : -
ITEM : PHOSPHORIC ACID STORAGE TANK (2 NO’S.)
ITEM NO. : T 1201 D / E
CONSTRUCTION OF PHOSPHORIC ACID STORAGE

PROJECT : TANKS AND ASSOCIATED FACILITIES AT Q10 BERTH,
WI.
CLIENT : FACT-CD
LOCATION : W.ISLAND
1 22-06-2020 Revised as marked GPG SK AAN

0 10-06-2020 Tank capacity revised GPG SK AAN
A 08-05-2020 For Review GPG SK AAN
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

PROCUREMENT
SPECIFICATION
1.0 GENERAL DESCRIPTION
FACT-CD has proposes to install 2 nos. additional Phosphoric Acid Storage Tanks &
associated facilities at W. Island adjacent to the existing three tanks for the purpose of
improving the Phosphoric Acid handling capability as a part of new NP Plant.
2.0 SCOPE OF WORK
The EPC Contractor scope includes but not limited to the following:
2.1 Design of the equipment based on the data sheet, drawing and specifications listed in the
“Attachments” sheet.
2.2 Detailed Engineering.
2.3 Submission of mechanical design calculations and fabrication drawings for review by
FEDO/FACT-CD
2.4 Submission of Drawings / Documents as per Vendor Data Requirements (Doc.No. 32644-02-
PS-001-VDR).
2.5 Vendor shall do the Wind and Seismic analysis and submit the same for review by
FEDO/FACT-CD.
2.6 Procurement of all materials and bought-out items such as CS plates and structurals, nozzle
pipes and flanges, anchor bolts and fasteners, material for Rubber lining, materials for
painting, etc.
2.7 Preparation and obtaining approval of Welding Procedure Specification, Procedure
Qualification Record and Welder Performance Qualification.
2.8 Fabrication and Erection of the equipment at site.
2.9 Inspection and Testing of the Tanks including Hydro Testing and submission of Testing
Procedure for approval by FEDO/FACT-CD.
2.10 Painting of the storage tank and structurals attached to the tank including supply of materials.
2.11 Rubber lining of the Storage Tank including supply of materials.
2.12 Pad plates for fixing brackets, pipe supports etc.
2.13 Pad plates and cleats required for fixing platforms and stairways.
2.14 Structurals such as stairway, hand rails and platforms.
2.15 Calibration of the Tanks.
2.16 Connected piping including Supply, Fabrication & Erection as per Schedule of Items of
Work, Specifications and Drawings attached.
2.17 Supply of Spare Parts as per Spare parts list (Doc.No. 32644-02- PS- 001-SPR).
2.17 Any other items covered in Doc. No. 32644-02-PS-001-SW and other documents / drawings
attached with the enquiry but not specifically mentioned above.
3.0 DESIGN
3.1 APPLICABLE CODES & STANDARDS
CODES DESCRIPTION
IS 803 : 1976(R2005) Code of Practice for Design Fabrication and Erection
of Vertical Mild Steel Cylindrical Welded Oil Storage

PROCUREMENT
SPECIFICATION
CODES DESCRIPTION
Tanks
th
API 650, 12 Ed. Inc. Add.3 Errata 2
Welded Steel Tanks for Oil Storage
Annex I
Code of Practice for Lining of Vessels and Equipment
IS 4682-1 : 1994
for Chemical Processes - part 1: Rubber Lining
IS 875(Part 3) : 2015 Amendment 1 Design loads (Other than Earthquake) for Buildings
and structures Part 3 -Wind Loads.
Criteria for Earthquake Resistant Design Structures
IS 1893 (Part 1) : 2016
Part 1 – General Provisions and Building.
Criteria for Earthquake Resistant Design Structures
IS 1893 (Part 4) : 2015 Part 4 – Industrial structures including Stack like
structures.
IS 2062 : 2011 Hot Rolled Steel for Medium and High Tensile
Structural Purposes
ASME/ANSI Pipes, Flanges, Fittings and Valves
3.2 Tank shall be designed in accordance with IS 803/IS 800 & Good Engineering Practice.
3.3 Tank bottom plate shall be designed in accordance with Annex I of API 650 Twelfth Ed.
3.4 The thickness shown in the drawings indicate only the minimum requirements. The EPC
Contractor shall check and satisfy the same before quoting. Any additional claim due to
increase in thickness / weight while doing the detailed design shall not be entertained.
3.5 The EPC Contractor shall design roof stiffeners for the tank. The structural for roof stiffeners
for tank shall be provided outside the roof, above the roof plates.
3.6 For wind load and seismic calculation actual specific gravity of the product shall be used.
3.7 Wind loading in accordance with Indian Standard Code IS: 875 (Part-3) shall be applied.
3.8 The Seismic Design shall be as per Indian Standard IS 1893 Part 1 & Part 4.
4.0 MATERIALS
4.1 EPC Contractor shall furnish complete, item wise MTO in the drawing.
4.2 Structural steel shall conform to IS 2062 or equivalent of weldable quality.
4.3 All the materials including CS plates required for shell, roof and bottom of the tank, pipes and
flanges required for nozzles, structurals required for roof and shell stiffeners / wind girders,
ladder, platforms, anchor bolts & fasteners etc, shall be supplied by Contractor.
4.4 All internal materials shall be of SS 904L.
4.5 All materials supplied by the EPC Contractor shall meet the requirements of applicable codes
and standards. Test Certificates for the materials shall be submitted for approval by
FEDO/FACT-CD.
4.6 Prior written permission shall be obtained from FEDO/FACT-CD for any change in the
material specification.
5.0 TESTING & INSPECTION
5.1 FEDO/FACT-CD or their representative shall carry out inspection at various stages of
fabrication/procurement, including raw material identification.

PROCUREMENT
SPECIFICATION
5.2 EPC Contractor shall submit a detailed Quality Assurance Plan (QAP) and Inspection Test
Plan (ITP) for review and approval by M/s FEDO/FACT-CD.
5.3 Approval of work by M/s FEDO/FACT-CD shall in no way relieve the EPC Contractor of his
responsibility in meeting all the provisions of the Enquiry conditions.
5.4 Testing of Tank shall be as per the relevant sections of Design Code.
6.0 RUBBER LINING
6.1 The entire (shell, bottom plate, roof plate and nozzles) inner surface of tank shall be Rubber
Lined.
6.2 Internal Rubber lining shall be provided for the tank, 5 mm thick rubber lining shall be
provided for the walls and roof and 10 mm thick rubber lining shall be provided for the
bottom plates and walls up to 1 Metre from bottom.
6.3 The lining shall be of soft Butyl Rubber. The cured hardness of the rubber lining shall be 650
+/- 50 Shore A.
6.4 For detailed specification of rubber lining refer FEDO Engineering Specification
02ES030/2010.
6.5 The tank shall be fabricated in such a manner that it complies with the requirements of IS
4682 – Part 1.
7.0 PAINTING.
7.1 For detailed specification of painting refer FEDO specification for painting 02 ES 023/2010.
7.2 Tank (Plates and structural sections) shall be painted as follows.
7.2.1 Primer – Chlorinated Rubber Based High Build Zinc Phosphate–2 coats of 20 microns each
after Shot / Grit blasting.
7.2.2 Finish Paint - Chlorinated Rubber Paint - 2 coats of 20 microns each.
7.3 The bottom side (underside) of the bottom plate is painted as follows.
7.3.1 Primer–Chlorinated Rubber Based High Build Zinc Phosphate–2 coats of 20 microns each
after Shot/Grit blasting.
7.3.2 Finish Paint- Bituminous Paint - 2 coats of 20 microns each.
7.4 Tank Numbers, Capacities and Name of the products stored shall be painted on the tank at
two locations in yellow color, in suitable sizes as per the directions of M/s FEDO/FACT-CD.
8.0 GENERAL
8.1 Relevant IS codes shall be followed. Entire work shall be carried out in accordance with
relevant standards and accepted codes of practices.
8.2 All butt welds shall have full penetration. When welding is carried out from both sides of a
joint, the root of first side shall be dressed back to sound metal before commencement of
weld on second side.
8.3 Structural items shall not be welded directly to the tank. Pad plates of the same material as the
shell plate shall be provided for this purpose.
8.4 All necessary cleats and pad plates required for platforms and ladders and pipe support cleats
are to be provided.
8.5 Earthing Boss shall be provided on Tank as per FEDO standard 02 DS 006/2010.
8.6 Name Plates shall be provided on Tank as per FEDO standard 02 DS 020/2010.

PROCUREMENT
SPECIFICATION
8.7 All internal weld joints shall be ground smooth before hydro testing is carried out.
8.8 Float Level Indicator of Type B shall be provided on Tank as per FEDO Standard
02DS007/2010. Material of construction of Float, Rope & Guide wire shall be SS904L. Level
Indicator Nozzle size shall be selected in such a way that float shall be removed & re-installed
through the nozzle. Preferred float diameter shall be 200 mm.
8.9 Circumferential Handrail, central walkway, central platform for accessing vent nozzle and
Inter-connecting platform between both tanks shall be provided on roof.
9.0 GUARANTEE
9.1 The equipment and parts shall be guaranteed against defects in design, materials,
workmanship and performance for a period stipulated in the commercial conditions of this
enquiry.
10.0 DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER
10.1 Dimensioned sketch of the Tank (General Arrangement drg. with detailed MTO) along with
the loading data.
10.2 Quality Assurance Plan.
10.3 Duly filled Scope of Work (Doc. No. 32644-02-PS-001-SW).
10.4 Duly filled Spare Parts List (Doc. No. 32644-02-PS-001-SPR).
10.5 Duly filled Vendor Data Requirements (Doc. No. 32644-02-PS-001-VDR).
***********************

Page 1 of 5
TECHNICAL 32644 -01-SPL-001
PROCUREMENT SPECIAL REQUIREMENT OF THE PROJECT
SPECIFICATION (PHOSPHORIC ACID PUMPS) Page 1 of 5 R1
1.0 INTRODUCTION
1.1 FACT-CD has proposes to install 2 nos. additional Phosphoric Acid Storage Tanks & associated
facilities at W. Island on EPC basis, adjacent to the existing three tanks for the purpose of improving
the Phosphoric Acid handling capability as part of new NP Plant.
1.2 Two numbers of Phosphoric acid truck loading pumps (1W+ 1S) with drive motors, two number of
Phosphoric acid sump pump (1W+1S) with drive motor, and one number of Rain Water pit pump
(1W) with drive motor, with all accessories for these pumps are required as part of aforesaid facility
at Q10 Berth, WI. Kochi.
1.3 The scope of work of the EPC contractor shall include the Design, Manufacture, Inspection, Testing,
Painting, Insurance, Supply, Erection supervision & Commissioning of the equipment with all
accessories, Training of owner’s personnel and Handing over the system to M/s. FACT- Cochin
Division as per the Technical Procurement Specification.
2.0 GENERAL
2.1 All documents as detailed in ‘Vendor Data Submission Procedure” & “Vendor Data Requirements”
shall be submitted by EPC contractor for review by FEDO.
2.2 All items indicated in “Scope of Work” attached shall be included in the Scope of EPC contractor.
Any item required for the safe and efficient operation of the system whether specifically mentioned
or not, shall be provided by the EPC contractor without extra cost.
2.3 Inspection / Tests shall be carried out by Vendor as detailed in “Scope of Inspection and Tests”.
Witnessing of tests where specified will be done by CLIENT/ FEDO or their authorized
representative.
2.4 Data sheets of Pumps are enclosed. EPC contractor shall submit all data sheets duly filled up along
with other documents/drawings indicated in “Vendor Data Requirements”, along with the offer.
Changes if any required for meeting system /operational requirements shall be indicated along with
reasons thereof.
2.5 Bidders or Representative of bidders shall visit the site and familiarize themselves of the site
conditions before submitting their bid with prior permission from CLIENT. The bidder shall collect
the necessary additional data as well as purchaser’s requirements before quoting so that full
coverage of the scope will be ensured in the offer itself.
1 06/07/20 For Enquiry - Revised LA SK AAN

0 09/06/20 Client Review LA SK AAN
00FT021A/94
REV. No. DATE DESCRIPTION PREPARED CHECKED APPROVED

SPECIFICATION Page 2 of 5 R1
2.6 First Fill of Lubricant, Mandatory Spares, Start-up and Commissioning spares, spares for two years
normal operation and Consumables for Testing, Commissioning and establishing Guarantees shall
be included in the scope of the EPC contractor.
2.7 Special tools required if any, for the normal operation and maintenance of the equipment shall be
included in the scope of the EPC contractor. Details of such special tools shall be furnished.
2.8 All equipment shall be properly tagged, packed, securely anchored and protected for domestic
shipment by rail / truck or suitable for ocean transport as the case may be. Rust inhibitors shall be
applied to the equipment to prevent rusting during shipment and site storage for minimum of 6
months.
2.9 EPC contractor shall submit a procedure/methodology for the Performance Guarantee Test Run
(PGTR) in the offer stage itself.
2.10 EPC contractor shall submit a Quality Assurance Policy for the system in the offer stage itself.
2.11 The equipment shall be as per the manufacturer’s standard.
2.12 All safety devices to protect the equipment from damage due to conditions of overload shall be
incorporated as per standard practice.
2.13 Corrosion allowance on carbon steel parts of equipment shall be 3 mm on thickness unless
otherwise specified.
2.14 Bought out items shall be from Sub Vendor list attached. Additional Sub Vendors if required by EPC
contractor shall be included only on approval by Purchaser. Any delay due to this shall be to EPC
contractor account.
2.15 Deviations if any from the Specifications shall be clearly spelt out in the “Compliance Statement”
attached failing which it will be taken to understand that there are no deviations from the
Specifications.
3.0 TECHNICAL
3.0.1 Design and documents of the system shall be in accordance with manufacturer’s standard.
3.0.2 Pumps duty shall be continuous.
3.0.3 Pumps shall have stable head / flow rate curves (continuous head rise to shutoff) for all
applications. If parallel operation is specified, the head rise from rated point to shutoff shall be at
least 10%. Unless otherwise specified, discharge orifice shall not be used to achieve required head
rise to shut off in case of parallel operation.
3.0.4 Unless specified otherwise, the maximum permissible sound level shall not exceed 88 dBA
measured at one (1) meter from the complete pump unit, when measured in any direction & from
any point of any equipment surface located on the equipment skid, for the recommended range of
operation.
00FT021B/94

3.0.5 Data sheets of Pumps are enclosed. All the specifications/ parameters specified in the data sheet
are the minimum requirements to be established by the EPC contractor, any additional
requirements/changes required for the safe and satisfactory functioning of the equipment shall be
indicated along with reasons thereof in the offer stage itself.
3.0.6 Pump shut-off pressure should not exceed 20% of rated discharge pressure.
3.0.7 Pumps offered shall have a minimum margin of NPSHA over NPSHR of 0.6 meter.
3.0.8 By changing the impeller it should be possible to attain 5% increase in discharge head over rated
discharge head.
3.0.9 Pumps shall be tested at shop with job motor in presence of authorized representative of Client
/FEDO.
3.0.10 Base plate shall cover full length of pump and motor.
3.0.11 Pump shall be designed to withstand the external forces and moments calculated in accordance
with API 610.
3.0.12 EPC contractor shall indicate Latest ASTM material designation for the parts used for the
equipment and accessories, etc.
3.0.13 EPC contractor to include any additional accessory and / or material in their scope of supply
required to meet the specified performance and guarantees, for satisfactory operation of
equipment, safe and reliable start up, normal shut down and emergency shut down and state
the same in specification sheet attached to the technical offer
3.0.14 Equipment shall be with direct drive without gear box.
3.0.15 For Electrics, specification indicated elsewhere in this Tender shall be followed.
3.0.16 Unless otherwise specified, equipment shall be designed to be suitable for outdoor installation
without a roof.
3.0.17 EPC contractor shall establish all guarantees as specified. Defect or shortfall in performance shall be
rectified by the EPC contractor within reasonable time failing which Purchaser (Owner) will make
arrangements to rectify the same at the risk and cost of the EPC contractor. All Performance
parameters specified in the data sheets, special requirements and engineering specifications
including Head and capacity of the pump at rated point without negative tolerance, NPSHR
requirements, shut off head, power consumption etc shall be guaranteed.
4.0 SPARE PARTS
4.1 General
4.1.1 The bidder shall include in his scope of supply all the start-up and commissioning spares, mandatory
spares and recommended two years operation spares and indicate these in the relevant schedules.
The general requirements pertaining to the supply of these spares is given below:
00FT021B/94

4.1.2 The EPC contractor shall also indicate the unit wise population of each item and the service
expectancy period for the spare parts under normal operating conditions before order placement.
4.1.3 All spares supplied under this contract shall be strictly interchangeable with the parts for which
they are intended for replacements. The spares shall be treated and packed for long storage under
the climatic conditions prevailing at the site, e.g. small items shall be packed in sealed transparent
plastic bags with dissector packs as necessary.
4.1.4 Each spare part shall be clearly marked or labeled on the outside of the packing with the
description. When more than one spare part is packed in single case, a general description of
contents shall be on the outside of such case and a detailed list enclosed. All cases, containers and
other packages must be suitably marked and numbered for the purpose of identification.
4.1.5 The EPC contractor shall provide the purchaser all the addresses and specification of his sub-
suppliers while placing the order on vendors for items / components / equipment covered under
purchase order and will further ensure with his vendors that the purchaser, if so desires, will have
the right to place order for spares directly on them on mutually agreed terms based on offers of
such vendors.
4.1.6 No Mandatory spares and recommended spares for 2 years will be used during startup and
commissioning of the equipment
4.2 MANDATORY SPARES PARTS
4.2.1 The mandatory spares, which are considered as essential by the purchaser are listed and attached
with the TPS.
4.2.2 The ƋŽƵƚĞĚprices ƐŚĂůůďĞŝŶĐůƵƐŝǀĞĐŽƐƚŽĨ mandatory spares indicated by the bidder͘
4.3 RECOMMENDED SPARES FOR 2 YEARS OPERATION
4.3.1 The Bidders shall submit the list including unit & quantity of recommended spares for two years
normal operation & maintenance in un-priced part as per format͘
.
4.3.2 The Purchaser reserves the right to buy any or all recommended spares.
4.4. START-UP & COMMISSIONING SPARES
4.4.1 Start-up commissioning spares are those spares which may be required during the start-up and
commissioning of the equipment/system. All spares used until the system is handed over to the
Purchaser shall come under this category. The EPC contractor shall procure and supply spare parts
00FT021B/94
for start-up and commissioning and shall be included in his scope of work without any extra cost to

purchaser. The quoted price in the price bid (supply) shall be deemed to be inclusive of provision for
such spares and additional spares.
5.0 TESTING & INSPECTION:
5.1 Pump testing shall be in accordance with API 610.

5.2 All equipment shall be subjected to inspection by Owner / authorized representative at all stages,
before, during and after manufacture.
5.3 Owner or their representative shall have free access to the works of the EPC contractor or his
subcontractors (if any) to carry out the inspection of all items covered under the scope of work. EPC
contractor shall submit a detailed quality assurance plan for review and approval by FEDO/FACT.
5.4 Equipment shall be tested at shop in the presence of authorized representative of FACT / FEDO.
5.5 Approval of work by FEDO / FACT shall in no way relieve the EPC contractor of his responsibility in
meeting all the provisions of the enquiry conditions.
5.6 Bidders shall provide a minimum of 10 days advance notice to Owner to arrange the inspection as
per agreed QAP / Inspection Test Plan (ITP).
5.7 The EPC contractor shall operate the equipment initially under his supervision after mechanical
erection. Once the system is stabilized / commissioned, the system shall be operated by M/s. FACT
in the presence of EPC contractor. The EPC contractor shall impart necessary training and assist the
owner to operate the system under his supervision.
6.0 PAINTING & PROTECTION:
6.1 All exposed parts other than SS / Machined surfaces, prior to painting, shall be blast cleaned to SA
2½ in an environment of relative humidity not exceeding 80%.
6.2 After surface preparation the protective painting shall done on all exposed parts other than SS as
follows,
a) Primer (at shop) : One coat of anti corrosive epoxy primer @ 50 µ DFT (min).
b) Intermediate coat (at shop) : One coat of anti corrosive epoxy paint @ 50 µ DFT(min)
c) Finish coat ( at site ) : One coat of anti corrosive epoxy paint @ 50 µ DFT(min).
6.3 All exposed machined surfaces and internals shall be protected against rusting, before dispatch,
suitable for 6 months of storage.
7.0 ERECTION & COMMISSIONING
7.1 Erection of the new equipment shall be under the scope of EPC Contractor.
7.2 Commissioning of the new equipment shall be under the scope of EPC contractor.
00FT021B/94
**********

TECHNICAL VENDOR DATA REQUIREMENTS
32644-02-PS-001 VDR
PROCUREMENT STORAGE TANK
CONSTRUCTION OF PHOSPHORIC ACID

PROJECT : STORAGE TANKS AND ASSOCIATED ITEM : T 1201 D / E
FACILITIES AT Q10 BERTH, WI (2 NO’S)
CLIENT : FACT-CD TPS No. -
STATUS X ENQUIRY COMMITMENT P.O No.

Qty. After Commitment Qty. of final
Sl. Grp
Description with Lead time in weeks docs. (@@ )
No. Code Qty.
offer Reqd. Propd @ Agrd
1 A Drawing Index 1S 4
2 A General Arrangement drawing 1S 1S 4
3 A Foundation loading diagram 1S 1S 4
4 B Detailed fabrication drawing of the following 1S 4 4P+1S
Shell and bottom plate
Roof & roof structure
Nozzles and flanges
Internals, pipes, coils, supports etc.
Platforms & ladders
External stiffeners, clips, pipe supports
5 B Internal rubber lining details 1S 6
6 B Design calculations for the following 1S 4 4P+1S
Shell, bottom plate
Roof, roof stiffeners & roof structure
Wind girder & wind analysis
Earth quake analysis
Anchor design
7 B Quality Assurance Plan 1S 4 4P+1S
8 B WPS & PQR 1S 4 4P+1S
9 A Bar-chart for anticipated activities 1S
10 A Manpower allocation chart for the site work 1S
11 A Site erection / assembly procedure 1S 4
12 B Hydrostatic test procedure 1S 8 4P+1S
13 B Rubber Lining application and Test Procedure 1S 8 4P+1S
14 C Data folder with the following documents

Drawing Index 4P+1S
As-built drawings 4P+1S
Quality Assurance Plan 4P+1S
WPS / PQR 4P+1S
Material test certificates 4P+1S
Inspection test reports 4P+1S
Hydrostatic test report 4P+1S
FRV Lining test report 4P+1S
Design calculations 4P+1S
Rubbing of name plate 4P+1S
Legend : Group code : A - For review and detailed engineering, B - For review, C - For information and record
Document type : R - Reproducible, P - Print, M - Microfilm. or Floppies
S- Soft copy in Autocad/ MS word/Adobe Acrobat.
Notes : @ Vendor shall fill in proposed lead time if different from the required lead time.
@@ Each set of final documents shall be submitted in a folder. Two such folders shall be packed and despatched
with the equipment. Balance documents shall be forwarded to FEDO.

00FT017/00

TECHNICAL
VENDOR DATA REQUIREMENTS 32644-01-PS-001 VDR
PROCUREMENT
PROJECT : Construction of Additional Phosphoric Acid ITEM : CENTRIFUGAL PUMP

Storage Tanks at Q10 Berth, WI
CLIENT : FACT CD TPS No : 32644-
STATUS : x ENQUIRY COMMITMENT PO No :
Sl. Grp Offer After Commitment Final@@

No Code Description Lead time in weeks Qty
Qty Qty
Reqd Prop@ Agrd
1.0 A
Data sheets 1S 1S 4 1P+1S
2.0 A
Predicted performance curves 1S 1S 4 1P+1S
3.0 A
Dimensioned G. A drawings 1S 1S 4 1P+1S
4.0 A
Foundation plan with load details 1S 4 1P+1S
5.0 A
Foundation bolt details 1S 4
6.0 B
Cross section drawing with list of parts and 1S 1S 4 1P+1S
material of construction
7.0 B Mechanical seal drawings 1S 4 1P+1S
8.0 B Auxiliary piping drawing
9.0 B & C Inspection and test procedure 1S 4
10.0 B Spares list for two years normal operation 1S
11.0 B Spares list Mandatory Spares 1S 1S 6
12.0 B Coupling drawings 1S 6 1P+1S
13.0 B Base plate drawing 1S 1S 4 1P+1S
14.0 A Allowable nozzle forces and moments 1S 6
15.0 A Utility consumption list 1S
16.0 C Reference list of previous supplies 1S
17.0 C Technical literature and catalogues 1S
18.0 C Lube data sheet 1S 6
19.0 C Packing list 1P+1S
20.0 C Inspection & test reports and material test 1S before despatch 1P+1S
certificates
21.0 B & C Installation, operation and maintenance manual 1P+1S
( Routine and preventive )
22.0 B Compliance statement 1S
Legend :
Group code : A - For review and detailed Engineering , B - For review , C - For information and record
Document type : R - Reproducible , P - Print , S - Soft copy
Notes :
'@' Vendor shall fill in proposed lead time if different from the required lead time
' @@ ' Each set of final documents shall be submitted in a folder. Two such folders shall be packed
and despatched with the equipment.

01FT010B / 94-R1
REV NO DATE DESCRIPTION PREPARED CHECKED APPROVED

TECHNICAL
SCOPE OF INSPECTION AND TESTS 32644-01-PS-001 INS
PROCUREMENT
TPS NO. 32644-
ITEM : CENTRIFUGAL PUMP
EQPT. NO.
The following inspection and test shall be conducted and records submitted.
Sl Inspn. Witness
Description Remarks
No. Reqd. Reqd.
1.0 Casing Inspection X
1.1 Non-destructive examination
Magnetic particle or liquid penetrant on cast casing X
Magnetic particle or liquid penetrant on repair welds X
Magnetic particle or liquid penetrant on weld joints, if any X
Spot radiograph on weld joints
Magnetic particle on forged casing
1.2 Hydrostatic test X X
1.3 Air leak test
2.0 Rotor inspection X X
2.1 Non-destructive examination
Ultrasonic or forging X
Magnetic particle or liquid penetrant on shaft X
2.2 Runout test
2.3 Dynamic balance test X
3.0 Performance test with job motor X X
4.0 NPSH test X X
5.0 Mechanical running test X X
Sound level test X X
6.0 Dismantling inspection X X
Bearing check
7.0 Clearance check X X
8.0 Appearance and dimensional inspection X X
9.0 Material test and chemical analysis X
10.0 Auxiliary Equipment
Hydrostatic test
Appearance and dimensional inspection
01FT010A/94-R1

TECHNICAL 32644-02-PS-001 VDI
PROCUREMENT VENDOR DATA INDEX
PROJECT: CONSTRUCTION OF PHOSPHORIC ACID
STORAGE TANKS AND ASSOCIATED FACILITIES AT Q10 PROJECT NO. : 32644 VENDOR:
BERTH, WI (2 NO’S)
ITEM: PHOSPHORIC ACID STORAGE TANKS (T-1201 D/E) P.O NO.: DATE:
Rev. 0 Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 Relevant to
Sl.
Doc. / Drawing No. Description This issue
No.
Date Date Date Date Date Date
ISSUE NO.
DATE
SIGNATURE
00FT020/94

TECHNICAL 32644-02-PS-001-SPR
PROCUREMENT
SPARES
Sl.
Description Quantity Unit Price Total Price
No.
1 GASKETS 200%
2 BOLTS, NUTS, WASHERS, CLAMPS 10%
( MINIMUM 2 NOS. OF EACH SIZE)
ABOVE SPARES SHALL BE APPLICABLE FOR ALL THE
NOZZLES INCLUDING NOZZLES WITH BLIND FLANGES
‐‐PRICES NOT TO BE FILLED IN HERE‐‐
0 09-06-20 Tank capacity revised GPG SK AAN

A 08-05-20 For Review GPG SK AAN
00FT022 / 94

TECHNICAL
SPARES 32644-01-PS-001 SPR(M)
PROCUREMENT
SPECIFICATION (MANDATORY) PAGE 1 OF 1
CENTRIFUGAL PUMPS
Sl
Description Quantity (% ) Unit Price Total Price
No
1 Impeller 100
2 Impeller nut 100
3 Mechanical seal ( complete assembly ) 100
Seal parts / kit ( seal faces, secondary
4 1 100
seal, gaskets, springs and pins )
5 Gland Packing 200
Coupling spares ( Flexible elements ,
6 100
bushes, pins, packings, etc ‐‐PRICES NOT TO BE FILLED IN HERE‐‐
7 Shaft sleeve 100
8 Impeller wear ring 100
9 Casing wear ring 100
10 Bearings
Pump 100
Motor 100
11 Oil Seal 100
12 Oiler 100
13 Coupling complete 100
Note:
1. Spares list shall be furnished separately for each pump.
2. Wherever suggested Quantity is less than 100%, minimum 1 set or 1 No: shall be provided
1 06-07-2020 FOR ENQUIRY - REVISED LA SK AAN

01FT010D/94-R1

TECHNICAL
SPARES 32644-01-PS-001 SPR(OP)
PROCUREMENT
SPECIFICATION (2 Years Operational Spares) PAGE 1 OF 1
CENTRIFUGAL PUMPS
Sl Suggested
No Quantity (% )
1 Impeller VTA
2 Impeller nut VTA
3 Mechanical seal ( complete assembly ) VTA
4 VTA
1
5 VTA
bushes, pins, packings, etc ‐‐PRICES NOT TO BE FILLED IN HERE‐‐
6 Gland packing VTA
7 Shaft sleeve VTA
8 Impeller wear ring VTA
9 Casing wear ring VTA
10 Throat bush VTA
11 Description VTA
12 Bearings VTA
Pump VTA
Motor VTA
13 Oil Seal VTA
14 Oiler VTA
15 Shaft with keys VTA
16 Coupling complete VTA
17 Gland packing VTA
Notes:
1. Spares list shall be furnished separately for each pump.
2 Wherever suggested Quantity is less than 100%, minimum 1 set or 1 No: shall be provided.
3 Purchaser reserves full right to purchase or not to purchase the 2 yrs operational spares fully or
partially as per rate quoted by the successful bidder. Quoted rate shall remain firm for 2 yrs from
the date of expiry of warrantee period.
4 Price quoted for 2yrs of operational spares shall not be considered for price bid evaluation.
* VTA- Vendor to advice

01FT010D/94-R1
REV No. DATE DESCRIPTION PREPARED CHECKED APPROVED

TECHNICAL
SPARES 32644-01-PS-001 SPR(CO)
PROCUREMENT
SPECIFICATION (Commissioning Spares) PAGE 1 OF 1
HORIZONTAL CENTRIFUGAL PUMPS

Sl Suggested
No Quantity (% )
1 Impeller VTA
2 Impeller nut VTA
3 Mechanical seal ( complete assembly ) VTA
4
1 VTA

5 VTA ‐‐PRICES NOT TO BE FILLED IN HERE‐‐
bushes, pins, packings, etc
6 Gland packing VTA
7 Shaft sleeve VTA
8 Impeller wear ring VTA
9 Casing wear ring VTA
10 Throat bush VTA
11 Description VTA
12 Bearings VTA
Pump VTA
Motor VTA
13 Oil Seal VTA
14 Oiler VTA
15 Shaft with keys VTA
16 Coupling complete VTA
17 Gland Packing VTA
Notes:
1 Spares list shall be furnished separately for each pump.
2 Wherever suggested Quantity is less than 100%, minimum 1 set or 1 No: shall be provided
3 In addition to the vendor listed commissioning spares, vendor binds to provide any additional
spare parts required for start-up and commissioning and shall be included in his scope of work
without any extra cost to purchaser.
4 Price quoted for commissioning spares shall be considered for price bid evaluation
* VTA- Vendor to advice
01FT010D/94-R1
REV No. DATE DESCRIPTION PREPARED CHECKED APPROVED

TECHNICAL
32644-01-PS-001 LD
PROCUREMENT EQUIPMENT LUBRICATION DATA
SPECIFICATION PAGE 1 OF 1
PROJECT : Construction of Additional Phosphoric Acid Storage Tanks at Q10 Berth, WI
PROJECT NO : 32644 LOCATION : Q10 Berth, WI
TPS NO : 32644- VENDOR :
CLIENT : FACT CD
SL ITEM NO
DESCRIPTION
NO
Type of Lubrication System
1 ( State Grease-Gun, Grease Packed, Drip, Splash,
Continuous )
Recommended Lubrication for Break in ( list two
2 Indian alternatives by trade name and number )
Quantity of Lubricant required for initial fill

3
(Litres or Kg )
Recommended Break - in period for
4
Initial application ( Hours )
Recommended Lubrication for normal operation
5 ( List two Indian alternatives by trade name
and number )
Refill quantities if different from initial charge
6
( Litres or Kg )
Quantity of Lubricant shipped with initial order
7
( Litres or Kg )
Recommended time between changes of Lubricant
8
( Hours )
Expected annual consumption of Lubricant
9
( Litres or Kg )
Remarks :
01FT304/94-R1

TECHNICAL
SUB VENDOR LIST 32644-01-PS-001 SV
PROCUREMENT
SPECIFICATION (Mechanical) PAGE 1 OF 2 R 0
SL. NO. Vendor Name
I PUMPS-HORIZONTAL CENTRIFUGALCRITICAL PROCESS SERVICES

1.0 NUOVO PIGNONE ITALY
2.0 SAM TURBO INDUSTRY LIMITED COIMBATORE
3.0 EBARA CORPORATION 144-8510, OHTA-KU
4.0 OCHSNER & SOHN GmbH & CO GERMANY
5.0 POMPE GABBIONETA SPA ITALY
6.0 KSB PUMPS LTD BENGALURU
7.0 KIRLOSKAR EBARA PUMPS LTD PUNE
8.0 SULZER PUMPS INDIA LTD CHENNAI
9.0 SULZER PUMPS AG SWITZERLAND
10.0 MITSUBISHI HEAVY INDUSTRIES TOKYO
11.0 AKAY INDUSTRIES LTD BELUR
12.0 SULZER ESCHER WYSS LTD SWITZERLAND
13.0 SIHI-HALBERG VERTRIEBSGES GmbH GERMANY
14.0 BW/IP INTERNATIONAL INC FLORENCE
15.0 NIIGATA WORTHINGTON CO LTD KAWASAKI
16.0 GOULDS PUMPS INC NEW YORK
17.0 UNION PUMP CO SPRINGFIELD
18.0 GILBERT GILKES & GORDON LTD KENDAL
19.0 KSB PUMPEN ARMATUREN FRANKENTHAL
20.0 FLOWSERVE INDIA CONTROLS PVT LTD COIMBATORE
II PUMPS-VERTICAL CENTRIFUGALPHOSPHORIC ACID APPLICATION

1.0 CHAS-S-LEWIS CO INC ST LOUIS
2.0 A R WILFLEY INDIA PVT LTD MUMBAI
3.0 SULZER PUMPS INDIA LTD CHENNAI
4.0 ENSIVAL MORET BELGIUM S.A BELGIUM
5.0 PAUL BUNGARTZ GmbH & CO KG GERMANY
6.0 FRIATEC AKTIENGESELLSCHAFT GERMANY
7.0 SULZER PUMPS AG SWITZERLAND
8.0 WILFLEY A R & SONS INC DENVER

00FT024/94

TECHNICAL
SUB VENDOR LIST 32644-01-PS-001 SV
PROCUREMENT
SPECIFICATION (Mechanical) PAGE 2 OF 2 R 0
SL. NO. Vendor Name
III RUBBER LINING OF VESSEL/STORAGE TANKS INCL. SUPPLY OF MATERIALS

1.0 NEO PAINTS & RUBBER INDUSTRIES KOCHI
2.0 ALPHA LININGS KOCHI
3.0 ELASTOMER LINING WORKS PUNE
4.0 K K NAG LTD PUNE
5.0 MIL INDUSTRIES LTD CHENNAI
6.0 MINI ENTERPRISES KOCHI
7.0 O R ELASTOMERS (P) LTD CHENNAI
8.0 POLY RUBBER PRODUCTS MUMBAI
9.0 LEBRACS RUBBER LININGS PVT LTD PONDICHERRY

00FT024/94

32644-01-DA 001 (Mech)
DATA SHEET CENTRIFUGAL PUMP
PAGE 1 OF 3
Job N o : 32644 TPS No : 32644-
Applicable to : Proposal X Purchase As built No of electric motors reqd : 2

Site : Q10 BERTH, WI, FACT CD Motor item No. :
Unit : PHOSPHORIC ACID STORAGE TANK Motor provided by : Pump vendor
Pump item No. : P3202A/B Motor mounted by : Pump vendor
Service : Phosphoric Acid Transfer Pump No. of turbines reqd :
No. of pumps reqd : 2 Turbine item No. :
Pump mfr. : Turbine provided by :
Pump size & type : Horizontal Centrifugal 2 Turbine mounted by :
Pump model No. : Remarks : Service specification:-
No. of stages : SINGLE 54% P2O5, 2-4%H2SO4, 1-2% Gypsum solids.
Notes : 1 Information to be completed : By Purchaser By Manufacturer
2 Units of measurement SI System X Metric System
3 VTS- Vendor to specify 4 VTC- Vendor to Confirm. 5 VTA Vendor to advice
OPERATING CONDITIONS ( TO BE COMPLETED BY PURCHASER )
Liquid : Phosphoric Acid NPSH available (NPSHA) : 6.51 MLC
Normal : 40 0
C pH Value :
Pumping
Minimum : 0
C Normal : 175 M3/Hr.
temperature
Maximum : 0
C Capacity @ PT Minimum : 3
M /Hr.
Sp. gravity @ PT : 1.63 - 1.7 Maximum : 175 M3/Hr.
Vapor press. @ PT : Negligible Kg/cm2A Discharge pressure : 4 Kg/cm2G
CP
2
Viscosity @ PT : 65 Maximum : 0.07 Kg/cm G
0
Maximum : C Suct. pressure Minimum : Kg/cm2G
Site 0
temperature
Ambient C Normal : 0.07 Kg/cm2G
Minimum : 0
C Differential pressure : 3.93 Kg/cm2
Un usual conditions : Differential head : MLC
Corrosion/erosion caused by : Hydraulic KW :
Duty X Continuous Intermittent Location Indoor Heated With roof
Remarks : Capacity Control: Remote and Auto 2 X Outdoor Unheated X Without roof
PERFORMANCE ( TO BE COMPLETED BY MANUFACTURER )

Proposal curve No. : Minimum Thermal : M3/Hr
Speed : RPM continuous flow Stable : M3/Hr
NPSH reqd. (NPSHR) *note 1 : MLC Rotation ( Viewed CW CCW
Rated BHP : KW from coupling end )
Max. BHP with rated impeller : KW Suction sp. Speed :
Max. head with rated impeller : M Efficiency (VTS) : %
Remarks : Necessity to start against system pressure: NO
CONSTRUCTION ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )
Centerline Near centerline Nozzles Size Rating Facing Location
Casing
mount X Foot Vertical In line Suction F.F
2
(VTS) Bracket Vert. barrel Sump pump Discharge F.F
Casing split Axial Radial
Miscellaneous connections
(VTS)
Casing type Volute Single Staggered Nozzles Drain Vent Pressure gauge
(VTS) Diffuser Double Suction X
Pressure Balancing: Discharge X
Note 1 : VTS (Margin between NPSHA and NPSHR should be minimum 0.6 meters.)
2 : MLC- Meters of Liquid column
3 : Also refer to Process data sheet 32644-11-SE-P3202A/B and P&ID 32644-11-PD-001.
PROJECT Construction of Additional Phosphoric Acid
2 06-07-2020 LA SK AAN CLIENT
01FT010C/94-R3
1 22-06-2020 LA SK AAN P.O No.

0 10-06-2020 LA SK AAN
VENDOR
Rev DATE PRPD. CHKD. APPRD.

32644-01-DA 001 (Mech)
PAGE 2 OF 3
2 0
Maximum Kg/cm G@15 C Bearings Radial Thrust
2
allowable pr. Kg/cm G@PT Type / No.
Hydro Lubrication Ring oil Oil mist
Kg/cm2G
static test pr. Type Flood Pressure Flinger
Rated Manufacturer
Impeller dia.
Maximum Coupling Type Flexible disc spacer
( mm )
Minimum Model
Impeller Driver half
Between bearings Overhung X Pump manufacturer
mount
Coupling
Impeller type Closed Semi-open X Open X Driver manufacturer
Manufact-
Manufacturer ured by Purchaser
Packing
Type Gland plate Quench Flush
Size/No.of rings taps reqd. Drain Vent
Single X Double Tandem Remarks :
Manufacturer
Mechanical Model
seal
Manufacturer code
API class code
Gland type / Material
Compatibility of Mechanical seal with respect to Seal Flush/Quench plan (VTC)
AUXILARY PIPING ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )
Seal flush piping plan Cooling water piping plan :
Tubing Carbon steel Tubing Carbon steel Copper
Piping Stainless steel Piping Stainless steel
Auxiliary flush plan Total cooling water reqd. : M3/Hr.

Tubing Carbon steel Aux.flush liquid Sight flow indicators reqd. :
Piping Stainless steel Packing cooling injection reqd. :
Seal flush pipng : M3/Hr. Kg/cm2G
Threaded Socket welded Flanged Remarks :
External seal flush fluid reqd. :
M3/Hr. Kg/cm2G
MOC X Base plate/ Foundation Bolt(material / type) SS 316L
X Casing/Cylinder : CD4MCu Base plate draining arrangement shall be provided to
X Impeller: CD4MCu prevent ingress of acid beneath the baseplate
X Case/impeller wear rings: CD4MCu API std.610 std. base plate No.
X Shaft : CD4MCu Remarks : Other wetted parts : CD4MCu
INSPECTION AND TESTS ( TO BE COMPLETED BY PURCHASER ) As per scope insp.& tests
Tests Non witnessed Witnessed Observed Inspection required for nozzle welds
Performance Magnetic Particle Dye penetrant
Hydrostatic Inspection required for castings
NPSH Radiographic Ultrasonic
Shop inspection Material certification Inspection required for
01FT010C/94-R3
Dismantle and inspect after test Magnetic Particle Dye Penetrant

Casting repair procedure approval Radiographic Ultrasonic
Remarks :
32644-01-DA 001 (Mech)
PAGE 3 OF 3
MOTOR DRIVER ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )
KW @ RPM Manufacturer
Service factor Type
Frame No. Bearings
Volts / phase / hertz Lube
0
Temperature rise C Insulation
Full load amps. Enclosure
Locked - rotor amps. Remarks:
Vertical shaft Hollow Solid

Vertical thrust capacity, Kg
Up Down
VERTICAL PUMPS ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )
(For vertical pumps attach Format No. 01FT010 X)
Pit or sump depth mm Carbon steel Stainless steel
Float & rod
Pump length mm Bronze None
(mount plate to suction flange) Float switch
Minimum submergence reqd. mm Pump At min. flow
Column pipe Flanged Threaded thrust, Kg At design flow
Line shaft Open Enclosed At run out Up
Guide bushings Bowl Line shaft Down
Guide bushing lube Remarks :
Water Oil Grease
Lube fluid
Quantity M3/hr Pr Kg/cm2G
WEIGHTS ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )

Weight of pump & base plate Kg Remarks:
Weight of motor Kg
Weight of turbine Kg
PACKING AND SHIPPING
Packing type Domestic Export
Packing specs. Mfr's standard Purchaser's specs.
Packed weight Kg
Packing size ( LXBXH ) mm
Shipping by Rail Road Ocean
Notes: 2
1) Pump shall be capable of running dry for few minutes.
2) Equipment shall be designed to be suitable for outdoor installation without a roof.
3) Bearing must have greasing provision
4) The scope of supply include the following items.
a) Pumps, b) Drive Motors, c) Mechanical Seals, d) Minimum flow recirculation valve e) Couplings, f) Coupling Guards,
g)Base Plate, h) Anchor Bolts with nuts, i) Piping confined to battery limit, j) Mating flanges for suction and -
dischargenozzles k) Mandatory spares, l) Commissioning spares - VTS, m) First-fill of lubricants - VTS.
5) Flange Rating : Flange rating for pump shall have a minimum requirement, confirm to the dimentional requirement
of ISO 7005-1 PN 50 and Equivalent to ANSI/ASME B 16.5 class 150#
01FT010C/94-R3
6) MAWP: It should be at least the max discharge pressure + 10% of the max differential pressure.
7) Downstream design Pressure is 1.5 Times of Max operating pressure. Maximum Shutoff considering max suction
pressure, including all tolerances shall not exceed this value.
8) Corrossion allowance for MOC other than CD4MCu: 3 mm
FACT ENGINEERING & DESIGN ORGANISATION

DATA SHEET 32644-01-DA 002 (Mech)
CENTRIFUGAL PUMP
PAGE 1 OF 4
Job No : 32644 TPS No : 32644-
Applicable to : Proposal Purchase As-built No of electric motors reqd : 2
Site : Q10 BERTH, WI, FACT CD Motor item No. : *
Unit : PHOSPHORIC ACID STORAGE TANK Motor provided by : Vendor
Pump item No. : P 3203A/B Motor mounted by :
Service : Phosphoric Acid Sump Pump No. of turbines reqd : -
No. of pumps reqd : 2 (1 Working + 1 Stand by) 1 Turbine item No. : -
Pump mfr. : * Turbine provided by : -
Pump size & type : Vertical Centrifugal Turbine mounted by : -
Pump model No. : *
Remarks :
No. of stages : *
2 * Vendor To Specify (VTS) 3. # Vendor To Confirm (VTC) 4. $ Vendor to advise (VTA)
5 Units of measurement SI System x Metric System

Liquid : Phosphoric Acid NPSH available (NPSHA) : 6.28 MLC
Normal : 40 0
C pH Value :
Pumping
Minimum : 40 0
temperature
Maximum : 40 0
C Capacity @ PT Minimum : M3/Hr.
Density @ PT : 1630 - 1700 Kg/M3 Maximum : 25 M3/Hr.
Vapor press. VP@ PT : Negligible Kg/cm2 A Discharge pressure(Nor/Max) : 4.4 / 4.4 Kg/cm2G
Dynamic Viscosity (cP) @ PT : 65 cP Maximum : Kg/cm2G
0
Maximum : C Suct. pressure Minimum : 0.034 Kg/cm2G
Site 0
temperature
Ambient : C Normal : Kg/cm2G
Minimum : 0
C Differential Pressure (Max) : 4.36 Kg/cm2
Solids in suspension : 54% P2O5, 2-4%H2SO4, Suction temperature : 40 0
C
Un usual conditions : 1-2% Gypsum solids. Differential head (VTS) : MLC
Corrosion/erosion caused by : Hydraulic KW (VTS) :
Remarks : Priming - Flooded suction X Outdoor Unheated X Without roof

NPSH reqd. (NPSHR) *note 1 : MLC Rotation ( facing CW CCW
Rated BHP : KW coupling end )
Remarks :
CONSTRUCTION (TO BE COMPLETED BY PURCHASER & MANUFACTURER)
Centerline Near centerline Nozzles Size* Rating Facing Location
Casing
ANSI B 16.5,
mount Foot X Vertical In line Suction 150#
F.F
Bracket Vert. barrel ANSI B 16.5, 1
X Sump pump Discharge 150#
F.F
Casing type X Volute Single Staggered Nozzles Drain Vent Pressure gauge
Diffuser Double Suction
Pressure balancing: Line and disc required Discharge X X X
Cooling water Inlet/outlet * Casing Steam Jacket Not Required
Note 1 : If not specified elsewhere, margin between NPSHA and NPSHR shall be minimum 0.6 MLC
2 : MLC - Meters of Liquid Column
3 : Suction pressure & NPSH available values indicated are calculated considering a minimum submergrnce
of 200 mm above pump centre line.
4 : Also refer to Process data sheet 32644-11-SE-P3203 and P&ID 32644-11-PD-001.
PROJECT Construction of Additional Phosphoric

Acid Storage Tanks at Q10 Berth, WI
1 06.07.2020 LA SK AAN CLIENT FACT CD
0 22.06.2020 LA SK AAN P.O No.
01FT010C/15
A 10.06.2020 LA SK AAN
VENDOR

32644-01-DA 002 (Mech)
PAGE 2 OF 4
Maximum * Kg/cm2 G @150C Bearings* Radial Thrust
allowable pr. * Kg/cm2 G @ PT Type / No.
Hydro Lubrication* Ring oil Oil mist
static test pr.
* Kg/cm2 G
Type Flood Pressure Flinger
Impeller dia
Rated * Manufacturer
( mm ) Maximum * Coupling * Type Flexible disc spacer
Minimum * Model
mount coupling to
Impeller type* Closed Semi-open X Open be supplied Driver manufacturer
Manufacturer by Purchaser
Packing Type Gland Packing Gland plate Quench Flush
Single X Double Tandem Remarks : Mechanical Seal Type: Dry Run
Manufacturer
Mechanical Model
seal
Manufacturer code
API class code
#
Compatibility of Mechanical seal with respect to Seal Flush/Quench plan
AUXILARY PIPING (TO BE COMPLETED BY PURCHASER & MANUFACTURER)
Seal flush piping plan VTA (If required)$ Cooling water piping plan : VTA (If required)$
Seal flush piping : ` M3/Hr. Kg/cm2G
M3/Hr. Kg/cm2G
All interface connection shall be terminated with Flanged Block Valves
Size/Rating (ANSI)/Facing
Lantern ring Inlet/Outlet *
Exit Seal Flush inlet/outlet *
Seal Quench Fluid Inlet *
X MOC: Base plate (material / type)
X Casing/Cylinder : CD4MCu API 610 std. base plate No.

X Impeller CD4MCu Base plate Drain Pan Type
X Case/impeller wear rings CD4MCu Base plate drain (Only flanged)*
X Shaft / sleeve CD4MCu Remarks :
INSPECTION AND TESTS ( TO BE COMPLETED BY PURCHASER )
01FT010C/15

Remarks : As per scope inspection & tests attched
32644-01-DA 002 (Mech)
DATA SHEET CENTRIFUGAL PUMP PAGE 3 OF 4
* KW @ * RPM Manufacturer *
Service factor * Type *
Frame No. * Bearings *
Volts / phase / hertz * Lube *
* Insulation*
0
Temperature rise C
Full load amps. * Enclosure*
Parallel Operation required
Locked - rotor amps.* Remarks:
Vertical shaft Hollow X Solid
Vertical thrust capacity, Kg*
Up Down
(For vertical pumps attached Format No. 01FT010 97) - Shall be filled by vendor.
Pit or sump depth As per GA attached mm Carbon steel Stainless steel
Float & rod
Water Oil Grease First dry critical speed of pump in vertical condition(rpm)*
Lube fluid
Weight of pump & base plate * Kg Remarks:
Weight of motor * Kg
Weight of coupling * Kg
Weight of turbine * Kg
Packing type* Domestic Export
Packing specs.* Mfr's standard Purchaser's specs.
Packed weight* Kg
Packing size* ( LXBXH ) mm
Shipping by* Rail Road Ocean
NOTES:
1. The scope of supply include the following items.
g) Mounting flanges with gasket, h) Anchor Bolts with nuts, i) Piping confined to battery limit, j) Mating flanges for suction and -
2. Area classification: Non Hazardous
3. Non sparking coupling guard to be provided.
4. MAWP: It should be at least the max discharge pressure + 10% of the max differential pressure.
5. Downstream design Pressure is 1.5 Times of Max operating pressure. Maximum Shutoff considering max suction pressure,
including all tolerances shall not exceed this value.
6 Process min flow shall be equal to Pump MCF (Minimum Continuous flow)
7 Flange Rating : Flange rating for pump shall have a minimum requirement, confirm to the dimentional requirement of ISO 7005-
1 PN 50 and Equivalent to ANSI/ASME B 16.5 class 150#
8 Material of construction for mounting plate shall be minimum IS 2062 Gr. E250C. Material of construction for Mounting fasteners
01FT010C/15
shall be SS 316L. Mounting Plate shall have 5mm thick rubber lining on the underside. (Rubberlining spec identical to Tank
lining)

32644-01-DA 002 (Mech)
PAGE 4 OF 4
9 This pump is to be installed in sump.

10 Pump manufacturer shall furnish dimensional details as per attachement of this data sheet
11 Shaft shall be solid cantilever. Bearings shall be above mounting plate. No intermediate and bottom bearing.
Discharge pressure as indicated is at pump discharge flange, bidder shall arrive/calculate the impeller head after accounting for
12
installation depth, frictional loses etc, so as to generate specified discharge pressure at pump discharge flange.
13 Corrossion allowance for MOC other than CD4MCu: 3 mm
14 Studs / Bolts shall be of minimum SS-316 L.
15 Minimum submergence is to be advised by vendor. Indicate minimum submergence value as per attachement of this data sheet.
16 Mounting plate / flanges along with bolts / nuts & gaskets shall be provided by the vendor.
17 The dimensions for the mounting plate, bolting, gaskets etc. shall be as per the following standards.
For Sizes ≤ 24 inches: ASME B16.5, For Sizes > 24 inches: ASME B16.47 Series B. Vend or to indicate the mounting plate size.
18 The thickness of mounting plate shall be minimum 20mm.
01FT010C/15

01FT010X/97
PAGE 1 OF 1
(1) VENDOR SHALL CONFIRM ADEQUACY

ITEM A B C D E F NB OF BOTTOM CLEARANCE
(2) VENDOR SHALL INDICATE DIMENSIONS

A, B, C, D, E, F & NB
PROJECT: CONSTRUCTION OF PHOSPHORIC ACID

STORAGE TANKS AND ASSOCIATED FACILITIES AT
01FT010X/97
Q10 BERTH, WI (2 NO’S)

TITLE: GA Phosphoric Acid Sump Pump P 3203
Rev DATE DESCRIPTION DRAWN CHKD APPD DWG NO:

32644-01-DA 003 (Mech)
PAGE 1 OF 3
Job N o : 32644 TPS No : 32644-
Applicable to : Proposal X Purchase As built No of electric motors reqd : 1

Site : Q10 BERTH, WI, FACT CD Motor item No. :
Unit : PHOSPHORIC ACID STORAGE TANK Motor provided by : Pump vendor
Pump item No. : P3204 Motor mounted by : Pump vendor
Service : STORM WATER No. of turbines reqd :
No. of pumps reqd : 1 Turbine item No. :
Pump mfr. : Turbine provided by :
Pump size & type : Horizontal Centrifugal Turbine mounted by :
Pump model No. : Remarks :
No. of stages : SINGLE
2 Units of measurement SI System X Metric System
3 VTS- Vendor to specify 4 VTC- Vendor to Confirm. 5 VTA Vendor to advice
Liquid : STORM WATER NPSH available (NPSHA) : 6.5 MLC
Normal : 40 0
C pH Value :
Pumping
Minimum : 0
temperature
Maximum : 0
C Capacity @ PT Minimum : 3
M /Hr.
Sp. gravity @ PT : 1 Maximum : 25 M3/Hr.
Vapor press. @ PT : 0.074 Kg/cm2A Discharge pressure : 1 Kg/cm2G
CP
2
Viscosity @ PT : Maximum : Kg/cm G
0
Maximum : C Suct. pressure Minimum : -0.308 Kg/cm2G
Site 0
temperature
Ambient C Normal : Kg/cm2G
Minimum : 0
C Differential pressure : 1.308 Kg/cm2
Un usual conditions : Differential head : MLC
Corrosion/erosion caused by : Hydraulic KW :
Remarks : Capacity Control: Local X Outdoor Unheated X Without roof

NPSH reqd. (NPSHR) *note 1 : MLC Rotation ( Viewed CW CCW
Rated BHP : KW from coupling end )
Remarks : Necessity to start against system pressure: NO
CONSTRUCTION ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )
Casing Centerline Near centerline Nozzles Size Rating Facing Location
mount X Foot Vertical In line Suction F.F
(VTS) Bracket Vert. barrel Sump pump Discharge F.F
(VTS)
Casing type Volute Single Staggered Nozzles Drain Vent Pressure gauge
(VTS) Diffuser Double Suction X
Pressure Balancing: Discharge X
Note 1 : VTS (Margin between NPSHA and NPSHR should be minimum 0.6 meters.)
2 : MLC- Meters of Liquid column
3 : Also refer to Process data sheet 32644-11-SE-P3204 and P&ID 32644-11-PD-002.
PROJECT Construction of Additional Phosphoric Acid
2 06-07-2020 LA SK AAN CLIENT
01FT010C/94-R3
1 22-06-2020 LA SK AAN P.O No.

0 10-06-2020 LA SK AAN
VENDOR

32644-01-DA 003 (Mech)
PAGE 2 OF 3
2 0
Maximum Kg/cm G@15 C Bearings Radial Thrust
2
allowable pr. Kg/cm G@PT Type / No.
Hydro Lubrication Ring oil Oil mist
Kg/cm2G
static test pr. Type Flood Pressure Flinger
Rated Manufacturer
Impeller dia.
Maximum Coupling Type Flexible disc spacer
( mm )
Minimum Model
mount
Coupling
Impeller type Closed Semi-open X Open X Driver manufacturer
Manufact-
Manufacturer ured by Purchaser
Packing
Type Gland Packing Gland plate Quench Flush
Single Double Tandem Remarks :
Manufacturer
Mechanical Model
seal
Manufacturer code
API class code
AUXILARY PIPING ( TO BE COMPLETED BY PURCHASER & MANUFACTURER )
Seal flush piping plan Cooling water piping plan :

Seal flush pipng : M3/Hr. Kg/cm2G
M3/Hr. Kg/cm2G
MOC X Base plate/ Foundation Bolt(material / type) SS 316L
X Casing/Cylinder : CD4MCu Base plate draining arrangement shall be provided to
X Impeller: CD4MCu prevent ingress of acid beneath the baseplate
X Case/impeller wear rings: CD4MCu API std.610 std. base plate No.
X Shaft : CD4MCu Remarks : Other wetted parts : CD4MCu
INSPECTION AND TESTS ( TO BE COMPLETED BY PURCHASER ) As per scope insp.& tests
01FT010C/94-R3

Remarks :
32644-01-DA 001 (Mech)
PAGE 3 OF 3
KW @ RPM Manufacturer
Service factor Type
Frame No. Bearings
Volts / phase / hertz Lube
0
Temperature rise C Insulation
Full load amps. Enclosure
Locked - rotor amps. Remarks:
Vertical shaft Hollow Solid

Vertical thrust capacity, Kg
Up Down
(For vertical pumps attach Format No. 01FT010 X)
Pit or sump depth mm Carbon steel Stainless steel
Float & rod
Water Oil Grease
Lube fluid

Weight of pump & base plate Kg Remarks:
Weight of motor Kg
Weight of turbine Kg
Packing type Domestic Export
Packing specs. Mfr's standard Purchaser's specs.
Packed weight Kg
Packing size ( LXBXH ) mm
Shipping by Rail Road Ocean
Notes:
1) Pump shall be capable of running dry for few minutes.
2) Equipment shall be designed to be suitable for outdoor installation without a roof.
3) Bearing must have greasing provision
4) The scope of supply include the following items.
g)Base Plate, h) Anchor Bolts with nuts, i) Piping confined to battery limit, j) Mating flanges for suction and -
5) Flange Rating : Flange rating for pump shall have a minimum requirement, confirm to the dimentional requirement
of ISO 7005-1 PN 50 and Equivalent to ANSI/ASME B 16.5 class 150#
01FT010C/94-R3
6) MAWP: It should be at least the max discharge pressure + 10% of the max differential pressure.
7) Downstream design Pressure is 1.5 Times of Max operating pressure. Maximum Shutoff considering max suction
pressure, including all tolerances shall not exceed this value.
8) Corrossion allowance for MOC other than CD4MCu: 3 mm
ENGINEERING 00ES001/2010
SPECIFICATION VENDOR DATA SUBMISSION PROCEDURE
PAGE 1 OF 4
CONTENTS
1.0.0. SCOPE
2.0.0. VENDOR DATA REQUIREMENTS
3.0.0. CLASSIFICATION OF DOCUMENTS
4.0.0. VENDOR DATA INDEX
5.0.0. QUALITY OF VENDOR DRAWINGS
6.0.0. CONDITIONS OF FEDO REVIEW
PRPD.BY:- JC CHKD.BY:-CK APPRD. BY:- JK ISSUED ON:-April 2010

00ES001/2010
ENGINEERING VENDOR DATA SUBMISSION PROCEDURE
1.0.0. SCOPE 3.1.0. Documents are classified based on

their status and nature of content.
1.1.0. This document together with
“VENDOR DATA REQUIREMENTS 3.1.1. Status of documents:
(VDR)” defines FEDO’s requirements 1. Preliminary documents
for vendor drawing and data for any required along with the offer.
enquiry, work order or purchase 2. Documents to be submitted
order. after commitment.
1.2.0. Bidders unable to comply with these 3. Final documents.
requirements must detail all 3.2.0. The documents are further classified
exceptions in their proposal. The into Groups A,B and C, depending on
timely delivery of quality drawings the nature of the documents as
and data is as crucial as delivery of explained below.
the equipment itself and hence the
same shall be strictly adhered to after 3.2.1. Group A requirements
commitment. These documents are urgent in nature
1.3.0. Failure to provide adequate and contain information that is
preliminary data / drawing may required for proceeding with the
render a proposal non-responsive and detailed engineering of surrounding /
hence may be rejected. After down stream equipments in the plant
commitment failure to provide and hence are to be submitted on
documents as per purchase order may priority basis.
delay progressive payments and 3.2.2. Group B requirements
adversely affect future invitation to
bids. These documents are to be reviewed
2.0.0 VENDOR DATA by FEDO for compliance with the
REQUIREMENTS (VDR) purchase order / work order
specifications but are not essential for
2.1.0 FEDO will provide a partially other engineering activities of FEDO.
completed VDR form along with each
enquiry. This form explains group 3.2.3. Group C requirements
code of the document, quantity of Documents in this group contains
each document required and lead time data / information / records which are
for submission. Columns are final in nature and that are required
available for the vendor to fill in his for the equipment user and need not
deviations, if any, from FEDO’s be reviewed by FEDO.
requirements.
4.0.0. VENDOR DATA INDEX (VDI)
2.2.0 The vendor shall forward a filled-in
VDR form along with his offer, if he 4.1.0. Vendor shall forward a filled up and
has got any deviation from FEDO’s updated VDI along with each vendor
requirements. In the absence of a data transmittal. VDI shall list out all
filled-in VDR form along with the documents that are being prepared for
offer, it will be presumed that the the particular order, their current
vendor is accepting FEDO’s revision status and indicate the
requirements specified in the VDR. documents included in the present
transmittal. A blank VDI is attached
3.0.0. CLASSIFICATION OF along with this document, which shall
DOCUMENTS be used for this purpose.

00ES001/2010
5.0.0. QUALITY OF VENDOR 5.8.0. All documents shall have a block of

DRAWINGS 100 mm x 100 mm space left vacant
for FEDO to put their stamp after
5.1.0. Vendor drawing and data shall be
review.
supplied in full size drawings,
reproducible and CDs as specified in 5.9.0. All drawing/document shall have a
the VDR. revision block explaining revision
number, revision description, data of
5.2.0. All drawings / documents shall be
revision, revision authorization etc.
clear, legible, right reading and made
When the revised drawings are
out of originals prepared in black ink.
submitted all currently revised area
English language and metric units
shall be clearly demarcated by
shall be used for the preparation of all
clouding. Any revisions made on
documents.
other parts of the documenting will
5.3.0. The documents shall be prepared n not be reviewed by FEDO.
any of the following standard sizes.
5.10.0. When drawings are received back
5.3.1. A1: 594 mm x 840 mm from FEDO with comments, vendor
5.3.2. A2: 420 mm x 594 mm shall incorporate all the comments
5.3.3. A3: 297 mm x 420 mm and resubmit the same. If the vendor
5.3.4. A4; 210 mm x 297 mm is not in a position to incorporate
certain comment made by FEDO,
5.4.0. All documents submitted to FEDO
then the reason for such deviation
shall be folded into A4 size (210 x
shall be highlighted in the forwarding
297 mm) except originals / re-
letter to FEDO.
producible which may be rolled. All
reproducible shall be in high quality 5.11.0 The respective engineering
polyester films. Soft copies shall be specification and other purchase order
furnished in CD for final drawings / spec. Will explain the minimum data /
documents. details required in various drawings.
In the absence of any such
5.5.0. Each drawing / document shall have a
information in the purchase order
title block at the right hand bottom
documents, vendor shall follow the
corner with the following
standard good engineering practices
information.
in detailing the drawing.
5.5.1. Name of Vendor.
6.0.0. CONDITIONS OF FEDO
5.5.2. Drawing title.
REVIEW
5.5.3. Name of Project, Owner and location.
5.5.4. Name of Consultant: FEDO 6.1.0. FEDO and / or its client reserve the
5.5.5. FEDO Purchase Order Number. right to review the vendor documents.
5.5.6. Equipment name & Number FEDO’s REVIEW WITH OR WITHOUT
5.5.7. Drawing number, revision and page COMMENTS OF THE VENDOR
DOCUMENTS SHALL NOT RELIEVE
number. THE VENDOR OF RESPONSIBILITY TO
COMPLY WITH ALL PURCHASE ORDER
5.6.0. All drawings shall be drawn to some TERMS AND CONDITIONS, including
standard scales only and the same all implied requirements relating to
shall be indicated in the drawing. fitness for service and good
5.7.0. The status of the document like engineering practices. Approval or
“PRELIMINARY, FINAL, FOR acceptance does not imply or infer
REVIEW” etc. shall be stamped on any determination relating to
all copies forwarded to FEDO. compliance by the vendor with its full

00ES001/2010
responsibilities under the purchase Comment Status of Review

order. As noted Revise and resubmit
6.2.0. FEDO’s comments are limited to for review
identifying requirements within the No Proceed as noted and
scope of the purchase order or failure comments submit revised docs.
by the vendor to comply with the For records
requirements of purchase order, as Not No further review
revealed by the limited review. reviewed required
Oversights in the above limited Forward final docs.
review cannot be taken as approval As per P.O.
for the vendor to deviate from the
purchase order conditions. FEDO 6.4.0. All documents received in FEDO
reserve the right to point out any such shall be dispatched after review
deviations at any stage of the order within 15 days from the date of
execution. The vendor shall comply receipt. Vendor shall notify FEDO of
with all such requirements without non-receipt of reviewed documents in
any price / delivery implications. time immediately, to take corrective
actions.
6.3.0. FEDO review will be authorized by
an official stamp as given below, 6.5.0. The delivery of the equipment shall in
properly filled and signed by the no case be linked with the review of
concerned. Comments if any will be the vendor drawings and data by
indicated in red ink or clouded in the FEDO. It is the sole responsibility of
case of copies of commented the vendor to execute the job as per
drawings. the purchase order conditions. If
Appropriate comment in the required the vendor shall depute his
‘comments’ column and ‘status of technical personnel to FEDO after
review’ column will be marked. submission of documents for timely
finalisation of documents.
***********************

STORAGE TANK
CONTENTS
1.0.0 GENERAL
2.0.0 DESIGN
3.0.0 MATERIALS
4.0.0 FABRICATION
5.0.0 PREPARATION & SHOP INSPECTION
6.0.0 PLATE TREATMENT
7.0.0 PAINTING
8.0.0 WELDING
9.0.0 TESTING
10.0.0 VENDOR DOCUMENTS
11.0.0 STATUTORY REQUIREMENTS
12.0.0 GUARANTEE
PRPD.BY:- JC CHKD.BY:- CK APPRD. BY:- JK ISSUED ON:- April 2010

02ES032/2010
ENGINEERING STORAGE TANK
1.0.0 GENERAL spark-proof rings shall conform to

material specifications IS-226/ IS-2062
1.1.0 SCOPE
and aluminium.
1.1.1 This specification covers the requirements
3.5.0 Reinforcement pads for nozzles,
for the design, selection of materials,
manholes etc. shall conform to same
preparation of drawings, fabrication,
specifications as that of shell plates.
erection, inspection, testing, repairing,
painting and calibration of the storage 3.6.0 Gaskets for manholes and nozzles
tanks. fitted with blind flanges shall conform to
1.1.2 FEDO means FACT ENGINEERING AND IS-2712. Thickness of gasket shall be 1.5
DESIGN ORGANISATION, their authorised mm for nozzles upto 450 NB and 3.2 mm
representative or their client. for nozzles above 450 NB. One set of
gaskets shall be supplied in addition to the
set used during testing at no extra cost to
1.2.0. CODES AND STANDARDS FEDO.
1.2.1. Tanks shall be designed generally in 3.7.0 Bolts and Nuts far all nozzles fitted with
accordance with IS-803 or API-650 (latest) blind flanges shall conform to A-193 Gr
as specified in the respective equipment B7, A-194 Gr 2H or equivalent and bolts
specification/data sheet. and nuts for structurals shall conform to
IS-1363/1367.
2.0.0. DESIGN
3.8.0 Platforms, stairways and gangways shall
2.1.0. CALCULATION all be of gratings.
2.1.1. The calculations justifying the size and 3.9.0 Floating roof pipe supports and pipe
plate thickness of the various items like sleeves shall be of carbon steel
shell, roof, bottom plates, and accessories conforming to A-106/ A-53 seamless / IS-
like wind girder, roof rafters/ girders, bleeder 1978 seamless or equivalent of Sch-80,
vents, drains, pipe supports etc. shall be unless otherwise specified.
established by the vendor, in conformity
with the codes and the same shall be 3.10.0 Electrodes used shall meet the minimum
submitted for review by FEDO. requirements of the applicable code and
appendix. Vendor shall get approval by
2.1.2. Floating roof design calculations shall be FEDO for the list of manufacturers for
submitted to FEDO for approval along with procurement of electrodes. Test
the quotation. Central deck and pontoon procedure as approved by FEDO shall be
shall be stiffened suitably and calculations carried out by the vendor.
for structural stability and strength of the
floating roof shall be submitted for FEDO 3.11.0 Materials indicated above are to be
review. considered as minimum quality and
materials of an equivalent or superior
2.1.3 General arrangement drawing of the tank quality may be substituted. No substitution
along with an approximate tonnage of plate of material is to be made without the written
requirement, thickness wise, shall be consent of FEDO.
furnished along with the quotation for
review by FEDO. 3.12.0 Vendor shall submit manufacturers test
certificates for all bought out items, and the
3.0.0 MATERIALS same shall be used only after approval by
FEDO.
3.1.0 All plates for shell, bottom, roof etc. shall
be as specified in the tank drawing. 4.0.0 FABRICATION
3.2.0 Nozzle neck thickness shall be as per 4.1.0 BOTTOM PLATE
code / tank drawing. Nozzle neck made
4.1.1 Bottom slope of tank shall be as indicted in
from rolled and welded plates of similar
the drawing.
grade as the shell to which they are
attached may also be used for nozzles 4.1.2 The plates (except annular plates) shall be
above 250 NB. lap welded with overlap not less than 5
times the plate thickness of sketch plates.
3.3.0 All flanges and couplings should be-as For sketch plate to annular plate overlap
indicated in the drawing. shall not be less than 65 mm. Overlaps
3.4.0 Pipes for handrails for tank shall shall be properly cleaned using steel
conform to IS-1239. Gauge hatches with wire brush before welding.

02ES032/2010
4.1.3 Annular plate shall be assembled by butt- 4.2.7 Wind girder shall be designed and
welding with backing strips and it shall be provided as per the specified design code.
lap welded to sketch plates. 4.2.8 Fixed roof shall be preferably self-
4.1.4 First course shell plates shall be supporting type.
arranged so that the vertical seams do not 4.2.9 Supported cone roofs may be provided
coincide with the butt welds of annular with internal or external structure supports
plates. Vertical joints of two consecutive as specified in the eqpt. spec/data sheet.
shell courses shall not coincide and shall be
offset by at least the minimum value for
such occurrence specified in the code. 4.3.0 FLOATING ROOF
The weld seams should not pass through
4.3.1 Floating roof shall be of low deck type.
the nozzle openings or reinforcement pads.
Type of deck (single or double) shall be as
4.1.5 Bearing plates shall be centred under specified in the eqpt. Spec.
each support attached to the tank bottom
4.3.2 Deck shall have a level surface or be
by a 5 mm continuous fillet weld. Plate
provided with a slope to the centre to avoid
shall be minimum 600 mm dia x 20 mm
stagnation of rainwater.
thick.
4.3.3 When floating roof is in the highest
4.1.6 Datum plate, of the tank shall be welded on
position tank shall be capable of holding
the pad plate provided on the bottom
the designed capacity.
vertically below the gauge well pipe after
calibration of the tank. 4.3.4 Floating roof design calculation shall be
submitted to FEDO for approval along with
4.1.7 Welding sequence adopted shall be
quotation.
shown in vendors drawing and should
give minimum shrinkage and distortion 4.3.5 Floating roof shall be annular and centre
and shall be got reviewed by FEDO. pontoon with multiple compartment type
or Buoy-roof type, liquid proof with minimum
4.1.8 Reinforcement shall be provided to the
requirement of IS 803 /API-650 (latest).
tank bottom where concentrated loads such
as heating coil supports, tank agitator 4.3.6. Centre deck shall be provided with 2 Nos.
supports etc. are located. manholes. One of these manholes should
be provided with a welded ladder for
stepping down to bottom when the roof is in
4.2.0 SHELL & ROOF its lowest position. This shall have suitable
4.2.1 All vertical and horizontal shell joints shall clearance from tank internals. The other
be full penetration and full fusion welds. manhole shall allow dismantling of roof
drains from the top of the roof.
4.2.2 Shell joints shall be double welded butt
joints using edge preparation permitted 4.3.7 Access manholes 600 NB dia. shall be
by API-650 latest edition. Details of the provided for entry into each of the pontoon.
weld must be shown in drawings and shall These shall have waterproof covers.
be approved by FEDO. Pontoons shall be numbered serially.
4.2.3 Wind girders shall be welded to the tank 4.3.8 Foam dam should be provided along with
as shown in the tank drawings. Welding pontoon. The minimum height of the foam
shall be of the same quality as used for dam shall be 610mm.
the shell. Drain holes shall be provided on
the horizontal plates. 4.4.0 STAIRWAYS
4.2.4 Curb angle/stiffening ring welds should not 4.4.1 For access to the top from the ground,
coincide with shell welds. spiral stairways may be provided
4.2.5 Vertical plates shall be offset at least one terminating at the top.
third of each plate length or 1000 mm 4.4.2 For the floating roof tanks, top-landing
whichever is higher and the internal platform shall be provided for the
weld seams shall be ground smooth and stairway. The same shall be extended
even, to allow proper movement of roof. over the roof to permit easy access to roof
4.2.6 Holes shall not be made in shell accessories.
plates for erection purposes.

02ES032/2010
4.5.0 ROLLING LADDER 4.9.2 Sealing system shall exert sufficient

sealing pressure in all directions to prevent
any evaporation loss and the arrangement
4.5.1 For the floating roof tanks, a rolling ladder shall touch the product during operation.
shall be provided for access from the Foam seal should have excellent flexibility
platform to the floating roof. Rolling ladder and recovery from compression and at the
tracks shall permit easy movement of the same time permit the roof movement up
ladder. and down freely with the level of tank
4.5.2 Brass rollers for the rolling ladder shall be contents.
provided to prevent sparking. 4.9.3 Vendor shall furnish details of seal and
seal cover along with catalogue for FEDO
4.6.0 ROOF VENTS review, at the time of quotation.
4.6.1 Roof shall be provided with vents as per Foam seal cover minimum thickness
eqpt. Spec/drawing. shall be 3mm.
4.6.2 Floating roof tanks roof shall be provided 4.9.4 Guarantee for sealing material for its
with automatic bleeder vents designed to durability and its life should also be
open before the roof reaches its lowest furnished.
position and to close when the roof rises 4.9.5 The weather shield of the foam seal shall
above this point. The contact surface of allow entry of foam into the seal space
bearing plate of automatic bleeder vent during fire fighting. The rubbing surface
shall be spark-proof. of the weather shield shall be
4.6.3 Rim vents shall be provided for the floating coated/covered with resilient material so as
roof tanks for venting the space to avoid scoring on the oil side of shell.
between stored liquid and the seal. Roof seal angle shall be with galvanised
Pressure-Vacuum vents shall be coupled S.S. shunts.
with rim vents. The peripheral spacing of
rim vents shall be about 50m.
4.10.0 FIXED ROOF SUPPORT
4.10.1 For fixed roof tanks the roofs shall
4.7.0 GAUGEWELL PIPE preferably be of the columnless self-
supporting type.
4.7.1 Gauge well pipe shall be of size 250 NB.
The gauge well pipe shall facilitate 4.10.2 Column and rafter arrangement is
installation of automatic tank gauging acceptable for large diameter tanks.
system and easy usage of dip rod/tape. However internally lined tanks shall be
provided with rafter or girder supports on
4.7.2 Gauge well pipe shall act as anti-rotation
the out side of the roof.
device in floating roof tanks to avoid
the rotational movement of the floating
roof. 4.11.0 FLOATING ROOF SUPPORT
4.11.1 Floating roof supports and pipe sleeves
4.8.0 GAUGE HATCH NOZZLE shall be carbon steel pipe with minimum
thickness conforming to schedule 80.
4.8.1 Gauge hatch nozzle size shall be as
indicated in the Eqpt. spec/drawing. 4.11.2 The number of supports shall be
4.8.2 Gauge hatch shall have a quick opening determined so as to ensure that the roof
spark- proof cover and shall be fitted with a when it rests on the supports does not
renewable aluminium guide channel for deform the tank bottom and/or the roof.
the dip tape. 4.11.3 Bearing plates shall be provided beneath
the roof legs so as to prevent damage to
the bottom during operation of the tank.
4.9.0 FLOATING ROOF SEAL
4.11.4 Support legs shall permit adjustment of the
4.9.1 The space between the outer rim of roof roof in two positions. The highest position,
and shell shall be sealed by an approved 1.8 m from the bottom, shall be for
sealing device (foam seal). The sealing inspection maintenance and cleaning the
material shall be resistant to stored inside of the tank. The lowest operating
product and also durable against friction position shall not interfere with the internal
due to roof movement. accessories.

02ES032/2010
4.14.2 Floating roof shall be provided with

4.12.0 EXTERNAL CLIPS wire cables for earthing rolling ladder
to track and ladder to shell.
4.12.1 Extension Plates, brackets, clips and
suitable stiffeners for Foam nozzle, Pad
Plates for fixing brackets, Pipe supports, 4.15.0 TANK ACCESSORIES
supports for Foam & Fire Hydrant system
4.15.1 All appurtenances and accessories
shall be provided.
shown in the tank datasheet/drawing
4.12.2 For Jackup type tank construction, pad shall be supplied by the vendor unless
plates for fixing hydraulic jacks and other otherwise noted.
fixtures at various elevations shall be
4.15.2 All appurtenances shall be supplied
provided earlier.
and fitted as per applicable codes.
4.15.3 Additional appurtenances if any
4.13.0 FLOATING ROOF DRAINS required for the satisfactory
4.13.1 Water shall be evacuated from the floating performance of the tank shall be
roof by means of articulated pipe drains provided.
with swivel joints, of approved make and
type.
4.16.0. SETTLING MARKERS
4.13.2 The inlet of each drain shall have a swing
type check valve to prevent product from 4.16.1 Markers shall be fitted on the shell
flowing on to the roof if the pipe drain fails. 500mm from the bottom, eight in
A minimum Clearance of 200 mm between number, to check tank settlement
the valve and the sides of the valve during hydraulic testing. These shall
chamber shall be maintained. All swivel be fitted at 450 equally placed.
joints shall be tested to a minimum Markers shall be 50x50x6x100mm
2
pressure of 3.5 kg/cm before putting long angle.
into roof drain assembly. 5.0.0 PREPARATION AND SHOP
4.13.3 The valve chamber shall be INSPECTION
accessible from roof.
5.1.0 PLATES
4.13.4 The drains should be so designed as
to permit the roof to be lowered upto 5.1.1 Edges of the plates shall be preferably
lowest operating level of roof. sheared or gas cut or m achine cut
as per code. All machined surface
4.13.5 Swivel joints should have double row shall be suitably protected before
ball bearings and Viton 'O' ring at both assembly. Grinding shall be done to
ends. the gas cut edges to the satisfaction of
4.13.6 Sufficient clearance shall be kept FEDO site engineer.
between roof drain pipe and roof 5.1.2 All shaped plates shall be match -
supports. marked with paint on the concave
4.13.7 The roof drains must cater to the side with the number shown on the
design rainfall intensity with 100% erection drawings.
run-off at the lowest level. Flow 5.1.3 The ends to be welded shall be
calculations for the same shall be properly cleaned to remove paint, oil,
submitted for FEDO review. grease, rust, oxides, sand, earth and
4.13.8 Emergency drains shall be provided other foreign matter. The ends shall be
in case of failure of drain and also to completely dry before the welding
prevent backflow of the stored commences.
product. These drains shall be
equipped with water seal sump inside
the tank. 5.2.0 STRUCTURALS
5.2.1 Structural steel fabrication shall be
done by the vendor to the required
4.14.0 EARTHING shapes and sections making up the
4.14.1 The tank shell shall be earthed as structure. All items shall be match
per NEC. marked.

02ES032/2010
5.3.0 NOZZLES AND OPENINGS 7.3.0. SPECIFICATION FOR PAINTING

5.3.1 Nozzles shall be provided as per the eqpt. 7.3.1. FEDO reserves the right to change the
data sheet/drawing. specifications of paint and approve the
5.3.2 Nozzles and manholes may be shop quality of paint before painting. All painting
fabricated and assembled at site. materials shall be approved by FEDO site
engineer and if in his opinion any tests are
5.3.3 Nozzle reinforcement shall be provided as to be conducted, the same shall be done by
per the code requirement. the vendor at his cost. All painting jobs
shall be carried out strictly according to the
6.0.0 PLATE TREATMENT
paint manufacturer's application procedure.
6.1.0 All plates shall be thoroughly cleaned and
freed from rust, scale and grease and 7.4.0 SURFACE PREPARATION
have a good appearance. 7.4.1. Dry Sand Blasting
6.2.0 It is required that the plates for the shell, Before sand blasting all greasy substance
roof and external structures and upperside shall be removed by means of adequate
of bottom plate of the tank shall be sand washing. Sand blasted surface shall have
blasted. Plates should have a uniform a finish of SA 2 ½ grade Swedish and be
matt-grey colour. rough enough to obtain the best condition
for moisture, oil. Sand blasting shall be
7.0.0 PAINTING
restricted to day time. Sand blasting
7.1.0 Tank shall be painted in accordance with should be stopped whenever the blasted
the data sheet/Equipment specification surface appears to be damp or the relative
and FEDO Engineering specification for humidity of the environment exceeds 85%.
painting. 7.4.2 Wire Brushing - Where overcoat painting is
carried out on the previously painted shell,
wire brushing shall be carried out to make
7.2.0 EXTENT OF PAINTING the surface sufficiently rough for proper
7.2.1 The areas that are to be painted for any bonding of the new layer of paint.
tank shall include all such areas that 7.4.3 The primer must be applied on the sand
are made of carbon steel and not in blasted surface the same day before sun-set
contact with the process fluid. This shall and in any case before any oxidation takes
include the following place.
Shell outer surface
7.4.4 When weld joints are left without
Roof top and bottom surfaces
painting till hydro test is completed, sand
Bottom side of bottom plate. blasting is to be done along weld joints
All structural like roof supports, rafters, before painting.
and girders
Platforms, ladders, stairways and 7.5.0 APPLICATION OF PAINTING
landings
Inside of shell above the maximum 7.5.1 No paint shall be applied without the
liquid level or overflow level approval of FEDO. A coat or paint can be
Nozzles and flanges except flange applied only after the previous one is dry,
facing FEDO reserves the right to ask for the
All external clips and pipe supports suspension of the work when humidity
increases 85% or during rain, fog or dusty
Top portions of internal column
environment. The overall thickness of the
supports above maximum liquid level
protective coats after drying shall be
7.2.2 For floating roof tanks, the following checked by FEDO and in case the
area are also to be painted. thickness of the paint is found insufficient,
Wind girder the vendor shall be obliged to give further
Top of deck/ pontoons / buoys coat at his own cost. All painting should be
Inside of pontoons done by brush of width not more than 150
Portion of shell inside for a height of mm.
900 mm. below curb angle
7.5.2 Machined faces of all flanges shall be
Pontoon outer rim above product varnished and protected with wooden discs.
level.

02ES032/2010
8.0.0 WELDING the containers shall be kept in ovens at

temperatures recommended by the
8.1.0. WELDING PROCESS electrode manufacturer. Out of the oven
8.1.1. Welding of various materials under this time of electrodes, before they are
specification shall be carried out using one consumed, shall not exceed the limits
or more of the following processes, with the recommended by the electrode
approval of FEDO. manufacturer.
a. Shielded metal arc welding process.
b. Automatic submerged arc welding 8.3.0 WEATHER CONDITION
process.
8.3.1 The parts being welded and the welding
8.1.2 A combination of different welding personnel should be adequately protected
processes or a combination of from rain and strong winds.
electrodes of different class/makes
could be employed for a particular joint only
after duly qualifying the welding pro- 8.4.0 WELDING TECHNIQUE
cedures to be adopted and obtaining the 8.4.1 On completion of each run, craters, weld
approval of FEDO. irregularities; slags, etc. shall be removed
8.1.3 All structural items shall not be welded by grinding.
directly on the shell. Pad plate of the same 8.4.2 The weld beads shall not be started at the
material as the shell shall be provided for same point in different layers.
this purpose.
8.4.3 The weld shall be free from undercuts and
other defects.
8.2.0 FILLER MATERIALS
8.4.4 Weld identification mark shall be
8.2.1 The electrode/filler wire shall be suitable for stamped clearly at each joint, just adjacent
the welding process recommended and to the weld. Suitable paint shall be used on
base metal used. Physical properties of thin weld joints for identification instead of
the welds produced by an electrode/filler stamping.
wire recommended for the welding of a
8.4.5 No painting shall be done until weld-joint
particular base metal shall not be lower
has been approved.
than the minimum values specified for the
base metal and shall correspond to the
physical properties of the class of electrode 8.5.0 WELDING PROCEDURE QUALIFICATION
used. The choice of electrode shall be
made after conducting the required tests on 8.5.1 Shielded metal arc welding, Automatic
the electrodes as per relevant standards submerged arc welding or a combination of
and shall be to the satisfaction of FEDO site the two will be used for welding of various
engineer. joints. Any welding process, combination of
welding processes, different
8.2.2 Qualification of electrodes as per ASME classes/makes/combinations of electrodes,
Section-II, Part-C is to be carried out for can be employed only after qualifying the
those electrodes, which have not been welding procedure. Procedure qualification
qualified by FEDO. The relevant sections is to be carried out as per ASME Section IX
of the code are given below and API 650, Chapter 7, vendor has to
SFA 5.1 - Carbon steel covered arc- submit procedure for approval before
welding electrodes starting qualification tests. For welds
involving high strength materials (group IV,
SFA 5.5 - Low alloy steel covered arc- IVA, V & VI of Table 2 - 3 of API 650,
welding electrodes. procedure qualification shall be carried out
8.2.3 The vendor shall submit batch test as follows
certificates from the electrode
8.5.2 Test to be conducted for plates of each
manufacturers giving details of physical
specification and grade to be used in the tank
and chemical tests carried out by them for
construction. Test plate to be as thick as the
each batch of electrodes to be supplied by
plate of same type used for the tank shell.
the vendor.
8.5.3 Test to be carried out for to each position
8.2.4 All electrodes shall be purchased in sealed
and for each process employed for the
containers and stored properly to prevent
tank construction.
deterioration. The electrodes removed from

02ES032/2010
8.5.4 The positions requiring qualification are 2G 8.6.2 The welders shall always have in their
and 3G to shell and 1G with backing for possession the identification card and
annular plates. For nozzle joints shall produce it on demand by FEDO. It
procedure qualification may be conducted shall be the responsibility of the vendor
in 5G position. to issue the identity cards after they have
8.5.5 No welding shall be taken up without been duly certified by FEDO.
approval of the welding procedure and 8.6.3 No welder shall be permitted to work without
welder qualification tests by FEDO. the possession of identity card.
8.5.6 Welding procedure qualification shall be 8.6.4 If a welder is found to perform a type of
carried out in accordance with the welding or in a position for which he is not
relevant requirements of ASME Sec.IX qualified, he shall be debarred from doing
latest edition or other applicable codes any further work. All welds performed by
and other job requirements. The vendor an unqualified welder shall be cut and
shall submit the welding procedure redone by a qualified welder at the
specifications immediately after the expense of the vendor.
receipt of order.
8.5.7 FEDO will review, check and approve the 8.6.5 Welders engaged by the vendor shall be
welding procedure submitted and shall tested and classified as follows
release the procedure for procedure a. 'A' Grade welders
qualification tests. The procedure
They will be permitted to weld shell. The
qualification test shall be carried out by
welders will be tested by the FEDO
the vendor at his own expense. A complete
Engineer for horizontal and vertical position
set of test results shall be submitted to
butt welds. Another set of welders will be
FEDO for approval, immediately after
given pipe welders test and will be
completing the procedure qualification
permitted to weld nozzles, appurte-
tests and at least two weeks before
nances and reinforcing pads.
commencement of work. It shall be the
responsibility of the vendor to carry out b. 'B' Grade welders
all the test required to the satisfaction of They will be allowed for fillet welding only.
FEDO. The welders will be tested by the FEDO for
fillet weld and butt-welding on down hand
8.6.0 WELDER QUALIFICATION position only. The vendor shall make
8.6.1 Performance Qualification arrangement for such test at his own cost,
in the presence of FEDO.
a. All welders employed for the job are to
be qualified as per ASME Section IX.
Each welder shall be qualified for the 8.7.0 INSPECTION OF WELDS
particular welding position and the
corresponding class of electrode to be Inspection of welds shall follow the steps
employed in the job. All welding including given below:
that for temporary fixtures, erection/fit-up a. Conduct welders’ qualification tests
at shall be done only by qualified and certifies their qualification.
welders. Each welder has to qualify
the mechanical tests as per QW 302.1 b. Verification and development of
of ASME Section IX.or other applicable welding procedure.
codes. c. Inspection of welding equipment and
electrodes used.
b. FEDO shall witness the test and certify
the qualification of each welder separately. d. Supervision and inspection of execution
Only those welders who have been of welds.
approved by FEDO shall be employed for e. Fixing up location and verification of
welding. Vendor shall submit the welder radio graphs submitted.
qualification reports in the standard
format and obtain express approval, f. Inspection of hydrostatic, bottom and
before commencement of the work. It roof tests and any welding repair.
shall be the responsibility of the vendor g. Develop and inspect any special
to carry out qualification tests of tests when those carried out by the
welders. vendor are considered insufficient.

02ES032/2010
h. Stamp the weld identification marks after presence of FEDO site engineer and
the inspection. test certificate will be issu ed
i Prepare inspection reports in accordance accordingly.
with relevant procedures. 9.1.5 Liquid penetrant examination and
acceptance criteria shall be as per
ASME Sec.VIII Div.l latest edition
8.8.0 RADIOGRAPHY & INSPECTION OF wherever specified in the draw -
WELDS ing/code.
8.8.1 Tank welds shall be radiographed and 9.1.6 Liquid penetrant test shall be
interpreted as per API 650 (latest) and substituted for radiography test for
applicable index. the annular plates. The annular
8.8.2 Quality control shall be done plate butt joint root run shall be 100%
progressively through out the job. dye penetrant tested.
8.8.3 Radiograph film length shall be 10 inches
minimum, except if the weld is less than 10 9.2.0 SHELL TESTS
feet long.
9.2.1 Bottom to shell joint testing shall be
8.8.4 Radiograph film shall be of approved
quality. a. Inner fillet weld shall be inspected
and tested prior to welding the outside
8.8.5 The vendor shall be responsible for taking fillet weld. The leak testing shall be
the radiography by his own equipment at performed with penetrating oil after
his own cost for the entire job. removal of slag. Oil shall be removed
8.8.6 Weld areas to be radiographed shall be before welding the outer fillet.
designated by FEDO.
b. Examination for inner fillet toe cracks
8.8.7 Radiographs of the welds shall be taken as shall be performed using either liquid
soon as the welding joint is completed. If penetrant or magnetic particle
repairs are required, they shall be carried method.
out, before continuing the other welds, by the
9.2.2 After completion, tanks shall be
contractor at his own cost.
thoroughly cleaned. All weld lugs
8.8.8 Welds attaching nozzles, manholes etc. and brackets used for erection
shall be inspected as per API-650 latest purposes shall be carefully removed
and applicable appendix. from outside and inside surface of
8.8.9 Welds found faulty as a result of the tank to the entire satisfaction of
radiographic, visual or other tests must FEDO or his representative. Parent
be chipped off to the satisfaction of metal damaged during removal of
FEDO or his representative and a re erection lugs, brackets etc. shall be
welded as per specifications and repaired by filling weld metal and
instructions. The weld portion shall be grinding to the satisfaction of FEDO
retested as per the instructions of site engineer.
FEDO or his representative. No claim 9.2.3 The vendor shall hydrostatically test
for compensation whatsoever shall be the tank including filling and
entertained by FEDO on this account. emptying. The approved procedure
shall be used for the hydro-testing. If
9.0.0 TESTING
salt water is used for testing and will
9.1.0 BOTTOM TESTS remain in the tank for more than 30
9.1.1 The weld joints along the periphery days, an oxygen scavenger and
shall be tested before erection and corrosion inhibitor shall be added.
welding of the first shell. After testing, the tank shall be
drained and thoroughly rinsed with
9.1.2 Leak tightness of the bottom will be clean fresh water. Water, silt or
checked by vacuum box. other dirt left in the t ank after
9.1.3 A detailed description of the proposed hydrostatic testing shall be cleaned
method shall be submitted for FEDO so that the tank interior is "broom"
review. clean and ready for operation.
9.1.4 Vendor shall test the tank bottom for 9.2.4 The vendor shall furnish, lay and
the entire weld length in the remove all lines required for testing

02ES032/2010
from the water supply source and to 9.5.0 TEST GAUGES

the water disposal point. This sh all 9.5.1 All pressure and vacuum gauges shall be
include all pumps, valves etc. calibrated and calibration certificates
9.2.5 After completion, tanks shall be shall be availability for verification
thoroughly cleaned. before their use on tests.
9.2.6 All openings not used for the hydrostatic
test or any other test shall be closed by
plugs and blind flanges supplied by the 10.0.0 VENDOR DOCUMENTS
vendor. 10.1.0 Vendor shall furnish documents as listed in
9.2.5 After equipment, required for testing, shall the Vendor data requirements form in
be supplied by the vendor. accordance with the vendor data
9.2.6 Vendor shall perform the hydrostatic test submission procedure.
in the presence of FEDO on each tank 10.2.0 Type of documents to be submitted shall
after erection. Any defects observed include
during the testing shall be repaired by the Fabrication drawings.
vendor. Calculation sheets.
9.2.9 When the tank is full upto the nominal Material test certificates
capacity, all welded joints shall be Radiographic results Test reports.
hammered by the vendor in the presence WPS S PQR
of FEDO. In case of any defect, it shall be Calibration charts.
repaired and retested by the vendor as
per the instructions of FEDO. 10.3.0 DRAWINGS
9.2.10 Tank shall be emptied at a maximum water 10.3.1 General arrangement drawings of the tank
level variation rate of 5m per day or as per with design data and material
the instructions of FEDO. specifications are attached with the
Enquiry/P.O documents.
9.2.11 All weld repairs shall be done with water
level minimum 300mm below the joint being 10.3.2 Vendor shall forward the general
repaired. arrangement drawing and plate
requirement of the equipment along with
the offer, if called for in the enquiry.
9.3.0 ROOF TESTS
10.3.3 On award of contract, vendor shall design
9.3.1 Tank roof shall be tested by vacuum the tank and prepare detailed fabrication
box or applying internal pressure at the drawings.
option of the FEDO. Vendor has to make
10.3.4 Fabrication drawing of tank shall
arrangements for required tests.
include the following details.
9.3.2 The roof drain is to be pressure tested
General arrangement with overall
at 4.0-kg/cm2 gauge pressure. After fixing
dimensions and plate thickness.
the roof seal there should not be any
clearance between shell and seal at any Detailed fabrication drawing of each
location for the entire tank height and this is component
to be verified during hydro-testing. Weld lines, weld profiles and sizes
Edge preparation and method employed.
9.3.3 Pressure - vacuum relief valves are to be Tolerance
tested before installing.
Quality, brand name. gauge of electrode
9.3.4 Proof testing of the floating roof to be used.
simulating the minimum floating roof Details of reinforcement pads with tell tale
design requirements as per code holes
requirements shall be done with the
Nozzle details
floating.
Details of brackets for supporting pipes,
platforms, ladders/staircase, earthing
9.4.0 NOZZLE REINFORCING PLATES connection etc.
9.4.1 These reinforcing plates shall be air Detail of appurtenances
pressure tested at 3 Kg/cm2 with soap Details of internal fixtures
solution. This test shall be done before
hydrostatic testing of tank.

02ES032/2010
Complete bill of materials indicating supply 10.4.2 Design calculation of floating roof tank
by FEDO/vendor with item wise weight shall also include the following item.
Total plate requirement Design of Pontoon & structural stability
analysis
All other information and general and
Pontoon support calculation
special instructions required as per FEDO
Flotation calculation of floating roof
drawings
Design and sizing of vent & drains
Plate cutting diagrams
Detail of structure for roof supports
Details of stairway, platforms and handrails 11.0.0 STATUTORY REQUIREMENTS
Development details of shell, roof, floating 11.1.0 Vendor shall arrange for all necessary
roof and bottom statutory clearances like IBR, CCE approval
WPS and PQR. etc. for drawings, fabrication and site work
Catalogues / drawings for bought-out at his own cost, unless other wise
items. specified in the purchase order.
10.3.5 The following details are also required in 12.0.0 GUARANTEE
the case of floating roof tanks.
12.1.0 Vendor shall guarantee that all materials
Arrangement drawing and fabrication used for the equipment have been
details of floating roof tanks submitted to regular acceptance
Pontoon support details procedure and free from any defect
regarding quality, form and appearance,
Rolling ladder and rack
12.2.0 Vessels must be guaranteed for design;
Rim vent, bleeder vent, PV valve, foam materials and workmanship for a period as
bund etc. specified in the Commercial conditions of
Centre drain and articulated drain pipe the Purchase Order.
Foam seal and fixing detail
12.3.0 Any vessel, or its part not having been
Deck nozzles, man ways and other submitted to wrong operating service or
pontoon accessories faulty manipulation and found defective
during erection, test or during operation,
10.4.0 DESIGN CALCULATIONS. shall be repaired / replaced by the vendor
10.4.1 The design calculations shall include design without delay and free of cost within the
of the following items guarantee period.
Shell, roof & bottom plates, Roof structure & 12.4.0 In case of defective equipment FEDO
supports shall have the option to repair / replace the
Wind and earthquake analysis equipment after intimating to the
Design of wind girder manufacturer, in order to avoid time delay.
Design of anchors In such an event, FEDO shall been titled to
Stress analysis of agitator mounted nozzles. recover the cost of such repair /
replacement from the vendor.
******************

SPECIFICATION
PAINTING
PAGE 1 OF 13
CONTENTS:
1.0.0. SCOPE
2.0.0. MATERIALS
3.0.0. SURFACE PREPARATION
4.0.0. STORAGE OF PAINTING MATERIALS
5.0.0. MIXING AND THINNING
6.0.0. PAINTING
7.0.0. SAFETY
8.0.0. INSPECTION
9.0.0. GUARANTEE
10.0.0. CODIFICATION OF PAINTING MATERIALS
11.0.0. SCHEME OF PAINTING
12.0.0. COLOUR CODING & MATERIAL FOR PIPING TABLES

02ES023/2010
ENGINEERING PAINTING
1.0.0. SCOPE a) Non ferrous surfaces, stainless

steel and High Alloy steel
1.1.0. This specification covers the surfaces.
requirements for surface preparation, b) Glass, tile or ceramic surfaces
painting and painting materials for c) Name plates and identification
equipment, structures and piping tags
(including those painted/primed at shop d) Valve stems
and those painted at Field/Site. e) Machined contact surfaces
f) Galvanised surfaces
1.2.0. Requirement of painting for any item g) Insulation covers
shall be as specified in any of the h) Plastics
following documents. i) Underground / buried piping
and equipments which are
a) Equipment Data Sheet provided with special type of
b) Piping line schedule protective coatings.
c) Design Basis for package j) Surfaces / Items which are
items excluded from painting due to
d) Painting schedule specific reasons.
1.3.0. The purpose of painting described in 1.7.0. This specification also covers painting
this specification is generally for of “Markings” and color-coding of
protection against corrosion. carbon steel, low/high alloy steel,
stainless steel, galvanized iron and
1.4.0. Painting for other reasons shall be as insulated pipes.
indicated in the respective equipment
data sheets or painting schedule. 2.0.0. MATERIALS
1.5.0. The following surfaces exposed to 2.1.0. All painting materials shall be of good
atmosphere are covered by this quality as covered by respective IS or
specification, which are not provided other international specifications
by any other form of covering/coating.
2.2.0. Special paints and painting materials
a) Pressure vessels, Tanks, Heat shall have proven quality and shall
Exchangers and other process meet the requirements laid down in the
equipment with Carbon steel respective data sheets for equipment
and low alloy steel as material and piping.
of construction.
b) Machinery items including 2.3.0. All painting materials shall not have
motors. passed the date of expiry or shelf life as
c) Steel structures recommended by manufacturer.
d) Carbon and low alloy steel
piping 3.0.0 SURFACE PREPARATION
1.6.0. The following items shall not be 3.1.0 All surfaces to be painted shall be free
painted unless otherwise specifically from rust, oil, grease, dust, stain,
required by respective equipment Data moisture or any other foreign
Sheets/Painting schedule material/contamination, as per IS 1477
Part I.

02ES023/2010
3.2.0 Surfaces to be painted shall be or when the relative humidity of air

completely dry. exceeds 90%.
3.3.0 Oil, grease, stains and other similar 3.9.3. Blasting operations shall not be carried
contaminants shall be completely out during rain, snow, or strong winds.
removed by using proper solvents and
removers, After cleaning, the surfaces 3.9.4. Blasting medium viz. Slag, grit, or shot
shall be free from even traces of shall be completely dry and shall be
contaminants and solvents/removers. free from any sort of contaminants like
dust, oil, grease etc.
3.4.0 Dust shall be removed by air blowing
or vacuum cleaning. 3.9.5. Blasting air shall be completely dry
and shall have minimum pressure of
3.5.0 Hard and caked dust, mud, mill scale 3.5 kg/cm2.
and rust shall be removed by
mechanical means like wire brushing, 3.10.0 Surfaces which are not suitable for
sand blasting , shot blasting or grit blast-cleaning or could not be blast-
blasting. cleaned due to practical reasons shall
be thoroughly wire brushed to exhibit a
3.6.0 Wet surfaces shall be dried by blowing pronounced metallic sheen, equivalent
warm air. to St 3 as per IS 9954.
3.7.0 All surfaces cleaned by different 3.10.1 Absence of compressed air,

methods shall be painted immediately slag/shot/grit and/or blasting equipment
with out allowing the clean surfaces and accessories shall not be a reason
togather dust, rust and other external for not carrying out blast cleaning.
substances.
4.0.0. STORAGE OF PAINTING
3.8.0 During the course of painting if it is MATERAILS
found that the surfaces are
contaminated due to any reason, the 4.1.0. Paints, varnishes, thinner, additives and
same shall be cleaned by any of the other volatile substances shall be stored
methods described earlier, before in a flame proof enclosure, away from
further proceeding with painting. heat.
3.9.0 All surfaces to be painted after sand, 4.2.0. Fire extinguishers or sand and water
grit or shot blasting shall exhibit almost for emergency fire fighting operations
clean white metal and shall have shall be provided near storage area at
surface finish of SA 2 ½ as per IS easily accessible place for use, in case
9954. of fire.
3.9.1 Blast cleaned surfaces shall be primed 4.3.0. Warning Boards and signs shall be
within 2 hrs, after blasting, before re- exhibited around the storage area.
rusting starts and before contamination.
3.9.2. Blast cleaning shall not be carried out
5.1.0 Mixing and thinning of paints shall be
when temperatures are less than 20C
carried out as per manufacturer’s
recommendations.

02ES023/2010
5.2.0 Mixing and thinning operations shall not be carried out in dusty and draught
be carried out in well ventilated rooms. conditions in damp areas and during
rainy seasons or cold atmosphere.
5.3.0 Only that quantity of paint which is
6.1.4 During painting, adjacent equipments
sufficient to cover the required area
or surfaces shall be protected from
within the specified painting time, shall
paint sprays, splashes or drips.
be mixed at a time.
6.1.5 Painting shall be carried out only by
5.4.0 Mixed paints shall be used with in the
using brushes, rollers, air/airless spray.
time span as recommended by
manufacturer. Mixed paints, for which
6.1.6 Caution boards indicating ‘wet paint’
standing time specified has elapsed,
shall be posted after painting is over
shall not be used.
and kept till the curing time is
completed.
5.5.0 Ready-mixed paints containers shall
be opened only at the time of painting. 6.1.7 For painting of multiple coating, each
Containers shall be closed air tight coat shall be applied only after
after drawing paint from it. sufficient curing time has elapsed after
the previous coat, as recommended by
5.6.0 Ready-mixed paints shall be stirred manufacturer.
well before drawing from the storage
6.1.8 All painted surfaces shall have a
container as well as during painting
uniform and smooth regular finish.
operations.
The surfaces shall be free from foreign
particles, brush marks, bristles, ridges,
5.7.0 Ready-mixed paints shall be thinned
waves, laps wrinkles etc. If such
only if absolutely necessary by using
surface defects occur, the same shall be
thinners commended by manufacturer.
removed by using abrasive paper/cloth
and re-painted.
5.8.0 Balance of ready-mixed paints shall not
be poured back into the main container
6.1.9 Surfaces inaccessible after assembly
after use, but shall be kept in a separate
shall be painted to requirement before
air tight container.
assembly.
6.0.0 PAINTING
6.1.10 Any imperfect or damaged layer/coat
shall be repaired before subsequent
6.1.0 General Requirements.
coating.
6.1.1 Painting of equipment, piping and
6.1.11 At places where welding is to be
structurals shall be carried out at shop
carried out at field after assembly, a
or site as prescribed in the respective
space of 100 to 200 mm width shall be
eqpt. data sheets, piping line schedule
left unpainted on both sides of the
or structural detail drawing.
welding joint.
.
6.1.12 Field welded areas shall be thoroughly
6.1.2 Painting shall not be carried out on
cleaned as required in clause 3.0.0 and
surfaces not prepared and not meeting
painted in the same manner as the
the requirements of clause 3.0.0.
remaining area.
6.1.3 Painting shall be carried out only under
favourable conditions. Painting shall 6.2.0 Shop Painting/Priming.

02ES023/2010
6.2.1 Shop painting/priming shall be carried 7.6.0 Adequate ventilation shall be ensured
out as specified in the respective data during painting and storage of paints.
sheets/line schedule etc. and shall meet
all the requirements of this 7.7.0 Painting workmen shall wear face
specification. masks, gloves and protective clothing
during painting and mixing operations.
6.3.0 Painting at Field /Site. In addition, workmen engaged in
blasting operations shall be earmuffs
6.3.1 Field/site painting shall be carried out also.
as specified in the data sheets/painting
7.8.0 Area where painting is carried out, as
schedule and shall meet all the
well as materials are stored shall be
requirements of this specification for
clean, After work, the areas shall be
painting.
cleared of all scaffoldings, balance
6.3.2 Where equipments/piping/structures materials etc. in order to prevent fire
have already received shop hazards and hinder fire fighting
painting/priming, the painted/primed operations.
surfaces shall be thoroughly cleaned
7.9.0 Painting materials shall be stored and
and inspected for any damage or
painting and blasting operations shall
defects. Such damages or defects shall
be carried out only in areas where fire
be repaired before starting the filed/site
fighting equipments/vehicles and
painting.
personnel evacuation vehicles can have
7.0.0. SAFETY easy access. In areas where such easy
access is not available suitable
7.1.0. Sufficient safety precautions shall be
precautions are to be ensured.
taken to ensure protection of Personnel,
equipments, piping structures and
8.0.0 INSPECTION
buildings in the vicinity, where
painting materials are stored and 8.1.0. All painting materials and related items
painting and blasting operations are shall be inspected to check the
carried out. suitability of the same for the specified
purposes.
7.2.0. Open flames and exposed elements or
sources of ignition of any kind shall be
8.2.0. Painting surfaces are to be inspected
prohibited in the area where painting
after cleaning operation, to ensure that
materials are stored and painting
the surfaces are fit for painting.
operations are carried out.
7.3.0. ‘Warning’ or ‘Caution’ boards 8.3.0. Finished surfaces shall be checked for
indicating chances of fire shall be uniformity in colour, finish and
displaced around the paint storage and appearance as well as for defects.
painting areas.
8.4.0. Thickness of each coat of paint shall be
checked after curing time. The total
7.4.0 Electrical fittings and appliances shall thickness of multiple coats shall be as
be spark proof and shall not cause a specified in the data sheets/piping line
fire in the painting storage and painting schedules/painting schedules.
areas.
8.5.0. Paint thickness gauge shall be either
7.5.0 Cleaning agents with flash point less
mechanical or electronic. The gauges
than 400C shall be used.

02ES023/2010
shall be calibrated regularly. Defective D.02 Single Pack High Temperature

gauges shall not be used. Silicon Aluminium Paint (upto
600oC)
8.6.0. Absence of paint thickness gauge shall
10.5.0. Polyurethane Coating. (For low temp.
not be made for each eqpt/line/structure
application)
separately.
E.01 Two-Pack Polyurethane Holding
8.7.0. A detailed quality / inspection report Primer
shall be made for each eqpt / line / E.02 High Build Polyurethane Coating
structure separately
10.6.0. General Purpose Paints
9.0.0. GUARANTEE F.01 Synthetic Resin based Enamel
F.02 Chemical Resistant Enamel
Guarantee shall cover materials and
F.03 Alkyd, Antiskid Abrasion
workmanship.
Resistant Synthetic Floor Paint
10.0.0. CODIFICATION OF PAINTING
10.7.0. Special Applications
MATERIALS
G.01 Bituminous Mastic Coating
10.1.0. Primers
G.02 Asphalt doping as per IS 10987
A.01 Synthetic Zinc Phosphate App-B
Primer G.03 Thermocolour Paint
A.02 Epoxy based Zinc Phosphate
10.8.0 As an alternative, in place of one coat
Primer
of E.01 – Two pack Polyurethane
A.03 Epoxy based Zinc Rich Primer
Holding Primer, one coat of Epoxy
A.04 Alkyd High Build Zinc
Zinc Phosphate Primer A02 (20
Phosphate Primer
microns) followed by one coat of High
A.05 Inorganic Zinc Silicate Primer
Build Epoxy containing Micaceous
A.06 Chlorinated Rubber based High
Iron oxide-Bo2 (20 microns) shall be
Build Zinc Phosphate Primer
applied before applying finish paint E-
10.2.0. Finish Paints 02-High build Polyurethane coating.
B.01 Epoxy Resin based Enamel 11.0.0 SCHEME OF PAINTING
B.02 Epoxy Resin based Micaceous
11.1.0. Scheme of painting of equipment,
Iron Oxide Paint
piping, structures and other items shall
B.03 Epoxy Resin based High Build
conform to class 1, class II or class III
Paint
as specified in the equipment data
B.04 Coal Tar Epoxy Resin based
sheet/ piping line schedule/ painting
Paint
schedule/ structural drawings.
B.05 Chlorinated Rubber Paint
11.2.0 Representation of painting
10.3.0. Bituminous Coating
Requirement of painting of an item
C.01 Nontoxic Inert Coating for shall be indicated in respective
drinking water tanks drawings/ data sheets/ line schedule/
C.02 Acid Alkali and Heat Resisting painting schedule as follows. Indicate
Coating primer or finish or both as required
10.4.0. Heat Resistant Paints followed by subclass indicated in Table
1, Table 2 or table 3 as the case may
D.01 Dual Pack Aluminium Paint
be.
(upto 250oC)

02ES023/2010
Eg 12.0.0 COLOUR CODING AND MARKING

Primer Class I (1)L FOR PIPING
Finish 12.1.0 In addition to the requirements of

Class I (1)L
painting as per 11.0 the finish painting
Primer & Finish of the piping shall have the specified
Class I (2)M
colors as per Table 4 – Color coding
Primer Class II (2)O for pipes, for purposes of identification
of service.
Primer & finish
Class II (3)O/P
12.2.0 All pipes and pipe lines covered under
Primer 1.7 shall be provided with “Markings”
Class III (1)
such as color bands, hazard markings,
Finish line identification markings, flow
Class III (1)
arrow markings etc. at specified
Primer & Finish Class III (3) locations/intervals and dimensions as
indicated in Table 5 – Marking of
pipes.

02ES023/2010
TABLE 1 – CLASS I – Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping
Sl. SERVICE OPERAT PAINT PRIMER FINISH

No. CONDITIONS ING SUB- Type No.of *DFT Type No.of *DFT
TEMP. CLASS coats coats
1 UN =/< 15 (1) L E.01 1 30 E.02 2 30
INSULATED =/< 65 (1) N A.01 2 20 F.01 2 20
NON =/< 125 (1) M D.01 2 20 D.01 2 20
CORROSSIVE =/< 400 (1) H D.02 2 20 D.02 2 20
ATMOSPHERE
2 UN =/< 15 (2) L E.1 1 30 E.02 2 20
INSULATED =/< 65 (2) N A.06 2 20 B.05 2 20
CORROSSIVE =/< 125 (2) M A.02 2 20 B.02 2 20
ATMOSPHERE =/< 400 (2) H D.02 2 20 D.02 2 20
3 INSULATED =/< 15 (3) L E.01 1 30 - - -
CORROSSIVE =/< 65 (3) N A.04 2 25 - - -
ATMOSPHERE =/< 125 (3) M D.01 2 20 - - -
=/< 400 (3) H D.02 2 20 - - -
4 INSULATED =/< 15 (4) L E.01 1 30 - - -
CORROSSIVE =/< 65 (4) N A.06 1 30 - - -
ATMOSPHERE =/< 125 (4) M D.01 1 30 - - -
=/< 400 (4) H D.02 1 30 - - -
5 SUPPORTS =/< 15 (5) L E.01 1 30 E.02 2 30
FOR ALL =/< 65 (5) N A.01 2 20 F.01 2 20
EQPTS.(INSUL =/< 125 (5) M D.01 2 20 D.01 2 20
ATED/UN =/< 400 (5) H D.02 2 20 D.02 2 20
INSULATED)
6 EQPT. AND =/< 15 (6) L E.01 1 30 E.02 2 30
STRUCTRURE =/< 65 (6) N A.06 2 20 B.05 2 30
S SUBJECTED =/< 125 (6) M A.02 2 20 B.01 2 30
TO SALINE =/< 400 (6) H D.02 2 20 D.02 2 20
ATMOSPHERE
UN
INSULATED
* DFT – Dry film Thickness per coat microns
Notation:
L – Low Temperature
N – Normal Temperature
M – Moderate Temperature
H – High Temperature

02ES023/2010
TABLE 2 – CLASS II – OTHER EQUIPMENTS

PRIMER FINISH
Sl. PAINT
No. TYPE OF ITEM SUB No.of No.of
Type *DFT Type *DFT
CLASS coats coats
Chimneys,Stacks,
Furnaces,heaters
1 (fired and Outside (1) A.05 2 25 D.02 2 20
unfired)operating
Temp upto450oC
D.M.Water Outside (2)O A.01 2 20 F.01 2 25
2
Storage Tanks Inside (2)P A.03 2 35 B.03 2 35
Fresh Water/fire Outside (3)O A.01 2 20 F.01 2 25
3 Water Storage
Tanks Inside (3)P A.03 2 35 B.04 2 75
Drinking Water Outside (4)O A.01 2 20 F.01 2 25
4
Storage Tanks Outside (4)P A.01 2 20 C.01 3 20
Acid/alkali
5 Outside (5) A.04 2 30 C.02 3 25
Storage Tanks
Storage Outside (6)O A.04 2 50 D.01 2 25
Tanks/Vessels for
6
Petroleum
Inside (6)P A.02 2 30 B.03 2 75
Products
Floating Roof
Tanks:Inside of
shell, top of Outside (7)O A.04 2 50 D.01 2 25
bottom
7
plate,topside and
underside of (7)P A.02 2 30 B.03 2 75
deck, inside of
(7)Q A.01 2 25
pontoon
Underside of
8 Bottom Plate of (8) A.01 1 20 G.01 1 80
Tanks
Underground
9 Outside (9) A.01 1 20 G.02
Tanks (buried)
Below Ground
10 (submersible) Outside (10) A.06 2 35 B.05 3 35
Tanks
Secondary
Reformer&Simila
11 (11) G.03 2 ** G.03 1 **
r Eqpt.(Thermo
colour paint)
*DFT : Dry Film Thickness per coat microns

** : As per Manufacturer’s recommendations
Notation: O- Outside P-Product Side Q-Specified Side

02ES023/2010
TABLE 3 – CLASS III – MISCELLANEOUS
PRIMER FINISH
PAINTING
Sl. TYPE OF ITEM No.
SUB No.of
No. Type of *DFT Type *DFT
CLASS coats
coats
Steel structures, Platform
1 Supports (1) A.04 2 20 B.01 2 25
Chequered
2 Plate,Floorplanks&Gang (2) A.04 2 20 F.03 2 25
ways
Handrails
3 Posts,Railings,Ladders (3) A.04 2 20 B.01 2 25
and Stairways
* DFT – Dry Film Thickness per coat microns

02ES023/2010
TABLE 4 – COLOUR CODING FOR PIPES
Sl. Service Identification Colour Band - 1 Colour Band - 2

No. Ground / Finish Colour
1 Instrument Air0 Sky Blue White -
2 Service Air Sky Blue Light Brown -
3 Plant Air Sky Blue French Blue -
4 Cooling Water Sea Green French Blue -
5 Service Water Sea Green French Blue Signal Red
6 Demineralised Water Sea Green Light Orange French Blue
7 Boiler Feed Water Sea Green - -
8 Steam Condensate Sea Green Light Brown -
9 Boiler Blow Down Sea Green White Signal red
10 Turbine condensate Sea Green White -
11 Process Condensate Sea Green Black -
12 Low Pressure Steam Silver Grey Light Orange -
13 Medium Pressure Steam Silver Grey Light Brown -
14 High Pressure Steam Silver Grey Signal Red -
15 Very High Pressure Silver Grey Signal Red French Blue
Steam
16 Naphta Liquid Light Brown French Blue -
17 Naphta Vapour Light Brown French Blue White
18 Fuel Oil Light Brown White -
19 Antifoam Solution Black Sea Green -
20 Phosphate Black Signal Red -
21 Hydrazinc Black Signal Red Sea Green
22 Waste Water Black Sea Green Signal Red
23 Oily Water Black White -
24 Ammonia Liquid Dark Violet French Blue -
25 Ammonia Water Dark Violet French Blue Sea Green
26 Ammonia gas Dark Violet French Blue Canary Yellow
27 MDEA Solution Dark Violet Black White
28 Process Vent Canary Yellow Light Grey Signal Red
29 Carbondioxide Canary Yellow Light Grey -
30 Hydrogen Canary Yellow Signal Red -
31 Nitrogen Canary Yellow Black -
32 LPG Canary Yellow French Blue -
33 Fuel gas Canary Yellow Light Brown -
34 Process Gas Canary Yellow Sea green -
35 Synthesis Gas Canary Yellow White -
36 Effluent Black Sea Green Signal Red
37 Drinking Water Sea Green Light Orange -

02ES023/2010
TABLE 5 – MARKING FOR PIPES

1.0. GROUND COLOUR UNIT OF MEASUREMENT
Insulated Line – all
(excludes buried line)
1.1. Un-insulated Lines–Stainless : Ground colour for a length Per Marking as per para 6.0
Steel,GI ,Alloy steels & of 2 meters below including pipe supports
Other non-ferrous pipelines
___________________________________________________________________________
1.2. Un-insulated carbon steel : Ground colour applied Run length in Meters along
Lines (excluded buried throughout entire length centreline including Markings
Lines) as per Para 6.0 below &
pipe supports
___________________________________________________________________________
2.0. COLOUR BANDS MARKINGS
2.1 Colour band(s)and its width,Band 2 downstream of Band 1(ie.after band 1
along the direction of flow)
Pipe size NB Band 1 B and 2

(D-pipe size in inches) mm mm
80 NB and below 75 ¼ of Band 1
Above 80 NB(3”) up to 100 NB(4””) D x 25 (Rounded to the
Above 100 NB(4”) up to 300 NB(12”) D X 20 nearest mm)
Above 300 NB(12”) D x 15
3.0 HAZARD Diagonal strips of Black and golden Yellow as per IS2379
MARKINGS superimposed on the ground color. If color bands exists, the hazard
marking shall be painted downstream of the bands (ie. after bands in
the direction of flow)
4.0 LINE Color shall be Black or White to contrast with the color on which
IDENTIFICATION they are painted. It shall consist of Line No., Line size, Fluid code
MARKINGS & Pipeline Spec. No. The lettering dimensions shall be as per
IS2379.
5.0 FLOW ARROW Color shall be Black or White to contrast with the color on which
MARKINGS they are painted. The dimension of the arrow shall be as follows and
is based on the size of the pipeline.
150NB & 200NB &

below above
d a a 65 90
b 30 50
c b c 95 125
d 20 30

02ES023/2010
6.0 LOCATION OF MARKINGS

7.0 PIPE SUPPORTS
Marking includes 2M long ground
color, color band(s), hazardous 7.1 This includes base springs, hanger
marking, Line No. & flow direction springs, shoes and trunnions etc. and
arrow which shall be located at the excludes pipe bridge structures,
following points with proper visibility platform, equipment support structures
as per IS2379. and such structures which do not
actually support the pipeline.
a. Battery Limit Points 7.2 The painting of pipe supports forms
b. Either side of walls & dyke walls part of the pipelines and a separate rate
c. For long yard piping – at 30M will not operate.
interval
d. Inter-section on pipe bridge 7.3 The painting specification for pipe
e. Any other location indicated by the supports shall be same as that for pipe
Engineer-in-charge at site ground colour.
****************

02ES030/2010
ENGINEERING
SPECIFICATION RUBBER LINING PAGE 1 OF 9
CONTENTS
1.0.0 SCOPE
2.0.0 GENERAL
3.0.0 DESIGN OF LINING
4.0.0 MATERIAL
5.0.0 SURFACE PREPARATION
6.0.0 APPLICATION
7.0.0 TESTING
8.0.0 INSPECTION
9.0.0 REPAIR
10.0.0 STORAGE
11.0.0 TRANSPORTATION
12.0.0 GUARANTEE
PRPD.BY:- JC CHKD.BY:- CK APPRD. BY:-JK ISSUED ON:- April 2010

02ES030/2010
ENGINEERING RUBBER LINING
1.0.0 SCOPE 2.2.0 SPECIAL REQUIREMENTS

1.1.0 This specification covers the 2.2.1 Special requirements pertaining to
requirements for design, supply of specific application shall be adhered
materials, surface preparation, to strictly.
application of rubber lining, curing,
2.2.2 It shall be the responsibility of the
inspection, testing and repairs of
vendor to ensure that all aspects of
lining with rubber for vessels, tanks
design, fabrication, inspection and
etc. made out of carbon steel
testing conform to the requirements
material.
of the specified codes, standards and
1.2.0 Rubber lining shall be provided to legal requirements.
the equipment on all portion
2.2.3 Conflicts, if any between the eqpt.
indicated in the respective data
Datasheet / drawing / this
sheet / drg. of the equipment.
specification / codes and other
1.3.0 The items shall be rubber lined at enquiry / purchase order
site or at the vendor’s shop as per specifications shall be referred to
the order. FEDO for clarification, prior to the
work. Changes in price and delivery
1.4.0 FEDO means FACT
due to such clarification shall be
ENGINEERING AND DESIGN
resolved and settled immediately. In
ORGANISATION, their authorised
any case the vendor is bound to
representative or their client.
accept the stringent of the
2.0.0 GENERAL conflicting clauses without any price
/ delivery change.
2.1.0 CODES AND STANDARDS
2.3.0 STATUTORY APPROVAL
2.1.1 The applicable codes, standards and
legal regulations shall be as 2.3.1 Vendor shall obtain approval from
indicated in FEDO drawings, data the statutory bodies for equipment
sheets and specifications. Such falling under such categories.
codes and standards shall be of
2.4.0 FEDO DRAWINGS AND
latest editions, unless otherwise
SPECIFICATIONS
specified.
2.4.1 FEDO will furnish the vendor the
2.1.2 The vessel to be rubber lined shall
drawing which are prepared based
in general confirm to the
on FEDO’s basic design work
requirements of Part-I of Indian
containing information such as the
standards 4682-1968 “Code of
shape, basic dimension, design
practice for lining of vessels and
conditions and material of
equipments for chemical processes
construction etc. required by the
Part1-Rubber lining”.
vendor to do the estimate of the
2.1.3 Vessels and Tanks to be rubber work and to make detailed
lined shall be fabricated in such a application drawings. Subsequent
manner that it complies with the revision, if any, in FEDO drawings
requirements of IS4682-Part-I. which will be communicated to the
vendor shall also be considered.
2.1.4 The lining shall be as per this
specification and confirm to the
requirements of IS 4682 Part-I.

02ES030/2010
2.5.0 VENDOR DRAWINGS / liberty to change the thickness and

DOCUMENTS also the hardness to suit the service
condition specified. Such changes
2.5.1 The drawing furnished to the vendor
shall be explained in the offer with
generally will not be a detailed
the reasons for the changes.
application drawing. Hence it is the
responsibility of the vendor to furnish 4.3.0 Lining shall be designed taking into
detailed application drawings. Refer account the proposed vulcanising
Vendor Data submission procedure method (autoclave vulcanisation /
(VDSP), and Vendor Data site vulcanisation / and with pressure
Requirement (VDR) for FEDO steam or open steam).
requirement.
4.4.0 The rubber sheet should be free from
3.0.0 DESIGN OF LINING blisters and other imperfections
which would affect the performance
3.1.0 The selection lining and its method
pf the lining. The thickness tolerance
application shall be based on the
of the lining shall not exceed plus or
following information’s supplied by
minus 10%.
FEDO.
4.5.0 The lining shall be done with nature
1. Full analysis of operating medium
rubber which shall be vulcanised
including constituents present in
thereafter or with pre-vulcanised
traces.
rubber of suitable grade and
2. Maximum, minimum and normal hardness of the service mentioned in
operating temp: and pressure the enquiry / order.
conditions including cycle of
4.6.0 Only virgin rubber shall be used for
variation.
the lining and the vendor shall
3. Cycle of operation, whether batch or provide an identification number for
continuous process. the approved mix and supply
samples of vulcanised sheets for test
4. Details of the amount, particle size
and reference in case of any dispute
and physical characteristics of the
which may arise in future.
suspended matter together with rates
of flow. 4.7.0 Alternate materials such as synthetic
rubber equal or superior in quality
5. Probable anticipated mechanical
may be offered as an alternative
damage, if any during construction or
when called for in the enquiry and
operation.
the properties and suitability of such
4.0.0 MATERIAL materials shall be established by the
vendor. Such materials shall be used
4.1.0 The quality of the rubber shall be
only with the approval of FEDO.
such that it should withstand the
chemical and physical conditions 4.8.0 Care should be taken in the
specified during its service life. It manufacture of the sheets to ensure
shall withstand deterioration by minimum of stress in the material
prolonged contact with the contents which could cause shrinkage during
of the vessel. vulcanisation.
4.2.0 Thickness and hardness of the lining 4.9.0 Care should be taken to see that the
specified by FEDO is the minimum rubber sheets used on the job are not
requirements and for general semi-vulcanised due to exposure to
guidelines only. The vendor is at outside temperatures / long storage.

02ES030/2010
4.10.0 VULCANISATION vulcanisation by providing suitable

insulation.
4.10.1 Generally vulcanisation of the lining
shall be done by steam curing. This 5.0.0 SURFACE PREPARATION
shall be achieved by keeping the lined
5.1.0 All surface to be rubber lined shall
equipment in autoclaves for the
be thoroughly cleaned using a
desired duration and temperature.
solvent or with live steam.
4.10.2 The equipment itself shall be used as
5.2.0 The cleaned surface is then
the autoclave by admitting steam
sandblasted to SA 2 ½ to remove
directly into the vessel, provided that
rust and scale. The sand / grit used
all parts of the equipment is designed
for the job shall be 30-40 mesh size
to withstand the applied steam
5 to 60 Kgs/cm2 g air pressure shall
pressure. Vendor shall submit
be used for blasting to prepare the
calculation to establish this aspect
surface fit for lining. The sand used
along with such offer. However this
for the job shall have sharp edges
method shall be adopted only with
and shall be preferably mountain
prior approval form FEDO.
sand. Sand used once shall not be
4.10.3 When the above two alternatives are reused. After each days sandblasting
impractical and the equipment is is over the surface blasted is cleaned
larger than 2m diameter pre- and first coat primer applied
vulcanised (pre-cured) rubber sheets immediately to prevent rust
shall be used for lining job. However formation.
this aspect shall be mutually agreed
5.3.0 Sharp changes in contours in the
upon before placement of order /
surface to be covered shall be
application.
avoided wherever possible. Edges
4.10.4 In any case during lining by formed by the junctions of plates etc
compartments or in parts is not in different planes and external
acceptable as the resultant angles including misalignment
vulcanisation will not be uniform. should be welded and finished by
grinding to a suitable radius. Internal
4.10.5 Alternate vulcanisation methods shall
angles should be fillet welded and
be employed when called for by the
ground concave so as to provide
design and overall dimensions of the
adequate radius. The radius should
equipment and depending on the
be as great as possible. The
facilities available at site, without
minimum radius shall be equal to the
risking the performance of the lining
thickness of lining vendor shall
to the required service with mutual
ensure that all the surface / contour /
agreement of vendor and FEDO.
welds etc are prepared to his
4.10.6 If the edges of flanges are blanked satisfaction before taking over the
off, a satisfactory method shall be equipment for lining work.
resorted to, to avoid under
5.4.0 All surfaces which are to be covered
vulcanisation of the flanges faces.
with rubber shall be free from pit
4.10.7 During vulcanisation abrupt increase holes and other physical
and decrease of pressure and imperfections. Pittings, corrosion,
temperature shall strictly avoided. cavities, depressions, laminations etc
shall be filled by welding and
4.10.8 The temperature difference between
ground to a smooth curvature.
the inside and outside of the shall be
limited to less than 10BC during

02ES030/2010
5.5.0 All weld spatters should be removed

from surface to be rubber lined.
6.1.3 The calendered rubber sheets shall
5.6.0 Any projections that are objectionable be made to fit the surface to be lined.
to soundness of lining shall be The edges of the rubber sheets shall
removed by grinding. be chamfered with the maximum
inclination of the knife to get a
5.7.0 An initial sandblasting may be
proper overlapping joint. That side
resorted to, if necessary to assess the
of the sheet which will be in contact
repairs to be done for the vessel to
with the adhesive shall be wiped
make it fit for rubber lining.
with the rubber solvent to clean its
5.8.0 Only after complete repairs have been surface and increase its tack. As
carried out and vessel made fit for soon as the solvent evaporates and
rubber lining, final sandblasting as the surface still retains its tack the
mentioned above shall be done and sheet shall be applied to the metal.
first coat primer applied.
6.1.4 Any pre-shrinking of the rubber
6.0.0 APPLICATION sheet shall be done at shop / site
before hand tailoring the sheet to fit
6.1.0 GENERAL
the surface to be lined.
6.1.1 All the surface of the vessel shall be
6.1.5 The air trapped between the rubber
lined as shown in the data sheets /
sheets and the metal surface shall
drawings with rubber sheets of
then be thoroughly and carefully
specified thickness secure by bonded
forced out by using suit able rollers.
to the metal surface.
6.1.6 Extreme care shall be taken during
6.1.2 Before applying the second coat of
rolling to avoid air entrapping. In
rubber solution the surface on which
unvulcanised sheets if air bubbles
the first prime coat has been given
are noticed, the same shall be
after sand blasting shall be cleaned
punctured at a suitable inclination,
with cloth moistured in petrol or other
with a needle / knife dipped in
suitable cleaning agent to remove the
rubber solution and the air pressed
possible dust accumulation due to
out through the hole formed and the
blasting. The surface shall be
puncture / cut rolled with the roller.
thoroughly checked for any rust
formation also. After cleaning petrol / 6.2.0 JOINING OF SHEETS
suitable cleaning agent sufficient time
6.2.1 Unvulcanised sheets shall be joined
lag shall be given for the vapour to
by using overlap bevel joints and
evaporate and to get a dry surface.
vulcanised sheets by strapped joints
Subsequent coats of rubber solution
as detailed in IS4682-Part I.
shall be applied after the solvent has
evaporated from the previous layer. 6.2.2 The staggering of the joints of the
The rubber coatings shall be applied first and second layer rubber lining
in a thin uniform continuous layer shall not be less than 100mm.
using brush. Care shall be taken not
6.2.3 Overlap joints shall be made in such
to for air bubbles while applying the
a way that the overlap flow the
coating. Drips or clots if any shall be
direction of liquid flow.
carefully rubbed into the metal with a
brush. The coating film shall be 6.2.4 Joints at corners and at the edge of
protected against contamination by rings shall be strictly avoided.
dust, fibres and hairs from the brush.

02ES030/2010
6.3.8 Bamboo or wooden scaffolding /

platforms used shall be sufficiently
6.3.0 SAFETY AND PRECAUTIONARY
strong and shall not have sharp
ASPECTS
edges which may damage the rubber
6.3.1 All safety precautions as per the lining.
Factories Act shall be strictly
6.3.9 Ladder used for the job shall have
followed while working inside the
the bottom covered with rubber shoe
vessels.
to prevent any possible damage to
6.3.2 All naked light shall be avoided 24 the lining.
volts safety lamps shall be used.
6.3.10 Any site cutting of the rubber sheets
6.3.3 While applying solution, frequent required shall not be allowed inside
check shall be conducted with a gas the vessel.
tester to ensure that no inflammable
6.3.11 Knives or sharp objects shall not be
or explosive gasses exist within the
allowed inside the vessel except for
limit.
any repairs of the rubber lining
6.3.4 The following precautions shall be being done.
adhered to while testing for continuity
6.3.12 Care shall be taken to ensure that
of lining with a spark tester.
semi-vulcanised rubber sheets are
a. Remove moisture from inside the not used on the job.
tank or other object being tested
6.4.0 SPECIAL REQUIREMENTS FOR
and from the surface of the rubber
LINING OF VACCUM VESSELS
so as to prevent electric shock.
6.4.1 The vendor shall decide the lining
b. Remove oil, dust, wood, metal etc
material and application procedure
from the rubber lining surface.
only after complete study of the
c. For vessels, tanks, ducts, pipe lines working conditions.
in open areas sparks test shall not
6.4.2 Triplex rubber lining with soft-hard-
be conducted while it is raining.
soft layer is preferred for vacuum
d. Inflammable objects shall be kept service rubber lining.
away from the test area.
6.4.3 For vessels which operate under
e. Confirmation shall be obtained vacuum, pre-vulcanised rubber
from the Owner that no flammable sheets shall not be used since it has
or explosive gasses or other less bond strength.
materials exist in the test area.
6.4.4 Since peeling of rubber from metal
6.3.5 Smoke inside or near the rubber surface can be due to improper metal
lining area or near the area where the surface, surface preparation is one of
compound adhesive etc and stored the most important factors in lining
shall be strictly forbidden. of vacuum vessels.
6.3.6 Workers of inside the vessel shall be 6.4.5 Wherever possible the rubber lining
instructed to wear only rubber shoes. of vessels under vacuum should be
There shall not be any nail or other done in the vendor’s shop so that
sharp objects in the shoes which can special attention can be given during
damage the rubber lining. application, vulcanised in an
autoclave.
6.3.7 Metal scaffolding shall be avoided
inside the vessel.

02ES030/2010
6.4.6 Wherever the rubber lining of vessel 6.4.13 Sample rubber pieces shall be put
under vacuum are done at site the inside the vessel during
vessel shall be vulcanised by pressure vulcanisation and checks shall be
vulcanisation method by using the made on the sample piece at the end
equipment as an autoclave by sealing of vulcanisation to ensure that
openings with blind flanges and uniform proposed hardness has been
taking all design / application obtained.
precaution. Adequacy of strength of
6.4.14 Care shall be taken to see that the
the equipment against the steam pressure and temperature inside the
pressure and temperature shall be
vessel is raised / lowered slowly at a
ensured before proceeding this
uniform rate and any abrupt increase
method.
/ decrease shall be strictly avoided.
6.4.7 The equipment shall be provided with
6.4.15 Steam traps and drain holes shall be
outside insulation to limit the
provided at the lowest point of the
temperature difference between
vessel to drain the condensed water
inside and outside within 10BC.
to prevent under vulcanisation of the
6.4.8 Each rubber sheet shall be spark rubber in those areas.
tested to detect defects / pinholes
6.4.16 A hammer test shall be conducted
before application. Spark testing with a wooden mallet to detect any
should be done before and after
separation of rubber from metal
vulcanisation. surface.
6.4.9 Peel test shall be conducted for each
6.4.17 During testing, if the rubber lined
batch of material and only after
surface shows defects in more than
ensuring that the bond strength is as 10% area, the vessel shall be
per IS 4682 Part I the lining job shall
completely relined and retested at
be carried out.
free of cost.
6.4.10 Wherever the lining thickness is more 7.0.0 TESTING
than 3mm, lining shall be done in
different layers with the maximum 7.1.0 Inspection and testing of rubber
thickness of the single layer being 2.5 lining shall be carried out at all
mm. All vertical and horizontal joints stages.
should be staggered and should have 7.2.0 The physical properties /
proper overlaps. composition of the rubber lining
6.4.11 After completion of the lining, shall be tested when specified by
before vulcanisation the lining shall FEDO as per the requirements of IS
be subjected to positive air pressure 3400.
(as limited by the design of the 7.3.0 Peel test shall be conducted on
equipment), which ensures even samples of each batch of compound
bondage between metal surface and
and adhesive and the values
rubber. obtained shall be as per IS 4682-Part
6.4.12 After completion of the rubber I.
lining, the vessel shall be kept for a 7.4.0 The vendor shall give test results
period of minimum 2 days for conducted on samples of hard rubber
natural drying before being for bond strength as per ASTM-429
vulcanised. and the values shall be as per IS
standards.

02ES030/2010
7.5.0 Continuity of the lining shall be 8.2.0 The vendor shall also notify FEDO
ensured by visual inspection and the test schedule sufficiently in
high frequency spark test as per IS advance as to enable them to witness
4682-Part I. Spark test shall be the tests.
conducted before and after
8.3.0 All expenses in connection with
vulcanisation. The voltage used shall
taking specimens and samples and
be as per IS 4682- Part I.
subsequent testing shall be borne by
7.6.0 Hammer test with wooden hammer the vendor.
shall be conducted before and after
9.0.0 REPAIRS
vulcanisation to detect any possible
air gaps / separation of sheets from 9.1.0 Any minor defects noticed on testing
metal surface. and inspection shall be rectified by
the vendor in a manner mutually
7.7.0 Hardness test shall be conducted on
agreed by the vendor and FEDO.
completion of vulcanisation as
The repair shall be done as per good
specified in IS 4682-Part I.
engineering practice and to the entire
7.8.0 The thickness of the lining shall be satisfaction of FEDO site engineer.
checked by direct measurement or by
9.2.0 After the repair, the vendor shall
using a thickness metre as the case
conduct further test and satisfy
may be.
FEDO regarding the suitability of
7.9.0 A hydraulic test, wherever required at the lining.
an agreed pressure and for an agreed
9.3.0 After conducting tests, if the lining
duration of times shall be conducted
again shows major defects, the
in a manner specified by FEDO and
vendor shall replace the complete
there shall be no leakage past the
lining to the satisfaction of FEDO
lining.
representative.
7.10.0 A vacuum test shall be carried out
9.4.0 In case of any dispute regarding the
maintaining the specified vacuum for
degree of the defect as to major
a period of 8 hour and by an agreed
defect or minor defect and the areas
method wherever specified by FEDO.
to be replaced, the decision of
7.11.0 Wherever contamination of the FEDO shall be final.
contents of the equipment by the
10.0.0 STORAGE
lining material in detrimental, check
shall be conducted on samples of the 10.1.0 STORAGE OF LINING
compound. MATERIALS
8.0.0 INSPECTION 10.1.1 The rubber sheets and adhesives
shall be transported from the works
8.1.0 FEDO or its representative shall
of the vendor and stored at site at the
have free access to the works of the
required temperatures.
vendor during execution of the job.
The vendor shall furnish all facilities 10.1.2 The air conditioned / cold storage
to the buyer or his representative to facilities provision required at site
satisfy himself that the materials and during transportation shall be
used and the quality of workmanship mutually discussed and arranged
are in conformity with this between the vendor and owner prior
specification. to placement of order. However it
shall be the responsibility of the
vendor to arrange all facilities for the

02ES030/2010
safe transport and storage of the 12.0.0 GUARANTEE

sheet and adhesives at his own cost.
12.1.0 Vendor must guarantee that all
10.1.3 The vendor shall ensure that the work materials used for the lining have
area is properly protected against been submitted to regular acceptance
unfavourable weather conditions such procedureand free from any defect
as rain, wind dust etc. regarding composition, strength,
quality, form and appearance.
10.2.0 STORAGE OF LINED VESSELS
12.2.0 Rubber lining must be guaranteed
10.2.1 The lined vessels shall be kept
for design, materials and
preferably in cool and dark place. In
workmanship for a period as
case of large equipment the outside of
specified in the commercial
the vessel shall be covered to protect
conditions of the purchase order.
from direct sunlight.
12.3.0 Any vessel lining or part not having
10.2.2 The rubber lined vessels may be filled
been submitted to wrong operating
with water until it is commissioned.
service or faulty manipulation and
10.2.3 The rubber lined equipment shall be found defective during test after
kept away from fire. installation or during operation, shall
be repaired / replaced by vendor
11.0.0 TRANSPORTATION OF
without delay and free of cost within
RUBBER LINED EQUIPMENT
the guarantee period.
11.1.0 Rubber lined equipment shall be
12.4.0 During guarantee period, in case of
properly crated to prevent possible
defective equipment, FEDO shall
impact and mechanical damage
have the option to repair / replace
during transportation.
the equipment after intimating to the
11.2.0 Extreme care shall be taken while vendor, in order to avoid time delay.
loading and unloading of rubber lined In such an event, FEDO shall be
equipment to prevent damage. entitled to recover the cost of such
repair / replacement from the
vendor.
********************

02ES041/2010
ENGINEERING
SPECIFICATION ANCHOR BOLT PAGE 1 OF 2
CONTENTS
1.0.0 SCOPE
2.0.0 CODES AND STANDARDS
3.0.0 MATERIAL
4.0.0 IDENTIFICATION MARKS
5.0.0 INSPECTION
6.0.0 PACKING AND FORWARDING
8.0.0 GUARANTEE

02ES041/2010
ENGINEERING ANCHOR BOLT
1.0.0 SCOPE
1.1.0 This specification covers the 4.0.0 IDENTIFICATION MARKS
requirement for manufacture,
inspection, testing and supply of 4.1.0 Anchor bolts supplied shall be
anchor bolts for static equipment. provided with proper identification
1.2.0 The vendor shall quote for all the items marks indicating the bolt designation
in the anchor bolt schedule. The listed in the schedule. The designation
requirement given in the schedule is shall be clearly stamped with low
indicative only. The purchaser reserves impression punching on the shank of
the right to delete/increase/decrease the each anchor bolt. In addition to this all
number of bolts in each category. The the anchor bolts shall be individually
quoted rates shall be firm even after provided with suitable leather tags with
such change in scope. The final the designation printed on it.
requirement will be intimated during
the time of placing the order. 5.0.0 INSPECTIION
2.0.0 CODES AND STANDARDS 5 . 1 . 0 Anchor bolts shall be subjected to

2.1.0 Bolt shall be Metric sizes as per the inspection / acceptance by FEDO /
anchor bolt schedule and threads shall Purchaser.
be as per IS 4218.
2.2.0 The threads shall be 2 pitch series for 6.0.0 PACKING AND FORWARDING
bolts below M24 size and 3 pitch series
of sizes M24 and above. 6.1.0 All items shall be properly packed so as
to enable easy identification of each
3.0.0 MATERIAL type of bolts. The packing shall be
3.1.0 The material of construction of bolt done as per the FEDO engineering
shall be as specified in the anchor bolt spec. 02ES022/2010. Threading of
designation. Anchor bolt designation bolts and nuts shall be coated with
is as explained below. suitable lubricant to prevent galling,
before despatch.
Eg.M24TP3A
M24 TP3 A
Size Type Material code 7.1.0 Relevant material test certificates,
certificate of manufacturing and
3.2.0 Refer FEDO standard 02DS002 for inspection shall be forwarded along
details and dimensions of various types with supply.
of anchor bolts. Material code shall be
as specified below. 8.0.0 GUARANTEE
Material 8.1.0 Vendor shall guarantee against

Part A B C defective materials and faulty
SA 193 B7 IS-2062 SS-304 workmanship for the period and terms
Bolt
as specified in the commercial
Nut SA 194 2H SA 194 2H SS-304 conditions of the enquiry/order.
Plates IS-2062 IS-2062 SS-304
**********************

iso2.sty
ENGINEERING 01ES010 / 94
SPECIFICATION
CENTRIFUGAL PUMPS
FOR GENERAL PURPOSE SERVICES PAGE 1 OF 7
CONTENTS 1. Max. Allowable Casing Working Pressure

1.0.0 SCOPE The greatest discharge pressure at the
specified pumping temperature for which
2.0.0 REFERENCES the pump casing is designed. Designs shall
3.0.0 DEFINITIONS conform to the requirements of this
specification. The pressure shall be equal
4.0.0 DESIGN AND MANUFACTURE to or greater than max. discharge pressure.
5.0.0 SHOP INSPECTIONS AND TESTS 2. Maximum Discharge Pressure
6.0.0 ASSEMBLY & PREPARATION FOR SHIPMENT The maximum possible suction pressure to
7.0.0 APPENDICES be encountered, plus the maximum dif-
ferential pressure the pump is able to
———————————— develop when operating at the specified
conditions of speed, specific gravity and
1.0.0 SCOPE pumping temperature with the furnished im-
peller. For vertical pumps, the pressure shall
This specification covers the engineering re- be referenced to bottom of base plate.
quirements for horizontal and vertical centrifugal
pumps for general purpose services. 3. Rated Discharge Pressure
1.2.0 Special requirements of the project. The discharge pressure of the pump at the
guarantee point related to rated capacity,
Special requirements of the project attached to speed, suction pressure and liquid specific
this specification cover modifications to this gravity. For vertical pumps, the pressure
specification, customer’s special or local re- shall be referenced to bottom of base plate.
quirement as well as specific job data pertinent
to this specification. Where special require- 4. Maximum Suction Pressure
ments of the project are in contradiction to this
specification, special requirements of the The highest suction pressure to which the
project shall govern. pump is subjected during operations. For
vertical pumps, the pressure shall be refer-
2.0.0 REFERENCES enced to bottom of base plate .
5. Rated Suction Pressure
The requirements contained in the latest edi-
tions (unless otherwise indicated) of the follow- The suction pressure for the operating con-
ing specification, standards and code shall form ditions at the guarantee point. For vertical
part of this specification, in the manner and to pumps, the pressure shall be referenced to
the extent indicated herein. bottom of base plate.
6. Rated Speed
1. ANSI B1.1 : Unified Inch Screw Threads (UN
and UNR Thread Form) The normal operating speed (in rpm) on
which the pump performance ratings and
2. ANSI B2.1 : Pipe Threads (Except Dryseal) guarantees are based. For motor-driven
3. ANSI B4.1 : Preferred Limits and Fits for pumps, rated speed shall be the actual
Cylindrical Parts speed of motor based on test report or
drawings of the motor.
4. ANSI B16.5 : Steel Pipe Flanges, Flanged Val-
7. Rated Brake Horsepower
ves and Fittings
The horsepower required by the pump at the
5. ANSI B31.3 : Chemical Plant and Petroleum specified rated operating conditions, includ-
Refinery Piping ing capacity, pressures, specific gravity and
6. ASME Boiler and Pressure Vessel Code viscosity.
a. Section III, Division 1 8. Pressure Casing
All major stationary pressure containing
b. Section V, Nondestructive Examination components of the pump unit, including all
c. Section VIII, Divisions 1 and 2 attached nozzles and other components,
but excluding the shaft and shaft sleeves.
7. Hydraulic Institute Standards for Centrifugal ,
Rotary &Reciprocating Pumps. 9. Net Positive Suction Head Available
8. AFBMA (Anti Friction Bearing Manufacturers’ NPSHA is determined by the purchaser
based on the pumping system require-
Association ) Standards for Ball and Roller Bear-
ments. NPSHA is the total suction head in
ings and Steel Balls. metres of liquid absolute - referred to the
9. MSS (Manufacturers Standardisation Society of pump centerline for horizontal pumps and
the valve and fittings industry) Standards. to the top of the foundation for vertical
pumps - minus the vapor pressure of the
3.0.0 DEFINITIONS liquid at pumping temp. in meters absolute.
The following terms as used in this specification 10. Net Positive Suction Head Required
shall have the meanings denoted: NPSHR i s d e t e r mi n e d b y t h e p u m p
manufacturer and is expressed as metres
PRPD. BY:B.K CHKD. BY:N.R.N APPRD. BY:A.N.J ISSUED ON: MAR ’94

SPECIFICATION
CENTRIFUGAL PUMPS
of liquid (water) required at the pump center- 3. Pressure containing components shall be
line for horizontal pump or at the top of the manufactured in accordance with the ASME
foundation for vertical pumps for the c od e, Se ct ion VII I, Divis ion 1. Th e
specified capacity. manufacturers’ data report forms and
stamping specified in the ASME Code are
11. Submergence not required.
The minimum liquid level above the suction 4. All vertical and horizontal pumps shall be
port necessary to prevent vortexing or furnished with flanged suction and dis-
cavitation. charge nozzles that conform to ANSI stand-
12. Minimum Flow ards unless otherwise specified. Pump suc-
tion and discharge nozzle of 32NB, 65 NB,
Based on the fluid characteristics, the lower 125 NB and 225 NB are not preferred. If the
flow rate at which the pump can continuous- pump manufacturer’s standard design of-
ly operate without danger of failure. fers a flange thickness and diameter greater
than necessary for the specified rating, the
4.0.0 DESIGN AND MANUFACTURE heavier flange may be furnished, but it shall
4.1.0 Pump Selection be faced and drilled as specified. Flange
bolt holes shall straddle the centrelines.
4.1.1 Pump head - capacity curves shall continuously
rise from rated capacity to shutoff unless other- 5. Each stage of a pump shall be self venting
wise approved by the purchaser. The rated by arrangement of the nozzles or be
capacity point shall be at or to the left of the peak provided with a vent connection. All horizon-
efficiency point on the head - capacity curve for tal pumps and vertical in-line pumps shall
the rated impeller diameter unless otherwise be provided with a drain connection. Vent
approved by the purchaser. and casing drain connections shall be 15NB
minimum.
4.1.2 The correction factors given in the 13th edition
of the Hydraulic Institute standards shall be 6. Pumps shall be provided with suitable
used for sizing pumps handling liquids more means, such as eyebolts, lugs or jack-
viscous than water. An NPSH correction factor screws, to facilitate disassembly of gas-
shall not be used. keted joints.
4.1.3 Turbine-driven pumps shall be designed to 7. The casing shall be supported by feet
operate continuously at 105% of rated speed beneath the casing or any other suitable
and, under emergency conditions, at 120% of support between the casing and the
rated speed (turbine overspeed trip setting). baseplate.
4.1.4 All equipment shall be designed for operation 4.2.2 Impellers
outdoors totally unprotected from the elements. 1. Impellers shall be of one piece fabrication.
4.1.5 All instruments and valves, including auxiliary Major components of rotating elements,
systems, shall be securely mounted and sup- such as the impellers and balancing drums,
ported to avoid damage during shipment, shall be individually statically balanced. In
storage, operation and maintenance. addition to static balancing, impellers shall
be dynamically balanced if the pump is to
4.1.6 For pumps with vertical sumps, the pump be operated under any of the following con-
manufacturer shall state the minimum submer- ditions:
gence required and the minimum clearance
from the sump bottom. a. At speeds over 1,800 RPM, where the
rated capacity exceeds 60 M3 /hr and the
4.1.7 Pump shall be designed so that the maximum impeller diameter exceeds 152 mm (6 in.)
allowable sound levels are not exceeded while
operating at specified conditions. b. At speeds over 1,800 RPM for two or
more stages.
4.1.8 Pump selection shall be such that it shall be
possible to obtain an increase in differential For pumps with impellers mounted between the
head to the order of 105% for the rated head by bearings, the shaft and impellers shall first be
changing the impeller with the same casing. individually balanced and then finally balanced
as an assembled unit. After balancing, vibration
4.1.9 Pumps shall be suitable for continuous duty shall be according to the limits specified in Sub-
unless otherwise specified. section 4.2.4.
4.2.0 MECHANICAL DESIGN 2. Impeller shall be fixed to the shaft using
keys. Screwed type fixing is not recom-
4.2.1 Pump Casing mended unless specifically accepted by
1. Pressure casings shall be sufficiently thick purchaser.
to withstand the maximum discharge pres- 4.2.3 Shafts and Shaft Sleeves
sure at pumping temperature and hydros-
tatic test pressure at ambient temperature. 1. Replaceable shaft sleeves are required for
All casings shall have a minimum 3.2mm all pumps. Shaft sleeves shall extend
corrosion allowance unless otherwise beyond the outer face of the gland and
specified. inward past the throat bushing.
2. The design stress, temperature restrictions 2. The pump shaft or shaft sleeve runout
and other requirements for materials shall measured by a dial indicator at the stuffing
conform to the limitations in the ASME code, box face shall not exceed 0.05 mm total
Section VIII, Division 1 for similar material. indicator reading.

SPECIFICATION
CENTRIFUGAL PUMPS
4.2.4 Vibration 2. Gear losses and transmission losses shall

be added to the pump power consumption
Peak-to-peak vibration limits shall apply to before driver rating factors are applied.
pumps with anti-friction bearings and sleeve
bearings. The limits shall cover rotor vibration 3. Motors for pumps covered by this specifica-
during shop and field tests at rated speed and tion shall have horsepower ratings at least
throughout the full operating capacity. equal to the following percentage of pump
rated brake horsepower.
Peak-to-peak limits in micrometers are as fol-
lows: Motor Nameplate Rating, KW Percent of Rated BHP
Rated Speed(RPM) Anti-Friction Sleeve

Bearings * Bearings* 18.5 and less 125
1,800 and below 75 75 Above 18.5 & below 75 115
1,801 to 3,600 50 50
75 and above 110
* Measured on the bearing housings.
Critical speeds shall be at least 20% above or 4. Motor or steam turbine drivers that are
below the normal operating speed for pumps specified on the individual pump specifica-
with flexible shafts and at least 20% above the tion sheets as operating in parallel or
maximum operating speed for pumps with stiff without discharge control valves shall have
shafts. a nameplate rating not less than the maxi-
mum power required by the pump when
4.2.5 Mechanical Shaft Seals furnished with the specified diameter im-
peller.
1. Mechanical seals shall be as specified in
pump data sheets. If mechanical seal 5. The rated power of steam turbine drivers
manufacturer has any alternate recommen- shall be 110% of the rated pump power,
dation for seals, same shall be submitted for based on the guaranteed pump efficiency.
purchaser’s consideration. The steam turbine power rating shall be
based on the specified minimum initial
2. Seal end plates shall be of the same steam conditions at the turbine inlet and the
material or better as the pump casing, ex- maximum exhaust pressure.
cept that carbon steel plates shall be fur-
nished for a cast iron, ductile iron or bronze 4.2.8 Couplings
casing. Seal end plates shall be retained by
a minimum of four stud bolts. 1. Horizontal pumps shall have flexible cou-
plings. Vertical pumps shall have rigid ad-
3. Mechanical seal flush piping shall conform justable, spacer-type couplings when the
to Appendix 2. Seal flush piping shall be of pump thrust load must be carried by the
18 Cr- 8 Ni stainless steel material. bearings of a solid-shaft motor. Vertical
pumps designed with integral thrust bear-
4. Heat exchangers used for cooling mechani- ings shall be supplied with suitable all metal,
cal seal flushing streams shall have 15NB nonlubricated couplings. (A spacer is re-
minimum size tubing for the process liquid. quired if it is possible to service the
The tube material shall be a continuous mechanical seal without completely disas-
fabrication. Material for the product side sembling the pump). Couplings for in-line
shall be 18Cr-8Ni stainless steel or as pumps need not be adjustable.
specified.
2. The pump manufacturer shall mount the
5. Horizontals pumps with impellers mounted pump half-coupling. Gear and driver half
between the bearings and vertical turbine couplings shall be furnished and mounted
type pumps shall be furnished with cartridge by the pump manufacturer unless otherwise
type mechanical seals. specified.
4.2.6 Stuffing Boxes for Conventional Packing 3. Couplings shall be mounted on shafts with
1. Stuffing boxes shall have adequate number a cylindrical fit and keyed in place. Cylindri-
of rings of packing plus the lantern ring. cal fits shall conform to ANSI B4.1, Class
Lantern rings shall have inlet and outlet FN-1.
liquid connection. 4. Couplings shall be dynamically balanced
2. Stuffing box glands shall be easily remov- when the size-speed relationship is such
able and must permit replacement of pack- that balancing is recommended by the cou-
ing without removal or disassembly of any pling manufacturer.
other part of the pump. Glands shall 5. Removable all-metal coupling guards are
preferably have complete bolt holes. Slotted required. They shall be sufficiently rigid to
holes, open at one side are acceptable only avoid contact with the coupling or shaft due
if studs are provided for securing the glands. to body contact.
4.2.7 Drivers 6. Type of couplings shall be as specified in
1. Drivers and gears for vertical pumps shall pump data sheet.
be designed for the maximum up and down 4.2.9 Bearings
thrusts that the pump may develop during
starting or stopping or while operating at any 1. Radial bearings shall be the standard avail-
capacity. able design (ball, roller, sleeve or pivoted
shoe) unless otherwise specified by the pur-

SPECIFICATION
CENTRIFUGAL PUMPS
chaser. the pump manufacturer. They shall be fully

assembled and installed on the pumps.
Anti-friction bearings shall be the standard Piping shall be thoroughly cleaned before
type and selected to give three years connection to a pump. Piping on vertical
(25,000 hrs) minimum (AFBMA) rating life pumps may be separately boxed for ship-
with continuous operation at rated pump ment.
conditions and not less than 16,000 hrs at
maximum axial and radial loads and rated 2. Seal Flushing
speed. The rating life is the number of hours
at constant speed that 90% of a group of a. Seal flushing systems shall be as specified
identical bearings will complete or exceed on the individual pump specification sheet
before the first evidence of failure. by a numeric code from Appendix 2. Sys-
tems shall be arranged for easy disassemb-
2. Horizontal pump bearings shall be arranged ly to permit maintenance and cleaning and
for oil lubrication. shall be properly supported to prevent vibra-
tion and damage. The temperature and
3. Thrust bearings for vertical pumps shall not pressure rating of the system shall not be
be located in the drivers. less than the pump casing maximum dis-
4. Non pressure oil-lubricated bearings shall charge pressure at the maximum pumping
be equipped with 60 cc (minimum) constant temperature.
level oilers. Constant level oilers shall be b. If alloy pump casings are specified, all
provided with protective wire cages. flushing system components shall be of
5. If a complete lube oil system is required, it equal specification or better than the casing
will be specified by the purchaser. material.
4.2.10 Piping c. 18Cr-8Ni stainless steel tubing shall be
used for flushing fluids to mechanical seals.
Piping shall terminate with a flanged connection. The minimum size of tubing shall be 15NB.
Piping shall be in accordance with ANSI B31.3 The minimum tubing wall thickness for
and flanges and flanged fittings in accordance 15NB and 20NB sizes shall be 1.65mm
with ANSI B16.5. Tapped openings and piping (0.065 inch). Tubing fittings shall be 18Cr-
threads shall con form to ANSI B2.1 and B16.5. 8Ni stainless steel.
1. Cooling Water d. Seal flushing systems, including all acces-
a. The cooling water systems shall be ar- sories such as gauges and valves, shall be
ranged for flow through the jacket, coolers, furnished by the pump manufacturer. They
and glands specified on the individual pump shall be fully assembled and installed on the
specification sheet by a letter code from pumps. Piping shall be thoroughly cleaned
Appendix 3. before connection to a pump. Piping on
vertical pumps, except in-line pumps, may
b. The system inlet and outlet shall be at the be separately boxed for shipment.
edge of the baseplate opposite the driver
unless otherwise specified. The system 4.2.11 Auxiliary Connections
shall be arranged for easy disassembly to 1. Tapped openings and threads shall conform
permit maintenance and cleaning and shall to ANSI B2.1 and B16.5. Auxiliary piping
be properly supported to prevent vibration connections that are supplied but not piped
and damage. Complete drainage is re- shall be plugged with solid plugs. Carbon
quired. Closed sight flow indicators and inlet steel plugs shall be used for cast iron cast-
and outlet shut off valves are required for all ings; otherwise, the materials for the plugs
closed cooling water systems. and casing shall be identical.
c. If cooling water is required for a pump and 4.2.12 Baseplates and Mounting
driver, the pump manufacturer shall provide
single inlet and outlet connections for the 1. All horizontal pumps shall be furnished with
cooling water piping. s t urdy drai n rim or drai n pan-ty pe
baseplates with a raised lip. Baseplates
d. Cooling water jackets or housings shall be material shall be as specified. They shall
designed for a minimum 5.3 Kg/cm2G work- extend the full length and width of the pump
ing pressure unless otherwise specified. and driver unit and shall be fully machined
e. Piping shall be 15NB minimum for pumps to receive pump and driver.
with discharge openings smaller than 80NB 2. Basic requirements for baseplates are as
and 20NB minimum for pumps with dis- follows:
charge openings 80NB and larger. Pipe wall
thicknesses shall be schedule 80 for a. Connections for drain shall be tapped 25NB
nominal pipe sizes 15NB through 50NB and in the raised lip at the pump side and shall
schedule 40 for nominal pipe sizes 80NB be located to effect complete drainage. The
and larger. pan or upper surface of the baseplate shall
be sloped at least 10 mm per meter toward
f. Copper tubing conforming to ASTM B88, the drain.
Type K (soft annealed) and brass fittings
may be furnished for cooling water, if b. A minimum of two 100 mm grout holes shall
specified by purchaser. If copper or its alloy be provided in each baseplate. They shall
are specified as not suitable for the service, be positioned to allow grouting with all the
then AISI 316 tubing shall be used. components in place and have vents to
promote even grout distribution. Grout
g. Cooling water systems shall be furnished by

SPECIFICATION
CENTRIFUGAL PUMPS
holes shall have raised lips to prevent liquid for superficial examination, if the material is
accumulating on the exposed grout. ferromagnetic and the surface is acces-
sible.
3. The centerlines of pump shafts shall be
sufficiently high above baseplates for cor- 2. The liquid penetrant method shall be used
rect installation of all auxiliary piping con- for superficial examination, if the material is
nections such as pump drains, steam tur- nonmagnetic or inaccessible for a magnetic
bine inlet end drain and leakoff connections. particle examination.
4. All vertical in-line pumps shall have a flat- 3. The procedure and acceptance criteria (as
bottomed casing. per ASME, except as noted) for the various
nondestructive examinations are:
4.2.13 Materials
Method Procedure Acceptance
1. Materials shall be as specified on the in- criteria
dividual specification sheet. Welds
2. Casings shall be sound, free from shrinkage Radiography Sect V, Art 2 Sect VIII, Div 1
holes, blowholes, scale, blisters and other
defects. Surfaces shall be cleaned by the Magnetic particle Sect V, Art 7 Sect VIII, Div 1,
App VI
pump manufacturer’s standard methods. Liquid Penetrant Sect V, Art 6 Sect VIII, Div 1,
All casting burrs shall be filed or ground App VIII
flush with the surface of the casting. Castings
3. Leaks and defects in pressure casings must Radiography ASTM E 94 MSS-SP-54
not be repaired by plastic or cement com-
pounds. When casting repairs are Magnetic Particle Sect V, Art 7 Sect VIII, Div
1,App VII
authorized by the material specifications, Liquid Penetrant Sect V, Art 6 Sect VIII, Div
repair welding shall be according to the 1,App VII
applicable ASTM specifications. Welding Forgings
repairs shall be made with a welding rod that
will give the same composition as the Magnetic Particle Sect V, Art 7 Sect III,
NB-2545
deposited material and of the same nominal Liquid Penetrant Sect V, Art 6 Sect III,
chemical composition. NB-2546
Ultrasonic ASTM A 368 Sect VIII, Div 2,
4. Cast iron materials are limited to a maxi- AM 203.2
mum design temperature of 1210C .
5.2.0 HYDROSTATIC TEST
4.2.14 Nameplates and Rotation Arrows
5.2.1 Each pressure casing shall be hydrostatically
1. A corrosion-resistant nameplate shall be tested with water at 160C or above. The mini-
permanently attached to each pump. The mum test pressure shall be 1 1/2 times the
nameplate shall be stamped with the follow- maximum allowable casing working pressure.
ing information.
5.2.2 Cooling water jackets shall be hydrostatically
a.Equipment number tested at a pressure of 1 1/2 times maximum
b.Manufacturer’s name cooling water system design pressure.
c.Serial number of pump 5.2.3 Auxiliary piping shall be hydrostatically tested
with water at 16 0C or above. The minimum test
d.Model number of pump pressure shall be 1 1/2 times the design pres-
e.Rated capacity sure of the auxiliary piping or 8.0 Kg/cm2G,
whichever is greater.
f. Pumping head 5.2.4 All hydrostatic tests shall be maintained for a
g.Specific gravity of fluid minimum of 30 minutes.
h.Speed in RPM 5.3.0 PERFORMANCE TEST
i. Driver rating. 5.3.1 Each pump shall be performance tested with
water and job motor. The purchaser’s driver
2. Each pump shall be provided with a cast-in shall not be used for shop running tests if there
or permanently attached arrow indicating is any possibility of serious overload.
the direction of rotation.
5.3.2 Unless otherwise mutually agreed upon, the
5.0.0 SHOP INSPECTIONS AND TESTS test speed of all pumps shall be the rated speed.
Allowable deviations are as follows.
5.1.0 Test procedures and correction factors shall be
agreed by purchaser and manufacturer. For this 1. Normal fluctuations of motor speed.
purpose detailed test procedure write up shall 2. Pumps manufactured for 50 Hz service may
be submitted by manufacturer well in advance be tested at a standard 60 Hz speed and
of test after placement of order. Typical calcula- vice versa.
tions shall form part of the write up.
The certified test curve shall be corrected to
5.1.1 Nondestructive examinations shall be carried actual speed of the job driver.
out according to the individual pump specifica-
tion sheet. All results must be certified by the 5.3.3 The performance test shall include a minimum
purchaser’s inspector. Other requirements are of five test capacities extending from zero flow
as follows. to at least 125% of capacity at peak efficiency.
Capacity test points shall generally be equally
1. The magnetic particle method shall be used

SPECIFICATION
CENTRIFUGAL PUMPS
spaced and include one capacity not more than 6.3.1 Unpainted Surfaces
+ 5% from rated capacity.
Stainless steel surfaces, interiors and finished
5.3.4 The complete pump assembly shall be guaran- surfaces such as flange faces, shafts and cou-
teed for head, capacity, power consumption and plings, shall not be painted.
water NPSH at the specified rated operating
conditions and satisfactory application to all 6.3.2 Painted Surfaces
operating conditions specified on the individual The exteriors of pumps, drivers, baseplates,
pump specification sheet.Permissible devia- accessories and piping, except where otherwise
tions from the specified performance ( in percent prescribed in subsection 6.3.1., shall be painted
of rated ) are as follows or as otherwise specified before the equipment is shipped from the pump
in the specification. manufacturer’s shop.
Rated Zero 6.3.3 Painting shall be carried out under the following
Condition capacity capacity* conditions.
Plus Minus Plus Minus a. Ambient temp. shall be above + 50C.
Rated differential head b. Relative humidity shall be below 80%.
1. 0 to 150M 5 2 10 10 c. Surface to be painted shall be dry.
2. 151M & above 3 2 8 8 6.3.4 Painting shall not be done during raining condi-
Power consumption
tions.
(KW) 4 - - -
6.3.5 Surface preparation is to be performed general-
NPSH required 0 - - - ly in accordance with SSPC standards so as to
Guaranteed efficiency - 0.5% - -
remove all rust, oil and foreign particle.
6.3.6 Painting shall be performed by spray gun.
* A minus tolerance on the head-capacity curve
at zero capacity (shut off) is allowed only if the 6.3.7 Shop painting requirements.
continuously rising characteristic is maintained. Dry Film
5.3.5 Each pump shall be checked for acceptable Service Coat Type of No. of Thk.
conditions Paint coats (microns /
vibration during the shop performance test in Coat )
accordance with subsection 4.2.4.
Extremely Epoxy
corrosive Primer based red 2 25
5.3.6 Mechanical seals shall be used during the shop environment like oxide
splash &
performance test if so specified, but are not spillage of High build
acids, urea upto Finish epoxy 2 35
required for the hydrostatic test. 1300C based paint
5.3.7 Pumps that are dismantled after the shop test Corrosive High build
environment like Primer chlorinated 2 25
solely to machine the impellers and achieve the exposure to salt zinc
dust, acid, acid phosphate
tolerances for differential head need not be fumes etc upto
650C Finish Chlorinated 2 35
retested unless the reduction in impeller rubber paint
diameter exceeds 5 percent of the original Corrosive Epoxy
diameter. environment like based red
exposure to salt Primer oxide / zinc 2 25
dust, acid, acid chromate
5.4.0 NPSH TEST fumes0 etc 65 to /zinc
120 C phosphate
An NPSH test is required, if the difference be- Finish Epoxy
based paint 2 35
tween the NPSH available indicated on the Corrosive -
pump specification sheet and the NPSH re- environment like Primer 2 35
exposure to salt
quired by the pump is 1.0 metre or less. dust, acid, acid Silicon
fumes etc 0 Finish based paint 2 35
above 120 C
6.0.0 ASSEMBLY & PREPARATION FOR SHIP- Ordinary Red oxide
environment Primer zinc 2 25
MENT upto 1200C chromate
( IS2074 )
6.1.0 GENERAL Synthetic
Finish enamel 2 35
( IS2952 )
Assembly and preparation for shipment shall be Saline Epoxy
according to the pump manufacturer’s standard environment
upto 1250C
based zinc
Primer chromate / 2 25
and this specification. The pump manufacturer zinc phosp
hate primer
shall be solely responsible for packing and ship-
ping the pumps. Finish Epoxy
based paint 2 35
6.2.0 EQUIPMENT TRAIN ASSEMBLY 6.3.8 Colour of finish paint for pumps and accessories
6.2.1 Pumps, drivers and all furnished auxiliaries (ex- shall be sea green shade No. 217 of IS-5. If any
cept coupling spacers and bolts) shall be of the catogories of paint are not available in
shipped fully assembled on the baseplates, ex- seagreen colour, then prime and finish coats can
cept where it is not possible or advisable to ship be given in avaiable colours. A final colouring
the pump in fully assembled condition. Coupling coat of enamel paint in sea green colour shall
spacers and bolts shall be separately boxed and be given over the finish coats in such cases.
securely attached to the base plate. 6.3.9 Motors shall be painted as specified in motor
6.2.2 Metal filter elements and screens shall be spec.
cleaned and reinstalled prior to shipment. 6.4.0 Other Protection
6.3.0 PAINTING 6.4.1 Interiors

SPECIFICATION
CENTRIFUGAL PUMPS
1. Bearings, bearing housings and oil systems 1. Each pump component shall be identified
shall be thoroughly cleaned and coated with by its purchase order number and equip-
a suitable rust preventive. ment number. Tags shall be corrosion-resis-
tant metal (not aluminum) and die- stamped
2. Surfaces that were in contact with fluids, with the purchase order number and equip-
including the stuffing boxes and flushing ment number.
piping, shall be thoroughly dried. Surfaces
that are susceptible to corrosion shall be 2. Tags shall be attached to each pump com-
coated with a suitable rust preventive. ponent with stainless steel wire (The tags
are in addition to the equipment nameplate).
3. Mechanical seal assemblies shall be fully Equipments shipped in fully en closed con-
protected from corrosion and ingress of tainers shall also have the purchase order
foreign materials. number and equipment number marked on
6.4.2 Exteriors the outside of the container.
1. Unpainted exteriors, except stainless steel, 3. Miscellaneous components shall be tagged
but including bolting and flange faces, shall or marked with the equipment number of the
be coated with a suitable rust preventive. pump for which they are intended.
2. Afterwards exposed shafts and shaft cou- 4. Equipment containing insulating oils, an-
pling shall be wrapped with waterproof mol- tifreeze solutions or other fluids shall be
dable waxed cloth or VPI barrier paper. The prominently tagged at openings to indicate
seams shall be sealed with adhesive tape. the nature of the contents and shipping and
storage precautions.
6.4.3 Openings
6.6.0 Packing
1. All threaded openings shall be plugged with
long shank pipe plugs. The plug material 6.6.1 All equipment shall be packed, securely
shall be equivalent to the material being anchored (skid-mounted when required) and
plugged, except that carbon steel plugs protected for domestic shipment by rail or truck.
shall be used for openings in cast iron. All unmounted components, except drivers,
shall be suitably crated and firmly attached to
2. Flanged openings shall be provided with full the main pump unit for shipment. Export boxing,
flange diameter protective covers. The if required, shall be mutually agreed upon by
cover material shall be 4.5mm (minimum) purchaser and manufacturer.
thick metal plate. A full diameter gasket shall
be supplied between the flange and the 6.6.2 One complete set of installation, operation and
cover. The cover shall be secured to the maintenance instructions shall be packed and
flange by a minimum of four full diameter shipped with the equipment, if required.
bolts and nuts.
7.0.0 APPENDIXES
6.5.0 Identification
6.5.1 Markings Appendix 1: Classification codes for Mechanical
seals
1. Each major piece of equipment having an
equipment number as per the purchase Appendix 2: Piping for Seals
order or specification sheet shall have a Appendix 3: Cooling Water Piping
permanently attached nameplate. The
nameplate shall comply with the project
specifications.
2. Connections furnished on the equipment
shall be die-stamped or permanently
tagged to agree with the pump
manufacturer’s connection table or general
arrangement drawing.
3. Each coupling half and spacer shall be
electrically etched or die-stamped with the
equipment number of the pump for which it
is intended.
6.5.2 Tags
*********************************

ENGINEERING CENTRIFUGAL PUMPS FOR HEAVY 01ES067 / 19
SPECIFICATION DUTY SERVICE PAGE 1 OF 5
4.0.0 MODIFICATIONS TO API STANDARD 610 8TH
CONTENTS EDITION
1.0.0 SCOPE Centrifugal pumps shall conform to API 610 – 8th
edition, except as modified in this section.
2.0.0 REFERENCES
Reference is made in this section only to those
paragraphs of API 610 – 8th Edition where additions
3.0.0 DEFINITIONS or modifications are made and to wholly new
paragraphs which are inserted in alphanumeric order
4.0.0 MODIFICATIONS TO API STANDARD 610 8TH in API 610 – 8th Edition. Other paragraphs of API
610 – 8th Edition which are not mentioned in this
EDITION section are to be followed without change.
-------------------------------------
1.0.0 SCOPE 4.1.1 The word in parenthesis following the
number or title of a paragraph indicates the
1.1.0 This specification covers the engineering following:
requirements for horizontal and vertical centrifugal ( Addition ) An addition of a part, section or
pumps for heavy duty service.
paragraph referred to.
1.2.0 Special requirements of the project, if attached to
this specification, cover modification to this (Modification) An amplification or rewording has
specification, customer’s special or local been made to a part of the corresponding
requirements as well as specific job data pertinent to section or paragraph but not a substitution
this specification. Where special job requirements replacing the entire section or paragraph.
are in contradiction to this specification, special job (Substitution) A substitution has been made for
requirements shall govern. the corresponding section or paragraph of the
standard in its totality.
1.3.0 This specification does not supersede API standard
610 8th Edition, but modifies it as required in (New) A new section or paragraph having no
following paragraphs. corresponding section or paragraph in the
Standard.
2.0.0 REFERENCES
(Delete) The paragraph is deleted.
2.1.0 The requirements contained in the latest editions 4.2.0 SECTION 1 : GENERAL
(unless otherwise indicated) of following standards
shall form part of this specification in the manner 4.2.1 Para 1.1 Scope (Substitution)
and to the extent indicated. 4.2.1.1 Para 1.1.1 The entire paragraph is substituted by
Hydraulic Institute Standard - Centrifugal Pump paragraph 1.0.0 herein above, excepting the note
Section. contained in the para.
3.0.0 DEFINITIONS 4.2.1.2 1.1.3 (Modification)
Unless otherwise specified, the pump types listed in
3.1.0 Following terms as used in this specification shall Table 1.1 of API shall not be offered.
have the meanings denoted. 4.2.2 Para 1.2 Alternative Designs (Deleted)
Heavy duty centrifugal pump 4.2.3 Para 1.3 Conflicting Requirements (Substitution)
a. Multi stage centrifugal pumps (more than 3 All conflicts between this specification, data sheets
stages) and specifications/codes/standards referred herein
b. Single or two stage, horizontal and vertical shall be referred to the purchaser for clarification
centrifugal pumps having either of following prior to the manufacture of the affected part.
rated service conditions. 4.2.4 Para 1.5.1 (Modification)
0 0 The editions of referenced publication that are in
Temperature : Below -10 C or above+150 C
effect at the time of inquiry or at a date specified in
2
Discharge pr. : 21 Kg/cm G or higher the inquiry documents shall be applicable.
3
Capacity : 150 M /h or higher
4.3.0 SECTION 2 : BASIC DESIGN
Speed : More than 3000RPM 4.3.1 Para 2.1 General
c. Any other centrifugal pump specifically include in 4.3.1.1 Para 2.1.8 (Addition)
the heavy duty classification by Purchaser. Pumps where margin between NPSHA and
NPSHR from quoted minimum flow to rated flow
is less than 0.6 meter are not acceptable. The said
NPSHR value shall correspond to the maximum
PRPD. BY: CHKD. BY: APPRD.BY: ISSUED ON:

SPECIFICATION
CENTRIFUGAL PUMPS
FOR HEAVY DUTY SERVICE PAGE 2 OF 5
Regions of double-casing and horizontal multistage
value of NPSHR from rated flow down to the pumps (pumps with three or more stages) that are
recommended minimum continuous stable flow subject only to suction pressure shall also be designed
specified by the vendor. However in case of parallel for the maximum allowable working pressure.
operation or auto-start against open discharge valve 4.3.2.2 Para 2.2.8 (Substitution)
conditions, NPSHR at End of the Curve shall not The pump's pressure casing shall be suitable to
exceed specified NPSHA in addition to above margin Withstand twice the forces and moments in Table
requirement. Pumps fitted with inducers for reducing 2-1A (2-1B) applied simultaneously to the pump
NPSHR are not acceptable. through each nozzle, plus internal pressure, without
4.3.1.2 Para 2.1.10 (Addition) distortion that would impair operation of the pump
Refer Performance Correction Chart of or seal.
Hydraulic Institute Standard. Correction factors Note: Vendor to note that the above criteria shall be
as applicable shall be indicated by the used for design of purchaser's associated piping system.
manufacturer on the filled-in data sheet.
4.3.1.3 Para 2.1.11 (Substitution) 4.3.3 Para 2.3 Nozzle & Pressure Casing Connections
Pumps shall have stable head/flowrate curves 4.3.3.1 Para 2.3.3.10 (Addition)
(continuous head rise to shutoff) for all Casing shall be provided with drain connection with
applications. If parallel operation is specified, nipple, threaded and seal welded and provided with a
the head rise from rated point to shutoff socket welded gate valve terminated at edge of the
shall be at least 10%. Unless otherwise base plate. Gate valve shall be of 800# rating with
specified, discharge orifice shall not be used to material of construction (MOC) equal or superior to
achieve required head rise to shut off in case of the pump casing. For multistage pumps with more
parallel operation. than one drain point, block valves at each drain
4.3.1.4 Para 2.1.12 (Substitution) point shall be provided and the piping shall be
Pumps shall have preferred operating region of terminated at edge of the base plate with a flange.
70% to 120% of best efficiency flow rate of the Unless made self venting design, vent connections
pump as furnished. Rated flow shall be within shall also be provided with a nipple, threaded and
110% of best efficiency flow rate of the pump as seal welded and terminated with a gate valve.
furnished. Vendor shall indicate "Preferred Pressure gauge connection shall not be provided
Operating Range" and " Allowable Operating unless specifically required in the inquiry. Nipples
Range "on the characteristic curve. shall meet the requirements of 2.3.3.5 & 2.3.3.6.
4.3.1.5 Para 2.1.14 (Substitution)
Unless specified otherwise, the maximum 4.3.4 Para 2.6 Wear Rings And Running Clearances
permissible sound level shall not exceed 88 dBA 4.3.4.1 Para 2.6.3 (Modification)
measured at one (1) meter from the complete The sentence " Other methods including tack
pump unit, when measured in any direction & welds, requires purchaser' s approval" stands
from any point of any equipment surface located deleted.
on the equipment skid, for the recommended 4.3.4.2 Para 2.6.4.1 (Addition)
range of operation. Vendor shall also furnish in the proposal the
4.3.1.6 Para 2.1.20 (Modification) maximum permissible running clearances which in
Maximum inlet temperature 33°C, maximum no case shall be less than twice the running
temperature rise 17°C, fouling factor water side clearances as specified in this clause.
0.0004 m2h°C/Kcal, maximum allowable
working pressure 8 kg/cm2g. 4.3.5 Para 2.7 Mechanical Shaft Seals
4.3.1.7 Para 2.1.29 (Modification) 4.3.5.1 Para 2.7.3.19 (Modification)
Unless otherwise specified, equipment shall be For the applicable flushing and cooling plans, the
designed to be suitable for outdoor installation vendor shall also include in his scope of supply, all
without a roof. items marked with an asterisks (*)and shown as
4.3.1. 8 (New) optional items in Appendix D - Mechanical Seal
For balancing axial thrust in multi-stage pumps, and Piping Schematics along-with all other
only the following arrangements shall be used: specified/ required items.
- Opposed arrangements of impellers.
- A balancing piston 4.3.6 Para 2.8 Dynamics
4.3.6.1 Para 2.8.2.6 (Modification)
Replace the words " when specified" by "If torsional
4.3.2 Para 2.2 Pressure Casings
4.3.2.1 Para 2.2.4 (Modification) analysis is performed".

ENGINEERING CENTRIFUGAL PUMPS 01ES067 / 19
SPECIFICATION FOR HEAVY DUTY SERVICE PAGE 3 OF 5
4.3.7 Para 2.9 Bearings & Bearing Housings operation shall not be less than the max. BKW
4.3.7.1 Para 2.9.2.6 (Modification) indicated on pump data sheet (Power at End of the
Bearing housings shall be equipped with curve for the rated impeller) and the pump motors
replaceable non contact type bearing isolators shall be suitable for start-up under open discharge
where shaft passes through the housing. valve condition.
4.3.7.2 Para 2.9.2.9 (Modification) 2. The motor nameplate rating for applications where
Requirement of oil heaters for bearing oil shall be the specific gravity of pumped fluid is less than 1.0
as per vendor's standard practice and shall be shall either be 100% of the BKW of pump at
provided by the vendor when the ambient or minimum continuous stable flow with clean cold
operating temperature dictates. water of sp. gravity 1.0 or shall have the specified
4.3.7.3 (New) margin as per this clause, whichever is greater.
Bearing housing shall be equipped with magnetic 4.4.1.2 Para 3.1.9 (Modification)
drain plug. Unless otherwise specified, steam turbine drivers
shall be sized to deliver continuously 110% of
4.3.7 Para 2.11 Materials pump rated power at minimum inlet and maximum
4.3.7.1 Para 2.11.1.1 (Modification) exhaust steam conditions. The steam turbine rating
The material of construction of pump parts shall be (with minimum inlet and maximum exhaust steam
in accordance with the data sheet. conditions) for pumps under parallel operation or
4.3.7.2 2.11.1.4(c)(Modification) for pumps with auto-start operation shall not be less
Unless specified otherwise, Casing in Cast Iron than the max. BKW indicated on pump data sheet
construction shall not be offered. (maximum power at any point on the pump
4.3.7.3 Para 2.11.1.7 (Modification) performance curve from shutoff to end of the curve
The words ' when specified' stand deleted. for the rated impeller). The turbine shall also be
4.3.7.4 Para 2.11.1.11 (Modification) suitable for start-up under open discharge valve
Requirements indicated in the referred clause are condition. In any case, Turbine Rating shall be at
applicable even if only trace quantity of wet H2S is least equal to the Motor Rating of the standby
indicated to be present. pump.
4.3.7.5 2.11.2.5 (Modification)
The words " when specified" stand deleted. 4.4.2 Para 3.2 Couplings & Guards
4.4.2.1 Para 3.2.2 (Addition)
The coupling service factor shall not be less than
4.4.0 SECTION 3 - ACCESSORIES
1.5 over the driver rating.
4.4.1 Para 3.1 Driver
4.4.1.1 Para 3.1.4 (Modification) 4.4.2.2 Para 3.2.12 (Addition)
Electric motor drivers shall have a maximum Coupling guard shall be non-sparking and shall be
continuous rating (MCR) (i.e. service factor equal open at the bottom to permit manual shaft rotation.
to 1) not lower than the following: The guard shall be sufficiently rigid to withstand
deflections as a result of bodily contact of
nominally 100 kgs.
Motor Name Motor MCR (% of Pump
4.4.2.3 (New)
plate Rating Rated BKW)
Unless otherwise specified, all couplings required
for multistage pump package(s) (greater than two
Upto 22 kW To suit maximum BKW
stages) shall conform to API standard 671 where
indicated on pump data sheet or
either the driver rating is greater than 160 kW or
125% of rated pump BKW,
the maximum continuous speed is greater than
whichever is higher.
3000 rpm. However in case of gear box driven
multistage pump units, both low speed and high
The electric motor shall be suitable for the
speed couplings shall conform to API standard 671
electrical area classification specified on the data
if any of the above criteria of speed or power is
sheet.
satisfied.
Note:
1. Over and above the requirements specified in
Table 3- 1 and the above modifications, the motor
nameplate rating for pumps under parallel

`
SPECIFICATION CENTRIFUGAL PUMPS
4.4.3 Para 3.3 Baseplates - Cables between transmitters and junction box.
4.4.3.1 Para 3.3.6 (Modification) 4.4.5 Para 3.5 Piping & Appurtenances
The vendor shall furnish the results of the pipe load 4.4.5.1 Para 3.5.2.4 (Addition)
test data for the proposed pump model(s) along Auxiliary process fluid piping material shall be SS-
with their proposal indicating the shaft deflections 316 as a minimum.
at coupling end. 4.4.5.2 3.5.2.10.1 (Modification)
Flanges are required in places of socket welded
4.4.3.2 Para 3.3.20 (Modification) unions.
Anchor bolts & suitable washers shall be furnished 4.4.5.3 (New)
by the pump manufacturer. Material for seal flushing liquid cooler shall be as
4.4.3.3 (New) under:
Pumps in corrosive service shall have provision to Tube or Coil : Type 316 stainless steel or Monel.
collect and drain the leakage from mechanical seal Casing (or Shell): Carbon Steel.
or packing, through a drip pan of metallurgy Cooling water shall be on the casing (Shell) side.
equivalent or superior to pump casing. Leakages 4.4.5.4 3.5.4.3 (Modification)
from drip pan shall be piped to baseplate with a Sight flow indicator shall have ball or flag for easy
flanged connection for onward disposal by verification of water flowing through pipes.
purchaser. Where the design of bearing prohibits Thermal Relief valves in each isolatable CW circuit
provision of drip pan, the material of bearing shall also be provided.
bracket shall be suitable for the corrosive
service. 4.5.0 SECTION 4 - INSPECTION TESTING AND
4.4.3.4 (New)
PREPARATION FOR SHIPMENT
Skid layout of pump trains along-with their
auxiliary systems (i.e. seal flushing plans) shall be 4.5.1 Para 4.1 General
designed in a manner so as to ensure that there is 4.5.1.1 Para 4. 1 .5 (Addition)
enough space within the skid for maintenance and Prior to start of test, manufacturer shall furnish
operation. Special care shall be taken for pumps the certificate of latest calibration / recalibration
provided with seal flushing plans 23 and 52 so that of driver and measuring instruments for review
couplings and seals can be attended for by purchaser' s inspection agency.
maintenance without disturbing any seal Unless electrical or mechanical failure occurs,
piping/cables/other items located on the skid. As driver used for shop testing need not be
far as possible, area on motor terminal box side recalibrated and original calibration certificate
shall be left clear of all piping and accessories for shall remain valid.
ease of maintenance. Duration of recalibration for all measuring
instruments shall be as per the
4.4.4 Para 3.4 Instrumentation recommendations of HI Standards.
4.4.4.1 3.4.3.1 (Modification)
The words ' when specified' stand deleted. 4.5.2 4.3 Testing
4.4.4.2 Para 3.4.3.2 (Modification) 4.5.2.1 Para 4.3.3.3.3 (Modification)
The words `when specified' stand deleted. The tolerances for guaranteed characteristics stand
4.4.4.3 4 (New) modified as under:
Horizontal multistage pumps intended for pumping -Rated Head : Zero negative tolerance @ rated flow
temperature above 120°C shall be provided with rate & rated speed
pump casing skin temperature monitoring system -Shut-off Head Following criteria shall apply:
consisting of the following: a) Positive tolerance permitted as long as maximum
- Four thermocouples along-with yoke mounted shutoff pressure corresponding to shut-off head (as
temperature transmitters with integral indicator for observed during the shop performance test) and the
each thermocouple. maximum suction pressure (as specified on pump
- One Junction Box (JB) to be mounted on the data sheet), does not exceed the downstream design
pump base-plate. pressure (as specified on pump data sheet).
- Cables between the thermocouples and
transmitters.

SPECIFICATION CENTRIFUGAL PUMPS
b) Negative tolerance (as per Table 4-2 of API Std. 4.6.2 Para 5.3 Vertically Suspended Pumps
610,8th edition) may be permitted only if test curve 4.6.2.1 5.3.1 PRESSURE CASINGS
still shows rising characteristics. 4.6.2.1.1 Para 5.3.1.2 (Addition)
c) Negative tolerance is not permitted for pumps Bowls and columns shall be flanged and bolted.
required for pumps under parallel operation.
[Note: Generally shutoff head should be limited 4.6.2.2 Para 5.3.2 ROTORS
within 120% of rated head.] 4.6.2.2.1 Para 5.3.2.3 (Addition)
-NPSHR Zero positive tolerance. Multi-piece vertical pump line shaft shall not be
-Rated BKW Zero positive tolerance. joined by threaded couplings.
4.5.2.3 Para (New) 4.6.2.3 Para 5.3.5 GUIDE BUSHINGS AND BEARINGS
During the performance test, the equipment shall be
checked for its sound level at minimum flow, at 4.6.2.3.1 Para 5.3.5.2 (Modification)
rated flow, at flow at best efficiency point and at Pump thrust shall not be transferred to driver
120% BEP flow. motor. Vertical pumps shall be provided with their
The maximum allowable value shall not exceed the own thrust bearing to carry rotor weight and pump
value specified under clause 2.1.14 or as specified
generated axial forces. Thrust bearing shall be
in the datasheet, whichever is lower, when
measured at one (1) meter from pump surface. positively locked on the pump shaft (shouldered
Where complete unit test is specified, vendor is shaft) and the bearing housing.
required to demonstrate the noise levels within the 4.6.2.4 Para 5.3.6 LUBRICATION
maximum permissible sound level for the complete 4.6.2.4.1 (New)
unit. Recorded sound levels during shop test shall For self lubrication pumps, guide bushing shall be
be taken for reference only & not for final suitable for dry running during startup.
acceptance or rejection. However sounds level as 4.6.2.5 Para 5.3.7 ACCESSORIES
specified in the inquiry document shall be 4.6.2.5.1Para 5.3.7.1.2 (Modification)
guaranteed at site. For vertical pumps, not provided with non-reverse
racket, vendor shall describe the precaution taken,
4.5.3 Para 4.4 Preparation for Shipment to prevent damage due to reverse rotation.
4.5.3.1 (New) 4.6.2.6 Para 5.3.9 SINGLE CASE DIFFUSER (VS1) AND
Unless otherwise specified, the equipment shall be VOLUTE (VS2) PUMPS
protected for a storage of 12 months at site. If any 4.6.2.6.1 Para 5.3.9.7 (Modification)
extra precaution is to be taken by the Purchaser for The words " when specified" stand deleted.
storage beyond 12 months the same shall be 4.6.2.7 Para 5.3.12 DOUBLE CASING DIFFUSER (VS6)
explicitly indicated in the operation and AND VOLUTE (VS7) PUMPS
maintenance manuals. 4.6.2.7.1 Para 5.3.12.6 (Modification)
The words " when specified" stand deleted.
4.6.0 SECTION 5 - SPECIFIC PUMP TYPES
4.6.1 Para 5.2 Between Bearing Pumps (TYPES BB1 - 4.7.0 SECTION 6 - VENDOR' S DATA
BB5) This section is deleted.
4.6.1.1 Para 5.2.8 TESTING
4.6.1.1.1 Para 5.2.8.5 (Modification) Submission of vendor’s data shall be in
The words " when specified" stand deleted. accordance with the requirements stipulated in
4.6.1.2 Para 5.2.9 PREPARATION FOR SHIPMENT the procurement specification vide documents
4.6.1.2.1 Para 5.2.9.2 (Modification) VDS & VDR.
The words " when specified" stand deleted.
*****************************************

TECHNICAL 32644-03-PS-001 ATT
PROCUREMENT ATTACHMENTS
TPS No.
SL. No. of Rev. No. with issue

Doc. No. Description
No. Pages 1 2 3 4
1 32644-03-PS-001 VDR VENDOR DATA REQUIREMENT 1 0
2 32644-03-PS-001 SPL SPECIAL REQUIREMENT (PIPING) 3 0
3 03ES001/10 PIPING DESIGN 11 0
4 03ES010/10 PIPING TURNKEY PACKAGE 2 0
5 03ES014/15 RUBBER LINING FOR PIPES& PIPE FITTINGS 14 0
6 03DS003 PIPING SPACING 1 0
7 03DS013 VENTS & DRAINS FOR PIPE LINES 1 0
8 03DS202 PIPING TRUNNION SELECTION 6 0
9 03DS305 TABLE OF BASIC SPANS AND UNIT LIGHT 3 0
WEIGHT WITHIN BATTERY LIMITS
10 02ES023/10 PAINTING 13 0
11 25ES205/10 FABRICATION , ERECTION OF STEEL PIPING 28 0
12 32644-03-PS-001 SV SUB VENDOR LIST 3 0
13 32644-03-OP-00001_Rev.0 OVERALL PLOT PLAN 1 0
Note: 1. The receipt of all attachments shall be checked and asertained.
2. All attachments of this TPS shall be retained since only revised sheets, if any, shall be issued
0 05.06.2020 FOR ENQUIRY AMN JTG KK

00FT011/10

TECHNICAL
32644-03-PS-001 VDR
PROCUREMENT VENDOR DATA REQUIREMENTS
PROJECT : CONSTRUCTION OF ADDITIONAL PHOSPHORIC ITEM PIPING SYSTEM

ACID STORAGE TANKS AT Q10 BERTH, WI
CLIENT : M/s. FACT TPS No
STATUS : √ ENQUIRY COMMITMENT PO No

Sl. Grp Offer After Commitment Final@@
No Code Description Lead time in weeks Qty
Qty Qty
Reqd Prop@ Agrd
1.0 A Specific plot plan 3P+1S 3P+1S 4 3P+1S
2.0 A&C Piping Layout drg. 3P+1S 4 3P+1S
3.0 A&C Quality control procedure & plan for piping system. 3P+1S 4 3P+1S
4.0 Design data and layout.
4.1 A&C Design basis 3P+1S 4 3P+1S
4.2 A&C Piping material specification 3P+1S 4 3P+1S
4.3 A&C Valve material specification ( with filled data sheet) 3P+1S 4 3P+1S
5.0 Issued for construction (IFC) Drawing. 4
5.1 C Piping GA DRGS. 3P+1S 4 3P+1S
5.2 C Isometrics 3P+1S 4 3P+1S
5.3 C Piping supports, operating platforms drg. 3P+1S 4 3P+1S
6.0 C Material Take-offs 3P+1S 4 3P+1S
7.0 Material and Purchase Requisitions 3P+1S 4 3P+1S
7.1 A Pipes 3P+1S 4 3P+1S
7.2 A Valves 3P+1S 4 3P+1S
8.0 Design calculation / Documents. 4
8.1 B Pipe stress analysis (CEASAR II ) report 1S 4 1S
8.2 A Flexibility Analysis of Piping 3P+1S 4 3P+1S
8.3 A Support and load data 3P+1S 4 3P+1S
9.0 Vendor Drawings 3P+1S 4 3P+1S
9.1 B&C Valves 3P+1S 4 3P+1S
10.0 As Built Drgs 4
10.1 C Piping GAD’s 3P+1S 4 3P+1S
10.2 C Isometrics 3P+1S 4 3P+1S
10.3 C All inspection, testing & NDT Records. 3P+1S 4 3P+1S
Legend :
Group code : A - For review and detailed Engineering , B - For review , C - For information and record
Document type : R - Reproducible , P - Print , M - Microfilm, S - Soft Copy
Notes :
'@' Vendor shall fill in proposed lead time if different from the required lead time
' @@ ' Each set of final documents shall be submitted in a folder. Two such folders shall be packed
and despatched with the equipment.
0 05.06.2020 For Enquiry AMN JTG KK

03FT044B / 2015
REV No DATE DESCRIPTION PREPARED CHECKED APPROVED

PIPING 32644-03-PS-001 SPL
SPECIAL REQUIREMENTS
DEPARTMENT (PIPING) Page 1 of 2
1. Associated piping for the construction of 2nos. of Phosphoric acid (P2O5) sto rage
tank each having capacity of 5900 MT at W.Island, FACT CD m ainly consist of inlet
line to new tanks, line from new ta nks to pu mp suction, recirculation lines , line to
barge, erection of new truck load ing bay and its associated p iping, utility piping etc.
Process and Utility pipin g system for this project shall be in a ccordance with Process
piping code ASME B 31.3.
2. Piping and its com ponents shall be designed as per the attached engineering
specification 03ES001/10 (Piping Design)
3. Bidder shall follow the attach ed engine ering specification 03ES010/10 (Piping
turnkey package) for the piping scope, desi gn consideration, battery limits for piping,
details of drawing and documents, general requirements etc.
4. Bidder shall submit documents as per attached Vendor Data Requirement.
5. General design, m aterial, procedure, testin g etc. for rubber lining shall be as per
attached rubber lining specification 03ES014/15.
6. All piping (Process lin es, Utilities etc.) with in the battery lim its are under the scope
of bidder
7. Piping scope includes design, detail engineer ing, procurem ent, testing at vendor' s
shop and supply of all piping’s as per the a pproved material classes and specification.
8. Design of piping system shall be as per the relevant codes and regulations specifies in
the engineering specifications .
9. Bidder shall furnish drawings & docum ents necessary for approval from statutory
bodies and that all m aterials used sh all be accompanied by the necessary certificates
as per the applicable codes.
10. Detailed painting specifica tions will be as per 02 ES023/2010 (FEDO). Sand blasting
will not be allowed under any circumstances.
11. All lines ter minating at the ba ttery limit shall be provided with a flange and m ating
flange, gasket, bolt & nuts.
12. Bidder shall provide break flanges on pipe lines where ever required for m aintenance
access.
13. Bidder shall provide temporary piping for blow-out. Blank & spacers’ gaskets etc. for
isolation during the line testing and temporary & permanent strainers.
0 05.06.2020 ORIGINAL ISSUE AMN JTG KK

REV DATE DESCRIPTION PRPD CHKD APPRD

PIPING 32644-03-PS-001 SPL
SPECIAL REQUIREMENTS
DEPARTMENT (PIPING) Page 2 of 2
14. For pressure relief valve and safety valve, reaction load calculation shall be carried out
and provide adequate supporting. Outlet vent shall be provided to safe height without
pockets.
15. If the pipe line at the floor level, bottom of the pipe shall be at the height of 500 mm
from the floor level.
16. Piping stress analysis and equipment nozzle loading analysis shall be in accordance
with ASME B31.3 and relevant API codes.
17. Nozzle analysis shall follow the guide lines of ASME Section VIII, Division 1, and
WRC 297 & 107 (Latest editions). Nozzle stresses shall fall within the allowable as
per ASME
18. Bidder shall use latest version of CEASAR II for the pipe stress analysis of critical
piping.
19. The procedure and conditions for hydro test will be followed as per the descriptions
given in engineering specification 25ES205. Sea water/ saline water shall not be used
for hydro testing and contractor shall arrange water for hydro testing at no extra cost.
Suitable corrosion inhibiters should be added.
20. All alloy steel and higher alloyed piping material shall be subjected to Positive
Material Identification (PMI) inspection.
21. Sufficient number of safety showers & eye wash shall be provided in the ISBL area.

iso2.sty
SPECIFICATION
PIPING DESIGN
PAGE 1 OF 11
CONTENTS 2.2.1 The expected continuous operating conditions

shall be specified on the process flow sheets /
line schedule.
1.0.0 GENERAL 2.2.2 The design pressure and metal temperature
shall be in accordance with ASME B31.3 /
2.0.0 DESIGN ASME B31.1 and the following.
3.0.0 MATERIALS a. In vacuum service, the normal design pres-
4.0.0 FABRICATION, HEAT TREATING, INSPEC- sure shall be the lowest value which the
TION AND PRESSURE TESTING vacuum producing means is capable of at-
taining.
————————————————————
b. Piping circuits on the upstream side of con-
1.0.0 GENERAL trol valve shall be designed for pressures
resulting from minimum flow conditions
1.1.0 SCOPE (closed or throttled control valve) and
1.1.1 This specification together with the Piping downstream of the control valve shall be
Specification and design data sheets is ap- designed for the downstream terminal pres-
plicable for the piping located within the Plant sure plus friction losses (pressures due to
Battery limits. closed or throttled block valves shall not be
considered except as short time conditions)
1.1.2 No variation shall be permitted unless approved and head losses.
in writing.
c. The design metal temperature of the piping
1.2.0 MODIFICATIONS conveying fluids with temperatures below
1.2.1 Piping which is furnished as a regular part of 15 deg.C shall be equal to the minimum,
proprietary or standardized equipment shall be normal operating tempera ture of the fluid in
in accordance with the equipment the pipe or fluid temperature during normal
manufacturer’s standards for the design condi- startup or shutdown. Metal temperatures
tions. resulting from emergency conditions
caused by equipment failures such as rup-
2.0.0 DESIGN tured tubes, etc. or operational errors shall
not be considered.
2.1.0 GENERAL 2.2.3 The short time design pressure and design
2.1.1 The design of piping shall conform to the re- metal temperature shall be those of higher value
quirements of the ASME Process which are expected to occur during starting-up,
Piping B31.3 except as modified by Paragraph shutting-down, or in any other short time operat-
2.12.4. When a code, rule, or regulation is speci- ing condition.
ied in the Piping Specification Sheets, the 2.2.4 A freezing climate shall be defined as one with
design shall conform to such specified requirem- a January average temperature of 4 deg.C or
ents and to such portions of this specification lower.
as do not conflict.
2.3.0 LOADS
a. Snubbers shall be furnished as proprietary
piping equipment, designed and fabricated 2.3.1 The design for wind and earthquake shall be
in accordance with Section VIII of the ASME based on and considered to the extent required
Boiler and Pressure Vessel Code. by the Bureau of Indian Standards.
b. Knockout pots and like items shall be fur- 2.3.2 Piping shall be designed to resist the effects of
nished as piping equipment designed and the following combinations of loads within the
fabricated as follows. limits of stress specified herein. Wind and
earthquake loads shall not be assumed to occur
1. Sizes 600NB outside diameter and simultaneously.
smaller in accordance with ASME B31.3.
a. Operation : The design pressure, the
2. Sizes greater than 600NB outside dia. operating dead load, and the maximum
in accordance with ASME section VIII operating contents load, combined with or
c. Piping, snubbers, knockout pots, and like without wind or earthquake load.
items with design pressures below those b. Test : The test pressure, the test
covered by the applicable listed code shall dead load, and the fluid test load.
be designed and fabricated in accordance
with ASME B31.3. c. Short time : The operating condition
without wind or earthquake load but
2.1.2 Piping connected to power boilers, waste heat modified or supplemented by the changes
boilers, dowtherm boilers or unfired steam resulting from the short time conditions
generating equipment shall be designed in ac- defined in 2.2.3.
cordance with section I of the ASME Boiler and
Pressure Vessel Code, with all addenda, Power 2.3.3 For the design conditions given, the calculated
Piping ASME B31.1 and IBR to the extent re- principal stresses for pressure parts shall not
quired thereby. exceed the following.
2.2.0 DESIGN PRESSURES & TEMPERATURES a. Operation and short time condition stresses
are covered by ASME B31.3/ ASME B31.1.
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: APR ’10

.
CONTROLLED COPY
ISO 9001 : 2015
SPECIFICATION
PIPING DESIGN
PAGE 2 OF 11
b. Test: Based on the test thickness and the - quarters depth of flow or to carry all normally
test temperature, the basic allowable stres- flowing streams plus the maximum expected fire
ses increased by 50%. water in the area, with an upper limit of 2840
litres (750 gpm), when running full, whichever
2.3.4 The basic allowable stresses for non-pressure results in the larger line size.
parts, including attachments (except threaded
parts and attachment welds to pressure parts) 2.5.3 Sanitary sewers and chemical sewers shall be
and devices for supporting or bracing piping, sized to carry the design quantity when running
shall be one-third of the ultimate tensile at three-quarter depth of flow.
strength, two-thirds of the yield strength, or the
stress producing a creep rate of 0.01% in 2.5.4 The minimum nominal size of underground
1000 hours, whichever is lower. sewer mains shall be 100 NB (4 inches).
a. The maximum allowable tensile stress for 2.6.0 OVER PRESSURE PROTECTION
carbon steel threaded parts, such as anchor 2.6.1 Over pressure protection (relief valves, safety
bolts and rods, based on the root area of the valves, rupture discs, open vents, and design
thread, shall be 15,000 psi (1055 kg/sq.cm) for maximum pressure) shall be provided for
2.3.5 The calculated principal stresses for non-pres- pressure equipment (pressure systems when
sure parts shall not exceed the basic allowable units are connected without intervening block
stresses for the operating conditions; the basic valves) as outlined in the following paragraphs.
allowable stresses increased by 20% for the test These provide the protection required by API
or short time conditions; and the basic allowable RP520 though it is not followed in detail.
stresses in creased by 33 1/3% when combined a. Vessels and heat exchangers shall be
with wind or earthquake. protected in accordance with Table 1 when
2.4.0 CORROSION ALLOWANCE & THK. OF PIPE pressures greater than the stamped maxi-
mum allowable working pressure of the
2.4.1 The allowance for corrosion or erosion in piping equipment may be produced by the causes
shall be determined by the intended service and indicated.
material of construction. This shall be added to
all surfaces exposed to the flowing medium. In b. Pumps, compressors, and blowers shall
general, beyond that inherent in the thickness be protected with relief valves or other
of the pipe selected, a minimum allowance of automatic shut down devices when pres-
1.3 mm (0.05 inches) shall be provided for carb- sures greater than the casing design pres-
on steel in process service and no allowance sure may be produced at normal equip-
provided for carbon steel in utility service or for ment design speeds.
alloy steel and non-ferrous materials. c. Steam ends of reciprocating pumps and
2.4.2 For threaded or grooved pipe the greater of steam turbines shall be provided with relief
either the corrosion allowance or the threading valves when the casing design pressure
or grooving allowance, shall be added to the may be exceeded.
pipe wall thickness. d. Piping systems shall be protected when
2.4.3 The corrosion allowance may be more than the pressures may be produced which are
above based on severity of service. greater than 133 1/3% of line equipment
(separators, etc.) design pressures or more
2.5.0 SIZING OF PIPING than 133 1/3% of the service rating of
fittings, valves, etc., or when the pressure
2.5.1 Piping shall be sized on the basis of the operat- stress in the pipe may exceed 133 1/3% of
ing conditions and, when required, with an al- the basic allowable stress.
lowance for normal control of approximately
25% of the design friction losses in pipe and e. Vacuum exhaust systems shall be provided
equipment, except for the following. with atmospheric relief valves when the
system may be over pressured during a
a. Pump, compressor, and blower piping shall loss of vacuum.
be sized on the basis of maximum pump,
compressor, and blower design capacities f. Vents shall be properly sized so that no
(at the equipment normal design speeds) additional protection need be provided
with allowance for control reduced, to zero against vacuum caused by emptying
if necessary. water after a hydrostatic test or condens-
ing steam after steaming out the equip-
b. Circulating fuel oil systems shall be sized to ment.
supply 125% of the specified equipment
design requirements with 25% being recircu- g. Fired furnace coils shall not be provided
lated. with separate over pressure equipment ex-
cept as required for steam generators and
c. Piping in intermittent service (such as start- superheaters by Section I of the ASME
ing- up and bypass lines) shall be sized on code.
the basis of the available pressure differen-
tials. h. Pumps, compressors, blowers, and piping
systems shall not be provided with over
d. Inlet and outlet piping at pressure-relieving pressure protection for pressures caused
safety devices shall be sized in accordance by fire.
with the requirements of 2.6.0.
i. Fixed roof atmospheric tanks shall be
2.5.2 Gravity flow oil-water sewers shall be sized to provided with open vents or vacuum
carry all normally flowing streams plus the max- breakers.
imum rainfall in one hour when running at three

SPECIFICATION
PIPING DESIGN
PAGE 3 OF 11
j. Airfin condensers and coolers shall be coverage except that trenches may be used at
protected by water fog nozzles with a changes in direction to provide for thermal ex-
remote, manually operated valve. A means pansion of hot lines. The center line of under-
shall be provided for remotely shutting off ground water lines shall be located below the
fan motors. frost line or furnished with other means to
prevent freezing. Minimum cover for water
2.6.2 Relief valves may be of the conventional, back pipelines not in trenches is 900 mm.
pressure, or spring pilot operated type.
2.9.2 Burner fuel piping shall conform to the following
2.6.3 Relief valves, safety valves, rupture discs and requirements.
vents shall be sized in accordance with the
following. a. Valves used to adjust the flame shall be
located at the side of low floor - fired fur-
a. For vessels and heat exchangers, the ini- naces convenient to peep holes, and adja
tial and maximum relieving pressures of cent to the burners of elevated floor fired
relief and safety valves and the relieving furnaces and wall- fired furnaces.
pressure of rupture discs shall be as
specified in Table 1. Values are given as b. Fuel oil supply piping shall be arranged as
functions of the equipment maximum allow- a circulating system for continuous recir-
able working pressure, P, stamped on the culation through the headers.
vessel.
c. Fuel gas supply piping shall be arranged to
b. For pumps, compressors, turbines, and produce equal distribution of flow to allow
blowers, the initial and maximum relieving condensate drainage.
pressures shall not exceed the values
recommeded by the manufacturer. 2.9.3 Relief and safety valves shall discharge to a
closed system when the valves release lethal
c. For piping the maximum relieving pressure vapors, mixtures of hydrocarbon vapors and
shall be as determined from 2.6.1.d. with other vapors (such as steam) with a molecular
the initial relieving pressure 90% of this weight of the mixture greater than 80, or lethal,
value. hazardous, or hydrocarbon liquids; and to at-
mosphere when they release mixtures of hydro
d. It is mandatory that the nominal size of the carbon vapors and other vapors (such as steam)
inlet and oulet piping be same as, or greater with a molecular weight of the mixture of 80 or
than, the nominal size of the pressure relief less, non-hazardous liquids, or non-hazardous
valve inlet and outlet connection. vapors. Bonnet vents of back pressure type
Refer Table I and Notes - Page 11 of 11. relief valves may discharge to atmosphere.
2.7.0 SUPPORTS a. Lethal vapors or liquids shall be defined as
poisonous gases or liquids of such a nature
2.7.1 Piping sections requiring frequent dismantling that a very small amount of the gas or of the
such as for removal of burners, etc., shall be vapor of the liquid mixed or unmixed with air
provided with permanent supports for the dis- is dangerous to life when inhaled. It is the
mantled condition. intent of this specification that the following
2.7.2 All piping with insulation, and piping operating are not lethal: chlorine, ammonia, natural or
at temperatures 343 deg.C (650 F) and higher manufactured gas, any liquefied petroleum
shall have steel shoes with bearing surfaces gas (propane, butane, butadiene, etc.), and
outside the insulation. Insulated piping in low vapors of any other petroleum products.
temperature service shall have the insulation This corresponds to the definition contained
locally reinforced at the point of support. All in Paragraph UW-2 of the ASME Code,
other piping may rest directly on the supporting Section VIII.
members. Small diameter lines may be sup- 2.9.4 Relief and safety valve piping shall conform to
ported by, or suspended from larger diameter the following requirements:
lines.
a. All relief and safety valves on towers shall
2.8.0 CLEARANCES preferably be located in the overhead line.
2.8.1 The clear headroom over platforms, walkways, b. Relief and safety valves discharging vapor
passage ways, and working areas shall be at to the atmosphere in hydrocarbon service
least 2 metres. shall have the outlet piping extend to at least
2.8.2 The clear headroom over outside areas desig- 3 metres above the highest working level or
nated for use as truckways shall be at least 3.6 building roof within a radius of 12 metres.
metres. Clear headroom over pump access The requirements of the local pollution con-
roads shall be at least 3 metres. trol board shall be followed if its more strin-
gent.
2.8.3 The clear headroom over railroads as measured
from the top of rails shall be at least 6.7 metres. c. Relief valve header shall not be pocketed.
Wherever this requirement cannot be met,
2.8.4 Walkways shall be at least 750 mm. a drain line discharging to a knockout pot
2.9.0 ARRANGEMENT OF PIPING shall be provided, with the vent from knock-
out pot connected back to the header.
2.9.1 When located below grade, piping provided with
protective heating and piping in acid, caustic, d. There shall be no isolation valves on the
phenol, and similar services requiring inspection inlet lines to pressure safety devices. Isola-
and servicing shall be in trenches; other piping tion valves if provided at inlet lines to pres-
shall be buried in earth with at least 300 mm sure safety devices shall be locked open.

SPECIFICATION
PIPING DESIGN
PAGE 4 OF 11
2.10.0 MAINTENANCE & OPERATION REQUIRE- outlet water lines. In freezing climates, an
MENTS antifreeze bypass from the inlet to the outlet
piping or other means to prevent freezing
2.10.1 Means shall be provided in the piping at pump shall be furnished.
and driver nozzles to permit the removal of the
pump or driver without removing the block val- 2.11.3 Block valves shall be provided at the following
ves. For this purpose, a flanged valve, fitting, or locations in pump, turbine, and compressor
strainer against the nozzle shall be considered piping.
satisfactory.
a. In suction and discharge piping to pumps.
2.10.2 Piping requiring removal of coke shall be
provided with flanged clean out points and b. At the equipment in auxiliary piping for gland
bends of a radius suitable for the cleaning tool oil, flushing oil, and cooling water.
or with flanged fittings at turns. The run of pipe c. At the header in overhead water supply
between clean out points shall be limited as branches located outdoors in freezing
follows. climates and in all auxiliary piping when
a. Straight runs: necessary to allow removal of the equip-
ment during operation of the unit.
Cleaning from one end - 12 metres.
2.11.4 Block valves shall be provided at the following
Cleaning from both ends - 24 metres. locations in steam piping.
b. Bends: a. At the steam main: In steam headers serving
grouped equipment such as steam drivers
Cleaning from both ends - 12 metres located in a pump room.
developed length.
b. At the equipment: In steam piping to steam
2.10.3 All piping equipment requiring frequent attention driven equipment.
of the operating personnel shall be readily ac-
cessible. Equipment such as automatic control c. At the steam header: In steam piping to
valves preferably shall be grouped at main steam driven equipment when the steam
operating levels. Equipment such as motor pressure exceeds 21 kg/sq.cm g.(300 psig)
operated valves and relief valves shall be acces-
sible from platforms or grade. d. At the equipment: In pressure exhaust steam
piping from steam driven equipment.
a. Man ua lly op erat ed val ves requiring
manipulation during operation or an emer- e. Adjacent to the equipment: In vacuum ex-
gency shall be located so that hand wheels haust steam piping from steam driven
are convenient to operate from a platform or equipment when the equipment may be
grade and so that the bottom of the hand shut down for sustained periods during
wheel is not higher than 2 metres above a operation of the unit.
platform or grade, otherwise such valves 2.11.5 Arrangements for block valves at spare equip-
shall be equipped with chain operators or ment that is to be isolated for maintenance and
exten sion ste ms. Valves with ch ain equipment that may be removed from service
operators shall be located or have stems during the operation of the unit shall conform to
turned so that chains do not hang in pas- the following.
sageways.
a. In chemical and other process liquid ser-
2.10.4 Driver steam exhaust lines shall be provided vices, single block valves shall be used for
with exhaust heads when discharging to the all pressure temperature ratings up to and
atmosphere. including 600 # ANSI. In services of higher
2.10.5 Funnels and drain lines shall be provided at ratings, double block valves shall be con-
sampling connections, gauge glasses, level sidered for each individual case.
controllers, etc.. b. In gas or vapor services block valves shall
2.10.6 Access shall be provided for heat exchanger be as indicated in the following table.
tube removal, tower tray removal, catalyst Pressure Temperature Valve size Selection
removal and for crane access to compressors.
o Upto 300 NB Single Gate
2.11.0 VALVING Upto and ( 450232
o
C Valve
including F) and
2.11.1 Block valves shall not be provided at vessel 300 psig below 350 NB and Single Plug
nozzles, except as required for operating and ( 212 above Valve
process control and for storage vessels contain- kg/cm g ) o
Above 232 C All sizes Single Gate
ing hazardous or toxic materials. ( 450 oF) Valve
2.11.2 Block valves shall be provided on the water side 232oC Single Plug
of exchanger units as follows: Above ( 450 oF) and All sizes Valve
300 psig below
a. Exchangers that are essential for the opera- ( 21
tion of the unit shall have one valve. kg/cm2g ) Above 232 o
C All sizes Double Gate
( 450 oF) Valve
b. Exchangers provided with process isolation
valves for frequent inspection and cleaning 2.11.6 A block valve shall be provided for the fire steam
during operation of the unit shall be system. Other utility systems shall be provided
provided with block valves in the inlet and with valves at service connections only.
outlet piping. All water cooled exchangers 2.11.7 Block valves shall be provided and located as
will have isolating valves on the inlet and required for bleed and aeration systems.

SPECIFICATION
PIPING DESIGN
PAGE 5 OF 11
2.11.8 A block valve shall be provided in the main line 2.11.13 Block valves shall generally be gate valves ex-
of fuel oil and fuel gas piping to furnaces or fired cept as follows.
heaters, be located remote from the equipment,
and be accessible for rapid operation in an a. Lubricated plug valves shall be used in
emergency. vacuum and caustic services and in fuel
gas piping except burner leads and may be
2.11.9 Block valves shall be provided for piping cross- used in gas compressor services and ser-
ing the unit limits as follows. vices with an ANSI rating of 600 # and over.
a. In outgoing lines only when required to b. Non-lubricated mechanical lift plug valves
divert product streams. shall generally be used in services contain-
ing abrasive solids in a gas or liquid. Branch
b. In all steam lines except exhaust steam line block valves, however, shall be of the
lines. type required for the branch line service.
2.11.10 Automatic control valves shall be furnished with c. Non-lubricated plug valves shall be used at
either block valves for isolating the control valve service air hose connections.
and a bypass for hand control, the sizes of which
shall conform to Table given below,or an d. Globe valves shall be used in furnace blow-
auxiliary means for manual operation. down lines, for venting and sampling con-
nections in caustic services and may be
Control Valve Line Size By-Pass & Block used in services with an ANSI rating of
Size Valve Size 2500 #.
50 NB and 50 NB and e. Butterfly type valves with resilient seats may
smaller smaller Line size
be used in water services.
50 NB and 2.11.14 Check valves shall be provided for the common
smaller 65 NB and larger 50 mm discharge of centrifugal and rotary pumps and
centrifugal compressors when the pumps or
65 NB and larger 65 NB and larger Control valve size compressors discharge into a system whose
pressure or volume is likely to cause backward
a. All three-way control valves shall be fur- rotation of the pump or compressor.
nished with an auxiliary means for manual 2.11.15 Check valves shall be provided in process
operation. steam and steaming out services connected to
b. Control valves in lethal, phenol, and process equipment or lines when such services
ethanolamine services shall be furnished are subject to contamination from the process
only with block valves located adjacent to equipment or lines. The check valve shall be
the control valves and an auxiliary means of located between the block valves required by
manual operation. Section II, Part M, Paragraph 11 and adjacent
to the valve nearest the process equipment or
c. Control valves in services containing line.
abrasive solids or viscous material (vis-
cosity at ambient temperature so high that 2.11.16 Hand control valves shall generally be of the
one-half the design flow rate cannot be type specified in Table below with the following
attained with the pressure available for exemptions.
starting circulation), boiler feed water ser- a. Globe valves shall be used for all sizes
vices, services with a pressure drop across when the operation pressure differential
the control valve greater than 14 kg/sq.cm across the valve is greater than 35 kg/sq cm
(200 psi), and steam services with a pres- (500 psi).
sure of 5 kg/sq.cm (75 psig) or higher shall
be furnished with block and bypass valves b. Angle type globe valves shall be used for all
except that when control valves are paired ratings and sizes in slurry services.
(separate control valves furnished for
drivers and their standbys) neither block c. Gate valves shall be used in services con-
and bypass valves nor auxiliary means of taining abrasive solids in a gas.
manual operation shall be furnished. d. Non-lubricated reducing port plug valves
d. When the pressure drop across the control shall be used for regulating fuel oil to
valve is over 70 kg/sq.cm (1000 psi) two burners, gate valves for fuel gas.
by-pass valves in series shall be furnished. Valve size 150#, 300#, 1500# &
NB 400# & 600# 900# 2500#
2.11.11 Two block valves with a bleeder shall be
provided in piping connecting systems in ser- 150 & larger Gate Gate Gate
vices in which contamination cannot be
tolerated. 100 & larger Globe Gate Gate
2.11.12 Two valves shall be provided in connections 80 & larger Globe Globe Gate
used during operation for venting, draining, or 65 & smaller Globe Globe Globe
sampling in liquid hydrocarbon services with a
vapor pressure over 4.5 kg/ sq cm-a (65 psia) at 2.11.17 The following flanged and butt welded valves 65
37 deg.C (100 F) for venting or draining in all NB and larger shall be bossed, if required, and
services with an ANSI rating of 900 # or higher; drilled, tapped and plugged at the locations
and for sampling in all services with an ANSI indicated, in accordance with MSS SP-45, latest
rating of 400 # or higher. revision.
a. In water and steam service, all gate valves

SPECIFICATION
PIPING DESIGN
PAGE 6 OF 11
at locations “A” and “G” and all globe valves e. Threaded and socket welded check valves
at location “C”. shall be of the ball type. Flanged and butt
welded check valves shall be of the swing
b. In services containing abrasive solids, in a -non-slam type in sizes 350 NB and over
gas all gate valves at locations “G” and “H”. and of the swing type in sizes 300 NB and
c. All ball check valves above the seat and all under except that valves with ANSI ratings
swing check valves at location “G”. of 900 and 1500 # shall be of the ball type
in sizes 100 NB and under.
2.11.18 Steel valves shall have the following construc-
tion. f. Lubricated plug valves shall be wrench
operated in the sizes listed and gear
a. Flanged and butt welded valves of the gate, operated in larger sizes.
globe, and angle type shall have bolted
bonnets and glands, and of the check type, 125 # ANSI - 250 NB size and smaller
bolted bonnets. Threaded and socket 150, 250 and 300 # ANSI - 200 NB size and
welded valves of the gate, globe, and angle smaller
type shall have gasketed union bonnets and 400 to 1500 # ANSI - 100 NB size and smaller
bolted glands, and of the check type, gas- 2500 lb ANSI - 50 NB size and smaller
keted union bonnets. Pressure sealed,
welded or integral bonnet for threaded and Such valves shall be fitted with giant button-head
lubrication.
socket welded gate, globe and angle valves
may be used for corrosive or high pressure g. Non-lubricated mechanical lift plug valves
services. for use in services described in Section II,
b. Gate, globe and angle valves shall be of the Part M, Paragraph 13 b. shall be of the
outside screw and yoke type. single operation mechanical lift type,
designed to permit sealing the plug and
c. Gate valves shall be provided with pressure blowing or flushing the seat. Such valves
equalizing by-passes and by-pass valves of shall be wrench operated in sizes 150 NB
the minimum sizes and ratings listed in and smaller and gear operated in sizes 200
Table below when a differential pressure NB and larger except that for chain opera-
approximately equal to the pressure rating tion, valves in sizes 150 NB and larger shall
of the valve may exist across the closed be gear operated.
valve (eg. 600 lb across a 600 lb valve).
h. Control valves shall have flanged or
By-pass and By-pass Valve Size, NB threaded end connections.
Gate-
Valve Gate and By-pass Valve Pressure Rating i. Gate valves in the 150 # and 300 # ANSI
Size
NB ratings may be reduced port.
150# 300# 400# 600# 900# 1500# 2500#
2.11.19 Cast iron valves shall have the same construc-
100 - - - - 15 15 15 tion as steel valves except as follows.
150 - - - 20 20 20 20 a. Flanged gate valves used in buried lines
200 - - 20 20 20 20 20 shall be of the inside screw non-rising stem
type.
250 - 25 25 25 25 25 25
b. Threaded gate valves shall have a clamp
300 25 25 25 25 25 25 25 type bonnet and be of the inside screw
350 25 25 25 25 25 25 ()
non-rising stem type.
400 25 25 25 25 25 () ()
c. Threaded check valves shall have a
threaded bonnet and be of the swing type.
450 25 25 25 25 25 () ()
2.11.20 Bronze and brass valves shall have threaded
500 25 25 25 25 () () () end connec tions. Gate, globe and angle valves
shall be of the inside screw rising stem type,
600 25 25 25 25 () () () check valves shall be of the swing type. Plug
d. Globe and angle valves shall be selected for valves shall be manufacturer’s standard.
the required sensitivity of control. Specially 2.12.0 PIPES AND BENDS
designed plugs may be used when the
operating differential pressure is greater 2.12.1 In general, for all except alloy steel pipe, seam-
than 35 kg/sq.cm (500 psi). Geared less and fusion welded pipe shall be used.
operators shall be furnished for the valves Welded pipe may be used for services with an
listed in Table below. ANSI rating of 300 # or less, and for utility
services with a temperature of 175 deg.C (350
F) or less. For alloy steel pipe, only seamless
shall be used.
ANSI Rating Valve size
2.12.2 Pipe, in sizes 32 NB, 65 NB and 125 NB shall
150# 300 NB and over not be used.
300# 200 NB and over 2.12.3 Changes in direction shall be made with fittings
400# & 600# 150 NB and over preferably or bends. Bends shall be used for
u nlined pipe conveying abrasive solids
900 # 100 NB and over suspended in gas or liquid.
1500# & 2500# 80 NB and over a. One weld miter elbows: atmospheric air

SPECIFICATION
PIPING DESIGN
PAGE 7 OF 11
co mp re ss or i nt a ke l in es whe n f low 2.14.0 BLANKS

straightening vanes are used. Vent lines
from compressor and sewer lines. 2.14.1 Blanks shall be provided in the piping at the
following locations only.
b. Two weld/ three weld miter elbows: process
lines larger than 600 NB in diameter with an a. At inlet and outlet connections of equip-
ANSI rating of 125, 150 or 250 # and all ment, other than pumps, compressors, and
utility (water, steam, air, etc.) and auxiliary blowers, which must be periodically taken
(vent, flare, etc.) lines. out of service for maintenance, inspection,
or alternate operation without interfering
c. Four weld miter elbows: process lines larger with the operation of the unit and when the
than 600 NB in diameter with an ANSI rating omission of such blanks would present a
of 300 # and over and internally lined pipe hazard to personnel.
conveying abrasive solids in gas or liquid.
b. In furnace piping at locations which will
2.12.4 The minimum radius for pipe bends shall be 5 permit the simultaneous testing of the fur-
times the nominal pipe size for upto 350 NB nace and as much of the piping as may be
inclusive and 6 times the nominal pipe size for sub ject to the test pressure.
pipe over 350 NB size. When bends are re-
quired with smaller radius or of any radius in pipe c. At the unit limits in utility piping conveying
operating at temperatures above 400 deg.C hydrocarbons and in process piping con-
(700 F), the possible thinning in the wall of the nected to other plant piping which may be
outer periphery due to bending shall be taken in use during a shut down of the unit.
into account. 2.14.2 The selection of the type of blank shall be in
2.12.5 Equal size 90 degree intersections, except in accord ance with Table VI and the following
low pressure utility piping (ANSI rating of 250 # subparagraph:
or less and temperature of 232 deg.C less (450 a. Blanks for piping in service at temperatures
F)) shall be made with tee fittings. In general, below -18 deg C (zero degrees F) shall be
all other intersections and all intersections in of the circular type with spades for rigid
low pressure utility piping shall be made by connections and without spacers for flexible
welding. When reinforcement is required for connections.
branches, branch welding fittings may be used.
Rigidity of connection
2.13.0 FITTINGS END CONNECTIONS, FLANGE Nominal size of
FACINGS AND GASKETS pipe (NB)
Rigid Flexible
2.13.1 Fittings and end connections in carbon and alloy
steel piping shall be as follows: 100 and smaller Figure 8 Circular
without spacer
a. In austenitic steel pipe at service tempera-
tures over 400 deg.C (750 F) butt welded or 150 and 300 incl. Figure 8 Figure 8
flanged for sizes 25 NB and larger. Socket
welded or threaded in smaller sizes. Larger than 300 NB Circular with Circular with
spacer spacer
b. In galvanized steel pipe - flanged in sizes
150NB and larger, threaded in smaller 2.14.3 Circular type blanks and spacers shall be
sizes. provided with attach ments for handling.
c. In all other services - butt welded or flanged 2.15.0 UTILITY OUTLETS
for sizes 50 NB and larger, threaded or 2.15.1 Utility steam, air, and water service outlets of
socket welded in 40 NB and smaller. 25NB minimum size for hose and fittings shall
2.13.2 Threaded connections shall be made up with be provided as required at such locations that
Teflon taped threads when the temperature is working areas at grade, in structures, and in
260 deg.C (500 F) and below. Threaded con- buildings can be reached with 15000 mm
nections shall be seal welded when the length of hose.
temperature is above 260 deg.C (550 F). When a. The steam supply to hose connections shall
so required in vent, drain, or sample piping be limited to a pressure of 8.75 kg/sq.cm g
discharging to an open system or in instrument (125 psig).
leads, seal welding shall be done only to the
upstream side of the first block valve. b. Service outlets for water shall be located at
grade for furnaces and at grade and the
2.13.3 Except for removable sections of pipe, erection lowest main operating level in structures.
requirements, and piping requiring dismantling
for clean ing, the use of flanges in piping shall c. Hose and fittings will not be furnished.
be limited to connections at flanged equipment. 2.16.0 VENTS, DRAINS AND SAMPLE OUTLETS
2.13.4 Raise faced flange shall be used for ANSI 2.16.1 Valved vent and drain connections shall be fur-
ratings of 900 # and below and ring joint flanges nished on all equipment not self venting or self
for process services with ANSI ratings of 1500 draining. Connections shall be located on
# and higher. All steam systems with ANSI rat- equipment if practicable but may be located in
ings of 150 to 2500 # shall have raised face connected piping when there are no valves or
flanges when flanges are used. blocks between the vent or drain connections
2.13.5 Gaskets for ring joint flanges shall be of the and the equipment. Vents and drains for pumps
octagonal type. in services containing abrasive solids shall be
located in connected piping.

SPECIFICATION
PIPING DESIGN
PAGE 8 OF 11
2.16.2 Valved vent connections shall be furnished for medium shall be used to remove the liquid by
trapped high points of piping 65 NB and larger pressure; otherwise, an auxiliary pumping out
except that when the connection is used for test system shall be provided.
purposes only, the valve shall be omitted and a
plug substituted. Valved drain connections shall 2.17.2 Connections for emptying vessels shall be at
be furnished for the low points of lines located least the drain sizes given in table 2.16.4: and
above grade. on heat exchanger units they shall be 40NB
when provided.
2.16.3 Vent connections shall be 20 NB minimum size
drain connections and sample outlet connec- 2.17.3 When required by the service, means shall be
tions shall be 20 NB minimum size, except as available for purging process equipment with
follows. steam or inert gas. Unless steam or inert gas is
otherwise available, the following provisions
a. All piping connections from equipment shall shall be made:
be the equipment connection size.
a. Vessels of volume from 2832 to 141600
b. All connections from piping in services in- liters (100 to 500 cu.ft.) and all sizes of
volving abrasive fluids or materials which vessels of low temperature service, shall be
are of high viscosity when cold shall be 25 provided with a 25NB connection to which
NB minimum size. a steam hose may be at tached. Other
vessels of volume greater than 141600
2.16.4 Vent and drain connections from vessels shall liters (5000 cu.ft.) shall be serviced by a 40
be at least the sizes given in Table given below. NB line connected to a source of steam.
Nominal size of vents and b. Furnace coils shall be serviced by piping
Volume of Vessel drains (NB) permanently connected to each coil inlet
(liters) line and to a source of steam.
Vents Drains
2.17.4 When required by the service, means shall be
1400 and smaller 25 25 available for filling process equipment with
water for washing out.
1400 to 5650 25 40 a. Vessels requiring frequent maintenance
shall be serviced by piping permanently
5650 to 17000 25 50 connected to a source of water.
17000 to 70800 40 80 b. Vessels not requiring frequent maintenance
shall be serviced by hose connected be-
over 70800 50 80 tween a service water outlet and the vessel
drain connection.
2.16.5 All single valved vents and drains in process 2.18.0 FIRE, SMOTHERING, SERVICE, SNUFFING
services only shall be provided with plugs or AND PROTECTIVE HEATING SYSTEM
blind flanges except for the following.
2.18.1 Smothering system shall be provided to furnace
a. Casing vents and drains for pumps in non- combustion chambers, header boxes, and to
volatile services shall be piped to the pump the spaces above the furnace arch and shall be
base plate or into a gutter or sewer. controlled by valves remote from the furnace
b. Casing vents for pumps in services handling area.
materials near the auto-ignition point shall 2.18.2 Smothering steam shall be provided to enclosed
be piped to a cooler and from the cooler to rooms housing pumps or compressors in flam-
a sewer. mable liquid or gas service and shall be control-
2.16.6 Vent and drain connections used during opera- led from outside the building.
tion in fuel gas supply piping and in services with a. Flammable liquids shall be defined as li-
a vapor pressure over 4.5 kg/sq.cm-g (65 psig) quids having a flash point below 93 deg.C
at 37 deg.C (100 F) shall discharge to a closed (200 F) as determined by ASTM D56-70 or
system or to a sealed and vented sewer inlet. D93- 66.
2.16.7 Sample outlets in piping or equipment in hot b. Flammable vapors shall be defined as
services shall be provided with means for cool- vaporized flammable liquids with molecular
ing the sample. One cooler may be used for weights greater than 80.
grouped sample outlets.
2.18.3 Snuffing steam shall be provided to relief valve
2.16.8 Means shall be provided for clearing sampling outlet piping discharging hydrocarbon vapors to
lines and coolers with steam in services involv- the atmosphere and shall be controlled from
ing materials which are of high viscosity when grade.
cold and in all services when grouped sample
outlets use the same cooler. 2.18.4 The steam supply for fire smothering, fire fight-
ing, snuffing, service hoses and protective
2.17.0 EMPTYING, STEAMING OUT AND WATER heating shall be from a separate steam system
FILLING connected to the plant steam header on the
2.17.1 Means shall be available for removing the supply side of the unit limit block valve.
operating liquid contents from all vessels and a. A separate fire steam header shall not be
heat exchange units and the connected piping. required if steam is normally available at a
Process lines and pumps shall be used for this pressure 3.5 and 8.75 kg/ sq.cm-g (50 and
purpose as far as practicable; or steam or other 125 psig) in the plant steam system.

SPECIFICATION
PIPING DESIGN
PAGE 9 OF 11
2.19.0 STEAM TRAPS AND SEPARATORS 2.21.2 The oil water sewer system shall conform to the
following:
2.19.1 Steam traps shall be provided for the removal of
condensate from collection points in steam a. Paved areas at grade, the bottoms of
system. trenches, and the floors of pumps or com-
pressor rooms shall be provided with drains
2.19.2 Steam traps discharging to the atmosphere for the collection of surface drainage except
shall be provided with upstream block valves. that drains shall not be furnished for con-
Steam traps discharging to a condensate col- crete floors of elevated open sided com
lecting system shall be provided with upstream pressor rooms. The floors of control rooms,
block valves and downstream block valves ex- switch rooms and lavatories shall not be
cept that steam traps for unit heaters shall be provided with drains. Drains located within
provided with downstream block valves only. enclosed buildings shall be provided with
2.19.3 Condensate from vacuum steam systems shall drain fittings of the sealed type.
be re-evaporated into the system by means of b. All equipment such as pumps, compres-
a condensate flash pot. sors, and vessels shall be provided with
2.19.4 A steam separator shall be provided in the sewer inlet receptacles as required..
steam piping to each group of steam turbines c. Roof areas upon which process equipment
and to each group of steam driven reciprocating is located shall be connected to the sewer
compressors. system through the down spouts.
2.19.5 Drip legs shall be provided on steam headers d. Sewers discharging from seperately
for collecting condensate. defined areas such as pump rooms, fur-
2.20.0 STRAINERS AND FILTERS naces, and grouped equipment shall con-
nect to the system through sewer boxes
2.20.1 Permanent strainers shall be provided in the having sealed inlets. When it is not prac
piping for the protection of the following equip- ticable to connect trench drains individually
ment when not furnished as part of the equip- to sewer boxes, such drains shall be sealed
ment. by means of “P” traps. Sewer boxes in
a. All pumps - in suction line. hazardous areas, such as around furnaces,
shall have sealed covers and be vented to
b. Steam turbines and steam jet ejectors - in a safe location.
steam inlet line.
2.22.0 EMERGENCY FIXTURES
c. Pumps and compressors - in sealing, gland,
and flushing oil and cooling water supply 2.22.1 Eye wash fountains and emergency showers
piping. shall be provided near equipment or pipe
manifolds in acid, caustic, phenol service and
d. Reciprocating compressors taking suction any other lethal service.The fixtures shall be
from process equipment in suction line. installed at locations conveniently accessible for
e. Burners - in main fuel oil supply piping. emergency use. Emergency showers shall be
arranged for overhead delivery of water spray.
f. Hydraulically actuated equipment - in
hydraulic oil supply piping. 2.22.2 Water for eye washing fountains and emergen-
cy showers shall be taken from the drinking
g. Pneumatically actuated equipment - in air water system. Self closing valves shall be used.
supply piping.
2.22.3 Eye washing fountains & emergency shower
h. Restriction orifices in bleed gas or air ser- heads shall be as per the relevant IS codes only
vice - in gas or air piping.
2.20.2 In addition to permanent strainers, temporary 3.0.0 MATERIALS
strainers with a mesh finer than the permanent
strainer mesh shall be placed over the per- 3.1.0 GENERAL
manent strainers, for use in preliminary opera- 3.1.1 The selection of materials for a given piping
tion in the suction piping to all pumps. system shall be based on the fluid conveyed and
2.20.3 Reciprocating compressors taking suction from the design temperature and pressure. The
process equipment shall be furnished with tem- materials of special elements, such as steam
porary strainers. traps and separators shall conform to the
manufacturer’s standards for the operat ing con-
2.20.4 A filter shall be provided in the air piping ditions. The material and corrosion allowance
upstream of air driers. for a particular service will be specified in the
design data sheets.
2.20.5 Screened intakes shall be provided for air com-
pressors and air blowers. 3.1.2 Low temperature piping (design metal tempera-
tures below -28.9 deg.C (-20 F) shall have
2.21.0 SEWERS materials for pressure containing parts in ac-
2.21.1 An underground oil water sewer system shall be cordance with the applicable code. Materials for
provided to collect and convey all oil drainage, non- pressure parts shall be as follows.
waste water, and storm water from paved areas a. Structural attachments which are welded
to the unit limits. Sewers, if required for raw directly to any pressure part and which nor-
sanitary and chemical waste, shall be run mally will be subject to dynamic loads while
separately to the unit limits. Treated chemical the pipe is at operating temperature such as
and sanitary waste may be conveyed through vacuum stiffener rings, pipe supports,
the oil water sewer system.

SPECIFICATION
PIPING DESIGN
PAGE 10 OF 11
guides, anchors, platform and ladder clips.

b. Structural attachments which are welded
directly to any pressure part but which are
not normally subject to dynamic loads while
the pipe is at operating temperature such as
davit clips,. lifting lugs, Nelson studs, insula-
tion clips and rings, etc.. mild carbon steel
(not impact tested) for piping of carbon or
ferrite alloy steel and AISI Type 304 steel for
piping of austentitic alloy steel.
3.1.3 Valve body materials shall be steel conforming
to the relevant codes / manufacturer’s stand-
ards for the valve type and pressure ratings
except as follows. Generally all valves 40 NB
and below shall be forged and 50 NB and above
shall be of cast material.
a. For water and low pressure air service, cast
iron and bronze or brass shall be used.
b. For low pressure steam, cast iron may be
used but not within 7.5 metres of furnaces.
Bronze and brass shall not be used.
c. For corrosive and high temperature service,
the material will be comparable to that indi-
cated on the Design Specification Summary
Sheet.
3.1.4 Valve body material may be ductile iron in 150
# and 300 # ANSI ratings. However, ductile iron
shall not be used in compressor piping.
3.1.5 Valve trim material shall be as per code or as
per the manufac turer’s standards for the service
conditions.
3.1.6 Bolting and gasket materials shall conform to
the relevant code/ IS/ ASTM standards.
3.1.7 In selecting materials the following are special
considerations.
a. When piping systems or equipment are
interconnected by a valve, the valve shall
be suitable for the services connected.
However should the particular service re-
quire the use of alloy valves because of high
temperature or corrosion, the block valve
located in connected piping which normally
is deadened or in which the service
temperature is lower may be of carbon steel
of the required pressure rating if suitable.
b. When a change in pressure or temperature
occurs at equipment such as a control
valve, a heat exchanger unit, or a trap, the
up stream block valve and the by-pass
valve (if any) shall be suitable for the
u p s t r e a m co n d i t i o n s wh e r e a s t h e
downstream block valve need be suitable
for the downstream design conditions only.
3.1.8 All steel pipe and fittings 100 NB and under for
drinking water service and air transmission
service to air motor operated valves shall be
galvanized.
4.0.0 FABRICATION, HEAT TREATING, INSPEC-
TION AND PRESSURE TESTING
4.1.0 Fabrication, heat treating, inspection and pres-
sure testing shall be as per the specification for
Fabrication And Installation of Steel Piping
25ES205.

SPECIFICATION
PIPING DESIGN
PAGE 11 OF 11
TABLE 1 FOR CLAUSE 2.6.0 - OVER PRESSURE PROTECTION FOR EQUIPMENT

EQUIPMENT CAUSE OF OVER PRESSURE PROTECTIVE RELIEVINGPRESSURE
SELECTED (NOTE 1) DEVICE Initial Maximum
Open Inlet (Control valve opens
wide)
Closed Outlet
Failure of Cooling Medium
Top or Side Stream Reflux Failure Relief Valve or
Towers, Drums & Lean Oil Failure to Absorber 1.00 P 1.10 P
Failure of Tower Pressure Safety Valve or
Kettle Type Rupture Disc
Evaporators Controller in the Closed Position
Driver Electric Failure
Steam Power Failure
Chemical Reactions Exclusive of
Explosions
External fire (Note 2) 1.20P
Thermal Expansion of Liquid when
closure of a Single Valve isolates Relief Valve
1.00 P
contents or if exchanger can be ( Min size )
dispensed with or is spared.
Light hydrocarbon service-blocked Safety Valve
inlet & outlet when the pressure ( Min size )
exceeds the Design Pressure
Heat Exchanger
(Shell & Single Type) Safety Relief
Valve ( Min size
External Fire ( Channel Side) except when deal-
ing with large ex-
changers) 1.20 P
Safety Relief
External Fire ( Shell Side ) Valve or Safety
Valve
Ruptured Tube ( Note 3 ) Relief Valve or

Safety Relief
Heat Exchangers Open Inlet (Contro Valve opens wide) 1.10 P
Closed Outlet Valve or Rupture
Disc
Thermal Expansion of Liquid when
Exchangers closure of a single valve isolates Relief Valve 1.00 P
(Double Pipe ) contents or if Exchanger can be (Min. Size)
dispensed with or is spared.
P - Maximum available working pressure ( MAWP ) of equipment
NOTES:
1. Each cause of overpressure shall be considered individ ually.
2. The heat input shall be calculated in accordance with the formula
0.82
Q= —— FA
21000
In which
Q = the total heat input to the wetted surface in Btu per hour
F = 1.0 for uninsulated vessels and 0.3 for insulated vessels.
A = the total wetted surface exposed to fire in square feet. The surfaces of vessels or heat exchangers
up to 25 ft. above grade or other fire supporting level shall be considered subject to fire expo sure.
3. Area of rupture assumed equal to the flow area of two tubes. Relieving device will not be required when
sufficient quantities of material can be discharged through the low pressure connecting system (with block
valves assumed thro’ open) to prevent an overpressure of more than 1.10 P.

iso1.sty
SPECIFICATION
PIPING TURNKEY PACKAGE
PAGE 1 OF 2
CONTENTS and forwarding.

1.0.0 SCOPE e. Insulation of all insulated lines and Painting
of all uninsulated CS / AS pipes and ducts
2.0.0 DESIGN CONSIDERATIONS shall be as per specification attached. Color
3.0.0 BATTERY LIMITS FOR PIPING coding shall be as per FEDO color coding.
4.0.0 DETAILS OF DRAWINGS/ DOCUMENTS f. All piping items covered by Indian Boiler
Regulations (IBR) shall be supplied along
5.0.0 GENERAL with IBR certificate
———————————— g. Any other work related to the completion of
the Package.
1.0.0 SCOPE
h. All items included in the vendor’s scope may
1.1.0 GENERAL be subjected to inspection by FEDO / Client.
1.1.1 The scope of work includes but is not limited to The items are to be cleared by the desig-
basic design, detailed engineering, supply, nated inspector before dispatch.
fabrication, erection, testing, painting, insula- i All piping larger than 50 NB shall be
tion, commissioning and guarantee run of the prefabricated. Pipes smaller than 50 NB
Piping / Ducting on turnkey basis. shall be delivered in commercial lengths,
1.1.2 The supply of hardware and engineering shall properly marked with type and material.
be completed as there will be no other supplier 10% excess pipe shall be supplied for all
other than the vendor within the battery limit sizes and materials.
indicated. j. All vents shall be at a safe location and shall
1.2.0 IDENTIFICATION include necessary supports.
1.2.1 The scope of work includes but not limited to: 2.0.0 DESIGN CONSIDERATIONS
a. Basic engineering for the piping / ducting 2.1.0 Design of all piping systems, except those listed
for the Package. below, shall be as per ANSI / ASME B 31.3.
b. Detailed engineering for piping/ducting a. All boiler feed water and steam lines shall
within the Package. This includes prepara- be as per the latest issue of IBR and ANSI
tion of plot plan, piping layouts, isometrics, / ASME B31.1.
support drawings, bill of materials, procure-
ment, special instructions for storage, spe- 2.2.0 All dimensions and elevations shall be given in
cial instructions for identification of pipe metric units.
lines and components, special instructions 2.3.0 Flange and valve ratings shall be as per class
for erection, special instructions for testing, designation in ANSI B16.5 and ANSI B16.34
special instructions for pickling of oil lines if respectively.
any, blowout procedure etc.. Submission of
these drawings to FEDO, incorporating 2.4.0 32, 65 & 125 NB pipe sizes shall not be used.
comments made by FEDO and obtaining 2.5.0 Traps & strainers shall be provided wherever
necessary IBR / Statutory approvals. necessary. Normally a shut off valve shall be
c. Stress Analysis of all pipe lines and ducts provided ahead of each strainer /trap. Union or
above 100 deg.C, all IBR lines and all lines flanges shall be provided for removal of traps.
connected with rotating equipments. 2.6.0 The clear headroom over platforms, walkways,
These stress analysis reports shall be sub- passage ways and working areas shall be at
mitted to FEDO for review and comments. least 2.2 m.
Compensators and spring supports shall be 2.7.0 All pipes shall have a slope of minimum 1 in
finalized and provided based on the stress 1000 and shall be provided with drain line at the
analysis reports. lower most point.
All pipe lines shall be anchored at the Bat- 2.8.0 All equipment location, layout, design and
tery Limit. general arrangements shall conform to the
Nozzle loads on rotating equipments, viz, relevant statutory requirements.
turbines, etc., shall comply to API/ NEMA 2.9.0 Valves shall be located where there is ease of
codes and the reports shall be submitted to operation and maintenance. Gear arrangement
FEDO for review. shall be provided for all valves as per clause 5.5.
d. Supply of all materials based on the piping
bill of materials and any additional material 3.0.0 BATTERY LIMITS FOR PIPING
required for the satisfactory completion of
the system. Supply includes all materials for 3.1.0 All incoming and outgoing lines shall be ter-
piping such as pipes & ducts, pipe & duct minated at the Battery Limits specified in the
fittings, flanges, gaskets, bolts and nuts, battery limit list attached.
pipe supports, valves, expansion bellows,
spring supports, shut-off plates, safety val- 4.0.0 DETAILS OF DRAWINGS/ DOCUMENTS
ves, etc. as per approved piping layouts and
P&IDs. Supply inclusive of testing, packing This is only a general guide line for preparing
various drawings / documents, highlighting the
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: APR ’10
CONTROLLED COPY
ISO 9001 : 2015
SPECIFICATION
PIPING TURNKEY PACKAGE
PAGE 2 OF 2
minimum details to be furnished. The vendor is 4.3.2 The isometric drawings shall indicate the
obliged to include any other details found to be relevant line numbers, flow direction, pipe
wanting in the drawing/document, after review specification, insulation / painting details, stress
of the same by FEDO. analysis requirements, pipe supports like trun-
nions, line fluid conditions such as pressure,
4.1.0 GENERAL LAYOUT DRAWING temperature, hydrotesting pressure, etc.
4.1.1 The Layout should be of A1 size and should give 4.3.3 Steam tracing isometrics:
the following details using the coordinate sys-
tem to locate each item. This shall be produced from the relevant
isometrics with details of steam tracing incor-
a. Size Location and Point Of Support (POS) porated. However the bill of materials will be that
elevation of all equipments, location and for the steam tracing line.
size of buildings.
4.4.0 PIPE SUPPORT PLAN
b. Battery Limits.
4.4.1 This drawing should indicate the location and
c. Pipe Bridge Locations. type of all supports used and should also give
d. Sewer and Drain Details. the pipe support detail sheet number to be
referred for getting details of the support.
e. Free area required around equipment / ex-
changers for maintenance / tube removal. 4.5.0 PIPE SUPPORT DETAIL SHEETS
f. Paved area and elevations. 4.5.1 This detail sheet should give all the data re-
quired for the fabrication and erection of a par-
g. Plant North. ticular pipe support.
h. The Layout shall also contain a table show- 4.6.0 LINE SCHEDULE
ing the complete list of equipments with
location and point of support details. 4.6.1 This document should give all line numbers, the
detail of connecting equipment lines, operating
4.2.0 PIPING LAYOUT conditions, service and insulation details.
4.2.1. The Piping Layout shall be drawn on a scale of 4.7.0 VALVE SCHEDULE
3:100. The layout shall give the following
details using the coordinate system to locate 4.7.1 This document should furnish tag numbers,
each equipment and line. type, pressure rating, size, material of constru-
ction and service of all valves.
4.2.2. Routing of all pipelines and ducts showing all
fittings, valves, strainers, springs, bellows, line 5.0.0 GENERAL
Nos., direction of flow, location and elevations,
pipe supports etc. 5.1.0 All piping items shall be procured from the at-
4.2.3. Nozzle schedule of all equipments giving the tached sub vendor list of approved vendors for
following details of all nozzles on each equip- indigenous vendors. For any deviation, prior
ment. approval from FEDO shall be obtained before
placement of order.
a. Size and Rating
5.2.0 Operating spares for valves, steam traps,
b. End Connection strainers etc. for two years of trouble free service
c. Orientation be included in the offer.
d. Elevation 5.3.0 A layout shall be included in the package for
reference.
e. Standout
5.4.0 Bypass, drain and vent connections for valves
f. Description shall be as specified in MSS-SP 45.
4.2.4 Separate details for lines / areas which cannot 5.5.0 Geared Operators for valves shall be provided
be clearly drawn on the layout. as per the following table.
4.2.5 All platforms on vessels and structural plat-
forms. ANSI Rating Valve Size
4.2.6 All instruments, control valves, MOV, PSV, 150 # 300 NB and over
traps, etc.
4.2.7 Any other detail required by FEDO during 300 # 200 NB and over
review.
4.3.0 ISOMETRICS: 400 # & 600 # 150 NB and over
4.3.1 Isometrics shall be drawn for all lines irrespec- 900 # 100 NB and over
tive of size, including isolation valves on equip-
ments. The isometric shall include a Bill of 1500 # & 2500 # 80 NB and Over
Materials showing the complete list of materials
and quantity required for fabrication and erec-
tion of the line.
————————————————————————-

RUBBER LINING FOR PIPES , DUCTS & PIPE FITTINGS
CONTENTS :
1.0.0 SCOPE
2.0.0 PIPE AND FITTINGS
3.0.0 LINING GUIDELINES
3.1.0 METAL PREPARATION
3.2.0 CEMENTING
3.3.0 LINING THICKNESS
3.4.0 LINING MATERIAL SELECTION
4.0.0 LINING PROCEDURE
4.1.0 PREPARATION
4.2.0 LINING PROCEDURE FOR STANDARD FLANGED PIPE
4.2.0 LINING PROCEDURE FOR LARGE DIAMETER PIPE
5.0.0 PROTECTING RUBBER LINED PIPES
5.1.0 SOURCES FOR POTENTIAL PROBLEMS
5.2.0 MEANS FOR PROTECTION
6.0.0 TESTING AND INSPECTION
6.1.0 ADHESION
6.2.0 VISUAL INSPECTION
6.3.0 SPARK TEST
7.0.0 MAINTENANCE
8.0.0 REQUIREMENTS FOR RUBBER LINING
ANNEXURES:
TABLE 1 RECOMMENDED MAXIMUM LINING THICKNESS
TABLE 2 CHEMICAL RESISTANCE OF VERIOUS LINING
PRPD BY : KR CHKD BY : AMN APPRD BY : KKK ISSUED ON : SEPT ' 15

1.0.0 SCOPE
1.1.0 This specification covers general requirements for 3.2.4 Sufficient drying time between cement coats is
lining of pipes, ducts. Piping fittings etc. including required.
fabrication, installation and testing.
1.2.0 Shop and field lined pipe are both included. 3.3.0 LINING THICKNESS
1.3.0 The thickness of rubber and areas to be covered shall 3.3.1 Lining thickness may vary from ¹∕₈" to ¹∕₄" in (3 to 6
be in accordance with each data sheet and mm). In some very abrasive conditions, up to 1"(25
specifications. mm) has been applied.
1.4.0 The lining must be resistant to the chemicals shown 3.3.2 Experience has proved that not only the rate of
under the conditions listed on data sheet and abrasion must be considered but temperature also.
specifications For temperatures greater than 140 F (60 C), ¹∕₄ in (6
mm) thick lining will provide better service.
2.0.0 PIPE AND FITTINGS
2.1.0 Pipes and fittings shall confirm to piping 3.3.3 The most commonly used and economical lining
specifications and to the requirements of this thickness is ¹∕₄ in (6 mm). It offers long life for a
standard. wide range of applications.
2.2.0 Pipe is to be seam-welded or seamless steel pipe 3.3.4 Recommended maximum lining thicknesses for
unless otherwise specified. Wall gauge is to be different pipe sizes are shown in Table-1.
specified if not shown or called for on purchase 3.3.5 Table-1 show that the smallest pipe size which can
orders or drawings. be lined is NPS 2 (DN50); however, NPS 1 nozzles
2.3.0 Where welding is used, internal welds shall be can be lined per the following specifications:
ground flush with the parent metal to ensure a 1. Maximum length of nozzle is 25mm
continuous smooth surface, all fittings shall be 2.Maximum thickness of rubber is ¹∕₈" (3 mm)
flanged type. 3.Maximum distance from end of pipe is 450mm
2.4.0 Flanges shall be flat-faced, Class 150 forged steel 4.Nozzle is attached to a minimum of 150NB pipe
slip-on, weld neck, or boiler plate. Raised face
flanges shall not be used. Class 125 cast-iron flanges 3.4.0 LINING MATERIAL SELECTION
or cast-iron pipe are not recommended for use with
3.4.1 The most important factor in selecting the right
rubber lining.
lining material is specific chemical resistance that
2.5.0 The weld on the front face shall be continuous and will be required.
rounded convex to a radius of 3.0 mm or 4.5 mm. 3.4.2 In-service testing may be needed to confirm the
3.0.0 LINING GUIDELINES suitability of the material selected.
3.1.0 METAL PREPARATION 3.4.3 Table-2 lists some common chemicals and the
3.1.1 All metal surfaces to be lined shall be blasted to a general polymer used for a lining.
white metal finish. White metal blasting is the 4.0.0 LINING PROCEDURE
process of removing all foreign matter (such as rust, 4.1.0 Sheets of rubber shall be unrolled and cut to the
scale, and paint)by the use of abrasives propelled by desired size and shape on a clean heated table and
using 100 psi (690 kPa) of air. The surface finish shall be taken so that the tie gum (sticky) side of the
will become a metallic gray-white color, with a lining is facing out for cementing.
roughened anchor pattern providing a 1.5 to 3 mil
(37.5 to 75 micron) profile. 4.2.0 The edges can be cut with a skive (30 to 45-degree
3.1.2 Other acceptable standards are provided by the angle) to aid forming the seam.
Structural Steel Painting Council (SSPC) or 4.1.0 LINING PROCEDURE FOR STANDARD
NationalAssociation Corrosion Engineers(NACE). FLANGED PIPE :
3.2.0 CEMENTING 4.1.1 A tube shall be formed with lining stock using
longitudinal skived seams by wrapping the lining
3.2.1 Primer shall be applied immediately after removal of
stock around a mandrel, using a liner inside the tube,
dust and sandblasting to prevent rusting.
or any other method to facilitate the making of a
3.2.2 Additional coats of primers and cements may need tube.
tobe applied as specified by the lining manufacturer. 4.1.2 The spliced tube’s outside circumference shall be
slightly smaller than the inside circumference of the
3.2.3 Primers and cements are normally applied on the pipe to be lined.
inside of pipe with a swab, spray, or roller.
4.1.3 When forming the tube, the seam is formed by using 4.2.2 Large diameter pipes shall be lined in the same
steady, firm, and overlapping strokes with a roller manner as tanks or ductwork.
and when rolling, always work toward the edges 4.2.3 The stock is flared over the flange face and trimmed
forcing all the air out from behind the overlapping or buffed flush after the cure and a covering is
layers of lining or along the butt skive. applied to the full face of flange.
4.1.4 The spliced tube’s length is longer than the pipe’s 4.2.4 Bleeder strings are used at the applicators option, to
length. facilitate the escape of gases during curing.
4.1.5 Twisted multifilament strings (called bleeder strings) 4.2.5 The I.D. of the flange stock is then skived to slightly
are then applied lengthwise to permit proper air less than the I.D. or lining and stitched firmly to the
venting between pipe and lining. String made from tube stock. On larger-sized pipe, the flange stock is
synthetic yarns is not to be used. Stringing is done lapped into the pipe lining instead of applying the
after cementing the pipe, and the individual strings skive technique used on smaller pipe or applying
are spaced equally around the circumference. lining to flange first. The lined pipe is cured as
4.1.6 Normally, four strings are used on pipe of sizes up to specified by the lining manufacturer.
and including NPS 6 (DN 150). Larger-sized pipe 4.2.6 After curing, the ends of the pipe are buffed to
normally requires the use of additional strings. The remove any excess rubber. This provides a smooth
use of strings is optional with applicators fit during installation at the plant site.
4.1.7 The tube is enclosed in a liner and a tow rope is 4.2.7 The best cure results will be obtained by using a
attached to it. The tube is then pulled into the pipe steam autoclave.
with a slow constant pull.
4.1.8 One of two methods is used to seal the liner against 5.0.0 PROTECTING RUBBER LINED PIPES
the inside surface of the pipe. 5.1.0 SOURCES FOR POTENTIAL PROBLEMS
METHOD 1 : The liner is removed and the tube 5.1.1 Ozone from welding: Ozone can and will cause
expanded against the pipe wall by using air pressure. severe cracking of natural rubber in linings, and the
A mechanical extension and flange arrangement is corrosion barrier may be breached permanently.
used to seal the pipe ends and a minimum of 100 psi
5.1.2 Portable generators, power relay stations, and
(690 kPa) internal pressure is maintained in the
electric motors are a potential source of ozone.
expanded tube for at least 5 minutes. If any air
blisters are found after the air pressure is removed, 5.1.3 Fumes from generators, such as nitrous oxide, are
they are punctured, vented, and repaired with a 2 in detrimental to rubber linings.
(50 mm) patch. 5.1.4 Arcing from electrical equipment and hook-ups
METHOD 2 : After the liner is removed, an air bag generate a corona (ozone) environment.
or balloon is pulled through the pipe, with stops at 5.1.5 Oils and liquids of many types cause softening and
intervals where it is alternately inflated and deflated. deterioration of the rubber.
Next, the extension is removed, the excess stock
5.1.6 Problems may occur from any one or more of the
flared over the flange face, and trimmed flush. A
above sources and can occur either inside or outside
covering is then applied to the full face of the flange.
of the structure being erected. Suitable protection
The inside diameter (I.D.) of the flange stock is
must be provided.
skived to slightly less than the I.D. of the lining and
stitched firmly to the tube stock or folded out and 5.2.0 MEANS FOR PROTECTION
onto the flange surface. When using hard rubber 5.2.1 Installation of rubber lining should be done as near
lining on flanges, it is important that the pipe the end of the construction phase as possible.
installer/user understand that soft rubber gaskets are 5.2.2 Openings to rubber-lined equipment should be
required over the face lining. closed as much as possible to prevent attack from
4.1.9 On pipe sizes larger than NPS 6 (DN 150), the hazards such as those noted.
flange stock is lapped onto the lining instead of the 5.2.3 The ends of rubber-lined pipe should be blanked off
skive used on smaller sizes. This lapping technique and kept that way until ready for use. Lining on
makes a stronger joint and is the preferred method. flanged faces should be protected during shipment or
4.2.0 LINING PROCEDURE FOR LARGE storage by covering with plywood or other suitable
DIAMETER PIPE material.
4.2.1 Piping that is too large to safely line by inflating a 5.2.4 All portable rubber-covered items should be covered
tube, but large enough to allow personnel to enter up for protection.
will be considered in this section.
5.2.5 Each piece should be identified by stamping on a
ground area in such a manner that numbers will
remain visible. Stencil: ‘‘Rubber Lined—Do Not
Cut or Weld.’’
5.2.6 Additional protective measures are available from
rubber lining manufacturer publications.
6.0.0 TESTNG AND INSPECTION
6.1.0 ADHESION
6.1.1 The adhesion of rubber bonded to metal shall be
satisfactory strong.
6.2.0 VISUAL INSPECTION
6.2.1 The inspection for visual defects should be carried
out over the entire surface in a good light the entire
surface shall be free of cracks, traces of bubble, lack
of adhesion, hollow spaces etc.
6.3.0 SPARK TEST
6.3.1 A high voltage. High- frequency spark test should be
carried out over the entire surface
6.3.2 Surface of the lining should be clean and dry when
the test is carried out.
6.3.3 The voltage shall be 5kV/mm thickness to 6kV/mm
thickness of lining unless the lining contains
considerable amount of carbon black filter in which
the voltage shall be 1.5kV/mm thickness.
7.0.0 MAINTENANCE
7.1.0 Rubber-lined pipe can be a large investment for a
company. Thus, proper care and maintenance are
always recommended. An experienced applicator
can offer many detailed suggestions.
7.2.0 Some basic considerations of maintenance are: avoid

impact, such as can occur from dropped tools;
prevent exposure to sunlight and outdoor
weathering; and protect from sudden temperature
changes, which may cause thermal stresses that
result in cracking, especially in hard rubber linings.
8.0.0 REQUIREMENTS FOR RUBBER LINING

8.1.0 The standards and requirements for rubber lining
shall be as per the figures and tables given in this
section.
8.2.0 When manufacturers intend not to apply this
standard, he shall submit his standard or practices in
order to get approval of purchaser.








ANNEXURES

TABLE 1

TABLE 2

CONTROLLED COPY
ISO 9001 : 2015
CONTROLLED COPY
ISO 9001 : 2015
CONTROLLED COPY
ISO 9001 : 2015
CONTROLLED COPY
ISO 9001 : 2015
SPECIFICATION
PAINTING
PAGE 1 OF 13
CONTENTS:
1.0.0. SCOPE
2.0.0. MATERIALS
3.0.0. SURFACE PREPARATION
4.0.0. STORAGE OF PAINTING MATERIALS
6.0.0. PAINTING
7.0.0. SAFETY
8.0.0. INSPECTION
9.0.0. GUARANTEE
10.0.0. CODIFICATION OF PAINTING MATERIALS
11.0.0. SCHEME OF PAINTING
12.0.0. COLOUR CODING & MATERIAL FOR PIPING TABLES

02ES023/2010
1.0.0. SCOPE a) Non ferrous surfaces, stainless

steel and High Alloy steel
1.1.0. This specification covers the surfaces.
requirements for surface preparation, b) Glass, tile or ceramic surfaces
painting and painting materials for c) Name plates and identification
equipment, structures and piping tags
(including those painted/primed at shop d) Valve stems
and those painted at Field/Site. e) Machined contact surfaces
f) Galvanised surfaces
1.2.0. Requirement of painting for any item g) Insulation covers
shall be as specified in any of the h) Plastics
following documents. i) Underground / buried piping
and equipments which are
a) Equipment Data Sheet provided with special type of
b) Piping line schedule protective coatings.
c) Design Basis for package j) Surfaces / Items which are
items excluded from painting due to
d) Painting schedule specific reasons.
1.3.0. The purpose of painting described in 1.7.0. This specification also covers painting
this specification is generally for of “Markings” and color-coding of
protection against corrosion. carbon steel, low/high alloy steel,
stainless steel, galvanized iron and
1.4.0. Painting for other reasons shall be as insulated pipes.
indicated in the respective equipment
data sheets or painting schedule. 2.0.0. MATERIALS
1.5.0. The following surfaces exposed to 2.1.0. All painting materials shall be of good
atmosphere are covered by this quality as covered by respective IS or
specification, which are not provided other international specifications
by any other form of covering/coating.
2.2.0. Special paints and painting materials
a) Pressure vessels, Tanks, Heat shall have proven quality and shall
Exchangers and other process meet the requirements laid down in the
equipment with Carbon steel respective data sheets for equipment
and low alloy steel as material and piping.
of construction.
b) Machinery items including 2.3.0. All painting materials shall not have
motors. passed the date of expiry or shelf life as
c) Steel structures recommended by manufacturer.
d) Carbon and low alloy steel
piping 3.0.0 SURFACE PREPARATION
1.6.0. The following items shall not be 3.1.0 All surfaces to be painted shall be free
painted unless otherwise specifically from rust, oil, grease, dust, stain,
required by respective equipment Data moisture or any other foreign
Sheets/Painting schedule material/contamination, as per IS 1477
Part I.

02ES023/2010
3.2.0 Surfaces to be painted shall be or when the relative humidity of air

completely dry. exceeds 90%.
3.3.0 Oil, grease, stains and other similar 3.9.3. Blasting operations shall not be carried
contaminants shall be completely out during rain, snow, or strong winds.
removed by using proper solvents and
removers, After cleaning, the surfaces 3.9.4. Blasting medium viz. Slag, grit, or shot
shall be free from even traces of shall be completely dry and shall be
contaminants and solvents/removers. free from any sort of contaminants like
dust, oil, grease etc.
3.4.0 Dust shall be removed by air blowing
or vacuum cleaning. 3.9.5. Blasting air shall be completely dry
and shall have minimum pressure of
3.5.0 Hard and caked dust, mud, mill scale 3.5 kg/cm2.
and rust shall be removed by
mechanical means like wire brushing, 3.10.0 Surfaces which are not suitable for
sand blasting , shot blasting or grit blast-cleaning or could not be blast-
blasting. cleaned due to practical reasons shall
be thoroughly wire brushed to exhibit a
3.6.0 Wet surfaces shall be dried by blowing pronounced metallic sheen, equivalent
warm air. to St 3 as per IS 9954.
3.7.0 All surfaces cleaned by different 3.10.1 Absence of compressed air,

methods shall be painted immediately slag/shot/grit and/or blasting equipment
with out allowing the clean surfaces and accessories shall not be a reason
togather dust, rust and other external for not carrying out blast cleaning.
substances.
4.0.0. STORAGE OF PAINTING
3.8.0 During the course of painting if it is MATERAILS
found that the surfaces are
contaminated due to any reason, the 4.1.0. Paints, varnishes, thinner, additives and
same shall be cleaned by any of the other volatile substances shall be stored
methods described earlier, before in a flame proof enclosure, away from
further proceeding with painting. heat.
3.9.0 All surfaces to be painted after sand, 4.2.0. Fire extinguishers or sand and water
grit or shot blasting shall exhibit almost for emergency fire fighting operations
clean white metal and shall have shall be provided near storage area at
surface finish of SA 2 ½ as per IS easily accessible place for use, in case
9954. of fire.
3.9.1 Blast cleaned surfaces shall be primed 4.3.0. Warning Boards and signs shall be
within 2 hrs, after blasting, before re- exhibited around the storage area.
rusting starts and before contamination.
3.9.2. Blast cleaning shall not be carried out
5.1.0 Mixing and thinning of paints shall be
when temperatures are less than 20°C
carried out as per manufacturer’s
recommendations.

02ES023/2010
5.2.0 Mixing and thinning operations shall not be carried out in dusty and draught
be carried out in well ventilated rooms. conditions in damp areas and during
rainy seasons or cold atmosphere.
5.3.0 Only that quantity of paint which is
6.1.4 During painting, adjacent equipments
sufficient to cover the required area
or surfaces shall be protected from
within the specified painting time, shall
paint sprays, splashes or drips.
be mixed at a time.
6.1.5 Painting shall be carried out only by
5.4.0 Mixed paints shall be used with in the
using brushes, rollers, air/airless spray.
time span as recommended by
manufacturer. Mixed paints, for which
6.1.6 Caution boards indicating ‘wet paint’
standing time specified has elapsed,
shall be posted after painting is over
shall not be used.
and kept till the curing time is
completed.
5.5.0 Ready-mixed paints containers shall
be opened only at the time of painting. 6.1.7 For painting of multiple coating, each
Containers shall be closed air tight coat shall be applied only after
after drawing paint from it. sufficient curing time has elapsed after
the previous coat, as recommended by
5.6.0 Ready-mixed paints shall be stirred manufacturer.
well before drawing from the storage
6.1.8 All painted surfaces shall have a
container as well as during painting
uniform and smooth regular finish.
operations.
The surfaces shall be free from foreign
particles, brush marks, bristles, ridges,
5.7.0 Ready-mixed paints shall be thinned
waves, laps wrinkles etc. If such
only if absolutely necessary by using
surface defects occur, the same shall be
thinners commended by manufacturer.
removed by using abrasive paper/cloth
and re-painted.
5.8.0 Balance of ready-mixed paints shall not
be poured back into the main container
6.1.9 Surfaces inaccessible after assembly
after use, but shall be kept in a separate
shall be painted to requirement before
air tight container.
assembly.
6.0.0 PAINTING
6.1.10 Any imperfect or damaged layer/coat
shall be repaired before subsequent
6.1.0 General Requirements.
coating.
6.1.1 Painting of equipment, piping and
6.1.11 At places where welding is to be
structurals shall be carried out at shop
carried out at field after assembly, a
or site as prescribed in the respective
space of 100 to 200 mm width shall be
eqpt. data sheets, piping line schedule
left unpainted on both sides of the
or structural detail drawing.
welding joint.
.
6.1.12 Field welded areas shall be thoroughly
6.1.2 Painting shall not be carried out on
cleaned as required in clause 3.0.0 and
surfaces not prepared and not meeting
painted in the same manner as the
the requirements of clause 3.0.0.
remaining area.
6.1.3 Painting shall be carried out only under
favourable conditions. Painting shall 6.2.0 Shop Painting/Priming.

02ES023/2010
6.2.1 Shop painting/priming shall be carried 7.6.0 Adequate ventilation shall be ensured
out as specified in the respective data during painting and storage of paints.
sheets/line schedule etc. and shall meet
all the requirements of this 7.7.0 Painting workmen shall wear face
specification. masks, gloves and protective clothing
during painting and mixing operations.
6.3.0 Painting at Field /Site. In addition, workmen engaged in
blasting operations shall be earmuffs
6.3.1 Field/site painting shall be carried out also.
as specified in the data sheets/painting
7.8.0 Area where painting is carried out, as
schedule and shall meet all the
well as materials are stored shall be
requirements of this specification for
clean, After work, the areas shall be
painting.
cleared of all scaffoldings, balance
6.3.2 Where equipments/piping/structures materials etc. in order to prevent fire
have already received shop hazards and hinder fire fighting
painting/priming, the painted/primed operations.
surfaces shall be thoroughly cleaned
7.9.0 Painting materials shall be stored and
and inspected for any damage or
painting and blasting operations shall
defects. Such damages or defects shall
be carried out only in areas where fire
be repaired before starting the filed/site
fighting equipments/vehicles and
painting.
personnel evacuation vehicles can have
7.0.0. SAFETY easy access. In areas where such easy
access is not available suitable
7.1.0. Sufficient safety precautions shall be
precautions are to be ensured.
taken to ensure protection of Personnel,
equipments, piping structures and
8.0.0 INSPECTION
buildings in the vicinity, where
painting materials are stored and 8.1.0. All painting materials and related items
painting and blasting operations are shall be inspected to check the
carried out. suitability of the same for the specified
purposes.
7.2.0. Open flames and exposed elements or
sources of ignition of any kind shall be
8.2.0. Painting surfaces are to be inspected
prohibited in the area where painting
after cleaning operation, to ensure that
materials are stored and painting
the surfaces are fit for painting.
operations are carried out.
7.3.0. ‘Warning’ or ‘Caution’ boards 8.3.0. Finished surfaces shall be checked for
indicating chances of fire shall be uniformity in colour, finish and
displaced around the paint storage and appearance as well as for defects.
painting areas.
8.4.0. Thickness of each coat of paint shall be
checked after curing time. The total
7.4.0 Electrical fittings and appliances shall thickness of multiple coats shall be as
be spark proof and shall not cause a specified in the data sheets/piping line
fire in the painting storage and painting schedules/painting schedules.
areas.
8.5.0. Paint thickness gauge shall be either
7.5.0 Cleaning agents with flash point less
mechanical or electronic. The gauges
than 400C shall be used.

02ES023/2010
shall be calibrated regularly. Defective D.02 Single Pack High Temperature

gauges shall not be used. Silicon Aluminium Paint (upto
600oC)
8.6.0. Absence of paint thickness gauge shall
10.5.0. Polyurethane Coating. (For low temp.
not be made for each eqpt/line/structure
application)
separately.
E.01 Two-Pack Polyurethane Holding
8.7.0. A detailed quality / inspection report Primer
shall be made for each eqpt / line / E.02 High Build Polyurethane Coating
structure separately
10.6.0. General Purpose Paints
9.0.0. GUARANTEE F.01 Synthetic Resin based Enamel
F.02 Chemical Resistant Enamel
Guarantee shall cover materials and
F.03 Alkyd, Antiskid Abrasion
workmanship.
Resistant Synthetic Floor Paint
10.0.0. CODIFICATION OF PAINTING
10.7.0. Special Applications
MATERIALS
G.01 Bituminous Mastic Coating
10.1.0. Primers
G.02 Asphalt doping as per IS 10987
A.01 Synthetic Zinc Phosphate App-B
Primer G.03 Thermocolour Paint
A.02 Epoxy based Zinc Phosphate
10.8.0 As an alternative, in place of one coat
Primer
of E.01 – Two pack Polyurethane
A.03 Epoxy based Zinc Rich Primer
Holding Primer, one coat of Epoxy
A.04 Alkyd High Build Zinc
Zinc Phosphate Primer A02 (20
Phosphate Primer
microns) followed by one coat of High
A.05 Inorganic Zinc Silicate Primer
Build Epoxy containing Micaceous
A.06 Chlorinated Rubber based High
Iron oxide-Bo2 (20 microns) shall be
Build Zinc Phosphate Primer
applied before applying finish paint E-
10.2.0. Finish Paints 02-High build Polyurethane coating.
B.01 Epoxy Resin based Enamel 11.0.0 SCHEME OF PAINTING
B.02 Epoxy Resin based Micaceous
11.1.0. Scheme of painting of equipment,
Iron Oxide Paint
piping, structures and other items shall
B.03 Epoxy Resin based High Build
conform to class 1, class II or class III
Paint
as specified in the equipment data
B.04 Coal Tar Epoxy Resin based
sheet/ piping line schedule/ painting
Paint
schedule/ structural drawings.
B.05 Chlorinated Rubber Paint
11.2.0 Representation of painting
10.3.0. Bituminous Coating
Requirement of painting of an item
C.01 Nontoxic Inert Coating for shall be indicated in respective
drinking water tanks drawings/ data sheets/ line schedule/
C.02 Acid Alkali and Heat Resisting painting schedule as follows. Indicate
Coating primer or finish or both as required
10.4.0. Heat Resistant Paints followed by subclass indicated in Table
1, Table 2 or table 3 as the case may
D.01 Dual Pack Aluminium Paint
be.
(upto 250oC)

02ES023/2010
Eg 12.0.0 COLOUR CODING AND MARKING

Primer Class I (1)L FOR PIPING
Finish 12.1.0 In addition to the requirements of

Class I (1)L
painting as per 11.0 the finish painting
Primer & Finish of the piping shall have the specified
Class I (2)M
colors as per Table 4 – Color coding
Primer Class II (2)O for pipes, for purposes of identification
of service.
Primer & finish
Class II (3)O/P
12.2.0 All pipes and pipe lines covered under
Primer 1.7 shall be provided with “Markings”
Class III (1)
such as color bands, hazard markings,
Finish line identification markings, flow
Class III (1)
arrow markings etc. at specified
Primer & Finish Class III (3) locations/intervals and dimensions as
indicated in Table 5 – Marking of
pipes.

02ES023/2010
TABLE 1 – CLASS I – Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping
Sl. SERVICE OPERAT PAINT PRIMER FINISH

No. CONDITIONS ING SUB- Type No.of *DFT Type No.of *DFT
TEMP. CLASS coats coats
1 UN =/< 15 (1) L E.01 1 30 E.02 2 30
INSULATED =/< 65 (1) N A.01 2 20 F.01 2 20
NON =/< 125 (1) M D.01 2 20 D.01 2 20
CORROSSIVE =/< 400 (1) H D.02 2 20 D.02 2 20
ATMOSPHERE
2 UN =/< 15 (2) L E.1 1 30 E.02 2 20
INSULATED =/< 65 (2) N A.06 2 20 B.05 2 20
CORROSSIVE =/< 125 (2) M A.02 2 20 B.02 2 20
ATMOSPHERE =/< 400 (2) H D.02 2 20 D.02 2 20
3 INSULATED =/< 15 (3) L E.01 1 30 - - -
NON =/< 65 (3) N A.04 2 25 - - -
CORROSSIVE =/< 125 (3) M D.01 2 20 - - -
ATMOSPHERE =/< 400 (3) H D.02 2 20 - - -
4 INSULATED =/< 15 (4) L E.01 1 30 - - -
CORROSSIVE =/< 65 (4) N A.06 1 30 - - -
ATMOSPHERE =/< 125 (4) M D.01 1 30 - - -
=/< 400 (4) H D.02 1 30 - - -
5 SUPPORTS =/< 15 (5) L E.01 1 30 E.02 2 30
FOR ALL =/< 65 (5) N A.01 2 20 F.01 2 20
EQPTS.(INSUL =/< 125 (5) M D.01 2 20 D.01 2 20
ATED/UN =/< 400 (5) H D.02 2 20 D.02 2 20
INSULATED)
6 EQPT. AND =/< 15 (6) L E.01 1 30 E.02 2 30
STRUCTRURE =/< 65 (6) N A.06 2 20 B.05 2 30
S SUBJECTED =/< 125 (6) M A.02 2 20 B.01 2 30
TO SALINE =/< 400 (6) H D.02 2 20 D.02 2 20
ATMOSPHERE
UN
INSULATED
* DFT – Dry film Thickness per coat microns
Notation:
L – Low Temperature
N – Normal Temperature
M – Moderate Temperature
H – High Temperature

02ES023/2010
TABLE 2 – CLASS II – OTHER EQUIPMENTS

PRIMER FINISH
Sl. PAINT
No. TYPE OF ITEM SUB No.of No.of
Type *DFT Type *DFT
CLASS coats coats
Chimneys,Stacks,
Furnaces,heaters
1 (fired and Outside (1) A.05 2 25 D.02 2 20
unfired)operating
Temp upto450oC
D.M.Water Outside (2)O A.01 2 20 F.01 2 25
2
Storage Tanks Inside (2)P A.03 2 35 B.03 2 35
Fresh Water/fire Outside (3)O A.01 2 20 F.01 2 25
3 Water Storage
Tanks Inside (3)P A.03 2 35 B.04 2 75
Drinking Water Outside (4)O A.01 2 20 F.01 2 25
4
Storage Tanks Outside (4)P A.01 2 20 C.01 3 20
Acid/alkali
5 Outside (5) A.04 2 30 C.02 3 25
Storage Tanks
Storage Outside (6)O A.04 2 50 D.01 2 25
Tanks/Vessels for
6
Petroleum
Inside (6)P A.02 2 30 B.03 2 75
Products
Floating Roof
Tanks:Inside of
shell, top of Outside (7)O A.04 2 50 D.01 2 25
7 bottom
plate,topside and
underside of deck, (7)P A.02 2 30 B.03 2 75
inside of pontoon (7)Q A.01 2 25
Underside of
8 Bottom Plate of (8) A.01 1 20 G.01 1 80
Tanks
Underground
9 Outside (9) A.01 1 20 G.02
Tanks (buried)
Below Ground
10 (submersible) Outside (10) A.06 2 35 B.05 3 35
Tanks
Secondary
Reformer&
11 Similar (11) G.03 2 ** G.03 1 **
Eqpt.(Thermo
colour paint)
*DFT : Dry Film Thickness per coat microns

** : As per Manufacturer’s recommendations
Notation: O- Outside P-Product Side Q-Specified Side

02ES023/2010
TABLE 3 – CLASS III – MISCELLANEOUS
PRIMER FINISH
PAINTING
Sl. TYPE OF ITEM No.
SUB No.of
No. Type of *DFT Type *DFT
CLASS coats
coats
Steel structures, Platform
1 Supports (1) A.04 2 20 B.01 2 25
Chequered
2 Plate,Floorplanks&Gang (2) A.04 2 20 F.03 2 25
ways
Handrails
3 Posts,Railings,Ladders (3) A.04 2 20 B.01 2 25
and Stairways
* DFT – Dry Film Thickness per coat microns

02ES023/2010
TABLE 4 – COLOUR CODING FOR PIPES
Sl. Service Identification Colour Band - 1 Colour Band - 2

No. Ground / Finish Colour
1 Instrument Air0 Sky Blue White -
2 Service Air Sky Blue Light Brown -
3 Plant Air Sky Blue French Blue -
4 Cooling Water Sea Green French Blue -
5 Service Water Sea Green French Blue Signal Red
6 Demineralised Water Sea Green Light Orange French Blue
7 Boiler Feed Water Sea Green - -
8 Steam Condensate Sea Green Light Brown -
9 Boiler Blow Down Sea Green White Signal red
10 Turbine condensate Sea Green White -
11 Process Condensate Sea Green Black -
12 Low Pressure Steam Silver Grey Light Orange -
13 Medium Pressure Steam Silver Grey Light Brown -
14 High Pressure Steam Silver Grey Signal Red -
15 Very High Pressure Silver Grey Signal Red French Blue
Steam
16 Naphta Liquid Light Brown French Blue -
17 Naphta Vapour Light Brown French Blue White
18 Fuel Oil Light Brown White -
19 Antifoam Solution Black Sea Green -
20 Phosphate Black Signal Red -
21 Hydrazinc Black Signal Red Sea Green
22 Waste Water Black Sea Green Signal Red
23 Oily Water Black White -
24 Ammonia Liquid Dark Violet French Blue -
25 Ammonia Water Dark Violet French Blue Sea Green
26 Ammonia gas Dark Violet French Blue Canary Yellow
27 MDEA Solution Dark Violet Black White
28 Process Vent Canary Yellow Light Grey Signal Red
29 Carbondioxide Canary Yellow Light Grey -
30 Hydrogen Canary Yellow Signal Red -
31 Nitrogen Canary Yellow Black -
32 LPG Canary Yellow French Blue -
33 Fuel gas Canary Yellow Light Brown -
34 Process Gas Canary Yellow Sea green -
35 Synthesis Gas Canary Yellow White -
36 Effluent Black Sea Green Signal Red
37 Drinking Water Sea Green Light Orange -

02ES023/2010
TABLE 5 – MARKING FOR PIPES

1.0. GROUND COLOUR UNIT OF MEASUREMENT
Insulated Line – all
1.1. Un-insulated Lines–Stainless : Ground colour for a length Per Marking as per para 6.0
Steel,GI ,Alloy steels & of 2 meters below including pipe supports
Other non-ferrous pipelines
___________________________________________________________________________
1.2. Un-insulated carbon steel : Ground colour applied Run length in Meters along
Lines (excluded buried throughout entire length centreline including Markings
Lines) as per Para 6.0 below &
pipe supports
___________________________________________________________________________
2.0. COLOUR BANDS MARKINGS
2.1 Colour band(s)and its width,Band 2 downstream of Band 1(ie.after band 1
along the direction of flow)
Pipe size NB Band 1 B and 2

(D-pipe size in inches) mm mm
80 NB and below 75 ¼ of Band 1
Above 80 NB(3”) up to 100 NB(4””) D x 25 (Rounded to the
Above 100 NB(4”) up to 300 NB(12”) D X 20 nearest mm)
Above 300 NB(12”) D x 15
3.0 HAZARD Diagonal strips of Black and golden Yellow as per IS2379
MARKINGS superimposed on the ground color. If color bands exists, the hazard
marking shall be painted downstream of the bands (ie. after bands in
the direction of flow)
4.0 LINE Color shall be Black or White to contrast with the color on which
IDENTIFICATION they are painted. It shall consist of Line No., Line size, Fluid code
MARKINGS & Pipeline Spec. No. The lettering dimensions shall be as per
IS2379.
5.0 FLOW ARROW Color shall be Black or White to contrast with the color on which
MARKINGS they are painted. The dimension of the arrow shall be as follows and
is based on the size of the pipeline.
150NB & 200NB &

below above
d a a 65 90
b 30 50
c b c 95 125
d 20 30

02ES023/2010
6.0 LOCATION OF MARKINGS

7.0 PIPE SUPPORTS
Marking includes 2M long ground
color, color band(s), hazardous 7.1 This includes base springs, hanger
marking, Line No. & flow direction springs, shoes and trunnions etc. and
arrow which shall be located at the excludes pipe bridge structures,
following points with proper visibility platform, equipment support structures
as per IS2379. and such structures which do not
actually support the pipeline.
a. Battery Limit Points 7.2 The painting of pipe supports forms
b. Either side of walls & dyke walls part of the pipelines and a separate rate
c. For long yard piping – at 30M will not operate.
interval
d. Inter-section on pipe bridge 7.3 The painting specification for pipe
e. Any other location indicated by the supports shall be same as that for pipe
Engineer-in-charge at site ground colour.
****************

iso2.sty
25ES205 / 10
ENGINEERING FABRICATION & ERECTION OF
SPECIFICATION STEEL PIPING PAGE 1 OF 28
CONTENTS tion ( color identification and die stamp ) shall be

checked and recorded in the material ledger.
1.0.0 GENERAL The materials shall be stored promptly and neat-
2.0.0 FABRICATION ly in the designated warehouse or storage yard.
3.0.0 WELDING 2.1.2 When the identification is inadequate, the
material shall be marked according to the colour
4.0.0 HEAT TREATMENT identification or an identification mark such as
5.0.0 THREADED AND FLANGED JOINTS die stamp shall be applied before storing the
material.
6.0.0 PROTECTION & SIZE OF PREFABRICATED
PIPE SPOOLS 2.1.3 Piping materials shall be issued only upon
presentation of Material Issue Slips signed by
7.0.0 INSTALLATION OF PIPE SUPPORTS the FEDO Engineer / Representaive. Piping
8.0.0 PIPING INSTALLATION materials shall be issued only against the
relevant isometrics.
9.0.0 TESTING AND INSPECTION
2.1.4 Issued materials shall be indicated on the draw-
10.0.0 PRESSURE TEST AND OTHERS ings or material use charts, etc., to prevent
duplication of issues.
11.0.0 APPENDICES
2.1.5 Any surplus materials found on the job - site
——————————- shall be returned promptly to the warehouse or
1.0.0 GENERAL storage yard.
1.1.0 SCOPE 2.1.6 When more material is needed as a result of
faulty fabrication or other similar reasons, the
1.1.1 This specification covers the general require- FEDO engineer shall promptly be in formed of
ments for fabrication and installation of steel the matter so that he can give further directions
piping (including carbon steels, low-alloy steels, and advice.
and stainless steels) within petroleum refineries
and chemical plants. 2.1.7 Special precautions shall be taken to keep
electrodes and gaskets dry during storage.
1.1.2 When conflict occurs between this specification
and the piping drawings or the individual 2.2.0 PRECAUTIONS FOR PREPARATI ON &
specification, the order of precedence shall be FABRICATION
piping drawings, individual specification, and 2.2.1 When the location of piping connections by field
this specification. welding is not shown on the piping drawings,
1.2.0 REFERENCES consideration shall be given to preparation and
fabrication of piping materials so that the field
1.2.1 The requirements contained in the latest edi- welding position is flat or horizontal as far as
tions of the following standards shall form a part possible.
of this specification, in the manner and to the
extent indicated herein: 2.2.2 The minimum clearance between the edges of
two adjacent welds shall exceed 25mm or 4
1. Indian Boiler Regulation (IBR) t imes the pipe n ominal wall t hickness,
whichever is greater.
2. ANSI B2.1, Pipe Threads
2.2.3 When both welded pipes and piping com-
3. ANSI / ASME B31.3, Chemical Plant and ponents having a longitudi nal welded joint are
Petroleum Refinery Piping joined at the end, in the girth butt welds the
4. ASME, Boiler and Pressure Vessel Code: dimension between the longitudinal welded
Section V- Non-destructive Examination, joints shall exceed 5 times the nominal pipe wall
Se c t i o n VI I I - D i v i s i o n 1 , U W- 5 1 - thickness of the thicker of those being joined. In
Radiographic Examination of Welded Joint, unavoidable circumstances when the dimen-
Section IX- Welding and Brazing Qualifica- sion is less than 5 times, both longitudinal
tions. welded joints in the girth butt welds shall be
examined by radiography over 100mm. In ad-
1.3.0 DEVIATIONS dition, Section 8.1 (14) shall be considered in
1.3.1 When piping cannot be fabricated and installed the preparation and fabrication.
as shown on the piping drawings, or when it is 2.3.0 CUTTING
deemed to be more appropriate to fabricate and
to install the piping in a manner other than as 2.3.1 Pipes shall be marked accurately and then cut
shown on the drawings, the FEDO Engineer / according to the dimensions shown in the piping
Representative shall be consulted and the drawing or the dimensions most suitable for the
piping shall be fabricated and installed in ac- conditions of field installation.
cordance with his instructions. 23.2 When irregular cutting is required for single and
2.0.0 FABRICATION multiple branch connections and for curved and
mitred segments of pipe, the cutting shall be
2.1.0 MATERIAL CONTROL performed by using a template.
2.1.1 Packages of piping materials delivered to the 2.3.3 In principle, pipes shall be cut mechanically with
jobsite shall be opened immediately, and the a pipe cutter or a high speed cutter. When
quantities, specifications, sizes, and identifica- cutting ss pipe using a high speed cutter, an
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: JAN 10
CONTROLLED COPY
ISO 9001 : 2015
25ES205 / 10
abrasive wheel for stainless steel shall be used. When carbon or low-alloy steel pipes and piping
components with the ends prepared are to be
2.3.4 When pipe is of a large diameter, or when a pipe stored for an extended period, a groove face rust
cutter or a high speed cutter cannot be used the preventive that will not damage the welding shall
following methods may be used. be applied to the ends (Appendix I). The rust
a) Carbon Steel preventive shall be removed prior to welding, as
far as possible.
Carbon steel pipe may be cut with automatic
or manual oxygen- acetylene gas ap- 2.5.0 BENDING
paratus. However, base metal with a carbon 2.5.1 In principle, ready-made elbows shall be used
content of more than 0.35% shall not be cut for bends of piping. However, when bends of a
with oxygen-acetylene gas apparatus. large radius are required due to fluid charac-
b) Low-alloy steel pipe teristics or plant performance, the pipe may be
bent to shape.The procedure for bending shall
Only when unavoidable, low-alloy steel pipe be as follows:
may be cut with oxygen-acetylene gas ap-
paratus pursuant to Subitem (a) above. 1. In principle, pipe shall be cold bent with a
pipe bender. However, when the pipe
c) Stainless steel pipe bender cannot be used because of the large
Only when unavoidable, stainless steel pipe pipe diameter, the pipe may be bent by
may be cut by plasma arc cutting or arc air heating or by high frequency induction.Low-
gouging. In this case, the pipe shall be alloy and stainless steel pipes shall not be
coated with spatter deposit prevention paint bent by heating.
to avoid adhesion of spatter. 2. Pipe bends shall be made of one piece of
2.4.0 END PREPARATION pipe with no welds at the bend.
2.4.1 Shape of Grooves 3 The pipe shall be smooth on both the ex-
terior and interior, and shall be bent so as
1. In principle, grooves for butt welding ends not to form any cuts, cracks, wrinkles, dents,
shall be shaped in accordance with ANSI etc.
B16.25 However, the grooves shall be in
accordence with the approved Procedure 4 Flattening of a bend shall not exceed the
Qalification Records(PQR). requirements shown in Section 2.8 figure 6.
2. Unless otherwise specified, the grooves 5 The minimum bending radius shall be
shall be in accordance with the require- greater than 1.5 times the nominal diameter
ments shown in Table below which conform of pipe, unless otherwise specified on the
to ANSI B16.25. piping drawings or the individual specifica-
tion.
PIPE WALL THICKNESS (t) GROOVE 6 Low-alloy and stainless steel pipe shall be
heat treated in accordance with the in-
3 mm or less (stainless Square groove dividual specification to relieve residual
steel) and or slightly
4mm or less (carbon steel bevelled stress and work hardening of the bend.
and low alloy steel) However, the heat treatment may not be
applied to austenitic stainless pipe or to
Over 4mm (but over 3mm Single v groove nickel-alloy steel pipe.
for stainless steel ) to 22mm asper figure 1a
7. For carbon steelpipe of 25 NB and smaller,
Over 22 mm Double v groove steam tracing, or discharge-end piping of
as per figure 1b vents, drains, etc., the pipe may be bent to
the required angle by heating with an
2.4.2 Shape of Internal Trimming and Misalignment oxygen-acetylene gas torch. However,
1. Radial misalignment at the joining ends of precautions shall be taken to prevent
piping components shall be such that full damage to the pipe by overheating and to
penetration can be attained. ensure that the roundness of the steel pipe
is maintained.
2. Where component ends have an internal
misalignment over 1.6mm, the thicker com- 2.6.0 MITRE BENDS
ponent with the wall extending internally 2.6.1 Unless otherwise specified, mitre bends shall be
shall be trimmed internally to an angle less used for piping 350NB and larger. For piping of
than 300C as shown in Figure2. However, 300 NB and smaller, ready-made smooth el-
such trimming shall not result in a finished bows shall be used.
wall thickness less than the required mini-
mum design thickness plus corrosion and 2.6.2 Mitre bends shall be fabricated as follows unless
erosion allowances. otherwise stated in the piping drawings or the
individual drawings.
2.4.3 End Preparation method
1 Mitre bends to be used at bends greater
In principle, the end preparation shall be per- than 450C shall consist of not less than three
formed by machine. However, when the segments. The minimum distance (l) be-
preparation is other than by machine, any tween alternate segments of the mitre bend
cracks, flaws, burrs or oxidation scale (rust) shall be 4 times the pipe nominal wall thick-
shall be removed from the surface with a grinder. ness or 25mm, whichever is greater (Fig-
2.4.4 Treatment after End Preparation ure3)

ENGINEERING FABRICATION & ERECTION OF 25 ES205 / 10
FIGURE 1 A FIGURE 1 B
WHEN t - 4mm to 22 mm WHEN t > 22 mm
33 1/2° ± 2 1/2° R 3.2mm 10°± 1°

37° ± 2.5°
19
1.6 ± 0.8
t
1.6 ± 0.8
3.2 ± 0.8 3.2 ± 0.8

FIGURE 2
TRIMMING AND PERMITTED MISALIGNMENT
OVER 1.6 mm THIS PORTION SHALL BE FINISHED

SMOOTHLY SO AS NOT TO HAVE A
SHARP EDGE, WHICH MAY HINDER
30° MAX
RADIOGRAPHIC EXAMINATION
FIGURE 3
SHAPES OF MITRE BENDS
15°
30°
30°
1.5 D
1.5 D
FIGURE 4
ANGLE OF MITRE BENDS

25ES205 / 10
2 The radius of the mitre bend shall be greater between branch and main run, and to provide
than the nominal diameter of the pipe. vent ing during welding and heat treatment
operations. If the reinforcement pad is made in
3 The maximum mitre angle (ß of Figure 4) of more than one piece, each piece shall be
each segment shall be as follows: provided with a vent hole.
When design pressure is : β ≤ 22030’ 2.7.7 The material of reinforcement pads shall be the
8kgf / cm2G or less same as the main run pipe.
When design pressure is 28 : β ≤ 15000’ 2.7.8 An examination of the welds joining reinforce-
kgf / cm2 G or less ment pad to the branch shall be made by FEDO
Engineer/ representative before installing the
When design pressure ex- : β ≤ 11 015’ reinforcement pad.
ceeds 28 kgf / cm2G
2.8.0 FABRICATION TOLERANCES
4 The segments shall be neatly cut so that 2.8.1 To avoid misalignment when joining a pipe or
they will closely fit with each other when fitting to a pipe, the pipe or fitting shall be turned
assembled. Cutting and end preparation of to check for any irregularities and shall be joined
pipe shall be in accordance with the require- correctly.
ments (Sections 2.3 and 2.4)
5 When designing the shape of a groove, the 2.8.2 Unless otherwise specified, tolerances for
mitre angle shall be considered and the fabrication shall be in accordance with the re-
shape of the groove shall be suitable for the quirements shown in Figure 6.
welding process used. 2.9.0 GALVANISED PIPING
6 When assembling the mitre bend, the seg- 2.9.1 Galvanised carbon steel piping shall be com-
ments shall be laid out and tack welded on pletly cold worked so as not to damage gal-
a surface plate or other flat surface to keep vanised surfaces
the centers of the segments aligned.
7 After welding is completed, the interior of the
3.0.0 WELDING SPECIFICATION
pipe shall be inspected and any internal 3.1.0 GENERAL
weld protrusions shall be removed.
3.1.1 This specification shall be adopted to all welded
8 Welding and heat treatment shall be per- pipe joints of carbon steel, alloy steel and stain-
formed in accordance with the requirements less steel piping system.
specified in Sections 3.0.0 and 4.0.0 of this
specification. 3.1.2 The welded pipe joints are defined as under:
2.7.0. BRANCH CONNECTIONS 1. All line joints of the longitudinal and circum-
ferential butt welded and socket welded
2.7.1 Branch connections shall be fabricated by as- type.
sembling the fittings that have dimensions and
configurations shown in the piping drawings.Un- 2. Attachments of castings, forgings, flanges
less otherwise specified, branch connections and other supporting attachments to pipes.
shall be made in accordance with Figure 5 and 3. Welded manifold headers and other sub -
as follows: assemblies
2.7.2 Branch connections, which are made by provid- 4. Welded branch connections with or without
ing a hole in the main run pipe and inserting a reinforcement pads.
branch pipe or a coupling, shall be as follows:
5. Manufacture of welded / fabricated piping
a The hole provided in the main run pipe shall components.
conform to the requirements of Section 6.
6. The attachment of smaller connections for
b When the main run pipe is welded pipe, the vents, drains, drips and other instrument
welds of branch connections shall be made tappings.
so as to avoid the welds of the main run
pipe. 3.1.3 All welding, and heat treatment, shall be in
accordance with the applicable codes and
2.7.3 Branch connections shall be made by means of specifications.
fully penetrated groove welds. The groove
welds shall be made in accordance with the a. codes for petroleum ANSI B31.3
same welding procedure as for girth butt welds. refinery piping
2.7.4 In no case shall scraps of metal resulting from b. Welding Qualifications. ASME Sec. IX.
making the hole be left inside the pipe.
c. Code of procedure for IS : 823
2.7.5 When making branch connections, a jig or a
metal fitting shall be attached to the main run metal arc welding of mild
pipe to prevent distortion of the main run pipe or steel (structural work only)
bending of the branch pipe due to welding. The d. The Indian Boiler Regula- IBR
material of the metal fitting shall be similar to the tions
main run pipe.
2.7.5 If reinforcement pads are used, unless other- All codes referred shall be the latest editions. In
wise specified, a 3.0mm dia vent hole shall be adition to the codes mentioned above, other
provided (at the side and not at the crotch) in the relevant international codes such relating to the
reinforcement pad to reveal leakage in the weld work, shall also be applicable. In case of con-
flicts between different codes or between codes

25ES205 / 10
25ES205 / 10

25ES205 / 10
and tender specifications the more stringent For piping covered by Indian Boiler Regula-
shall be applicable. tions, welders with valid IBR certificate,
qualified by Boiler Inspectors and accept-
3.2.0 INSPECTION & TESTING able to the local Boiler Authority shall only
3.2.1 General be employed.
1. The owner’s inspector shall have free ac- 2. The welders shall always have in their pos-
cess to all concerned places, where the session the identification card as per Format
actual work is being performed. The con- and shall produce it whenever demanded
tractor shall also provide the owner’s in- by owner’s Inspector. It shall be the respon-
spector all means and facilities necessary sibility of the contractor to issue the identity
for carrying out inspection. cards after duly certified by the Inspector.
2. The owner is entitled to depute his own 3. The identity card shall contain the following
inspector to the field or shop where pre- minimum details.
fabrication and erection of pipe lines are
a. Name of Contractor
being done with ( but not limited to ) the
following functions : b. Name of welder
c. Stamp No.
a. To check the quantity, consumables and d. Address
welding equipments used on the job
e. Recent passport size photograph
b. To supervise welding procedure & welders f. Details of qualifications
performance qualification tests. i Welding process and P numbers
c. To ensure that only qualified welders are ii Range of pipe diameters
engaged for welding. iii Range of thickness
d. To check that shop / field welding is in con- iv Welding positions
formity with the relevant specification and g. Date of qualification test
codes of practice followed in pipe line con- h. Period of validity
struction. i. Signature of manufacturer
e. To carry out Non Destructive Examination j. Signature of Engineer —in—charge
of welds. 4. No welder shall be permitted to work without
3. Contractor shall intimate sufficiently in ad- the possession of identify card.
vance the commencement of qualification 5. If a welder is found to perform a type of
tests and welding work to enable the welding or in a position for which he is not
owner’s inspector to be present to supervise qualified, he shall be debarred from doing
them. any further work. All such welds so per-
3.2.2 Welding procedure qualification formed shall be cut and redone at the ex-
pense of the Contractor.
Welding procedure qualification shall be carried
out in accordence with the job requirements and 6. Engineer-in-charge reserves the right to ask
relevant requirements laid down in the standard the contractors to perform requalification
ASME Sec. IX and other relevant applicable test at their cost for welders whose
codes. The contractor shall submit the welding workmanship technique etc. are found un-
procedures in QW — 482 format given in ASME satisfactory during the execution of the job.
Sec. IX. immediately on receipt of work order. 3.3.0 SELECTION OF WELDING MATERIALS
Owner’s inspector will review, check and ap-
prove the welding procedure after conducting 3.3.1 Selection of welding electrodes shall be as per
the necessary tests. It shall be the responsibility Appendix - II
of the contractor to carry out the tests, at his Table - I : Selection of welding electrodes & rods
costs. All the necessary arrangements for the for joining similar materials except Aluminium
procedure qualification i.e. supply of material for
assembly welding consumables, welding equip- Table - II : Selection of welding electrodes & rods
ments, preparation of test coupons, welding, for joining dissimilar materials except Aluminium
heat treatment, machining of test specimen, 3.4.0 STORAGE AND ISSUE OF ELECTRODES
conducting N.D.T, mechanical & chemical test
and maintaining qualification records, shall be Electrodes shall be stored and issued as fol-
by the contractor at his cost. He shall submit the lows:
test results to the Engineer-in-charge in QW- 3.4.1 Electrodes shall be stored indoors free from
483 format given in ASME Sec. IX. for approval. moisture as far as possible.
3.2.3 Welder’s Qualification 3.4.2 Electrodes shall be dried in a heating cabinet in
1. Welder’s qualification shall be in accord- accordance with the manufacturer’s recommen-
ance with the relevent codes specified in dation before welding.
scope of work. Owner’s inspector shall wit- 3.4.3 Immediately after drying, electrode shall be
ness the test and certify the qualification of stored in a portable dryer, or in a heating cabinet
each welder. Contractor shall submit the at the following temperature, and shall then be
welder qualification report as per Format used.
before the commencement of work. It shall
be the responsibility of the contractor to a. Illumenite : 70 - 1000C
carry out the qualification tests of welders.

25ES205 / 10
b. Others : 100 - 1500C shall be removed of any slag or other foreign

matter with a chipping hammer, a grinder, or
a wire brush. To prevent spatter adhering to
3.4.4 During welding, electrodes shall be kept in a the base metal, a spatter deposit prevention
portable dryer or equivalent. The electrodes paint may be applied around the outside of
shall not be laid down directly on the ground or the groove. Wire brushes and abrasive
any other damp places. wheels shall be distinguished so that those
for stainless steel shall not be confused with
3.4.5 Electrodes exposed to the atmosphere for more those for carbon steel or low-alloy steel.
than 4 hours shall be redried. However, only two Moreover, any arc starts, craters, or inferior
redryings are permitted. beads of each layer shall be removed
3.4.6 When the day’s work has been completed, the before the welding is continued.
electrodes shall be collected and stored in a 7. Peening on the welds is prohibited.
heating cabinet at the temperature specified in
3.3.2 above. 8. Unless required, the external surfaces of
welds shall not be finished with a grinder or
3.4.7 Issue of electrodes shall be controlled by the any other tool. However, when finishing the
assigned person. end of weld beads with a grinder, special
3.5.0 SURROUNDING CONDITIONS FOR WELD- precautions shall be taken not to reduce the
ING thickness of base metal by over grinding.
3.5.1 Welding shall not be performed under the fol- 9. Arc strike shall not be generated on the pipe
lowing climatic conditions. surface. Care shall be taken not to lay down
the electrode holder or move it around by
1. In the rain the electrode.
2. In winds of 8 m/s or more 10. To prevent damage from sparks, care shall
3. In snow be taken to ground the welding equipment
by strict use of ground clips and to ground
However, welding may be performed if the area each piece of material.
is fully protected from the inclement weather.
11. When welding galvanized steel, the coating
3.5.2 When the item to be welded is wet with rain or shall be removed from the surface to be
covered with snow or ice, the snow or ice shall welded, 50mm on either side.
be removed and the surface dried completely
before welding. 12. For the joints of P-Number 5 materials,
when welding is unavoidably interrupted,
3.6.0 GENERAL FOR WELDING postheating shall be applied and the welds
3.6.1 Welding shall be performed in accordance with shall be cooled gradually by the use of
welding procedure specification (WPS), which insulation or other suitable materials. ( Para
has been approved by FEDO/Representative. 4.3.0 ).
Before welding, the WPS shall be prepared 3.7.0 BUTT WELDS
which has been qualified by the welding proce-
dure qualification test based on the specification 3.7.1 When welding a pipe to a pipe, fitting, valve, etc.,
for welding procedure qualification, according to the components shall be placed on a revolv ing
this specification and ASME Section IX. stand, aligned accurately within the tolerances
specified in Section 2.8. of this specification by
3.6.2 As a general rule, welding for steel pipes shall the use of tack weld pieces (fit-up pieces), line-
be performed as follows. up clamps, etc., and shall then be welded.
1. The welding process used shall be SMAW, 3.7.2 Backing rings shall not be used unless other-
GTAW, or GMAW (MIG Welding). Any other wise specified.
welding process may be used only when
approved by FEDO / Representative. 3.7.3 The number of tack welds made shall be the
minimum required to secure the pipe, and a
2. Preferably, the first layer of butt welded joint minimum of three shall be made for pipes of 50
shall be made by GTAW. For the first layer NB and larger.
on 3Cr. and higher low-alloy steel pipe, or
stainless steel, GTAW shall be performed 3.7.4 When tack weld pieces are used for pipe
with back shielding gas such as argon. materials of stainless steel,the material of the
pieces shall be similar to that of the pipe. When
3. The surface to be welded shall be cleaned the pipe material is low-alloy steel, carbon steel
thoroughly and any paint, rust, scale, oil, may be used for the pieces unless otherwise
dust, moisture, or any other foreign matter specified.The welding for the tack weld pieces
that would be detrimental shall be removed shall be performed with electrodes equivalent to
at least within the extent of 50mm from the those used for the base metal and shall be
groove end before welding. performed by a welder or welding operator
4. The welding position shall be performed in qualified for fillet welds.
flat position as far as possible. 3.7.5 Tack welds, which are made directly at the root
5. Full consideration shall be given to the weld- of the joint, shall be made by a qualified welder
ing progression to keep distortion to a min- or welding operator specified in Section 3.2.3
imum. and shall be made by the same welding proce-
dure as the product welding. Tack welds that
6. In multi-layer welding, before welding the are cracked or not fused properly shall be
following layer, the surface of each layer removed.

25ES205 / 10
3.7.6 Pieces for tack welds shall be removed with a gasket contact face and that the gasket contact
grinder. If a concave surface due to overgrind- face is not damaged by welding. If the gasket
ing, etc., is produced on the pipe, the repair contact face is damaged,or weld reinforcement
welding shall be performed in accordance with protrudes onto the gasket contact face, such
WPS, which has been approved by FEDO En- defects shall be removed by polishing the gas-
gineer / Representative. Any convex weld beads ket contact face.
formed on the pipe surface shall be removed. 3.10.5 When welding flange joints, care shall be taken
When defects are found while removing tacks /
cleats they shall be fully removed, repaired by to handle the flanges carefully so that the gasket
welding, and a magnetic particle or liquid contact face will not be damaged. The gasket
penetration examination shall be performed to contact face shall not be in direct contact with
confirm that there are no defects. the ground, and grounding shall not be taken
directly from the gasket contact face.
3.7.7. Internal weld protrusions of butt welds for orifice
flanges shall be finished smoothly to the pipe 3.10.6 In the case slip-on flanges which are to be heat
inside diameters with a grinder. treated, and also require to be front welded,they
shall be provided with a 3mm dia vent hole at
3.7.8. The root pass of all buttwelds on pipe of size the hub as shown in FIG.8.
less than 50NB shall be made in GTAW grove
only. 4.0.0 HEAT TREATMENT
3.8.0 FILLET WELDS 4.1.0 PREHEATING
3.8.1 Fillet welding shall be performed as follows: 4.1.1 Unless otherwise specified, the preheating ap-
1. Fillet welds shall be multi-layered and of plies to gas cutting and welding (all welds includ-
sufficient strength. ing butt welds, fillet welds, socket welds, repair
welds, tack welds, and seal welds of thread ed
2. Fillet welds shall be as shown in Figures 7A joints ). Preheating shall be performed as fol-
and 7B. lows:
3. Fillet welds for socket welding flanges shall 1. Materials to be pre heated and preheating
be as shown in figure 7C. temperature shall be in accordance with
4. Fillet welds for socket welding components relevant codes as a rule, but for steam lines
shall be as shown in figure 7D. fallen under the purview of IBR, the same
shall be followed.
3.9.0 SEAL WELDS
2. If the maximum specified carbon content is
3.9.1 Seal welding shall be performed as follows: more than 0.38, or if the material is under a
1. Threaded joints to be seal welded shall not high degree of restraint (weld-all- around
be coated with a compound or covered with such as pipe shoe), carbon steel shall be
a seal. After any oil on the threads has been preheated to a minimum of 800C and main-
fully removed, the threads of joint shall be tained at that temperature for surface weld-
screwed in securely in accordance with ing.
Section 5-1.0, and shall then be welded. 3. When welding dissimilar metals, unless
2. If threaded joints are seal welded, all ex- o th er wise sp eci fied , the preh eatin g
posed threads shall be covered by a seal temperature shall be that for the higher
weld. grade steel
3. Seal welding shall be performed by a 4. The width of the heated circumferential
qualified welder. band shall be 4 times the pipe nominal wall
thickness or 100mm, whichever is greater,
4. Electrodes of 3.2 mm dia or less shall be extending on both sides of the welds.
used.
5. Heat shall be applied by the use of a gas
3.10.0 FLANGE ATTACHMENT WELDS burner or a heating coil. The use of a gas
Flange attachment welding shall be performed burner for cutting shall not be permitted
as fol lows: since it tends to heat locally.
3.10.1 Unless otherwise shown on the drawings, in 4.1.6 Temperature measurements of preheating, in-
principle, flange bolt holes shall straddle the terpass temperature, and postheating shall be
established centerlines. The only exception is at performed by a temperature crayon ( tempil
equipment flanges required for matching orien- stick), thermocouple temperature indicator, etc.,
tation. and it shall be confirmed that the specified
temperature is maintained.
3.10.2 When installing flanges, flange square or other
jig shall be used, and the center line of the pipe 4.2.0 INTERPASS TEMPERATURE
and the perpendicular of the flange face shall be 4.2.1 The following items shall be confirmed for inter-
within the tolerances specified in Section 2.8. pass temperature:
3.10.3 Joining welding neck flanges to the pipe shall be 1. Interpass temperature of the materials that
performed in accordance with the requirements require to be preheated shall be the same
of Section 3.7. as the preheating temperature and shall be
3.10.4 Front welding shall be performed on slip-on maintained until welding has been com-
flange joints except for pipes class less than pleted.
50NB (Figure 8). Care shall be taken so that the 2. Interpass temperature of austenitic stain-
weld reinforcement does not protrude on to the less steel pipe shall not exceed 1500C.

25ES205 / 10

25ES205 / 10
4.3.0 POSTHEATING the exposed surface of pipe. For this pur-

pose temperature at the exposed surface of
4.3.1 When postheating is required it shall be carried pipe should not be allowed to exceed
out for more than 30 minutes within the tempera- 4000C.
ture range of 300 to 4000C, and the material
shall be cooled gradually by the use of insula- 10. All online pipe item ( eg. Valves, Instruments
tion, etc. However, when post weld heat treat- etc. )within 500mm of the weld which is
ment is performed immediately after welding, beingheat treated, shall be dismantled prior
post - heating is not necessary. to commencement of heat treatment of
weld.
4.4.0 POST WELD HEAT TREATMENT
11. The no. of thermocouples to be used for the
4.4.1 Procedure monitoring of tempreature shall be as fol-
Unless otherwise specified, post weld heat lows.( HAZ - Heat Affected Zone )
treatment shall be performed in accordance with
the following procedure. However, post weld DIA OF NOS. OrientatIO LOCATION
PIPE N(0)
heat treatment for dissimilar metals shall be in
accordance with the individual specification. 15NB & 2 0 , 180 One on weld & one
below in HAZ
1. The requirements for heat treatment shall
be in accordance with applicable codes. But 200 to 0 , 120 , one on weld & rest in
500 NB 3 240 HAZ on either side
for steam lines IBR shall be followed. Heat of weld
treatment of welded joints between dis-
similar ferritic metals shall be within the 600 Nb & 4 0 , 90 , two on weld & rest in
temperature ranges for the higher grade above 180 , 270 HAZ on either side
of weld
steel.
2. Al l th e m ach ine d surf aces sha ll be 4.4.2 Heating Methods
protected adequately by the use of paint or For heat treatment, application of heat in a
compound to prevent damage from scaling furnace is preferable, however, heat may be
during heat treatment. applied locally by the following methods:
3. In case of furnace heat treatment, all the 1. Heating by electrical resistance
pipes shall be supported properly during
heat treatment to minimize warps and other This is a method where a programmed mov-
distortions. able automatic heater applies heat by
means of nickel-chrome wire applied
4. In principle, after heat treatment has been around the welds. Special attention shall be
completed, neither rewelding nor reheating given to the following items:
shall be performed. However, if rewelding is
performed because of repairs, etc., heat a. Protective measures shall be taken to
treatment shall be performed again. prevent damage to the pipe surface or in-
5. If welding is intrrupted before completion or jury to the workers due to a short circuit
the weldment is allowed to cool prior to heat of the lead wire, and to prevent persons
treatment, adequate heat treatment or con- other than the operator entering the work
trolled rate of cooling shall be applied to area.
ensure that no effects detrimental to the b. The width to be heated shall extend
piping shall result. The pre-heat tempera-
ture in the welding must be applied before 25mm beyond the edges of the weld on
welding is resummed. each side
6. When heat treatment is performed, the hold- c. The width to be insulated shall extend at
ing temperature, holding time, rate of heat- least 150mm on each side of the weld.
ing and cooling, and the hardness after heat d. The heating and cooling rates above
treatment required shall be recorded and
the records shall be submitted to FEDO 3150C shall be determined by the follow-
Engineer / Representative. ing formula, but in no case shall the rate
exceed 2200C per hour.
7. The measurement of heat treatment
temperature shall be performed by measur- 25 x 220
( oC ⁄ h)
ing the metal temperature by the use of a wall thickness (mm)
thermocouple,or by other suitable methods.
Ho w e ve r, w he n t he h e at t r ea t me n t 2. Heating by gas burner
temperature is measured by the furnace
temperature, the relation between the a. This is a method where heat is applied
temperature of metal and furnace shall be by a propane or butane gas burner. This
considered. method shall not be used unless
specified by FEDO Engineer/ Repre-
8. A hardness test shall be performed in ac-
cordance with Section 9.4.0 to determine if sentative.
the heat treatment has been performed
satisfactorily. 5.0.0 THREADED AND FLANGED JOINTS
9. Throughout the cycle of heat treatment, the 5.1.0 THREADED JOINTS
portion out side the heated band shall be
suitably wrapped under insulation so as to Threading of joints shall be as follows.
avoid any harmful temperature gradient at 5.1.1 Taper pipe threads shall be as per ANSI B2.1,

25ES205 / 10
ANSI Standard Taper Pipe Thread (NPT). 5.2.6 The thread and bearing surfaces of bolts and
nuts to be used on piping at temperatures of
5.1.2 Unless otherwise specified, when threading on 2500C or higher shall be coated thinly and
pipes of NPS 11/2 or smaller, the pipe thickness uniformly with a lubricant to prevent them be-
shall be Schedule 80. coming burnt and stuck.
5.1.3 In principle, all threads shall be cut with a thread- 5.2.7 Lubricant shall not be applied to machine bolts
ing machine or lathe. When threading with hand unless other wise specified.
dies such as an oster or reed type, a lubricant
shall be used to avoid an irregularity of screw 5.2.8 Bolts shall be of material and length as
thread or scratches due to coarse machining. specified. In principle, all the bolts shall extend
2 or 3 threads through their nuts.
5.1.4 All the threads shall be cleaned thoroughly.
5.2.9 Flanges shall be tightened with a wrench or
5.1.5 In principle, teflon seal tape shall be used for spanner of the specified length and with a ham-
threaded joints used in services of 1500C and mer if required, or with a torque wrench. Care
lower. Once the joints are screwed, they shall shall be taken so that the bolt is not tightened
not be unscrewed. Fillers such as hemp, jute, excessively or unevenly.
lead scraps, and white paint shall not be used.
5.2.10 As the tightening force varies according to the
5.1.6 Seal welding of threaded joints shall be in ac- flanges, gaskets, and bolts used, the tightness
cordance with Section 3.9 shall be controlled with care. In particular, flan-
5.1.7 In no case shall threaded joints be made with a ges of piping for low temperature and dangerous
length of engagement less than specified. services shall be tightened only with a torque
wrench. For large diameter bolts, the use of an
5.1.8 When pipe is screwed into a threaded flange, impact wrench with torque control or a power
the pipe end shall not extend beyond the gasket machine ( hydraulic torque wrench ) is preferred.
contact face. If the pipe end protrudes even
slightly, the pipe end shall be ground off with a 5.2.11 Bolts of flanged joints shall be successively and
grinder or a file so that the gasket contact face evenly tightened in a symmetrical pattern ( Ap-
is not scratched. pendix IV ).
5.1.9 When screwing a pipe into a threaded bronze 5.2.12 Cast iron flanges of equipment such as pumps,
valve, the pipe shall be gripped by a pipe vice turbines, compressors, or other similar equip-
and the valve shall be screwed on by clutching ment shall be tightened carefully so that the
the end of the valve with a wrench. Threading flange does not break.
and screwing shall be carried out carefully so 5.2.13 The flange clearance with connections of
that the pipe does not enter the valve too far and pumps, compressors, or other similar equip-
damage the valve due to the threads being ment, and ring-joint flanges shall be measured
overcut on the pipe. by the use of a clearance gauge and the paral-
5.1.10 Scraps of metal due to threading and oil used lelism shall be checked, and then the bolts shall
for cutting shall be removed before screwing on be tightened evenly.
instrument air piping. 5.2.14 Ring-joint gaskets shall be ground with the
5.1.11 Any compound or lubricant used on the threads groove of the flange for a tight fit prior to instal-
shall be suitable for the service conditions, and lation. The grinding shall be performed by using
shall not react unfavourably with either the ser- a compound (coarse, intermediate, or fine), and
vice fluid or piping material. red paste shall be applied to confirm the rough-
ness of the contact face between the ring and
5.2.0 FLANGED JOINTS the groove of the flange. The paste shall be
Flanged joints shall be made as follows: removed completely before the ring is installed.
5.2.1 In principle, Class 125 and 250 flanges of valves 5.2.15 If the gasket contact face of the flange is
and other equipment made of gray cast iron damaged, the defects shall be removed by
shall be of flat face with full contact area gaskets. polishing evenly the gasket contact face, or the
flange shall be replaced.
5.2.2 Steel to gray cast iron flanged joints shall be
assembled with care to prevent damage to the 6.0.0 PROTECTION OF PREFABRICATED PIPE
cast iron flange.
SPOOLS AND SIZE
5.2.3 Unless otherwise specified, gasket paste shall
be applied uniformly on the gasket contact face 6.1.0 PROTECTION OF PREFABRICATED PIPE
of the flange when a metal jacketed gasket or a SPOOLS
metal gasket is used. However, when the flange 6.1.1 All prefabricated pipe spools that have been
material is austenitic stainless steel, the use of inspected shall be protected as follows until they
gasket paste shall be approved by FEDO En- are installed in a plant.
gineer / Representative. As the choice of paste
is limited by the fluid handled, the paste shall be 1. All dust, rust, weld slags, or other foreign
suitable for the service fluid. The gasket paste matter in the pipe shall be removed carefully
shall be kept in a container with a lid and handled by brushing or by flushing with compressed
with care to prevent entry of sand, dust or other air, or by other suitable means. After clean-
foreign matter. ing, all openings of austenitic stainless steel
shall be blanked.
5.2.4 For asbestos-sheet gasket, gasket paste may
not be applied. 2. Pipe spools to be stored temporarily shall
be laid on suitable sleepers and not directly
5.2.5 For spiral-wound gaskets or ring-joint gaskets, on the ground.
gasket paste shall not be applied.

25ES205 / 10
3. Pipe spools shall be marked with the area 2. Stanchions requiring foundations shall have
number (major divisions such as offsite, anchor bolts of the correct size, position,
onsite), line number, and piece number. projection, etc.
After cleaning the pipe spool surface and
applying rust preven tive, it shall be marked 3. Before installing the supports, the finished
clearly with paint by the use of a stencil. conditions of the cut ends of all members
When specified, in showing the line number, and welded conditions shall be checked.
etc., a color code identification or tag plate 4. Pipe supports shall be made level and
(die stamped to the sheet metal) for each plumb to facilitate alignment during piping
area shall be made, and it shall be attached installation.
with coated iron wire. However, zinc coated
iron wire shall not be used for austenitic 5. In principle, when the main run pipe is low-
stainless steel. alloy steel or ss, either a pad plate or support
members of the same material as the main
4. If hydrostatic test is performed, the water run pipe shall be used, and carbon steel
shall be removed completely. supports shall not be welded directly to
6.1.2 When prefabricated pipe spools are to be stored these. In this case, when welding the pipe
for a long period of time or are to be shipped, to the support, the same electrodes as ap-
the pipe interior shall be checked to see that it plied to the pipe shall be used, and the
is clean, and the openings of pipe ends shall be qualified welder specified in Section 3.1.0
protected as follows: shall perform the welding in accordance
with WPS. When the main run pipe requires
1. When the pipe ends are prepared, the ends heat treatment, the welds for attachment of
shall be coated with rust preventive ( Appen- pipe supports shall be heat treated if re-
dix — 1 ) and covered with a plastic cap, etc. quired,as per ANSI B31.3.
2. When the pipe ends are flanged, the gasket 6. Welds for anchor supports shall be double-
contact face shall be coated with rust layer welds to provide a bond of sufficient
preventive and be protected with a wooden strength.
or plastic cover bolted on to the flange. In
case of a wooden cover, poly ethylene or 7. When welding dummy pipe to elbows, tees,
other suitable film shall be inserted between etc., the welding shall not melt through to
the flange and the cover. their interior.
3. When the pipe ends are threaded, the 7.2.0 SLIDING SUPPORTS
threads shall be coated with rust preventive 7.2.1 Sliding supports shall be assembled so that the
and threaded end connections shall be expected movement of the supported piping due
covered with wooden or plastic plugs or to thermal expansion and contraction or other
caps. design requirements is possible.
4. When masking tape is intended to be used 7.3.0 SPRING HANGERS
instead of the protection mentioned above,
it shall be subject to FEDO Engineer’s/ Rep- 7.3.1 The lock-pin or preset-piece of spring hangers
resentative’s approval. shall not be taken off until pressure testing and
flushing have been completed, except only
6.1.3 However, austenitic stainless steel pipes and when a high temperature fluid such as flushing
prefabricated pipe spools that may be affected steam is streamed.
by chlorine ions, shall be protected in accord-
ance with the individual specification. 7.3.2 Adjustment of spring hangers shall be per-
formed by taking off the lock-pin or preset-piece
6.2.0 SIZE OF PREFABRICATED PIPE SPOOLS prior to ini tial operation. It shall be confirmed
6.2.1 The size of prefabricated pipe spools shall be that spring hangers operate on the expected
determined by consideration of the conditions of movement according to temperature increase in
transportation, etc. Consideration shall be given the initial operation.
to the conditions of inland transportation, size of 7.4.0 ADDITIONAL SUPPORTS
the carrier’s hatch, means of transportation, traf-
fic regulations in the country and the economy. 7.4.1 If additional supports are required to prevent
shaking of piping in the field, they shall be
6.2.2 The standard size of a package to transport installed in accordance with the instructions of
prefabricated pipe spools is limited to 2.5 meters the FEDO Engineer’s / Representative’s En-
width by 2.5meters height by 13 meters length gineer in consideration of the effects due to
with a weight of 5 tons per package. thermal expansion of the piping.
7.0.0 INSTALLATION OF PIPE SUPPORTS 7.5.0 INSULATION SUPPORTS
7.5.1 The configuration, material, and installation pro-
7.1.0 PIPE SUPPORTS cedure of support rings for hot or cold insulation
7.1.1 Pipe supports whose materials & dimensions of vertical piping shall be in accordance with the
conform to fabrication drgs, shall be installed individual specification.
accurately at the positions shown on the draw-
ings prior to piping installation. When installing 8.0.0 PIPING INSTALLATION
the pipe supports, pay attention to the following:
8.1.0 GENERAL ITEMS FOR PIPING INSTALLA-
1. Each support shall be fabricated and as- TION
sembled so that piping does not become
disengaged from the support by movement The general items for attention relating to piping
of the piping itself due to operation. installation shall be as follows:

25ES205 / 10
8.1.1 Pipes shall be stored in accordance with each 8.1.13 Alignment tolerances of flange connections in-
category of material, and stacked on sleepers stalled in piping shall be as per Figure 9 ( Page
with wedges or stakes provided to prevent the 28 of 28 ). However, alignment tolerances of
stack from collapsing. pipe flanges for the rotational equipment nozzle
shall be as per Section 8.3.0 ( Item 6 ).
8.1.2 Before installation, pipe spools shall be checked
with the piping drawings as to dimensions, 8.1.14 In principle, the longitudinal welded joint of
material, class, etc. In principle, the installation welded pipe shall be located above the horizon-
of pipe spools shall start from elevated lines or tal centerline, if the pipe is installed horizontally.
larger size lines. The precedence for installation
shall be determined after confirming that all 8.2.0 PIPING AROUND COLUMNS, DRUMS AND
equipment has been installed and aligned, and HEAT EXCHANGERS
steel structures and pipe racks are ready for The piping installation around columns, drums,
installation of the piping. The part which cannot and heat exchangers shall be as follows:
be painted after piping installation shall be
painted beforehand. 8.2.1 Piping for columns shall be installed in the order
of the overhead line and the risers, and the
8.1.3 In principle, underground piping shall be in- installation of instrument take-off nozzles, sup-
stalled before above ground piping. ports, spring hangers,etc. The levelness and
8.1.4 Before installation, the pipe spool shall be plumbness of piping shall be complete and true.
suspended at one end by a crane, etc., and ham 8.2.2 For piping installed at high elevations at the top
mered to remove the dust inside. of columns, drums, etc., assembly and non-
8.1.5 Supports such as stanchions shall be checked destructive examination and pressure testing
for the accuracy of position, dimensions, eleva- shall be performed on the ground, as far as
tion, levelness and plumbness. possible, to minimize work at high elevations.
When piping installation is unavoidably per-
8.1.6 When temporary supports are installed un- formed at high elevations, the area below shall
avoidably to the piping, welding shall not be be fenced in with a safety rope and “MEN AT
performed on the main run pipe. WORK ABOVE” signs shall be posted.
8.1.7 Temporary work for piping installation shall be 8.2.3 When piping components are to be lifted into
planned in advance, and the necessary equip- place at high elevations by means of large
ment and materials shall be selected and cranes, in advance, the work data such as the
prepared in time with the schedule. Moreover, weight, position of center of gravity, reach of
the scaffolding required for field connections crane, crane boom length, and other vital data
shall be checked, and whether the required shall be ob tained, and they shall be studied
number of scaffold pipes and boards shall be sufficiently.
sufficient.
8.2.4 Temporary supports shall not be taken from the
8.1.8 Scaffolding shall be provided to permit safe shell (body) of equipment.
operation, and the use of small size piping, 8.2.5 After the pipe spool has been installed accurate-
pumps, instruments, etc., in lieu of scaffolding
shall be prohibited. All scaffold boards shall be ly to the nozzle of the equipment, field welding
securely tied to the scaffold pipes or piping with shall be performed. In such cases, blinds shall
metal connectors or iron wire. not be inserted for purposes of pressure testing,
etc.
8.1.9 The primary cards, cables, and grounding wires
of all welding equipment shall be of sufficient 8.3.0 PIPING AROUND PUMPS AND COMPRES-
size, and any conductors with damaged insula- SORS
tion shall not be used. They shall be inspected The piping installation around pumps and com-
periodically. pressors shall be as follows.
8.1.10 Piping components such as pipe spools and 8.3.1 All piping except for the connections to the
valves shall be lifted with the designated wire nozzle of rotating machinery shall be assembled
rope slings, and the use of iron wire shall be on the ground.
prohibited.
8.3.2 Before installation of piping to rotating
8.1.11 Piping components shall be hauled by mechani- machinery, the required heat treatment, pres-
cal equipments as far as possible. Even for a sure test ing, interior cleaning, etc., shall be
short haul, the components shall be securely completed. Pressure testing shall not be per-
tied to prevent them from falling. formed by inserting the blinds directly between
8.1.12 Piping requiring cold spring may become the nozzle of rotating machinery and the flange
misaligned during field welding, therefore, the of the connected piping.
dimensions shall be checked thoroughly in ac- 8.3.3 The protective cover placed on the nozzle of
cordance with the piping drawings. After it has rotating machinery shall not be removed until
been confirmed that guides and anchors have the piping is to be connected.
been installed at the specified location, the
piping shall be installed. Furthermore, when 8.3.4 The preset-piece of spring hangers shall be
there are flanged joints in the same direction taken off and spring hangers shall be adjusted,
requiring cold spring, a spacer with the same so that piping is located accurately.
thickness as the dimension of cold spring shall 8.3.5 It shall be confirmed that alignment work of
be inserted between the flanges, and when the rotating machinery and measurement prepara-
entire piping system has been assembled, the tion for inspecting misalignment has been com-
spacer shall be removed and the flange fas- pleted.
tened.

25ES205 / 10
8.3.6 Pipe flanges shall be aligned with all the nozzles adjustments.
of rotating machinery. The alignment shall be 8.5.3 After the pipe has been laid on the rack, the pipe
performed by the adjustment of pipe supports
and flange connections. Unless otherwise speci shall be tied with wire to prevent it from falling
fied, the misalignment between flanges shall be off until the weld joints are made.
within the following permissible limits: 8.5.4 The pipe fittings and welded lines shall be in-
stalled so as not to be positioned on the beams.
a. Flange face separation : ± 0.8mm
( space for gasket ) 8.6.0 OFFSITE PIPING
b. Flange face parallelism : 0.2mm Installation of offsite piping shall be as follows:
c. Rotational offset : 0.8mm 8.6.1 Piping installation inside the dike shall be per-
formed after a thorough study of the work
d. horizontal and vertical bolt : 0.8mm schedule has been made, with consideration
hole offset given to other related work such as the confirma
tion of time of tank water filling and of access for
8.3.7 If the piping alignment specified in Item (6) handling materials.
above is not within the permissible limits, it shall
be corrected. The correction of piping alignment 8.6.2 Pipe sleepers and support footings inside the
or the adjustment work of supports shall be dike shall be installed after confirming that the
performed by dismantling piping from rotating levelness of the ground has not been disturbed
machinery. Care shall be taken so that expan- by the water filling test of the tank.
sion or distortion due to welding, etc., does not 8.6.3 Piping to be connected to the tank nozzle shall
have a detrimental influence on the rotating be installed after checking that the valve and
machinery. accessories installed on the tank are in accord-
8.3.8 When connecting piping to a rotating machine, ance with the specification.
if the machine misalignment is more than the 8.6.4 Flexible hoses and expansion joints to the tank
values specified, alignment work of the machine nozzle shall be installed accurately in accord-
and piping shall be performed again by disman- ance with the drawings.
tling the piping from the machine.
8.6.5 When laying pipe on sleepers, the sleepers shall
8.3.9 After piping is connected to rotating machinery, be checked to confirm that they are at the
the rearrangement of pipe supports or retighten- specified elevation, level in line, and painted.
ing of flange bolts shall not be performed without
permission. 8.6.6 Piping on pipe sleepers shall be laid on sleepers
that have been marked off. Slide shoes and
8.4.0 PIPING AROUND FIRED HEATERS stoppers shall be installed accurately in accord-
Piping installation around fired heaters shall be ance with the drawings. The pipe fittings and
as follows: welded lines shall be installed so as not to be
positioned on the sleepers.
8.4.1 Since piping around the burner tends to become
complicated, piping for one or two burners shall 8.6.7 For piping penetrating an oil dike, the flanged,
be installed first, and after confirming operability, threaded, or welded joints shall not be em-
clearance, safety, and other matters, other bedded in the dyke.
piping shall be installed. 8.7.0 INSTALLATION OF VALVES
8.4.2 Drain piping around the burner shall not be The installation of valves shall be as follows:
placed on the ground or in such a way as to
obstruct passage of persons. 8.7.1 The valve shall be installed accurately so that
its location and the orientation of the handle is
8.5.0 PIPING ON PIPE RACK in accordance with the piping drawings. How-
Piping installation on pipe rack shall be as fol- ever, when the orientation of the handle is
lows: deemed inappropriate from the viewpoint of
operation or passage, the FEDO engineer shall
8.5.1 Generally, since air cooled heat exchangers are be contacted for directions.
placed on top of the pipe rack, and pumps are
placed underneath, the precedence for install- 8.7.2 The valve shall be checked for its class, body
ing piping shall be determined in consideration materials, and trim materials to prevent any
of the time of installing such equipment, the misuse.
number of stages of the pipe rack itself, etc. In 8.7.3 Before installing the valve, the flange faces of
principle, piping installation will be performed the valve and the connected piping shall be
from the bottom to the top level. When installing checked to see that they are not damaged or
piping, a check shall be performed to ensure that dirty, and that they are parallel with each other.
the pipe rack beams have been painted.
8.7.4 Valves shall be installed in the closed position,
8.5.2 Before connecting piping to other equipment, except for plug valves and ball valves. After
piping on pipe racks shall be laid down accurate- being installed, valves shall not be opened ex-
ly in the places specified beforehand, and then cept for pressure testing. Especially, welding for
slide shoes and stoppers shall be installed ac- installation of the butt weld and socket weld type
curately in accordance with the drawings, so valves shall be performed in the closed position,
that baseline for dimensional adjustments in to prevent the valve seat being damaged.
field installation may be made. However, el-
bows, tees, etc., required for take-off connec- 8.7.5 For lubricant plug valves, the disc shall be left in
tions to outside the pipe rack may be left in place the open position and the lubricant shall be
temporarily since it may be re quired to perform replenished to prevent loss of the sealant.

25ES205 / 10
8.7.6 Globe valves, check valves, control valves, and have specified lateral deflection as noted on the
other similar valves shall be installed in accord relevent drawings.
ance with the marked direc tion by checking the
flow direction. 8.9.11 The pipe ends / flanges shall be spaced at a
distance specified in the drawings.
8.7.7 To prevent the stem threads from rusting,
grease shall be applied prior to installation of the 8.9.12 The Expansion Joint shall be placed between
valve. the mating pipe ends/flanges and shall be tack
welded/bolted. The mating pipes shall again be
8.8.0 INSTALLATION OF SAFETY VALVES checked for correct alignment.
The installation of safety valves shall be as 8.9.13 Butt welding shall be carried out at each end of
follows: the expansion joint. For flanged Expansion
Joint, the mating flange shall be bolted.
8.8.1 Until line pressure testing has been completed,
in principle, the safety valves shall not be in 8.9.14 After the Expansion Joint is installed the con-
stalled with the piping. If safety valves are tractor shall ensure that the mating pipes and
necessary to assemble the piping, a spool of the Expansion Joint are in correct alignment and
same face-to face dimension shall be fabricated that the pipes well supported and guided.
and installed. For threaded safety valves, the
piping shall be capped. However, the safety 8.9.15 The Expansion Joint shall not have any lateral
valve with test gag may be installed with piping deflection. The contractor shall maintain paral-
and subjected to line pressure testing. lelism of restraining rings or bellows convolu-
tions.
8.8.2 All safety valves shall be installed after the 8.10.0 INSTALLATION OF INSTRUMENTS
specified set pressure has been tested in the
field. 8.10.1 Kinds of instrument handled
8.8.3 The seal securing the cap to the safety valve 1. The following instruments shall be installed
body shall not be removed without FEDO / in the scope of piping installation work:
Representative’s approval.
a. Flow meters to be installed directly on the line
8.8.4 The safety valve with a lever shall be installed (area type, volume type, magnetic type, etc.).
with the lever oriented as shown on the drawing. b. Orifice flanges and orifice plates
8.9.0 Installation of expansion joints c. Displacer type or ball float type level meters
The installation of expansion joints shall be as d. Control / self control valves & safety valves
follows: e. Other instruments installed directly on the line
8.9.1 Expansion joints shall be installed accurately 2. In addition, instruments up to the first valve
and shall be at the location and of the dimen- or flange in the nozzle take-off connections
sions shown on the piping and detailed draw- for the instrument lead piping are included.
ings, and in a manner so as not to be connected 8.10.2 General Procedure : General installation proce-
eccen tric with the pipe. dure for instruments shall be as follows:
8.9.2 Expansion joints shall be installed after confirm- a. All instruments shall be checked as to in-
ing that the line has been completely assembled strument number and shall be installed true
with all anchors, guides, and stoppers installed to level, plumbness, or the specified angle
in place as shown on the piping drawings.
b. The instruments and the associated piping
8.9.3 Expansion joints shall be installed so that no (excluding instrument piping) shall be sup-
stress except in the direction intended occurs. ported so that problems will not result due
8.9.4 After pressure testing and flushing, all shipping to distortion or vibration
bolts and fixtures shall be removed and the c. It is preferred to have all the instruments
joints shall be checked to ensure that nothing installed after the interior of piping, columns
obstructs the expansion movement. and drums have been cleaned. When in-
8.9.5 Prior to installation, expansion joints with inner struments are to be installed unavoidably
sleeves shall be checked to ensure that the during piping construction, measures shall
sleeve inlet (fixed) is on the upstream side. be taken to prevent the instruments from
being damaged and to prevent foreign mat-
8.9.6 Bellows of expansion joints shall be handled ter from entering the instruments. Orifice
with utmost care, so that no objects will be plates shall be installed only after testing
dropped upon it. and flushing of pipes.
8.9.7 Each expansion joint shall be blown free of dust d. Flow control valves shall be installed after
/ foreign matter with compressed air or shall be checking the flow direction mark.
cleaned with a piece of cloth.
8.10.3 Installation of Flow Meters : The installation of
8.9.8 For handling and installation of expansion joints, flow meters shall be as follows:
great care shall be taken while aligning. An
expansion joint shall never be slinged with bel- a. When installing orifice flanges, the straight
lows corrugations/external shrouds, tie-rods, lengths of pipe required upstream and
angles etc. downstream shall be checked to see that
they comply with the piping drawings. In
8.9.9 An expansion joint shall preferably be slinged principle, the upstream straight pipe length
on the end pipes/flanges or on the middle pipe. shall be of one piece. When there is an
8.9.10 The pipe ends in which the expansion joint is to unavoidable welded line in the length, the
be installed shall be perfectlyaligned or shall distance between the orifice and the weld

25ES205 / 10
line shall be not less than 14 times the pipe 9.0.0 INSPECTION AND TEST
diameter. The straight lengths of pipe shall
not be provided with a vent, drain, or other 9.1.0 DOCUMENTS
similar branch. The Contractor shall submit the following in-
b. Jack screws for orifice flanges shall be inspection records for each items of test and
stalled so that they are 180O apart from inspection:
each other. 9.1.1 Non-destructive inspection
c. When taps are to be taken off from a pipe,
the holes shall be drilled where shown on a. Record of radiographic inspection
the drawings, the burrs removed and the b. Record of magnetic particle inspection
holes made smooth. Sockets shall not be
embedded in the pipe. c. Record of liquid penetrant inspection
d. The orientation for pressure differential taps d. Record of ultrasonic inspection
shall be accurate as shown on the drawings
e. Records of stress relieving
e. Orifice plates shall not be installed until the
pipe interior has been cleaned. f. Records of hardness test
f. When installing orifice plates, the orifice g. Records of hydrostatic & pneumatic pr. tests
plate number and the flow direction shall be
checked. In general, the handle is pointed 9.1.2 Destructive inspection
upwards and the inlet die stamp mark end Record of welding procedure qualification test
is pointed upstream. 9.1.3 Others specifically instructed
g. An orifice plate shall be installed with its Following are to be indicated on the test and
center coinciding with the center of the pipe
and with the gasket not protruding into the inspection record
pipe. 1. Name of customer
g. An orifice plate shall be installed with its 2. Job number and name of work
center coinciding with the center of the pipe
and with the gasket not protruding into the 3. Name of contractor
pipe. 4. Line number
h. Installation of flow meters such as area 5. Date of test and inspection
type, column type, and magnetic type shall
be in accord ance with the instructions of the 6. Name(s) of attendant (FEDO, Customer, or
FEDO Engineer. third party)
8.10.4 Installation of Control Valves : The installation of 9.2.0 ITEMS OF INSPECTION AND TEST
control valves shall be as follows: 9.2.1 Prior to, during and after completion of the
a. Control valves shall be installed by checking works, the following tests and inspections shall
the flow direction and, except for special be performed.
cases, with the diaphragm at the top in a ITEMS FOR INSPECTION AND TEST
vertical position.
PRIOR TO COMMENCING WORK
b. To prevent internal and external damage
and entry of foreign matter during construc- Checking Legal qualification certificate
materials
tion, control valves shall be installed during
the last stage after pressure testing and Welding proce-
flushing of the line. In this case, a spool dure test
having the same face-to-face dimension as Welder’s techni-
the control valve shall be inserted to keep que qualification welder’s techniqe qualifica-
test tion certificate
the distance during construction. Further
more, after the piping around the control Welding rod
valve has been installed, the dimensions check
shall be checked to confirm that the valve PRIOR TO WELDING WORK
can be fit in place.
Edge preparation Angle, Root opening, Thick-
c. When installing control valves unavoidably ness of land, Cleanliness
during construction, a blind gasket, gal-
vanized iron sheet, or other suitable Shape of pipe Out of roundness, Thick-
end ness, Uneven thickness
material of the same thickness as the main
gasket shall be inserted to prevent entry of Degree of flattening at bent
foreign matter. During construction, control Bending part, Radius of curvature,
Thickness reduction at bent
valves shall be covered with vinyl sheet or part
other suitable material, and care shall be
taken not to damage the valves. During Tack welding Bevelled end misalignment,
Root opening
pressure testing and flushing of the line, the
valve shall be removed and the end flanges Method of preheating,
of the valve shall be covered up. Temperature of preheating,
Preheating width of heating, Tempera-
ture measurement, Heating
temperature, Others

25ES205 / 10
Welding rod Drying temperature, Drying 6 Under cut

time No under cut is al- : Within 0.8mm or
lowed for piping of 12.5% of thickness
DURING WELDING WORK cold or high tempera- whichever smaller
Welding parameters, Flow ture service.
rate of sealing gas, Protect-
Welding condition ing measure for welding, 7 Over lap : 1.5mm or less
Condition of ambient
temperature 8 Height of reinforcement
Inter-layer temperature Nominal Wall Thk.
Re-examination of welder
Up to 6.4mm : 1.6mm or less
AFTER COMPLETION OF WELDING WORK
Inside surface misalignment, Over 6.4mm up to
Outer surface misalignment, 12.7mm ; 3.2mm or less
Inside surface weld
Visual ap- protrusion, Wave irregularity, over 12.7mm up to
pearance inspec- Uneven leg length, Irregular : 4.0mm or less
tion height of bead, Undercut, 24.5mm
Overlap, Bead centre shift,
Height of reinforcement Over 24.5mm : 4.8mm or less
welds
Non-destructive Radiography, Dye penetrant, Throat thickness of : 70% of thickness of
inspection Magnetic particle fillet welds the inner plate or
more
Stress relieving temperature and method
Hardness test 9.4.0 Non-destructive inspection
DURING OR AFTER COMPLETION OF 9.4.1 Non-destructive inspection shall be performed
WELDING WORK according to the grade of inspection stipulated
Dimension, Condition of con- in the next table. (Pressure classes in accord-
Product inspec- nection to equipment, Visual ance with ANSI B16.5)
tion apperance inspection
Grade of Inspection
Treatment of pipe inside
Material I II III
Thread
Pressure classes - ANSI B16.5
Seal welding of threaded portion (psig.)
AFTER COMPLETION OF WORK P - NO: 1
Completion of work w.r.t piping drawings Service Less 2500 lb
temp. than 300 400 lb - and
Pneumatic pressure test below 3500C lb 1500 lb above
Carbon
Flushing steel Service
temp. 150 lb - 1500 lb
Removal of temporary supports / scafoldings 3500C or - 900 lb and
more above
AT TRIAL OPERATION
Appearance inspection 150 lb - 1500 lb
Al-killed Steel - 900lb and
above
9.3.0 VISUAL APPEARANCE EXAMINATION
P - NO: 3, 4, 5
9.3.1 Following shall be met, checking visually or in
C- 0.5 Mo Steel 150 lb - 1500 lb
using measuring instrument - and
Cr- Mo Steel 900 lb above
1 Inside surface : 1.5mm or less
misalignment P - NO: 9
2 Outer surface 1500 lb
misalignment due to 3.5 Ni steel - 150 lb - and
difference of : 3.0mm or less 900 lb above
diameter of thick-
ness P - NO: 8
3 Inside surface weld protrusion Less 900 lb
A312 Gr. than 150 300 lb - and
Nominal Wall Thk. Aus- TP304 lb @ 600 lb above
tenitic
Up to 6.4mm : 1.6mm or less stainless
steel Other than 150 lb - 400 lb
Over 6.4mm to above - 300 lb and
12.7mm : 3.2mm or less above
Over 12.7 up to : 4.0mm or less Note: @ When A312 Gr. TP304 is used for cold or
25.4mm high temperature service, the grade II of inspec-
Over 25.4mm : 4.8mm or less tion shall be applied even if it is not above 150
lb.
4 Wave irregularity ; 2.5mm or less 9.4.2 Items of non-destructive inspection and number
5 Irregular height of of samples for the random inspection shall be
bead : 2.0mm or less as follows:

25ES205 / 10
ITEM OF INSPECTION 200 to 300 300 x 4 sheets

R - Radiographic Inspection
M - Magnetic particle Inspection 350 to 400 300 x 5 sheets
L - Liquid PenetrantInspection
450 300 x 6 sheets
Object of inspection
500 300 x 7 sheets
Material Noz- Non
Peri zle Soc pres- 600 300 x 8 sheets
phery (1) ket sure
part With film overlap of
GRADE - I 25mm or more, no of
650 & above photographs shall be
Less equivalent to peripheral
than 150 3% length of the pipe
Carbon lb
steel 9.4.3 Radiographic examination
R Over 150 - - -
lb to 300 10 % Unless otherwise specified, radiographic ex-
lb amination shall be as follows:
A312 Gr. TP304 10 % 1. Radiographic inspection shall be performed
GRADE - II in accordance with Article 2, Section V of the
R All materials 20 % - - - ASME Boiler and pressure vessel code.
Carbon steel - 2. The welds to be examined shall be selected
based on the number of work products of
M C-0.5 Mo steel each welder and welding operator engaged
(3) Cr-Mo steel in all welding operations. A minimum of one
Al-killed steel 10 % 10 % 10 %
3.5-Ni steel 10 % (4) weld per sample shall be examined.
(2)
Austenitic 3. All welded joints in a designated lot of piping
L stainless steel shall be radiographed over the complete
(3) Non-ferrous metals circumference.
GRADE - III 4. When a random type examination reveals a
R All materials 100 % - - - defect, additional examination shall be per-
formed in accordance with the requirements
All materials except of appendix IV.
M for austenitic stain-
(3) less steel, non-fer-
rous metals & 5. The radiation source shall, in principle, be
non-magnetic metal 20 % 100 % 100 % 20 %
(4) x-ray or Gama-ray.
L Austenitic 6. Film such as Sakura RR, Fuji #100, Kodak
(3) Stainless steel AA, or Equivalent shall be used.
Non-ferrous metal
7. Identification mark as shown in Figure 10
Notes ( Page 28 of 28 ) shall be marked on every
(1) In “nozzle welding”, welded parts of reinforcing radiograph, and radiographs of repair weld
plate and slip-on flange are included. shall be marked with repair mark (R).
(2) This inspection shall be performed for the 8. The image quality indicator (IQI) specified
welded parts other than those to which in B UB-51, ASME Section VIII, Division 1,
radiographic inspection was applied. or equivallent shall be used.
(3) Either magnetic particle inspection or liquid 9. Limitations on imperfection shall be in ac-
penetrant inspection shall be performed. cordance with ANSI B31.3 TABLE 327.4.1
(A) for the degree of radiography involved.
(4) This inspection shall be performed for Cr-Mo
steel (A335 Gr. P5 or over grade) and 3.5Ni 9.4.4 Magnetic Particle/Liquid Penetrant Examination
steel. Liquid penetrant or magnatic particle examina-
Remarks tion shall be as follows:
1. Radiographic inspection for peripheral joint 1. Liquid penetrant inspection shall be per-
shall be performed for pipes of nominal formed in accordance with Article 6, section
diameter of 2" or more having the same V of ASME Boiler and pressure vessel code.
condition. 2. Limitations on imperfection shall be in ac-
2. Number of random sampling test shall be at cordance with ANSI B31.3 Table 327.4.1 (A)
least one, when less than one is obtained in 3. The weld surface, to which liquid penetrant
percentage of sampling or maganetic particle examination is ap-
3. Number of photographs to be taken for one plied, shall be finished smoothly with a
peripheral joint at radiographic inspection grinder as necessary.
shall be as follows: 4. If a defect is found in welds, the defect shall
NO. OF
be removed, and liquid penetrant examina-
PIPE SIZE NB PHOTOGRAPHS tion or maganitic particle examination shall
be performed again to confirm that no more
50 to 80 150 x 2 sheets defects exist., and then rewelding shall be
100 to 150 300 x 3 sheets performed. After rewelding has been com-
pleted, liquid penetrant examination or
maganetic particle examination shall be

25ES205 / 10
performed again to confirm that the rewelds 2. Removal of spatter and slag
are sound.
3. Any harmful flaw on the flange face, inner
a. Magnetic particle inspection shall be per- and outer surface of pipe.
formed in accordance with Article 7, Section 4. As-erected condition
V of the ASME Boiler & pressure vessel code
5. Shape and size of branches and other at-
b. Limitations on imperfection shall be in ac- tachment shall comply with drawings.
cordance with ANSI B31.3 Table 327.4.1 (A) 9.7.0 Inspection for treatment of pipe inside
9.5.0 HARDNESS TEST 9.7.1 Inspection shall be performed visually and
9.5.1 After stress relieving (SR) is performed, hard- touching by hand to confirm that no rust, slag,
ness shall be tested as follows: spatter, sand, or other foreign matters are left.
Inspector must confirm whether sufficient flush-
1. If SR is performed by heat coil, the hardness ing was performed.
test shall be carried out for all welds.
2. If SR is performed in furnace, hardness test 10.0.0 PRESSURE TEST AND OTHERS
shall be performed for 10% of all welds (at 10.1.0 GENERAL
least one-when 10% of all is less than one)
10.1.1 Prior to initial operation, the installed piping shall
3. Point to be tested shall be finished flat with be pressure tested under witness of FEDO En-
file before the test. gineer/ Representative.
4. The hardness points shall be tested to weld 10.1.2 Prior to the pressure test, a line check shall be
and to heat affected zone. Hardness test of performed based on P&I diagrams and the
the heat affected zone shall be made at a piping draw ings, in accordance with the instruc-
point as near as practicable to the edge of tions of the FEDO Engineer/ Representative.
the weld. When dissimilar materials are
welded, both heat affected zones shall be 10.1.3 Types of pressure test are as follows, however
tested. the test shall be performed in accordance with
the individual specification:
9.5.2 Hardness limit is given in following table ( Hard-
ness In Brinell Max. ) 1. Pressure tests
HB Hydraulic test (using water or other liquids)
P-No. MATERIAL (MAX)
Pneumatic test
P-3 A335 Gr.P1 (STPA12) 225
2. Leak test
P-4 A335 Gr.P12 (STPA22) 225
A335 Gr. P11 (STPA23) Overall air tightness test
A335 Gr. P22 (STPA24) 10.1.4 Before filling it with the test fluid, the entire line
P-5 A335 Gr. P5 (STPA25) 241 to be pressure tested shall be examined in the
manner described in Section 9.0.0, and any
9.6.0 PRODUCT INSPECTION faults shall be repaired. The piping affected by
Inspection for the finished product shall be per- any repairs or additions made after the pressure
formed as follows: test shall be retested.
9.6.1 Dimension: Right angle, perpendicularity, paral- 10.1.5 In principle, piping shall be pressure tested at a
lelness, dimension, etc. shall be measured metal temperature not less than 20C. However,
visually and by measuring tools and checked carbon and alloy-steel piping exceeding 25mm
against the drawings. Dimensional tolerances in thickness shall be pressure tested at a
are as follows: temperature not less than 160C.
1. Length + 0 ; -3.2mm or less 10.1.6 The following equipment and instruments shall
not be connected to the piping before comple-
2. Inclination of flange surface: less than 0.5o tion of the pressure test:
against the surface perpendicular to the
axis of pipe. (but, not to exceed 2mm at 1. Rotating machinery such as pumps, tur-
outside circumference of flange). bines, and compressors.
3. Perpendicularity of vertical line: 2/1000 or 2. Pressure relieving devices, such as rupture
less. discs and pressure relief valves.
4. Horizontality: 2/1000 or less 3. Equipment that has a castable or lining
material .
5. Misalignment between flange center and
pipe center: 1.6mm or less 4. Instruments.
6. Shift of bolt hole center: 1.0mm or less. 5. Piping which is normally open to the atmos-
phere such as drains, vents, and discharge
9.6.2 Inspection of connection to equipment: For piping from pressure relieving devices.
those pipings which are connected with pump,
compressor, turbine, etc., the above dimen- 6. Any other designated equipment.
sional tolerance shall be submitted by the 10.2.0 TEST FLUID
tolerances required by each of such machinery.
Test fluid shall be as follows:
9.6.3 Appearance inspection:
10.2.1 In principle, the fluid for hydrostatic testing shall
1. Correction for jig mark. be fresh water. Unless otherwise specified, the

25ES205 / 10
chlorine ion concentration in the fluid used for P = internal design pressure in kgf/cm2 G
austenitic stainless steel piping shall not exceed
30 ppm. After completion of the test, the water ST= allowable stress in kgf/cm2 at test
shall be drained immediately, and the interior of temperature
the pipe shall be dried by an air blower, etc.
S = allowable stress in kgf/cm2 at design
10.2.2 For piping systems having strong acids and So2 temperature
where water may become corrosive, or piping
systems operated at a temperature of 00C or 3. If the test pressure as defined in Item (2)
less, kerosene or similar light oils (with a flash above produces a stress in excess of the
point not less than 500C) or air is preferred as yield strength at the test temperature, the
the test fluid. test pressure may be reduced to the maxi-
mum pressure that will not exceed the yield
10.2.3 The air to be used for pneumatic testing shall be strength at test temperature.
compressed air from a portable compressor.
However, for instrument air lines or where 10.4.2 Hydrostatic testing piping with vessels as a sys-
specifically specified, oil-free dry compressed tem
air or inert gas shall be used. For high pressure 1. Where the test pressure of piping attached
piping (not less than 100 kgf/cm2G), the use of to a vessel is the same as or less than the
inert gas is preferable. When pneumatic testing test pressure for the vessel, the piping may
is performed by the use of an air compressor, be tested with the vessel at the test pressure
precautions against combustion shall be taken of the piping. However, the test pressure
by blowing clean the oil separator thoroughly so shall be controlled carefully so as not to
that no lubricant enters the air. exceed the test pressure of the vessel.
10.3.0 TEST PREPARATION 2. Where the test pressure of piping exceeds
The preparation for pressure test shall be as the vessel test pressure, the piping shall be
follows: tested by isolating it from the vessel.
10.3.1 All joints (including welds) are to be left uninsu- 10.4.3 Hydrostatic testing of externally pressured
lated and exposed for examination during the piping : The test pressure for piping subjected
test. However, joints previously tested in ac- to external pressure shall be as follows:
cordance with this standard may be insulated. a. Lines in external pressure service shall be
10.3.2 When filling water into piping that is designated subjected to an internal test pressure of 1.5
for vapor, gas, etc., not filled with water during times the external differential design pres-
operation, temporary supports or other reinfor- sure, but not less than a pressure of1.0
cements shall be provided beforehand. kg/cm2G (15 psig).
10.3.3 Special fittings in piping components, such as b. In jacketed lines, the internal line shall be
expansion joints, filters, and flame arrestors, pressure tested on the basis of the internal
shall be disconnected from the piping. or external design pressure, which ever is
critical. The jacket shall be pressure tested
10.3.4 Equipment which is not to be subjected to the on the basis of the jacket design pressure
pressure test shall be either disconnected from unless otherwise specified.
the piping or isolated by blinds or other means
during the test. 10.4.4 Pneumatic testing
10.3.5 If a pressure test is to be maintained for a certain 1. In principle, pressure tests shall be per-
period and the test liquid in the system is subject formed hydraulically, however, when it is
to thermal expansion, precautions shall be inappropriate to fill piping with water, the test
taken to avoid excessive pressure. In particu lar, may be performed with air or inert gas. The
for hydrostatic testing, care shall be taken to test pressure shall be 1.1 times the design
ensure that the water will not be subject to pressure.
thermal expansion so that the piping is not 2. Any pneumatic test shall include a prelimi-
damaged during the test. nary check at not more than 1.75 kgf / cm2G
10.4.0 TEST PRESSURE (25 psig) pressure. The pressure shall be
increased gradually in steps providing suffi-
10.4.1 Hydraulic Testing of Internally Pressured Piping cient time to check for leaks.
1. The test pressure for piping subject to inter- 10.5.0 TESTING METHOD
nal pressure shall be as follows:
The method of pressure testing shall be in ac-
a. Not less than 1.5 times design pressure cordance with the instructions of FEDO. How-
b. For a design temperature above the test
ever, the general method by using water shall
be as follows:
temperature, the minimum test pressure
shall be calculated by the following for- 10.5.1 In principle, pressure tests shall be performed
mula. for each piping system. However, when design
conditions do not permit testing in such a man-
1.5PST ner, the system may be tested in sections.
PT =
S 10.5.2 Test blinds shall have a handle extending out
Where from the flange. The handle shall be painted in
red, to ensure removal of blind after testing.
PT= minimum hydrostatic pressure in
kgf/cm2 G 10.5.3 Installation and removal of blinds shall be per-
formed in accordance with the instructions of

25ES205 / 10
FEDO. The number or all the blinds used and 10.6.0 REPAIR OF DEFECTS
the location of the insertion shall be recorded at The repair of defects found during test and
all times.
inspection of piping systems shall be as follows.
10.5.4 Test pressure gauges with graduations up to two In principle, the repair shall be performed under
times the prescribed test pressure shall be witness of FEDO after the approval of the FEDO
provided. All the pressure gauges shall be cer- Engineer has been given.
tified by the national authority, and the calibra-
tions shall be checked by periodic inspections. 10.6.1 Repair of welds
10.5.5 Two or more pressure gauges shall be installed a. Repair welding shall be performed after the
so that they are easily observed. When the pressure and liquid remaining in the pipe
piping system to be tested extends from a low have been removed.
to a high level, pressure gauges shall be in- b. The defects to be repair welded shall
stalled at both the lowest and the highest points. be removed completley with a grinder, etc.
10.5.6 For each piping system, an outlet for discharg- c. The welding, the heat treatment, and the
ing the pressure in case of emergency shall be test and inspection shall be the same as
designated and marked to that effect. required for the initial welding, and per-
10.5.7 During pressure testing of piping, operation of formed in accordance with the applicable
valves shall be prohibited and the valves shall provisions of this specification.
be marked to that effect. d. In principle, repair welding of the same por-
10.5.8 Prior to pressure testing, it shall be confirmed tion shall not be performed more than twice.
that a strainer is provided at a designated loca- 10.6.2 Repair of Threaded Joints
tion to remove foreign matter.
All defective threaded joints shall be replaced
10.5.9 Vents on piping subjected to hydrostatic testing with complete new ones.
shall be opened to remove the air when filling
the piping with water. 10.6.3 Repair of Flange Joints
10.5.10 Prior to hydrostatic testing, the piping shall be All defective flange joints shall be replaced with
checked to confirm that it is free from air pockets complete new ones, except those which can be
and if necessary, temporary vents shall be repaired in accordance with Section 5.2 (15).
provided to eliminate the air pockets until testing 10.7.0 FLUSHING AND CLEANING
is completed.
10.7.1 Selection of cleaning method
10.5.11 For piping systems with a check valve, the pres-
sure shall be applied from upstream of the valve. Cleaning method shall be selected in the follow-
If this is impractical, the check valve shall either ing methods considering kind of fluid, pipe
be reversed or shut off with blinds. However, material and condition of internal surface of
when reversed, the valve shall be reinstalled piping to be cleaned. Cleaning method and ex-
correctly after testing. tend of cleaning shall be as per specific Project
Requirements.
10.5.12 When the test pressure is not less than 50 kgf /
cm2G, pressure shall be increased gradually. a. Water Flushing
b. Air Blowing
10.5.13 The test pressure during a pressure increase
shall be read by the pressure gauge installed at c. Steam Blowing
the lowest point of the piping in consideration of d. Acid Cleaning
the water head pressure. e. Oil Cleaning
10.5.14 The check for any leaks during the pressure test f. Others
shall be performed after the prescribed pressure
is maintained for a time not less than 10 minutes. 10.7.2 Procedure of cleaning in general
All connections and all welded joints shall be 1. Cleaning of fabricated pipings
inspected thoroughly.
Inside surface and face of weld of fabricated
10.5.15 After the completion of pressure testing, the piping shall be made free from slag, cham-
water shall be drained immediately from the line fer, scale and other foreign matter, with
to prevent the piping system from being grinder, chisel, wire brush, etc., and be air-
damaged by freezing or thermal expansion. blown. After completion of air blowing and
Also to prevent vacuum forming in the piping, checking, ends of the piping shall be
the vents shall be opened when the water is covered with vinyl or veneer cap, etc. till the
being drained. installation in the field.
10.5.16 On completion of pressure testing, the line shall 2. Temporary Strainers
be checked to see that no residual pressure is
present, and the line shall be drained. All blinds Temporary strainers shall be used as fol-
shall be removed. lows:
10.5.17 Short pieces of pipe, which must be removed for a. After installation of piping, and before
installing blind plates and blind flanges, shall be commencement of flushing/cleaning.
tested separately.
b. The temporary strainers shall be installed
10.5.18 All valves, orifice plates, expansion joints, short at pump suction piping, upstream of con-
pieces of pipe, and other items removed or trol valve and other locations as specified.
installed for the test, shall be reinstalled with the
prescribed gaskets in the correct position.

25ES205 / 10
c. Mark plate shall be attached to the tem- factory or not

porary strainers to distinguish from other 3. The primary cleaning shall be performed for
strainers. each assembled piping. The secondary
cleaning shall, as a rule, be performed for
d. After a constant period of initial operation, piping from eqpt. to adjacent eqpt. Whether
all temporary strainers shall be removed, or not the equipment is included shall be
cleaned and reinstalled. determined considering shape, internal
construction & packing of the eqpt. and
10.8.0 WATER FLUSHING according to overall cleaning planning.
10.8.1 Cleaning method by water 10.8.3 Steam blowing
1. As a rule, pure water, service water, steam 1. Execution of steam blowing
condensate, industrial water, etc. shall be
used. If there is any requirement about the Steam blowing shall be executed after com-
quality of water to be used, it shall be ob- pletion of pressure test and insulation work.
served. 2. Preparation of steam blowing
2. After flushing, drying by compressed air or
natural drying shall be carried out. Drying by a. Temporary piping work, countermeasure
superheated steam shall be carried out with for safety & confirmation of preparation
agreement between Customer and FEDO. shall be done according to blowing plan.
3. Flushing shall be performed till the water b. Support shall be attached to exhaust
becomes free from foreign matter, scale, piping to prevent accident caused by the
etc. This shall be decided by observing tur- reaction force during blowing.
bidity of water taken out ( into beaker or
cup). 3. Procedure of steam blowing
4. Water flushing shall be performed by the a. Warm up the piping with cooperation by
method of running by pressurised water and operator
hammering, or rapid draining with water
filled. Hammering shall, however, not be b. Check expansion joints, spring hangers,
performed for austenitic stainless steel etc., for expected thermal expansion.
pipe, copper pipe, aluminum pipe.
c. Steam blowing shall be performed at the
5. The primary cleaning shall be performed for temperature near to the operating tempera-
each assembled piping system including ture, considering operating condition of
the equipment. boiler.
6. Where instruments are included in piping
system to be cleaned, the instruments shall, d. To remove the scale effectively by tempera-
as a rule, be disconnected and spool pipe ture change, it is required to perform flush-
(distance piece) shall be inserted instead. ing and cooling cyclically, having
temperature difference as large as pos-
7. When cleaning is carried out in the condition sible between the flushing and cooling.
that control valve is connected, the proce-
dure shall be as follows: 4. Judgement criteria of steam blowing
a. Disconnect companion flange at upstream a. Judgement on result of steam blowing
side of the control valve and cover open- shall generally be done by checking color
ing of the control valve. or quantity of foreign material present in
b. Clean the piping of upstream side. the drain sampled.
c. Connect the control valve and the piping b. If necessary, especially for suction line of
of upstream side after cleaning. steam turbine etc., result of flushing shall
be judged by observing whether scratch
d. Close the control valve, open by-pass was produced or not on the test piece in-
valve, and then clean the piping of down serted in the line.
stream side. Where the by-pass valve is
not installed, the temperory strainer 10.8.4 Acid cleaning
having austenitic stainless steel screen of 1. Applicable piping of acid cleaning
No. 50 specified in ASTM E-11 shall be in-
serted. Unless otherwise specified in specific job
requirements, acid cleaning shall apply to
10.8.2 Air blowing oil piping system of rotating machinery.
1. Air blowing shall be performed by the 2. Cleaning method by acid
method of blowing by pressurized air and As a rule, acid cleaning procedure shall be
hammering. Hammering shall, however, not as follows:
be performed for austenitic stainless steel
pipe, copper pipe and aluminum pipe.
2. Blowing shall be performed till there
remains no scale in the piping. FEDO per-
sonnel in charge shall make judgement of
whether the result of the cleaning is statis-

25ES205 / 10
a. Ten-percent hydrochloric acid solution or 10.10.0Disposition

Ten-percent sulphuric acid solution with 10.10.1All construction equipment used for the piping
temperature 30 to 400 C shall be used, and work, and all surplus, scrap and debris shall be
piping shall be pickled in the acid solution disposed of in accordance with the instructions
for 1 to 6 hours. of the FEDO Engineer.
b. After pickling, the piping shall be washed 10.11.0 Test record
sufficiently to remove the acid solution by 10.11.1 All inspection and test results shall be made into
water. re cords in accordance with the instructions of
FEDO. The records shall be submitted for ap-
c. And the piping shall be rinsed for proval to FEDO.
neutralization of the acid solution by
sodium hydroxide solution, followed by 11.0.0 APPENDICES
water flushing.
11.1.0 The following Appendices shall form a part of
d. The piping shall be well dried by super- this manual:
haeted steam or dry air and the inside of
pipes given a coat of the oil of the same TITLE REFER TO:
quality as specified to be used in the oil Grove face Rust Preventive APPENDIX I
piping.
Selection of welding electrodes APPENDIX II
Remarks: Oil piping of stainless steel shall not be acid
cleaned. Procedure for Flange Bolt up APPENDIX III
10.8.5 Oil cleaning Additional Random Type APPENDIX IV

Examination for weld defects
1. Applicable piping of oil cleaning
Oil cleaning shall apply to the oil piping
system after the acid cleaning specified in
par. 10.8.4 has been performed.
2. Cleaning method by oil
The procedure shall be as follows:
a. Oil to be used shall have good quality
suitable for the machinery, and shall be
completly replaced with the specified oil
after cleaning.
b. The cleaning shall be performed by the
method of circulation of the oil and ham-
mering. Hammering shall, not be per-
formed for copper pipe.
c. After completion of cleaning, it shall be
checked that no foreign matter is present
in temporary strainer screen of No.200
specified in ASTM E- 11 for oil pipings of
centrifugal compressor, and screen of
No.100 specified in ASTM E-11 for other oil
pipings.
10.8.6 Other cleaning method
1. Cleaning method by pig or cushion ball
Cleaning by the use of pig or cushion ball
shall confirm to specific job requirements.
2. Cleaning method by sodium hydroxide
Cleaning by sodium hydroxide solution shall
conform to specific job requirements.
3. Special cleaning
Special Cleaning, if specified for special
piping components or systems, shall con-
form to specific job requirements.
10.9.0 Overall airtightness test
10.9.1 When specified, an overall airtightness test shall
be performed for the piping of process line by
the use of air or inert gas after completion of
flushing.

25ES205 / 10
APPENDIX — I Procedure for Bolt Up

Procedure for flange bolt up shall be as follows
GROOVE FACE RUST PREVENTIVE
5. Hand tighten bolts with a short wrench by the
Features of Product procedure shown in Figure 11.
1. As rust preventive applied to the groove face, in 6. Tighten bolts a second time with a spanner
general, deoxialuminite is used as it is not wrench and light hammer (about 1 kg), again by
detrimental to the weld. Deoxialuminite is the the procedure shown in Figure 11.
brand name of a product of Special Chemical
Co., Ltd.of USA. This was first produced in 7. Continue tightening gradually by the procedure
Japan by Nippon Oil & Fats Co., Ltd. and is sold shown in Figure 11, using a heavy hammer
under the brand name of Tasteto Silver. (about 2 kg) until bolts are completely drawn
tight. This may take two or three additional
2. The composition of the product is 40% resin, rounds by the same procedure.
50% solvent, 5% pigment, etc., and the percent-
age of resin in the compound is high to reduce 8. For bolts larger than 25mm in diameter, a final
the amount of gas produced during welding. round or two with a heavier hammer (about 3.5
kg) is recommended to reach the correct bolt
3. This product is recommended for both marine tension.
and overland transportation. The thickness of
the applied product shall not be more than 30 Precautions
microns. Special precautions shall be taken for the follow-
4. The adherent durability is not more than three ing items for bolt up:
months. 9. Never draw up tight on one or two bolts only.
Directions for Use This will cause local gasket crushing or pinch-
ing, which will result in leaks.
5. Before applying the rust preventive, it shall be
confirmed that the groove face is clean. 10. After each round of tightening, the alignment
may be checked by measuring the distance
6. After the rust preventive has been applied, weld- between flange faces.
ing shall not be performed within two weeks.
11. The bolts should be gradually and evenly
7. In principle, the application shall be sprayed by tightened with a wrench and hammer until the
maintaining a distance not less than 30 cm from hammer begins to “bounce” with a distinct ring.
the spray nozzle to the object. Unless otherwise
specified, the product shall not be applied with
a brush.
APPENDIX — IV
ADDITIONAL RANDOM TYPE EXAMINATION FOR
APPENDIX — II WELD DEFECTS
SELECTION OF WELDING ELECTRODES & RODS (Taken from ANSI / ASME B31.3b-1982, 336.5)
Table - I : Selection of welding electrodes & rods When the required examination of a spot or
for joining similar materials except Aluminium random type reveals a defect requiring repair,
two additional examinations of the same type
Table - II : Selection of welding electrodes & rods shall be made on the same kind of item (if of a
for joining disimilar materials except Aluminium weld, others by the same welder or welding
operator). If the second group of items ex-
( Tables overleaf ) amined is acceptable, all items represented by
these additional examinations shall be ac-
cepted.
For each of the second group of items which
reveals defects requiring repair, two additional
items shall be examined. If all of the third groups
of items examined are acceptable, the items
requiring repair shall be repaired or replaced to
APPENDIX — III meet the requirements of the code, and all items
represented by the examined items shall be
PROCEDURE FOR FLANGE BOLT UP accepted.
Confirmation Prior to Bolt Up If any of the third group of items examined reveal
The following items shall be confirmed prior to defects requiring repair, all comparable items
bolt up: may be replaced or they shall fully examined
and repaired as necessary to meet applicable
1. The gasket has been inserted and centered. quality requirements.
2. Bolts and nuts have been lubricated.
3. Bolts have been inserted and are finger tight.
4. There are at least two threads extending beyond
the nut on either side.

25ES205 / 10
TABLE - I : SELECTION OF WELDING ELECTRODES & RODS FOR SIMILAR MATERIALS EXCEPT ALUMINIUM
MATL. BASE COVERED ELECTRODES WELDING RODS
NO. MATERIAL AWS SPEC PREFERRED ELECTRODE AWS SPEC. CLASSIFICATION
1 UTS UNDER 60,000psi A 5.1 E6010/E6013 (1) (2) (3) (4) —
2 carbon UTS 60,000psi & above A 5.1 E6010/ E7018 (1) (2) (3) (4) —
steel
2a A333 Gr - 1 A 5.1 E7018 -1(5) (5) --
3 carbon-molybdenum A 5.5 E70XX-A1 (2) (3) (4) —
1
4 2 /4 nickel A 5.5 E80XXC1 (2) —
5 31/2 nickel A 5.5 E80XX-C2 (2) —
6 9 nickel A 5.11 ENi Cr Fe - 3 A5.14 ER Ni Cr -3
1
7 /2Cr–1/2Mo A 5.5 E8015-B2L (2) 0.05C max.
1
8 1Cr– /2Mo A 5.5 E8015-B2L (2) 0.05C max.
9 low 11/4Cr–1/2Mo A 5.5 E8015-B2L (2) 0.05C max.
10 chromium 1
2 /4Cr–1Mo A 5.5 E9015-B3L (0.05C max.) (2) 0.05C max.
ferrtic
11 steels 5Cr– /2Mo1
A 5.4 E502-I5 (0.05C max.) A5.9 ER502(0.05C max)
12 7Cr–1/2Mo A 5.4 E7Cr-I5 (0.05C max.) (2) (0.05C max.)
13 9Cr–1Mo A 5.4 E505-I5 (0.05C max.) A5.9 ER505(0.05C max)
14 AISI Type405 A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05C max)
15 ferrtic AISI Type 410S A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05Cmax)
stainless
16 steels AISI Type410 A 5.4 E410-I5 (0.05C max.) A5.9 ER410(0.05C max)
17 AISI Type430 A 5.4 E430-I5 A5.9 ER430
18 AISI Types 304&304H A 5.4 E308-I5 or 16 A5.9 ER308
19 AISI Type 304L A 5.4 E308L-I5 or 16 A5.9 ER308L
20 AISI Types321&321H A 5.4 E347-I5 or 16 A5.9 ER347
21 AISI Types 347 & 347H A 5.4 E347-I5 or 16 A5.9 ER347
austenitic
22 stainless AISI Types 316 & 316H A 5.4 E316-I5 or E 16 -8 -2 A5.9 ER316
steels
23 AISI Type 316L A 5.4 E316L-I5 or 16 A5.9 ER316L
24 AISI Type309 A 5.4 E309-I5 or 16 A5.9 ER309
25 AISI Type310 A 5.4 E310-I5 or 16 A5.9 ER310
26 Incoloy(32Ni46Fe20Cr) A 5.11 ENi Cr Fe-2 A5.14 ERNiCr -3
27 AluminiumBronze A 5.6 ECu Al-A1 A5.7 RCu Al-A2
28 Phosphor Bronze A 5.6 ECuSn-C A5.7 RCuSn-A
29 Copper A 5.6 ECu A5.7 RCu
30 non– 67Ni-30Cu Monel A 5.11 ENiCu-4 A5.14 ERNiCu-7
31 ferrous Hastalloy(60Ni-28Mo-5Fe) A 5.11 ENiMo - 1 A5.14 ERNiMo-4
metals &
alloys
32 Inconel(75Ni 15Cr8Fe) A 5.11 ENiCrFe -1 A5.14 ERNiCrFe-5
33 70Cu-30Ni A 5.6 ECuNi A5.7 RCuNi
34 Nickel A 5.11 ENi-1 A5.14 ERNi-3
35 20Cr-29Ni-21/2Mo-3Cu - Alloy 20 Cb - 3 — Alloy 20Cb3
Notes:
(1) For materials Nos.1 and 2 (Carbon steel) where SMAW is followed, the root run shall be with E 6010 electrodes.
(2) Where no AWS specification exists for base wire, it is acceptable to use wire or rods of the same nominal composition as
the base material with substantially neutral flux or inert gas, provided they have been qualified in the procedure test.
(3) MIG wire shall conform to AWS A5.18 and A5.20
(4) SAW wire and flux shall conform to AWS A5.17
(5) The root run of butt welds for material No. 2a shall be made in GTAW process using ER70S - 2 wires.

25ES205 / 10
TABLE II — SELECTION OF WELDING ELECTRODES & RODS FOR WELDING DISSIMILAR MATERIALS EX-
CEPT ALUMINIUM
Lower Higher base material number
base
mat’l 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 35
No.
1 A A A A A B B B B B B B B B B B C C C C C C D D E C
2 A A A A B B B B B B B B B B B C C C C C C D D E C
3 @ @ @ B B B B B B B B B B B C C C C C C D D E C
4 A A @ @ @ @ @ @ @ @ @ @ @ C C C C C C D D E @
5 A @ @ @ @ @ @ @ @ @ @ @ C C C C C C D @ E @
6 @ @ @ @ @ @ @ @ @ @ @ E E E E E E E @ E @
7 A A A A A A A A A A C C C C C C D E C @
8 A A A A A A A A A C C C C C C D E C @
9 A A A A A A A A C C C C C C D E C @
10 A A A A A A A C C C C C C D E C @
11 A A A A A A C C C C C C D E C @
12 A A A A A C C C C C C D E @ @
13 A A A A C C C C C C D E @ @
14 A A A C C C C C C D E @ @
15 A A C C C C C C D E @ @
16 A C C C C C C D E @ @
17 C C C C C C D E @ @
18 A A A A A A A A C
19 F F F A F F F C
20 A A A A A A C
21 A A A A A C
22 A A A A C
23 A A A C
24 C E C
25 E C
26 C
DESCRIPTION OF CODE LETTERS IN ABOVE TABLE

A As specified in table I for material corresponding to either the higher or lower base material number
B ASME SFA-5.5, E8015-82L electrode
C ASME SFA-5.4, E309 electrode. Acceptable alternatives shall be as specified in table I for the higher base
material number
D As specify in table I for the material with the higher base material number
E ASME SFA-5.11, ENiCrFe-2 electrode and ASME SFA-5.4. ERNiCr-3 rods shall be used where design
temperature exceeds 10000F (5380C). ASME SFA-5.4, E310 electrodes are to be used where service
temperatures are below 10000F (5380C) and expected to be relatively constant after start up. All rods, exclud-
ing alternatives shall require written approval from designated authority.
F ASME SFA-5.4, E308 electrode or as specified in table I for the material with the higher base material number
@ Welding of these material combinations are not permitted without written approval from designated authority.

25ES205 / 10
TECHNICAL
PROCUREMENT 32644-03-PS-001 SV
SPECIFICATION SUB VENDOR LIST
PAGE 1 OF 3 R 0
A) CS & SS PIPES
1. M/s Surindra Engg. Mumbai

2. M/s Indian Seamless Metal Tubes, Bangalore
3. M/s Ajantha Tubes, N.Delhi
4. M/s Bharat Steel, Mumbai
5. M/s Sreevatsa Tube Corpn, Chennai
6. M/s Sanghvi Metals, Mumbai
7. M/s Nagardas Kanjishah, Mumbai
8. M/s M.J.Patel & Co. Mumbai
9. M/s Maharashtra Seamless, Mumbai
10. M/s Madras Steels & Tubes, Chennai
B) CS & AS PIPING FITTINGS
1. M/s Tube Products, Baroda

2. M/s Metal Forge, Mumbai
3. M/s Sivananda Pipe Fittings, Chennai
4. M/s Teekay Tubes, Mumbai
5. M/s Eby Industries, Mumbai
6. M/s Precision Forgings, Mumbai
7. M/s M.J.Industries, Mumbai
8. M/s Tube Weld Engg., Mumbai
C) FLANGES
1. M/s Abassi Engg. Works, Chennai

2. M/s Echjay Industries, Mumbai
3. M/s Metal Forge, Mumbai
4. M/s M.J.Industries, Mumbai
5. M/s Precision Forging Industries, Mumbai
6. M/s Punjab Steel Works, N.Delhi
7. M/s Golden Iron & Steel Works, N.Delhi
8. M/s Britex Engg. Works, Mumbai

00FT024/94

TECHNICAL
PAGE 2 OF 3 R 0
D) NON METALLIC PIPES & FITTINGS
1. M/s Chemplast, Mumbai

2. M/s Emco General Plastic Industries, Kochi
3. M/s Kodoor Engrs., Kochi
4. M/s Manikya Plastichem,Mysore
5. M/s National Organic Chemical Industries, Mumbai
6. M/s Polyplast, N.Parur, Kochi
7. M/s Sunrise Polymers & Industries, Vadodara
8. M/s Sangir Plastics P.Ltd., Mumbai.
E) DUCTILE IRON PIPES & FITTINGS
1. M/s Electrosteel Castings Ltd., Thiruvananthapuram

2. M/s LANCO Industries Ltd., Thiruvananthapuram
F) GATE, GLOBE & CHECK VALVES
1. M/s BDK Marketing, Hubli

2. M/s Fouress Engg., Mumbai
3. M/s Intervalve (I), Mumbai
4. M/s Kirloskar Brothers, Pune
5. M/s Larsen & Toubro, Chennai
6. M/s Neco Schubert & Salzer, Nagpur
7. M/s Nitone Valves, Mumbai
8. M/s VIP Valves, Mumbai
G) CAST IRON VALVES
1. M/s H. Sarkar & Co., Calcutta

2. M/s Upadhyaya Valvesmanufacturers, Calcutta
3. M/s Kirloskar Brothers, Pune
4. M/s Ronex Engg.Co., Howrah
5. M/s Geeta Valves, Baroda
6. M/s Intervalve India Pvt. Ltd
7. M/s Ajay Valves, Bhavanagar

00FT024/94

TECHNICAL
PAGE 3 OF 3 R 0
H) BOLTS & NUTS
1. M/s Echjay Industries, Mumbai

2. M/s Fasteners & Allied Products, Hubli
3. M/s Fasteners India Manufacturers, Mumbai
4. M/s Hardwin Fasteners, Mumbai
5. M/s Nagabhushanam Industries, Bangalore
6. M/s Pacific Forgings, Mumbai
7. M/s Vaibhav Industries, Mumbai
8. M/s Fix fit Fasteners, Kolkota
I) GASKETS
1. M/s Industrial Minerals And Mill Store Traders, Calcutta

2. M/s Plastofab, Madras
3. M/s Mechanical Packaging Industries Pvt. Ltd.,Bombay
4. M/s Metro Agencies, Kochi
5. M/s Popular Mill Stores, Cochin
6. M/s Reinz-Talbros Pvt. Ltd. New Delhi
7. M/s Southern Gasket Products, Madras
8. M/s Sealings And Jointings, Kalamassery
9. M/s SUJAYA RUBBER INDUSTRIES,PALAKKAD
10. M/s High Tech Seals (P) Ltd., Aluva
11. M/s Igp Engineers Ltd., Chennai
12. M/s Spiraseal Gaskets Pvt. Ltd., Chennai
13. M/s Unique Industrial Packings, Mumbai
14. M/s Vircap Sealing Tech, Pvt, Ltd, Chennai

00FT024/94

TECHNICAL PROCUREMENT SPECIFICATION 32644-12-PS-003
FOR CIVIL & STRUCTURAL WORKS – CONSTRUCTION OF
ADDITIONAL PHOSPOHORIC ACID STORAGE TANKS AT Q10 PAGE 1 OF 1 R1
BERTH, WI
TPS NO. 32644-12-PS-003
STATUS ENQUIRY COMMITMENT
ORIGINATING DEPT. CIVIL
P.O / W.O NO.
CONSTRUCTION OF ADDITIONAL PHOSPHORIC ACID STORAGE

PROJECT
TANKS AT Q10 BERTH, WILLINGDON ISLAND
LOCATION WILLINGDON ISLAND, KOCHI, KERALA
CLIENT M/S. FACT-CD
PURCHASER M/S. FACT-CD
VENDOR
ITEM: CIVIL & STRUCTURAL WORKS
1 22-06-2020 SECOND ISSUE AVR NJ ASOK

0 09-06-2020 ORIGINAL ISSUE AVR NJ ASOK
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CONTENTS 32644-12-PS-003
TECHNICAL PROCUREMENTSPECIFICATION FOR
CIVIL
CIVIL & STRUCTURAL WORKS – CONSTRUCTION
DEPARTMENT Page 1 of 1
OF ADDITIONAL PHOSPHORIC ACID STORAGE
TANKS AT Q10 BERTH, WI
Rev. No. with Issue
No. of
Pages
1 2 3 4
1.0 TECHNICAL DOCUMENTS

1.1 32644-12-DA-003 Specific Requirements of Work 4 0 1
Design Philosophy and Basis for Civil &
1.2 32644-12-PS-003-DB 69 0 1
Structural Works
1.3 32644-12-PS-003-SIW_A Schedule of Items of Work (Unpriced) 3 0 1
Engineering Specification-Civil & Structural
1.4 12ES001/18 14 0 0
Works
2.0 DRAWINGS
Construction of Phosphoric Acid Storage
2.1 32644-12-DG-00001 Tanks at Q10 berth,WI - 1 0 0
Details Of Dyke Wall, Pipe Rack And Drains
Tanks at Q10 berth,WI -
2.2 32644-12-DG-00002 1 0 1
Layout And Details Of Pile And Foundation
Details Of Phosphoric Acid Tanks
Tanks at Q10 berth,WI -
2.3 32644-12-DG-00010 1 0 0
Truck Loading Platform-Plan,Elevation And
Section
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0 09-06-2020 ORIGINAL ISSUE AVR NJ ASOK

CIVIL 32644-12-DA-003 R1
SPECIFIC REQUIREMENTS OF WORK
DEPARTMENT PAGE 1 OF 4
CIVIL WORKS FOR THE CONSTRUCTION OF ADDITIONAL PHOSPHORIC ACID

STORAGE TANKS AT Q10 BERTH, WILLINGDON ISLAND
1. INTRODUCTION
FACT Cochin Division proposes to construct additional PhosphoricAcid Storage
Tanks and its allied facilities such as dyke wall, drains, pipe supports, stairs and
truck loading platforms at Q10 berth in Willingdon Island.
The work to be performed under this contract includes Detailed Engineering,
preparation of Good for construction drawings, Procurement, Supply and
construction activities as defined in this document and prepared with reference to
the Tender drawings and design basis (32644-12-PS-003-DB)
2. SCOPE OF WORK
As part of the construction of additional Phosphoric Acid Storage Tank, following
civil &structural works are in the scope of the contractor:
2.1 Design Engineering and preparation of good for Construction drawings for the
various Structure and Foundation as indicated in the scope of this document
satisfying the requirements mentioned in Doc-32644-12-PS-003-DB and Tender
drawings.
2.2 Demolition of existing sheds like service station, mechanical workshop and light
tower inside the dyke enclosed area of proposed tanks. .
2.3 Filling up the area consumed by crossing cable trench inside dyke with red earth
as per specification.
2.4 Dismantling of existng drain in dyke enclosed area and rerouting the drain as per
32644-03-OP-00001.
2.5 Arranging and Conducting routine pile load test on Single pile.
2.6 Casting of bored castin-situ concrete piles in appropriate depth and dimension for
the proposed tank foundation
2.7 Construction of Pile cap and Grillage beams over the pile cap
2.8 Construction of Dyke wall for the proposed Phosphoric Acid Storage Tank
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CIVIL 32644-12-DA-003 R1
DEPARTMENT PAGE 2OF 4
2.9 Construction of Acid spill drain around tanks and from tank to drain pitwith
appropriate length and dimensions along with required drain pipes
2.10 Construction of drain pit inside dyke wall for meeting contingency
2.11 Construction of Pipe rack from tank area to shore side, Truck loading piping, Barge
loading piping
2.12 Construction of Pipe sleepers as Utility supports within and around dyke for laying
suction lines and unloading lines
2.13 Construction of crossover platforms, approach ladders, stairs for providing
access to the tank from outside the dyke wall
2.14 Construction of truck loading platforms and roof
All the works mentioned above shall be executed strictly as per detailed, design,
specifications & good for construction drawings reviewed and approved by FEDO.
The above referred work is not conclusive. Any other items of work as provided in
the schedule of items of work and items for the successful completion of the project
shall be under the scope of the Contractor.
3. GENERAL CONDITIONS
3.1 All Tools / tackles/ materials/scaffolding /machinery/ manpower, all incidental items
not specified but implied necessary for the successful completion of the work etc
shall be arranged by the Contractor.
3.2 Tenderers are advised to visit the site and get a clear idea of the work before
quoting. The offers shall be, deemed to have been made with full knowledge of all
features of the area as well as the procedures to be followed for executing the
work.
3.3 All materials shall be subject to approval of Owner / Consultant and if any material
is rejected the same shall be removed from site by the Contractor at his own cost.
3.4 The tender purpose drawings enclosed with the tender document are preliminary to
indicate the scope of the job and are for tender purpose only which are not
complete and final and do not show the full range of the work under the scope of
the contract.
3.5 Work shall be carried out only on the basis of drawings marked “Good for
Construction” with addition, alteration, modifications, if any made to aforesaid
drawings as required from time to time and also according to other drawings that

12FT012/18
CIVIL 32644-12-DA-003 R1
would be supplied from the contractor side (after getting approval from FEDO),
from time to time.
3.6 The schedule of items of work attached indicates the quantities of various items of
work and the work shall be executed as per the detailed specification issued for
each item of work.
3.7 Tenderer should consider that the entire job has to be carried out in the operating
plant and the required safety measures shall be considered so that the work is
completed without disturbing the routine operations.
4 TIME OF COMPLETION
4.1 The time of completion for the work shall be as per work order
5 MATERIALS
All materials used for construction shall be bought by the contractor with the
approval of Engineer in-charge. The contractor shall furnish the product manual
with full specification and application methods of materials to the Engineer in-
charge and obtain his/her approval in writing before commencement of work
a. Due to time and space constraints, contractor is advised to use Ready mixed
concrete of specified grade for reinforced concrete works. ULTRATECH / ACC /
NEPTUNE are the recommended vendors for supply of ready-mix concrete to site.
In case of machine mixed concrete, the contractor should get the design mix done
through approved agencies/institutions and approval of Engineer-in-charge shall be
obtained.
b. ULTRATECH / SANKAR / COROMANDAL / MALABAR / ACC / AMBUJA / BIRLA
are approved brands of cement.
c. SAIL / RINL / TISCON / JINDAL / JSW are the only approved brands for HYSD
reinforcement bars of Fe500D grade steel
d. SAIL / RINL / TISCON / JINDAL / JSW are the only approved brands for
structural steel
e. ASIAN / BERGER / JOTUN / ICI DULUX / SHALIMAR are the approved brands
of Paint products. Thinner used for the painting work shall conform to the brand
specified by the manufacturer in the product literature.

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CIVIL 32644-12-DA-003 R1
f. FOSROC / ACC / BASF / SIKA / CERA are approved brands for Epoxy bonding
agents, Non-shrink grouts& Epoxy based chemical resistant coatings (Acid
resistant)
g. HILTI is the only approved brand for post installation rebars / bolt anchoring
using chemical or mechanical anchoring
The contractor shall provide samples of all materials mentioned in the list of makes
as required by the Engineer-in- charge. A written approval of these samples shall be
sought prior to commencement of any work. Engineer-in-charge reserve the right to
enquire the genuineness of any material used at site directly from the manufacturer /
Dealer. If the material of approved make is not available in the market, the choice
and the approval of the equivalent makes shall be made by Client.
6 GUARANTEE PERIOD
6.1 Guarantee period of the above work shall be as per work order

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DESIGN PHILOSOPHY AND BASIS FOR CIVIL& 32644-12-PS-003-DB
TECHNICAL
STRUCTURAL WORKS - CONSTRUCTION OF
PROCUREMENT
ADDITIONAL PHOSPHORIC ACID STORAGE TANKS AT PAGE 1 OF 42 R1
SPECIFICATION
Q10 BERTH, WI

TPS No. : 32644-12-PS-003
DESIGN PHILOSOPHY AND BASIS FOR

Item :
CIVIL& STRUCTURAL WORKS
Item No. : 32644-12-PS-003-DB
CONSTRUCTION OF ADDITIONAL
Project : PHOSPHORIC STORAGE TANKS AT Q10
BERTH, WI
Client : M/s. FACT-CD
Location : WILLINGDON ISLAND, KOCHI
1 Second Issue 22-06-2020 AVR NJ ASOK

0 First Issue 09-06-2020 AVR NJ ASOK
Rev. Description Date Prepared Checked Approved


DESIGN PHILOSOPHY AND BASIS FOR CIVIL& 32644-12-PS-003-DB
TECHNICAL
STRUCTURAL WORKS -CONSTRUCTION OF
PROCUREMENT
ADDITIONAL PHOSPHORIC ACID STORAGE TANKS AT PAGE 2 OF 42 R1
SPECIFICATION
Q10 BERTH, WI
CONTENTS
1. INTRODUCTION 4
2. SCOPE 4
3. SITE INFORMATION 4
4. REFERENCED STANDARDS & PUBLICATIONS 5
4. 1 Indian Standards – General 5
4. 2 Indian Standards Foundation 6
4. 3 Indian Standards RCC 6
4. 4 Indian Standards – Steel 6
4. 5 Special Publications 7
5. CATALOGUE OF STRUCTURES, MOC & STIPULATIONS 7
6. CATALOGUE OF BUILDING UNITS & ITEMWISE SPECIFICATIONS 8
7. CATALOGUE OF MATERIALS & STANDARDS 10
8. DESIGN PHILOSOPHY 12
8. 1 Site Arrangement 13
8. 2 Tank foundations 13
8. 3 Dyke wall & Yard 14
8. 4 Utility supports / Crossings 14
8. 5 Drain & pit 15
8. 6 Truck loading Bay 16
8. 7 Clearance above Structures 16
8. 8 Soil Investigation Report 17
9. UNITS OF MEASUREMENT 17
10. ORDER OF PRECEDENCE 19
11. DESIGN LOADS 19
11. 1 Dead Loads 19
11. 1. 1 Dead Load on utility/Equipment Supports 20
11. 2 Imposed loads 21
11. 2. 1 General 21
11. 2. 2 Imposed Loads for Piperacks 21
11. 2. 3 Piping/ Equipment Loads for Foundation 23
11. 2. 4 Miscellaneous Imposed Loads 23
11. 3 Wind Loads 24
11. 3. 1 Dynamic Effects of Wind 25
11. 4 Seismic Loads 26
11. 5 Erection Loads 26
11. 6 Load Combinations 27
12. ANALYSIS AND DESIGN OF RCC STRUCTURES 30
12. 1 General 30
12. 2 Design of RCC Slab 30
12. 3 Design of RCC Beam 31
12. 4 Design of RCC Column 31
12. 5 Design of RCC Foundation 31
12. 6 Minimum thickness for RCC elements 32
12. 7 Minimum clear cover to main reinforcement 33
12. 8 Design of RCC Liquid Retaining Structures 33
12. 9 Reinforcement Detailing 35

DESIGN PHILOSOPHY AND BASIS FORCIVIL& 32644-12-PS-003-DB
TECHNICAL
PROCUREMENT
ADDITIONAL PHOSPHORIC ACID STORAGE TANKS PAGE 3 OF 42 R1
SPECIFICATION
AT Q10 BERTH, WI
12. 10 Expansion Joints 35
13. ANALYSIS AND DESIGN OF STEEL STRUCTURES 35
13. 1 Minimum thickness of steel sections 36
13. 2 Deflection Control for structural steel members 36
13. 3 Connections 36
14. Design – FACTORS OF SAFETY 37
15. DELIVERABLES 38
ANNEXURE A 42


TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
1. INTRODUCTION
FACT Cochin Division proposes to construct an additional Phosphoric Acid Storage Tanks of
capacity 5900 MT and its allied components such as dyke wall, drains, pipe supports, stairs and
platforms for truck Loading with Roofing at Q10 berth in Willingdon Island.
2. SCOPE
This specification summarises the standards, design criteria and practices that shall be taken in
to account for detailed structural design, engineering, construction and commissioning of all
industrial structures, buildings and foundations for the proposed project of additional
phosphoric acid tanks at Q10 berth, WI.
The design considerations given hereunder establish the minimum basic requirements of
reinforced concrete structures, structural steel works and masonry structures. However, all
structures shall be designed for the satisfactory performance of the functions for which the same
are to be constructed.
3. SITE INFORMATION
Proposed Site for constructing additional Phosphoric Acid Storage Tanks shall be sited within
OWNERs existing Ship unloading and Material Storage facility at Q 10 berth, Willingdon Island,

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
Cochin Division (CD) located at Willingdon Island with in Kochi city limits inErnakulam district
of Kerala state. The site is connected with road and inland waterways.
Village/ Tehsil : Willingdon Island/ Kochi
Nearest Railway Station : ErnakulamJn 8 km approx.
Nearest Airport : Cochin International Airport Ltd. Nedumbassery 40 km approx.
Nearest Water bodies : Island location within the Cochin backwaters.
4. REFERENCED STANDARDS & PUBLICATIONS
The design shall be in accordance with the latest editions and revisions of established codes,
sound and economical engineering practices and shall conform to the statutory regulations
applicable in India.
The main codes, standards and statutory regulations considered as minimum requirements are
as follows. Latest revision of these shall be followed.
4. 1Indian Standards – General
IS 875 Parts (1 to 4) Design Loads (Other than earthquake) for Buildings and structures – Code

of Practice
IS 1893Parts (1 to 4) Criteria for Earthquake Resistant Design of Structures
IS 816 Code of Practice for use of Metal arc welding for General Construction in
mild steel
IS:4326 Code of Practice for earthquake resistant design & construction of buildings
IS:1172 Code of basic requirements for water supply, drainage & sanitation IS:1742
Code of practice for building drainage
IS:1905 Code of practice for structural use of unreinforced masonry
IS:2212 Code of practice for brick work

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
IS:2065 Code of practice for water supply in buildings
IS: 8835 Guidelines for design of surface drains

4. 2Indian Standards Foundation
IS 1904 Code of practice for design and construction of foundations in soils : general
requirements
IS 2911 (Part 1 to Part Code of Practice for Design and Construction of Pile Foundation
4)

IS 2950 (Part 1) Code of Practice for design and construction of Raft foundation
IS 2974 (Part 1 to Code of Practice for design and construction of Machine Foundations
Part 5)
IS 6403 Code of practice for determination of bearing capacity of shallow foundations

IS 8009 (Part 1) Code of practice for calculation of settlements of foundations: shallow
foundations subjected to symmetrical static vertical loads
4. 3Indian Standards RCC
IS 456 Plain and reinforced concrete – Code of Practice
IS 1786 Specification for High strength deformed steel bars and wires for concrete
reinforcements
IS:13920 Code of Practice for ductile detailing of reinforced concrete structures
subjected to seismic forces
IS:3370 Code of Practice for Concrete Structures for storage of liquids
4. 4Indian Standards – Steel
IS 800 General Construction in Steel Code of Practice
IS 801 Code of Practice for use of light gauged steel structures
IS 2633 Methods for testing uniformity of coating of zinc coated articles
IS 2062 Hot rolled medium and high tensile structural steel — Specifications
IS 2629 Recommended practice for hot dipped galvanizing on iron and steel
IS 4923 Hollow sections for structural use
IS 1161 Code of Practice for Circular hollow sections/pipes

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
4. 5Special Publications
SP 6 Parts (1 – 7) Handbook for Structural Engineers
SP 7 National Building Code of India: 2005
SP 38 Handbook of Typified Designs for Structures with Steel Roof Trusses
SP 34 Handbook on Concrete Reinforcement and Detailing
SP 16 Design Aids for Reinforced Concrete to IS: 456
SP 24 Explanatory Handbook on Indian Standard Code of Practice for Plain and
Reinforced
SP 20 Explanatory Handbook on Masonry Design and Construction
4. 6
Note: The above list is suggestive and not exhaustive. Apart from these basic codes any other

related codes shall also be followed wherever required.
5. CATALOGUE OF STRUCTURES, MOC & STIPULATIONS
Following are the tentative list of buildings and structures envisaged for the proposed project.
Sl. Building / Structure MOC Requirement
Tank foundations RCC Pile foundation, Sizing as per

1
Loading
Storm water Drain RCC drains on sides of Dyke Minimum depth – 300mm
2
wall in slope 1: 600 Minimum width – 300mm
Cable trench / Utility RCC Sizing as per electrical
3
trench requirement
Road crossing culverts RCC culverts with precast cover Minimum width 600mm,
4
for drains slab Maximum width 1200mm

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
Utility Crossings below RCC Hume pipe / HDPE Sizing as per utility requirement

5
ground: encased in concrete

Utility Crossings above Structural steel pipe racks on Sizing as per utility requirement
6
ground: RCC foundations

Platforms, Structural Steel with FRP Sizing as per utility requirement
Ladders,
7
Crossovers, Stair gratings founded on RCC
pedestals and foundation
Pipe supports / Overhead Structural Steel with RCC Sizing as per utility requirement
8
cable tray supports footings
Pipe sleepers on ground RCC Sizing as per utility requirement
9
Yard inside dyke RCC Sizing as per volume to be
10
encased
Equipment foundations RCC Sizing as per Loading
11
Dyke wall RCC Sizing as per volume to be
12
encased
Truck Loading bay Structural Steel roof with RCC Sizing as per utility requirement
13
footings. Platforms shall be RCC
Reclamation Pit RCC Sizing as per volume to be
14
encased

Note: This list is not conclusive and any additional building or structure if required as per the
requirement of the contractor/vendor for the successful installation of Acid Storage tank and
pumping of Phosphoric acid shall be included with this list and shall be binding to the entire
project.
6. CATALOGUE OF BUILDING UNITS & ITEMWISE SPECIFICATIONS
Following are the minimum requirements for the building components / elements. For
components not mentioned here within, the requirement shall be as per CPWD specifications /
best engineering practices for the durability of the structure.
Sl. Building Component Requirement

Equipment / Tank M30 grade RCC with cement content not less than 330kg/cum
1


TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
foundations
RCC piles / pile cap M35 grade RCC with cement content not less than 400kg/cum
2
Underground sump tanks M30 grade RCC with cement content not less than 350kg/cum
3
with waterproofing compound mixed with concrete. Additional
water proofing on concrete surface – surface coating / membrane
application shall be done to make underground structures water
tight.
Masonry work below Minimum 230 thick solid cement block (200 thick brick) or First
4
ground class bricks plastered on both sides
Masonry work in super Minimum 100 thick half brick partition walls. 230 thick walls for
5
structure exterior. 100/150/200thick walls are permitted for interior walls as
required. Use of Solid Cement Concrete blocks / Clay bricks are
permitted
Plastering 15mm thick plaster in CM 1:4 over rough / exterior face of
6
masonry
12mm thick plaster in CM 1:4 over fair / interior face of masonry
6mm thick plaster in CM 1:3 over / under RCC elements
Concrete Columns / M30 grade RCC with cement content not less than 330kg/cum
7
beams / slabs/ Lintels /
Sunshades
Lean concrete Cement concrete mix 1:3:6 with an average thickness of 75mm
8
under foundations / grade beams etc.
Cement concrete mix 1:5:10 for site grading / site levelling
Handrails In plant buildings / External: MS or FRP
9
Inside building: Stainless steel SS304 grade, brushed finish
Antitermite treatment Preconstruction antitermite treatment of soil with chemical
10
agents
Fire proofing
11 Fire proofing to steel structures wherever required as per Tariff
Advisory Committee (TAC) rules and regulations and other Codes
/ requirements asapplicable.
Painting
12 Masonry / RCC work (dry Area) exposed to corrosive environment
to be painted with Corrosion resistant epoxy paint.
Steel structures in corrosive environment shall be painted as
follows:
Surface shall be prepared by shot blasting to near white metal
grade SA 2.5 as per IS 9954. Two coats of red oxide zinc
chromate primer (one shop coat and one coat after fixing
/erection) shall be applied. One intermediate coat of Micaceous
Iron Oxide epoxy paint of 70micron DFT. One coat of two pack
polyamide cured epoxy finish paint of 40microns DFT and one
coat of aliphatic acrylic polyurethane finish paint of 40microns
DFT.
Any parts of structure which are prone to aggressive alkali / acid

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
substances shall be protected by suitable protective membranes or
methods (including cathodic protection, if required)
Other RCC / Masonry structures to be painted with two coats of
acrylic / plastic emulsions over one coat of cement primer
Wood work shall be painted with two coats of enamel paint over
two coats of wood primer.
Precast Cover slabs RCC M25
13
Grouting NonShrink cement Grout with minimum strength of 40 N/mm²
14
at 28 days, 25mm thick or as specified by equipment
manufacturer for Structural bases of Columns and static
equipment
NonShrink cement Grout with minimum strength of 40 N/mm²
at 28 days, 50mmthick or as per vendor’srequirements for
Dynamic Equipment, Reactors / Process Columns
Roofing / Cladding NonAsbestos cement sheets / High impact resistant Polypropylene
14
roofing sheets shall be used for roofing/ cladding
Epoxy Coating high build epoxy based chemical resistant coating for outer
15
surface of tank foundation (CERACOTE EP CR of CeraChem or
equivalent) with a minimum dry film thickness of 500 microns

7. CATALOGUE OF MATERIALS & STANDARDS
Specifications of materials used for construction are as follows:
Specification
Sl. Material
Cement OPC 53 grade conforming to IS 12269 or PPC conforming to
1
IS 1489 – Part 1
Reinforcement steel HYSD bars of grade Fe500 with 14% elongation conforming
2
to IS 1786. Binding wires shall conform to IS 280
Aggregates Conforming to IS 383
3
Water Conforming to IS 456
4
Admixtures in Conforming to IS 9103
5
concrete
Structural steel Conforming to IS 2062 (Fe250 Grade A)
6
Minimum thickness of plates 5mm
Structural hollow Conforming to IS 4923 / IS 1161 with YST310 grade. Tubes
7
sections / tubes used shall be medium class.Structural pipes shall be either
seamless or mild welded. Spiral welded pipe is not acceptable.

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
Stainless steel SS 304 Grade
8
Bitumen Bitumen grade VG – 10 conforming to IS 73
9
Nonshrink grouts
10 conforming to ASTM C 1107
Paints Plastic emulsion paint Type 1 for interior use and Type 2 for
11
exterior use conforming to IS 15489
Curing compounds ASTM C30919
12
MS anchor bolts, Conforming to IS 432
13
Rungs, metal inserts,
grating
Hexagonal head bolts, Conforming to IS:1363
14
screws and nuts of
product Grade C.
Plain washers Conforming to IS:2016
15
Steel Chequered Conforming to IS:3502
16
plates
Hexagonal Bolts and Conforming to IS:3138
17
nuts (M42 to M150)
NonAsbestos Nonasbestos high impact Polypropylene reinforced cement 6 mm
18
Polypropylene sheets thick corrugated sheets conforming to IS: 14871
Note: The materials list is not conclusive and for the materials required and not mentioned in
the list shall conform to relevant IS codes / ISO / ASTM / Engineering standards as per nature of
use of the material.


TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
8. DESIGN PHILOSOPHY
Preparation of detailed design and drawings, sketches, specifications for all civil & structural
works, shall be in the scope of contractor’s work. List of various facilities given are only
indicative. Therefore, sizing, nos., location etc. of various facilities viz. Tank foundations, Dyke
floor and wall sections, Utility supports, drains, etc. shall be in the scope of the bidder, with
approval and satisfaction of FACT CD/FEDO.
All the facilities shall conform to all Local Rules and Regulations, Factory Inspector Rules, TAC
rules, etc. whichever is more stringent.
The vendor shall carryout Analysis and Design of the structures required for this document and
prepare all the required Civil and Structural drawings needed for correct and accurate
construction as per the Design Specifications given in this document.
It shall be the responsibility of the vendor to accommodate all the functional requirements such
as access, cut outs, clearances, interference etc. while designing / detailing of various structures
/facilities. Complete analysis, design and all drawings of each independent structure / facility
shall be submitted in one lot so as to facilitate overall systematic review by FEDO.
Preparatory and site clearing jobs (as enlisted in Drawing No 3264403OP00001) will be
executed by FACT CD, in a span of time organized in such a way that jobs for construction of
PA tanks will be executed unhindered.
The philosophy for the design of individual structures is as follows:

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
8. 1Site Arrangement
The site arrangement shall conform to applicable laws, regulations, Layout drawings issued from
Piping dept. and environmental standards. Utility interconnections will be optimized as much as
practical. Spill containment measures shall be provided.
The following criteria shall be followed regarding site arrangement:
 Tank yard and dyke shall be designed to contain spills
 Storm water drains along the Dyke wall shall be constructed to take out rain water
accumulated in the Dyke floor to the nearest drain with control arrangement as per the
scheme indicated in the Drg3264403OP0001
 Locations and requirements for piping supports shall conform to piping requirements
8. 2Tank foundations
Proposed phosphoric acid tank foundation shall be RCC pile group with a system of grillage and
drain above the pilecap ( below the tank base plate), designed for the worst case ofloads and
their combinations. The clear Spacing between each grillage beam running below tank plate shall
be kept to a max of 300mm, so that the thickness required for bending action of base plate is
optmised.
Piles of sufficient depth and number shall be accommodated to resist base shear from seismic
action or wind, whichever is critical.
Portions of pile cap exposed to yard area, or area where chances of acid leak or spill is there,
shall be protected with acid proof lining, wherever possible.


TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
8. 3Dyke wall & Yard
Dyke wall shall be of RCC. The dyke wall shall be designed as liquid retaining structure in the
inside face.
Suitable drainage arrangements shall be provided within curbed areas around pumps, for
drainage leaks.
Finish of 50 thick concrete screed, with nonmetallic (Quartz based) hardener topping shall be
provided on paving after erection and commissioning of tank is over.
Paving within Tank farm& Utility areas for maintenance compatible to crane 200 mm thick, M30

movements / dropout / Loading / Unloading areas / Vehicular movement areas grade RCC
Nonvehicular movement areas 150 mm thick M20

grade RCC
Under Pipe rack & foot paths 100mm thick PCC
1:3:6
Expansion joints & Contraction joints shall be as per relevant IS codes and standards.
8. 4Utility supports / Crossings
For all utility supports 500mmabove Paved level, RCC sleeper supports resting on RCC isolated
foundations shall be provided with spacing of 3m c/c for the pipes. For all Supports at 3.5m or
7m or at any specified elevation above paved/Ground level, Structural steel supports shall be
raised from RCC pedestals supported on RCC foundation slab, at a spacing of 6 to 18 m c/c
depending on the crossings and obstructions enroute.

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
8. 5 Drain & pit
The proper surface drainage of rain water from all parts of the scope area shall be envisaged.
All drain work shall be in RCC. The drainage system shall be bygravity.
Rain water falling on such portion of paved areas of layout where it is not likely to get
contaminated in regular usage other than a tank burst, shall be collected in open rectangular
RCC drains provided in floor paving. These drains shall be covered by FRP gratings and shall be
generally connected to peripheral storm water drains as per the scheme indicated in the layout
drawing No 3264403OP00001.
Proposed Project mainly include following different types of drain system:
 Drain below tank surface towards cleanouts (Coating as indicated in tender drawing)
 Drain around Tank for accommodating acid leaks, if any (Acid proof lined)
 Drain from tank to Reclamation pit / Drain pit (Acid proof lined)
 Drain inside dyke for routing for storm water
Grillage beams shall be provided with a minimum height of 900mm and with maximum clear
spacing of 300mm below tank base plate for facilitating leakages from the tank bottom, if any.
The top of pile cap shall be constructed to be sloping towards the outer corners from the center
so that spillage flows towards the surrounding drain.
Cleanouts to be kept diametrically opposite corners at minimum 2 locations or as per the
Mechanical requirement for the tank cleaning..
These cleanout drainshall be connected to circular drains provided around tank (above pile cap).
Spills/ Leaks in thesedrains shall be further routed towards the drain pit.

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Runoff from possible chemical contamination areas, such as the acid storage and handling areas,
will be contained. Small neutralization pits may be provided near drain around tank to treat
floor wash in yard areas as per process requirement. Water from these pits will further be
routed to storm water drains.
8. 6Truck loading Bay
Truck loading bay with RCC platform for mounting the loading arm shall be provided for acid
loading to the trucks. The proposed location of truck loading has been indicated in drawing No
3264403Op0001. The roof shall be with Non Asbestos fibre reinforced corrugated sheets over
steel roof truss. The minimum clear height for the loading platform for Phosphoric acid loading
shall be 4500 mm from the pavement.
An additional bay at +4.0m lvl shall be provided with platform at same level as existing platform
as in Sulphuric acid an additional requirement as indicated in the Tender drawing no 3264412
DG00010
8. 7Clearance above Structures
Minimum overhead clearances shall be as follows:
Above platforms and walkways 2100 mm
Clearance below Truck Loading Platform 4500 mm
Vertical head room for stairs 2400 mm
Safety gauge for ladders 2400 mm
Access for forklift trucks 2800 mm
Above main roads, crane access and Conveyor crossings 7000 mm

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Above other plant roads and truck access 4200 mm
The guidelines of NBC 2005 shall be followed for all offsite buildings.
8. 8Soil Investigation Report
The recommendations from the investigation conducted in the nearby area is summarised as
follows:
The land is previously dredged fill area near the Product Handling Berth(Q10) in Cochin Port
area at Willington Island. The soil profile for a considerable depth is marine clay with shallow
pockets of decayed wood at random depths. Hence it is advised to found heavy loaded
structures at denser strata available at deeper depth. Water table was met at 0.50m to 1.0 m
depth below ground level in the bore holes at the time of investigation during April 2014.
For heavily loaded structures pile foundation of sufficient depth and number shall be
accommodated to resist vertical and uplift load including base shear from seismic / wind,
whichever is critical.
Piles shall be bored cast in situ DMC type with depth ranging from 60 to 65m resting the pile
in the very dense silty sand layer with minimum 2 times the diameter penetration in the layer.
Safe load carrying capacity of bored cast in situ piles of depth 65m below cut off level, arrived
from the soil investigation conducted nearby area for design are as follows:
Pile diameter (mm) Vertical capacity (kN) Shear capacity (kN) Uplift capacity (kN)
750 2350 105 500
900 3400 135 680

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1000 4250 155 850
Portions of pile cap exposed to yard area, or area where chances of acid leak or spill are
expected, shall be protected with acid proof lining.
For lightly loaded structures safe bearing capacity of soil for different size of shallow footings
shall be considered as follows:
Type of Size of Depth of footing below the Safe Load carrying

foundation footing E.G.L (m) capacity (kN/m2)
(m x m)
Isolated 2 x 2 2 50
Isolated 3 x 3 2 40
Isolated 2 x 2 4 55
For structures with light loading aforementioned Safe bearing pressures can be adopted with
due consideration to settlement criteria.
The soil Investigation report conducted in the nearby area is enclosed as AnnexureA for
information.
9. UNITS OF MEASUREMENT
Units of measurement shall be in SI system and shall be as follows:
Entity Unit of measurement
Elevations millimeter (mm)
Dimensions millimeter (mm)
Force kilo Newton (kN)

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Mass kilogram (kg)
Moment kilo Newton meter (kNm)
Stress Newton/square millimeter (N/mm2)
Pressure kilo Newton/ square meter (KN/m2)
10. ORDER OF PRECEDENCE
In case of any conflict / deviations amongst various documents, the order of precedence shall be
as follows:
 Statutoryregulations
 Job specifications
 Engineering designbasis
 Standard specification
11. DESIGN LOADS
11. 1Dead Loads
Dead load is the vertical load due to actual weight of all permanent structural and non
structural components of building such as floors, roofs, walls, staircases, fixtures etc. Dead loads
shall be estimated for purposes of design using the actual weights of material of construction
and finishes on the basis of unit weights given in IS 875 Part 1.
The following unit weightsshall be considered for computation of dead loads:
Material Unit weight (kN/m3)
Plain concrete 24.00
Reinforced concrete 25.00
Structural Steel 78.50
Soil 18.00

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Saturated soil 20.00
Water 10.00
Solid Brick masonry 20.00

11. 1. 1 Dead Load on utility/Equipment Supports
The following dead loads shall be included in the design of support structures:
 Weights of fixed process equipment and machinery, piping, valves, electrical cable trays,
and the contents of these items
 Fireproofing on structural steel, vessel skirts and equipment.including all internals,
refractory linings and hydrotest.
 Insulation installed on piping and equipment
 Steel platform framing and floor plate.
 Weight of platforms, piping and ladders on towers shall be as specified onthe vessel
drawings.
any other permanent load if applicable.
Following super imposed loads shall also be considered (if not stated otherwise) along with dead
loads as applicable:
Item Loading
Cable tray single tier 1.00kN/m2
Cable tray two tier 1.90kN/m2
Piping load (for pipes less than 300mm dia) 1.90 kN/m2
FRP gratings 0.50 kN/m2

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11. 2
11. 3Imposed loads
11. 3. 1 General
Imposed loads are the greatest loads assumed to be produced by the intended use of the
structure. For the design of each structural element the imposed loads shall be applied in the
least favourable pattern. Imposed loads on floors shall be the actual loads when these are known,
but shall not be less than the distributed loads given below:
Pump and compressor houses 7.5 kN/m2
Warehouses and open storage areas 7.50 kN/m2
Sheeted roofs with access for maintenance only 0.75 kN/m2
Main Access Platforms and Floors 5.0 kN/m2
Platforms subject to storage of heavy equipment 7.0 kN/m2
Walkways and Minor Platforms used for access to equipment only 2.5 kN/m2
Piping load (for pipes less than 300mm dia) 0.75kN/m2
Crane beams and supports for travelling cranes shall be designed in accordance with IS 800/ IS
807/ IS 3177.
11. 3. 2 Imposed Loads for Piperacks
Pipe racks shall be designed for live load only if permanent accesses (walkways) are provided. If
the width/height of pipe rack is equal or more than 7 m, provide a walkway of min width 0.8m.
In such cases, loadings shall be given as follows:
 Loading for maintenance bay: Min. 1.0 kN/Sqm
 Loading for Equipment bay : Min. 2.5 kN/Sqm

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When individual pipe loads are not available for racks with pipes exceeding 300 mm diameter,
but not exceeding 400 mm diameter, the piping shall be considered as a distributed load of not
less than 1.2 kN/m2 for the operating condition and 2.5 kN/m2 for the test conditions.
Note that piping loads for the operating condition are considered as live loads since they do not
represent the “pipe full” condition.Test loads (“pipe full”) may be applied with a reduced load
factor equivalent to a dead load.Test loads should not be applied to more than one tier
simultaneously.
The location and magnitude of anchor forces for all pipes over 400mm diameter shall be
established before the design is started.
Point loads from pipe supports on piperacks shall be the actual loads when they are known. In
the absence of known point loads from pipe supports each piperack member (excluding bracing)
shall be checked for a single point load of 4.5 kN in the least favourable position in addition to
the distributed loads specified above.
A longitudinal thermal force of 10 per cent of the operating load per tier shall be assumed to act
uniformly distributed at each bent. The piperack shall be checked when the actual pipe stress
anchor forces are known.
Transverse anchor or guide forces equivalent to 0.75 kN per metre of rack width per tier shall
be assumed to act on each bent, applied as a single force at each tier level. The piperack shall be
checked when the actual pipe stress anchor forces are known.
When considering the erection load combination, piping shall be considered as a distributed load
not greater than 0.5 kN/m2 irrespective of pipe diameter.The piperack structure self weightshall

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be considered as a distributed load of 0.5 kN/m2 per tier unless the pipe rack is fireproofed
prior to erection, when the actual weight of fireproofing shall be included.
11. 3. 3 Piping/ Equipment Loads for Foundation
Consideration shall be given to loads on the foundation from pipework where the configuration,
operating loads and operating temperatures may give rise to significant horizontal forces due to
friction at supports.Pipe anchor forces and thermal forces on equipment and vessels shall be
included under normal operation and test conditions, whichever gives the most severe effects.
The contents of equipment shall be considered as live load and shall be applied in the least
favourable pattern. Ensure the correct specific gravity is applied when calculating the
load.Exchanger and horizontal vessel foundations shall be designed for thermal forces due to
vessel expansion.
The following coefficients of static friction shall be used to determine forces at sliding surfaces:
a) Teflon on Teflon 0.10
b) Steel on steel 0.30
c) Steel on concrete 0.45
11. 3. 4 Miscellaneous Imposed Loads
Consideration shall be given to loads of a special nature such as piping counterweights, spring
hangers, thrusts from expansion joints, expansion loads from horizontal vessels and exchangers,
purpose made handling equipment such as counterbalanced crane hooks, and thermal expansion
of the structure.

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In the absence of any suitable provision for live loads in this specification or relevant IS codes
for any particular type of floor or structure, the assumed loading shall be got approved. Apart
from the specified live loads, any other equipment load or possible overloading during
maintenance/ erection shall also be considered in the design.
11. 4Wind Loads
Design wind loading shall be in accordance with IS 875: Part 3 “Code of practice for design
loads for buildings and structuresWind loads” and as per clause given below. Basic wind speed
shall be 39 m/sec for a 50year return period for structural and equipment design.
Wind load design should be done as per IS: 875 (Part 3) 2015
Design wind pressure,
Pd = Kd x Ka x Kc x pz N/m2 Ref Clause 7.2 of IS: 875 Part3
Where wind pressure pz = 0.6Vz2
Design wind speed, Vz = Vb x k1 x k2 x k3 x k4 Ref IS: 875 Clause 6.3
Basic wind speed, Vb = 39 m/s
Probability factor, k1 = 1.0 Risk coefficient
Terrain height and k2 Ref. Table 2 of IS: 875 Part3, based structure size factor on terrain
category 2
Topography factor k3 = 1.0
Cyclonic factor k4 = 1.0
The values of Pd, however shall not be taken as less than 0.70 Pz

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The effective exposed area of open framed structures which support piping and equipment shall
be estimated as a percentage of the gross projected area.Vessels or other large equipment
supported on a structure shall be calculated separately and be additive in computing the total
wind load.
Transverse forces due to wind acting on pipes in racks shall be calculated in accordance with IS
875. The effect of wind on all pipes shall be considered, but the shielding effect shall be taken
into account. Wind forces on longitudinal beams shall also be included, but shielding effect shall
be neglected.
11. 4. 1 Dynamic Effects of Wind
Structures such as, but not limited to, heater stacks, chimneys and tall towers, may be sensitive
to wind gust effects and/or vibrations due to vortex shedding. In general, the following
guidelines may be used for examining the problems of wind induced oscillations:
Building and closed structures with a height to minimum lateral dimension ratio of more than
about 5.0,
Or
Buildings and structures whose natural frequency in the first mode is less than 1.0 Hz.
Any building or structure which satisfies either of the above two criteria shall be examined for
dynamic effects of wind.
If vortex shedding analysis results indicate that unacceptable levels of vibrations can occur, then
helical strakes, dynamic vibration absorbers or other means shall be adopted provided prior
approval is obtained from Owner.All calculations for gust or vibration analysis on purchased
equipment shall be submitted for review prior to release for fabrication.

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11. 5Seismic Loads
The plant structures must be designed for design basis earthquake (DBE) as per clause no. 7.0
and the design spectra given in IS: 1893 (PartIV), Annex B for Type2 medium soil.
The design value of horizontal seismic coefficient Ah shall be computed by the following
expression:
Ah = (Z/2) . (I/R) . (Sa/g)
Seismic load on the structures shall be calculated as per IS 1893 by taking Zone factor Z
corresponding to Zone III.
Response reduction factor “R” shall be taken as per Table 4
Importance factor I should be considered as per Table3, IS1893, Part4 based on the category
of structure defined in Table6 of IS1893: pt4). Equipment support structures/ pipe racks/ /
storage tanks Category2, so Importance factor I = 1.5
Sa/g is the average Response acceleration coefficient to be taken from Annex B corresponding to
the natural period of the structure. Damping (for DBE) 5% (for concrete) 2% (for steel).
Ductile detailing of reinforcement is mandatory for moment resisting RCC frames and hence
response reduction factors corresponding to special momentresisting frame shall be considered.
11. 6Erection Loads
All loads to be carried by the structure or any part of it due to storage or positioning of
construction material and erection of equipment including all loads due to operation of such
equipment shall be considered as erection load. Proper provision shall be made including
temporary bracings to take care of stresses due to erection loads. The structure as a whole and

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all part of the structure in conjunction with temporary bracings shall be capable of sustaining
this erection load without exceeding the permissible stresses subject to the allowable increase of
stresses. Dead loads, wind loads and all such parts of live load as would be imposed on the
structure during the period of erection shall be taken as acting together with the erection load.
11. 7Load Combinations
All buildings, structures, equipment, and foundations shall be investigated for each of the loading
combinations given in Table below and the most severe shall determine the final design.
LOADING LOADING COMBINATIONS
Normal Abnormal Empty or
DEAD Erection Test Operation Operation Shutdown
Structures Include (7) Include Include Include Include
Equipment Include (7) Include Include Include Include
Internals Include (6) Include (3) Include Include Include
Internals
linings Include (6) Include Include Include Include
Piping Include Include Include Include Include
Floors/
Platforms Include Include Include Include Include

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Insulation Include Include Include Include Include
Fireproofing Include (6) Include Include Include Include
Vessel
Platforming Include Include Include Include Include
IMPOSED
Floors/
platforms Modified (4) Include (9) Include Include
Normal Fluids Include Maximum(1)
Test Fluids Include (5)
Vessel
Platforming Modified (4) Include Include Include
Surge (normal
contents) Include Include
Thermal
(piping) Include Include
Wind or Greater of Modified Greater of Modified Greater of
Earthquake two wind (2) two wind (2) two

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Construction
Equipment IInclude (8) Include (8) Include (8)
Notes below refer to numbers in brackets shown in Table :
(1) Load shall be computed due to faulty unit operation from items such as catalyst or liquid
backup.
(2) Wind loading shall be based on a wind speed of 0.77 times the design wind speed, but not
greater than 39 m/sec.
(3) Loads shall be included only if in place during the future test condition.
(4) Include only 50% of the platform live load for the test condition.
(5) Load for vertical vessels includes only the test fluid as permitted by the vessel design for the
hydrostatic field test.
(6) Include only if installed in shop or before lift.
(7) The erection load shall be calculated in conjunction with the clause of this Specification.
(8) The construction equipment load shall only be included if it is greater than the operating
load or increases the overturning moment.
(9) Live load reduction may be considered as defined in this Specification.
Following Load factors in limit state of strength shall be applied for the design:
Load cases Dead Live Wind / Erection / Construction

Seismic
Erection 1.2 1.2 1.5
1.2 1.2 0.6 1.2


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0.9 1.5 1.0

Test 1.2 0.5 1.2
Operation 1.5 1.5
1.5 1.5
1.2 1.2 1.2
0.9 1.5

12. ANALYSIS AND DESIGN OF RCC STRUCTURES
12. 1General
Main RCC structures under this scope comprises of Tank Foundation, drains, truck loading bay,
dyke wall, drain pits etc. Frame analysis shall be carried out for all structures for all load
combinations using structural analysis and design software STAAD Pro.Limit state design shall
be adopted for design of all structural elements.However, water retaining structures may be
designed using working stress method.
While considering earthquake effects, EL shall be substituted in place of WL and appropriate
portion of IL shall be considered as stipulated by IS 1893. Ductile detailing of RCC frames shall
be done as stipulated in IS 13920 for RCC structures in Zone 3.
12. 2Design of RCC Slab
Twoway slabs shall be designed based on the Bending moment coefficients given in annexure D
of IS 456. For continuous oneway slabs moment coefficients given in Table 12 of IS 456 shall be
used. Deflection check of the slabs as envisaged in IS 456 shall also be done.

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12. 3Design of RCC Beam
Beam reinforcement steel shall be provided for the required moment of resistance obtained from
the analysis of frames. Shear stirrups shall be provided to withstand balance shear after
deducting the shear capacity of concrete section based on the percentage steel provided to resist
Bending Moment. Spacing of stirrups shall be detailed in accordance with IS 13920.
12. 4Design of RCC Column
Columns shall be designed for the combined effect of axial loads and biaxial moments due to
frame action obtained from the analysis for the worst load combination and the detailed design
output specifying the percentage steel to be provided and the interaction ratios shall be
furnished.
12. 5Design of RCC Foundation
All foundations shall be designed to suit the existing soil conditions. Where available, drawings
showing existing buildings, foundations, underground services and any other information
pertinent to the design and construction of foundations shall be used to assist in establishing the
foundation design criteria. Information obtained from such drawings shall be verified on site
preferably before finalising the new designs.
The sizing of foundations & design shall be done as per recommendations given in the soil
investigation report. The bearing capacity / safe pile capacity shall satisfy strength as well as
settlement criteria. The permissible increase in bearing capacity/ pile capacity in wind and
seismic load combinations shall be as per IS 875 part5 and IS 1893 respectively. Foundation
design for major structures shall be verified by a Geo Technical expert. While designing
foundations at various levels, effect of uplift/ subsoil water table shall also be considered.

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All underground pits, sumps, etc. shall be designed to take care of the uplift forces due to
buoyancy, if required.If the sub soil is of aggressive nature, suitable precautions are to be taken
as recommended in the soil investigation report in respect of type of cement, concrete cover etc.
for foundations / underground structures.
PCC 1:3:6 is proposed for levelling course for all RCC structures. The thickness of levelling
course shall be 80mm and when used as a structural element, the minimum thickness shall be
150mm.
12. 6Minimum thickness for RCC elements
Footings (All types, with or without beams) 300 MM
(Note : Tapered footings shall not have thickness less than 150mm at the
edges, minimum average thickness shall not be less than 300 mm)
PileCap 500 MM
Basement
a) walls 150 MM
b) Base Slab with beams 200MM
c) Base Slab without beams 300 MM
Slab thickness in raft foundations with beam & slab construction 150 MM
Floor/Roof Slab, Walkway and CanopySlab 150 MM
Cable/ Pipe Trench / Launder Walls & baseSlab 125 MM
Parapet 100 MM
Louvre /Fin. 100 MM
Precast Trench Cover / Precast FloorSlab 125 MM
Louvre (in contact withliquid) 125 MM
Liquid Retaining / Leak proofStructure
a) Walls 150 MM
b) Base Slab with beams 200 MM
c) Base Slab without beams 300 MM
UndergroundPit
a) Walls 150 MM


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b) Base slab with beams 200 MM

c) Base slab without beams 300 MM
Pedestals
a) Pedestal / encasements of structural columns in open area 300 MM
b) Pedestal / encasements of structural columns in yard area 150 MM
c) Pedestal / encasements of equipment in open area 300 MM
d) Pedestal / encasements of equipment in yard area 150 MM
For all other Sleeper supports, corresponding thickness mentioned in drawing shall be used

12. 7Minimum clear cover to main reinforcement
As otherwise stated, minimum thickness to main reinforcement for RCC members shall be as
follows:
STRUCTURAL MEMBER CLEAR COVER
Floor / Roof / stair waist 20 mm
Grade Slab 40mm
Roof beams / Floor beams / Lintels 30mm
Columns and pedestals 50mm
Basement walls, retaining walls & pit walls 40 mm
Water /liquid retaining structure 40mm
Foundation slab /plinth beams 75 mm
Pile 60mm (Sides), 150mm (Bottom)
Pile cap 100 mm (Bottom), 75 mm (Sides)

12. 8Design of RCC Liquid Retaining Structures
1. Design shall conform to IS 3370 Part I to IV. All elements of water retaining structures or
similar structures in contact with water shall be designed as uncracked section.
2. M30 grade concrete shall be used.

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3. For tanks resting on grounds cement concrete 1:3:6 mix levelling course shall be provided.
4. The provisions regarding expansion joints, contraction joints, construction joints, bitumen
sliding layer above levelling course, etc. shall be provided as recommended in the standards.
5. Hydro swelling gasket kept in place by a single component hydro swelling polyurethane
sealant for sealing or other approved treatment shall be provided at construction joints in
concrete both at vertical and horizontal construction joints of water retaining structures to
make it leak proof.
6. For underground storage tanks, pits, trenches etc. where protection against uplift due to
buoyancy from subsoil water is to be considered, a min. factor of safety of 1.2 shall be
ensured. For purpose of calculating downward load due to overburden, only the mass
located vertically over the projected area of the base shall be taken into account.
7. All liquid retaining/ storage structures shall be designed assuming liquid up to the full
height of wall irrespective of provision of any overflow arrangement.
8. The walls and base slab of liquid retaining/ storage structure shall be provided with
reinforcement on both faces irrespective of any thickness.
9. All embedded parts such as nozzles, pipes, bolts, etc. shall be provided at the time of
concreting.
10. Plastering with cement mortar 1:4, 10 mm thick, mixed with integral waterproofing
compound like Conplast X4211C of M/s. FOSROC or equivalent shall be provided for inside
surface after hydro test.
11. All leaks or wetting noticed during hydro tests shall be rectified as per approved methods,
using approved materials.

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12. 9Reinforcement Detailing
1. All requirements governing quantum of reinforcement and detailing of reinforcement as
per clause 26 of IS 456 and as detailed in SP 34 for detailing of reinforcement shall be adhered
to while preparing the construction drawings.
2. The recommendations for detailing for earthquake resistant construction given in IS 13920
shall also be followed.
12. 10Expansion Joints
1. Expansion joints in concrete structures shall be provided as per IS 456/ IS 3414 Code
provisions.
2. Bitumen impregnated fibre boards of approved manufacture as per IS 1838 Part 1 shall be
used as fillers for expansion joints.
3. The gap between the expansion joints shall be thoroughly cleaned and the bitumen fibre
boards placed in position as per manufacturer’s specification and the surface shall be sealed
with elastomeric silicone rubber sealants.
4. All expansion/ separation joints in ground floor slabs shall be filled with sand for the full
depth of the slab except top 25 mm, which shall be filled with approved mastic sealing
compound.
13. ANALYSIS AND DESIGN OF STEEL STRUCTURES
Basic consideration of structural framework shall primarily have strength to withstand the
various loads mentioned above. Ease of fabrication, erection and overall economy satisfying IS
stipulations shall also be a criterion for design. Design shall be done in accordance with IS
800.The deflection limits specified in IS 800 shall also be complied with.

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13. 1Minimum thickness of steel sections
Trusses, Purlins, side girts & bracings 6mm
Columns & beams 7mm
For gussets, stiffeners, plate guides, etc. 8mm
For base plates 10mm
Chequered plates 6mm
Grating 5mm
The minimum thickness of tubes shall be as specified in IS 1161 for medium class tubes. The
minimum thickness for rolled beams and channels shall be mean flange thickness regardless of
web thickness. The slenderness limits of sections shall conform to IS 800.
13. 2Deflection Control for structural steel members
The permissible vertical and lateral deflection for structural steel members shall be as specified
in IS 800:2007.The lateral deflection of Conveyor supporting Trestles shall be as per IS11592.
Permissible deflections of members shall be as follows:
Type of deflection Loading Maximum Deflection

Member
Vertical DL+WL Span /180
Purlin
Lateral DL+WL Span/180
Purlin
Vertical DL+WL Span/120
Truss
Vertical DL+IL+CL Span/500
Monorail
Lateral DL+WL Height/150
Column
13. 3Connections
As far as possible, all the shop connections shall be welded and site connections shall be bolted.
Minimum thickness of any structural weld shall be 6mm. Field connections shall be made with
black bolts for ladders, hand rails posts, stair stringers, removable members and floor plates,
platform forming members 200mm and under in size, purlins, girts and minor pipe support


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members that require not more than three bolts per connection. The minimum size of bolts
shall be 16mm unless limited by the size of the connected parts. Any connection shall have at
least two bolts.
Expansion joints in steel structures shall be provided as per the guidelines in IS 800.
Roofing over steel trusses shall be with nonAsbestos fibre reinforced cement corrugated sheet
(as per IS: 14871) roofing 6 mm thick up to any pitch and fixing with polymer coated J, or L
hooks, bolts and nuts 8 mm dia. G.I. plain and bitumen washers or with selfdrilling fastener and
EPDM. All accessories like flashing, capping, shall be made of the above specified material. The
gutter shall be of 180mm dia half round moulded PVC.
Roofs shall generally have a slope of 1:3. Rain water gutters and pipes shall be provided for
proper roof drainage and collection of rainwater in accordance with SP 35.
14. DESIGN – FACTORS OF SAFETY
All structures above ground shall be designed for Limit state of strength and shall be checked
for serviceability conditions. In case of foundations, following factor of safety shall be adhered to
in different load combinations to establish the most economical design that is compatible with
life expectancy and service life of structures.
Minimum Factor Of Safety Minimum Factor Of Safety
Against Overturning Against Sliding
Type Of Structure With Wind Without With Wind Without Wind
Or Seismic Wind Or Or Seismic Or Seismic
Seismic
All structures/Eqpmnt Supports 1.5 2 1.5 1.5
Pipe rack 1.5 2 1.5 1.5
Retaining / Dyke wall 1.5 2 1.5 1.75

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Minimum Factor of safety against UPLIFT shall be 1.2 for all structures. (Note: In case of
sumps/pits, lining weight shall not be included)
For machine foundation design IS 2974 shall be strictly followed and additional safety checks for
frequency and mass ratio shall be performed depending upon the vibration range of machinery
above it.
In addition to stablitiy ratio check, foundation settlement shall also be restrained to the limits
specified in IS 1904. Longterm and differential settlement criteria shall be determined while
designing and special consideration shall be given to differential settlement of foundations
supporting interconnected, settlementsensitive equipment or piping systems.
15. DELIVERABLES
The CONTRACTOR shall prepare and submit the following:
1. Architectural drawings, Civil & structural design & construction drawings based on the
standard accepted practice and guidelines
2. Bar bending schedules
3. Fabrication drawings
4. Asbuilt drawings
5. Design calculations based on the standard accepted practice and guidelines

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All design calculations shall be written or typed systematically in MS Excel, legibly and submitted
for approval as per standard accepted practice. For structures, analysis and design shall be done
on latest version of STAAD.pro software.
Detailing / drafting shall be done on latest version of CAD software only. Drawing size used shall
be preferably of A1 size only. For foundation layout, drainage plans and paving plans, A0 size
drawings can be used if necessary
All Drawings shall be in metric units showing dimensions and elevations in millimetres.
Drawings shall indicate quantities of concrete grade wise and or nominal mix wise,
reinforcement bars diameter wise and structural steel section wise and or thickness wise as
detailed therein.
The contractor shall submit requisite number of prints (as mentioned elsewhere) of the
supporting design calculations along with explanatory notes/ sketches, computer inputs &
outputs and Drawings (complete in all respects) to Owner/ Consultant for review and checking
purposes. All the above design calculations and Drawings submitted by the Contractor shall be
completed in all respects and thoroughly checked, Approved, stamped as "Approved for
Construction" and signed by the Contractor's authorised representative (irrespective of the fact
that whether the same are prepared in the Contractor's own Design Office or by an Approved
Agency to ensure accuracy and correctness) before submission to the Owner/ Consultant.
Incomplete, unchecked and unsigned Drawings and design calculations shall not be accepted for
review/ checking and will be returnedforthwith.
The design calculations and Drawings prepared for this works shall have to be got checked and
Approved by the Owner/ Consultant as per mutually agreed time schedule and the Contractor


TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
should strictly adhere to these Approved Drawings and specifications. Construction work shall
be carried out only with the Approved Drawings and specifications. Correctness / soundness of
the designs/ Drawings and their execution at site shall be the sole responsibility of the
Contractor irrespective of the fact whether the same has been Approved by Owner/ Consultant
or not. Any defect, observed during construction or during the defect liability period of works,
shall be rectified and removed by the Contractor. The contractor shall carry out whatever
modification or reconstruction is needed for the purpose, to the entire satisfaction of the
EngineerinCharge / Owner without any extra cost to the Owner. But this will not in any way
absolve Contractor of the final responsibility for fulfilment of all Guarantee Clauses specified
elsewhere.
If due to any unavoidable reason, the contractor wishes to use any other software, other than
mentioned in the Tender, he shall indicate the names of the computer software to be used for
drafting and analysis/design work. The Contractor must get the approval of the Owner/
Consultant for the computer software prior to their use. The Contractor shall forward to
Consultant four prints of design calculations and Drawings preferably for the whole work at a
time along with all the concerned civil scope Drawings and load data sheets. After reviewing the
above design calculations and Drawings, Consultant will send comments to the Contractor
within four weeks’ time from the date of receiving the above. The Contractor will send their
designer, if required, to Consultant's office for clarifications /modifications/ incorporations and to
finalize designs/Drawings across the table. The design calculations and Drawings for each
independent building/structure along with scope/load data shall be submitted by the Contractor
in one lot so as to facilitate systematic review/ checking and approval. The contractor shall start
submitting such first set of design calculations and Drawings within thirty days from the date of

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
issue of Letter of Intent and complete the submission of the same for all the items/ units to
Consultant's Office within the period mutually agreed upon depending on the volume of job.
Any delay in submission of design calculations and/ or Drawings with complete data and getting
the same Approved from Consultant shall not absolve the contractor of their responsibility to
complete the work within the completion time.
If at a later stage, the contractor feels the necessity for any addition or alteration, prior approval
of Owner / Consultant must be taken for effecting the changes. The contractor shall also be
bound to incorporate any addition and alteration which Owner/ Consultant may suggest at a
later stage.

TECHNICAL
PROCUREMENT
SPECIFICATION
AT Q10 BERTH, WI
ANNEXURE A

SCHEDULE OF RATES
Name of Work:
General Notes:
SCHEDULE OF RATES
Sr. No. PARTICULARS QTY. UNIT RATE AMOUNT IGST Total Amount
(Rs.) (Rs.) (%) (Rs.)
DESIGN, DETAIL ENGINEERING, PREPARATION OF DRAWINGS GOOD FOR CONSTRUCTION, SUPPLY, DELIVERY AT SITE, UNLOADING ,FABRICATION, INSTALLATION, THIRD PARTY
A
INSPECTION, TESTING AND COMISSIONING OF INTAKE SCREEN SYSTEM AS PER TECHNICAL SPECIFICATIONS MENTIONED IN THE TENDER DOCUMENT.
A Mechanical ERECTION OF TANK

1 Tank
2 PA Pumps
SUB TOTAL
B PIPING
SUB TOTAL
C CIVIL
Demolishing R.C.C. work manually / by mechanical means including cutting and stacking of reinforcement bars and disposal of unserviceable material with in premises of FACT
1 at Q10 as per direction of Engineer in‐charge.
102 Cum
Demolishing stone rubble masonry in cement mortar manually / by mechanical means including stacking of serviceable material and disposal of unserviceable material within
2 premises of FACT at Q10 as per direction of Engineer in‐charge
48 Cum
Dismantling doors, windows and clerestory windows (steel or wood) shutter, of area 3sqm and below, including chowkhats, architrave, holdfasts etc. complete and stacking
3 within premises of FACT at Q10
5 Each
Dismantling doors, windows and clerestory windows (steel or wood) shutter, of area beyond 3 sq. metres , including chowkhats, architrave, holdfasts etc. complete and
4 stacking with in premises of FACT at Q10
5 Each
Dismantling steel work manually/ by mechanical means in built up sections without dismembering and stacking within premises of FACT at Q10 as per directions of Engineer in‐
5 charge.
1678 kg
6 Dismantling Asbestos sheet roofing including ridges, hips, valleys and gutters etc, and stacking the material within premises of FACT at Q10 as directed by Engineer in‐charge. 23 Sqm
Surface dressing of the ground including removing vegetation and inequalities not exceeding 15cm deep and disposal of rubbish, with in premises of FACT at Q10 and lift up to 1.5m
7 in all kinds of soil
2000 Sqm
Felling trees of girth (Measured at a height of 1m above ground level) including cutting of trunks and branches, removing the roots by uprooting, stacking of serviceable material
8 and disposal of unserviceable material ‐ Beyond 60cm girth up to and including 120cm girth.
3 Each
Felling trees of the girth (measured at a height of 1m above ground level), including cutting of trunks and branches, removing the roots and stacking of serviceable material and
9 disposal of unserviceable material ‐ Beyond 120cm girth up to and including 240cm girth
3 Each
Disposal of moorum / building rubbish / malba / similar unserviceable, dismantled or waste material by mechanical transport including loading, transporting, unloading to
10 approved municipal dumping ground for lead up to 30km for all lifts, complete as per directions of Engineer in‐charge. Note ‐ Item to be applicable in urban areas having 206 Cum
directions for restricted hours for movement/ plying of load carrying motor vehicle of 3.5cum or more.
Casting 750mm diameter bored cast in‐situ reinforced cement concrete piles in M35 grade ready mix concrete after boring through Direct mud circulation method as per IS 2911‐
Part 1/sec 2, having minimum cement of 400 kg/cum of concrete, using Portland Pozzolana cement conforming to IS 1489, river sand / manufactured sand conforming to IS 383,
20mm or less size graded hard granite broken stones, admixtures to concrete as per IS 9103, water as per IS 456 and reinforced with High strength deformed bars of 500D grade
conforming to IS 1786 for the entire length of piles. All the materials used in the casting of concrete shall be done with the approval of Engineer in‐charge.
The rate shall include the cost for all plants, tools, materials labour and other services for boring the piles including mobilisation and de‐mobilisation of piling rigs, boring to the
11 required depth and stabilisation of hole with bentonite slurry or other required material to suit site conditions, making channels in the ground, making service roads and
8450 Rm
arrangements for transportation and disposal of muck (The muck will be treated as owned by the contractor and it will be the responsibility of the contractor to dispose the muck
without causing environment damage with necessary permission from the concerned authority and consultant / client to be informed well in advance on the disposal methodology
before starting the work), cleaning the bores with water, lowering the reinforcement cages, concreting, excavating and levelling the ground exposing piles to a depth of 100mm
below cut‐off level after curing and gaining sufficient strength. Rate of reinforcement alone shall be paid extra ‐ For piles of length 65m below cut‐off level. (payment shall be made
Chipping and removing weak concrete at the top of RCC piles to the cut off level in line and levels carefully, manually / mechanically without damaging the remaining portion of pile
12 and exposing the reinforcement, cleaning the reinforcement off any loose concrete particles and removing the debris to places pointed out within the project premises as directed 60 Cum
by the Engineer in‐charge.
Charges for empty boring through various strata to the required diameter of pile specified in the Item above, clearing the area, collecting, conveying and disposal of muck of all
types such as liquid, fluid, solid and spoil earth (The muck will be treated as owned by the contractor and it will be the responsibility of the contractor to dispose the muck without
13 causing environment damage with necessary permission from the concerned authority and consultant / client to be informed well in advance on the disposal methodology before 130 Rm
starting the work) including hire charges for tools and plants, rigs, cost of labour, etc. complete for all depth. (Payment will be made for abandoned pile due to reasons attributable
to owner and for empty boring involved in between ground level at the time of casting the piles and cut‐off level of piles.) 500 mm dia. piles
Arranging and conducting routine tests on single pile of diameter 750mm and length up to 65m below cut off level described in Item above as per IS: 2911 (Part‐IV) latest revision
including all required arrangements materials, machineries such as test cap, loading platform, hire and labour for kentledges, cost of all materials, tools and plants, instruments for
14
1 Each
loading and recording settlements with dial gauge / LVDTS (calibrated), and labour charges, submitting reports etc complete as per technical specifications for 750mm dia piles for a
maximum load of 3525kN or the load at which the maximum settlement of test loading in position exceeds the permissible value.
Earth work in excavation by mechanical means (Hydraulic excavator) / manual means in foundation trenches or drains , in all kinds of soil, including dressing of sides and
15 ramming of bottoms, lift up to 1.5m, including getting out the excavated soil and disposal of surplus excavated soil as directed with in premises of FACT at Q10 and close 3450 Cum
timbering in trenches including strutting, shoring and packing cavities wherever required and bailing out water to keep the excavated trenches suitable for concreting.
Filling available excavated earth (excluding rock) in trenches, plinth, sides of foundations etc. in layers not exceeding 20cm in depth, consolidating each deposited layer by
16 ramming and watering
1039 Cum
Supplying and filling contractor's own good quality earth to the required levels and grades to level uneven areas at site in layers of 200 mm including watering, ramming, etc
17 complete with all leads and lifts as directed by Engineer in charge (Measurement will be given for consolidated filled volume as per initiasl and final levels as approved and 9 cum
certified by Engineer ‐ in ‐ charge)
Charges for conveying the surplus earth to places approximately 30 kms away and dumping at low lying places as directed by the Engineer in‐charge. Note ‐ Item to be
18 applicable in urban areas having directions for restricted hours for movement/ plying of load carrying motor vehicle of 3.5cum or more.
2411 Cum
Providing hard core layer of required thickness using 40mm Nominal size graded hard granite broken stones after compacting the underlying soil, spreading and levelling the stones
and then spreading a layer of 6mm downgraded crushed aggregates on top of the broken metal layer and it shall be watered in order to force the crushed fine aggregates into the
19 void spaces of the broken stone and repeat the process till all the voids are filled with crushed fine aggregates right up to the edges of hard core layer, including cost of all materials
345 Cum
and labour charges etc., complete
Providing 50mm thick bitumen sand mix with blown type bitumen of penetration 85/25 and clean river sand (120kg. bitumen/cum of sand) over a tack coat (total industrial asphalt
20 to be used at 62.5kg /10sqm of surface (including 2.5 kg/10sq.m. of tack coat) including all charges for cleaning the surfaces, heating bitumen, mixing, laying, consolidating, finishing, 1010 Sqm
etc. complete.
Supplying and providing high build epoxy based chemical resistant coating for outer surface of tank foundation (CERACOTE EP CR of Cera Chem or equivalent) as per manufactures
21 specification to achieve a minimum dry film thickness of 500 microns
2600 Sqm
Acid proof lining after cleaning the cement finished surface well with water and allowing to dry, brushing and removing all dust, apply two coats of approved quality bitumen based
primer conforming to IS. 1580 as per manufacture's specification, applying 12 mm thick asphalt membrane with hot melt asphalt free from filler conforming to IS. 1580, then laying
22 acid resistant tiles of class II quality conforming to IS. 4860 over a bed of 6 mm thick potassium based silicate cement mortar conforming to IS. 4832 ‐ part. I & 4441 and joints 5 mm 315 Sqm
thick, raking the joints to full depth from the top surface, removing the raked‐out mortar and filling the entire depth of joints with Furan base resin cement mortar conforming to IS.
4832 ‐ part. II including acid washing curing etc. complete as per relevant IS. 4443 specifications at all heights. ‐ 230X112X38 mm or nearest size tile
Cement concrete work in 1:3:6 mix (1 Portland Pozzolana cement: 3 coarse river sand/manufactured sand: 6 20mm nominal size graded hard granite broken stones) including all
charges for mixing concrete, necessary shuttering, laying, consolidating, curing, removal of shutters, cost for bailing out of water, oil, liquid mud etc. from all sources in excavated
23 pits, trenches, etc. complete at all levels as per standard specifications and as directed by the Engineer in‐charge for foundation / levelling course etc. Approved make of materials
220 Cum
are furnished in Specific requirements of work – 32644‐12‐DA‐003.
Providing and laying in position ready mixed M‐35 grade concrete for reinforced cement concrete work, using fly ash and cement content as per approved design mix, and
manufactured in fully automatic batching plant and transported to site of work in transit mixer for all leads, having continuous agitated mixer, manufactured as per mix design of
specified grade for reinforced cement concrete work, including pumping of R.M.C. from transit mixer to site of laying, excluding the cost of centering, shuttering, and
reinforcement, including cost of admixtures in recommended proportions as per IS : 9103 to accelerate / retard setting of concrete, improve workability without impairing strength
24 and durability as per direction of the Engineer in ‐ charge. NOTE‐ (1) Minimum Cement content shall be @ 350 kg/cum. Excess/ less cement used as per design mix is payable/
1308 Cum
recoverable separately. “(2) Fly ash conforming to grade I of IS 3812 (Part‐1) only be used as part replacement of OPC as per IS: 456. Uniform blending with cement to be ensured in
accordance with clauses 5.2 and 5.2.1 of IS:456 in the items of BMC and RMC – for pile caps . Approved make of materials are furnished in Specific requirements of work – 32644‐12
DA‐003
specified grade for reinforced cement concrete work, including pumping of R.M.C. from transit mixer to site of laying, excluding the cost of centering, shuttering, finishing and
25 and durability as per direction of the Engineer ‐ in ‐ charge.
322 Cum
NOTE‐ (1) Cement content considered in this item is @ 350 kg/cum. Excess/ less cement used as per design mix is payable/ recoverable separately.“ (2) Fly ash conforming to grade I
of IS 3812 (Part‐1) only be used as part replacement of OPC as per IS : 456. Uniform blending with cement to be ensured in accordance with clauses 5.2 and 5.2.1 of IS:456 ‐2000 in
the items of BMC and RMC ‐ All works above plinth level upto and including floor V level
specified grade for reinforced cement concrete work, including pumping of R.M.C. from transit mixer to site of laying, excluding the cost of centering, shuttering, and
26 and durability as per direction of the Engineer in ‐ charge. NOTE‐ (1) Minimum Cement content shall be @ 340 kg/cum. Excess/ less cement used as per design mix is payable/
260 Cu.m
recoverable separately. “(2) Fly ash conforming to grade I of IS 3812 (Part‐1) only be used as part replacement of OPC as per IS: 456. Uniform blending with cement to be ensured in
accordance with clauses 5.2 and 5.2.1 of IS:456 in the items of BMC and RMC – for all works up to plinth level except pile cap. Approved make of materials are furnished in Specific
requirements of work – 32644‐12‐DA‐003
specified grade for reinforced cement concrete work, including pumping of R.M.C. from transit mixer to site of laying, excluding the cost of centering, shuttering and reinforcement,
including cost of admixtures in recommended proportions as per IS : 9103 to accelerate / retard setting of concrete, improve workability without impairing strength and durability
27 as per direction of the Engineer in ‐ charge. NOTE‐ (1) Minimum Cement content shall be @ 340 kg/cum. Excess/ less cement used as per design mix is payable/ recoverable
114 Cu.m
separately. (2) Fly ash conforming to grade I of IS 3812 (Part‐1) only be used as part replacement of OPC as per IS: 456. Uniform blending with cement to be ensured in accordance
with clauses 5.2 and 5.2.1 of IS:456 ‐ in the items of BMC and RMC – for all works above plinth level . Approved make of materials are furnished in Specific requirements of work –
32644‐12‐DA‐003
manufactured in fully automatic batching plant and transported to site of work in transit mixer for all leads, having continuous agitated mixer, manufactured as per mix design
of specified grade for reinforced cement concrete work, including pumping of R.M.C. from transit mixer to site of laying, excluding the cost of centering, shuttering, and
reinforcement, including cost of admixtures in recommended proportions as per IS : 9103 to accelerate / retard setting of concrete, improve workability without impairing
28 strength and durability as per direction of the Engineer in ‐ charge. NOTE‐ (1) Minimum Cement content shall be @ 300 kg/cum. Excess/ less cement used as per design mix is
381 Cum
payable/ recoverable separately. “(2) Fly ash conforming to grade I of IS 3812 (Part‐1) only be used as part replacement of OPC as per IS: 456. Uniform blending with cement to
be ensured in accordance with clauses 5.2 and 5.2.1 of IS:456 in the items of BMC and RMC – for yard concreting, drains, stairs. Approved make of materials are furnished in
Specific requirements of work – 32644‐12‐DA‐003
Reinforced cement concrete work of M25 grade for precast cover slab using Portland pozzolana cement containing more than 25% of fly ash, river sand / manufactured sand
conforming to IS 383 and 20mm nominal size graded hard granite broken stones including all charges for designing the mix, weigh batching, including installation of batching
plant at the designated location in the site premises or arranging RMC, mixing concrete, cost of adding concrete admixtures as required, transporting, formwork, laying,
vibrating, consolidating, curing with minimal use of potable water subject to provision of IS 456, handling, transporting, loading, unloading, keeping and fixing in position, at all
29 levels etc., complete but excluding cost of providing reinforcements. (Exposed surfaces of pre‐cast elements shall have good finish with no blemish or mark on the finished
18 Cum
surfaces) NOTE‐ (1) Minimum Cement content shall be @ 330 kg/cum. Excess/ less cement used as per design mix is payable/ recoverable separately. (2) Fly ash conforming to
grade I of IS 3812 (Part‐1) only be used as part replacement of OPC as per IS: 456. Uniform blending with cement to be ensured in accordance with clauses 5.2 and 5.2.1 of IS:456
in the items of BMC and RMC ‐for cover slabs (50mm to 100mm thick) on drain. Approved make of materials are furnished in Specific requirements of work – 32644‐12‐DA‐003.
30 Add for using extra cement in the items of design mix over and above the specified cement content therein. 158625 kg
Providing form work to cement concrete and RCC works with necessary plywood / steel sheet, steel joists, runners, struts, posts etc with adjustable spans and telescopic posts,
31 wooden planks for beam sides etc. including removal after completion /curing at all levels ‐ foundation footings, bases of columns and walls. for mass concrete with straight sides
635 Sqm
32 wooden planks for beam sides etc. including removal after completion /curing at all levels ‐ foundation footings, pile caps, RCC kerb wall around pile cap, bases of columns and 210 Sqm
walls. for mass concrete with circular sides
Providing form work to cement concrete and RCC works with necessary plywood/steel sheet, steel joists, runners, struts, posts etc with adjustable spans and telescopic posts,
33 wooden planks for beam sides etc. including removal after completion / curing at all levels – Drain wall (any thickness).
1642 Sqm
34 wooden planks for beam sides etc. including removal after completion /curing at all levels ‐ Suspended floors, roofs, landings, balconies and access platform
50 Sqm
35 wooden planks for beam sides etc. including removal after completion /curing at all levels ‐ Lintels, beams, plinth beams, girders, bressumers and cantilevers
1113 Sqm
36 wooden planks for beam sides etc. including removal after completion / curing at all levels ‐ Columns, Pillars, Piers, Abutments, Posts and Struts
46 Sqm
37
11 Sqm
wooden planks for beam sides etc. including removal after completion /curing at all levels ‐ Stairs, (excluding landings) except spiral‐staircases
Supplying , fabricating, conveying and fixing reinforcement to RCC works at all levels with high strength deformed bars Fe500D grade Thermo Mechanically Treated (TMT) bars
38 conforming to IS 1786 including all charges for uncoiling and straightening rods, cutting rods, bending cold, placing in position and supplying & tying with black annealed tying 469487 kg
wire of 16 gauge, etc. complete. Approved make of materials are furnished in Specific requirements of work – 32644‐12‐DA‐003
Supplying, conveying fabrication and erection of MS single section members such as channels, guard rail, MS angle hand rails verticals, etc. with fixtures such as end stops, clamps,
bolts and nuts etc. including charges for cutting, splicing, drilling holes as required, fixing to lines and levels and cleaning thoroughly with power tools and painting with two coats of
39 red oxide zinc chromate primer ( one shop coat and one coat after fixing / erection) Approved make of materials are furnished in Specific requirements of work – 32644‐12‐DA‐003,
99377 kg
Refer painting specs for applying priming coats
Supplying and fixing MS inserts of all types fabricated out of MS plates, angles, channels, flats, rods, fabricated pieces, etc. in RCC / masonry works at all levels including all charges
for cutting, welding, fixing to lines and levels and painting the exposed surfaces with two coats of chemical resistant enamel paint of approved quality and colour over two coats of
40 red oxide zinc chromate primer, etc. complete Approved make of materials are furnished in Specific requirements of work – 32644‐12‐DA‐003, Refer painting specs for applying
1337 kg
priming coats
Providing and fixing mild steel round holding down bolts with nuts and washer plates complete to all lines and levels and applying petroleum jelly / grease after erection on exposed
41 surface of bolts to prevent corrosion
190 kg
Painting of structural steel work over priming coats (paid with the steel supply item) as follows:
42 a) One intermediate coat of Micaceous Iron Oxide epoxy paint of 70‐micron DFT 2778 Sqm
b) One coat of two pack polyamide cured epoxy finish paint of 40‐microns DFT
Supplying and fixing pultruded GRP gratings made of Isophthalic polyester resin containing glass fibre content not less than 60% and having fire retardant characteristics, of 38mm
height with I bar spacing not exceeding 40mm c/c and crossbars not exceeding 90 mm c/c, suitable for imposed load of 500kg/sqm of colour grey and designed for a max support
span of 1300mm over cable trenches / drains / stairs with bonded grit antiskid surface including fixing to the existing structural steel frames / RCC walls by means of SS hold down
43 clamps, locking arrangement etc. For step ladders, gratings have to be fabricated as per site measurement and shall be rigidly fixed to the existing structural by suitable locking 183 Sqm
arrangement. 2 Piece locking system of size 700 wide (I‐bar) x 1mtr (Cross Rod) Length. The GRP material shall be fire retardant meeting ASTM E84 Class A with Flame Spread less
than or equal to 25 & Smoke Density ±200 and UV resistant meeting ASTM G154 with flexural strength not reducing by more than 7% on accelerated UV radiation exposure.
Approved make of materials are furnished in Specific requirements of work – 32644‐12‐DA‐003.
Supplying and grouting pockets, base plates, etc. at all levels for static equipment / structural steel supports using non‐shrink grouts. Approved make of materials are furnished in
44 Specific requirements of work – 32644‐12‐DA‐0032.
2 Cum
Civil & Structural Design,Detailed Engineering and preparation of Good for Construction Civil & Structural drawings for the Phospohoric Acid tanks and Allied facilities as per the
45 Design philosophy and Design Basis for Civil & Structural Works and Tender Specifications.
1 LS
SUB TOTAL
D Elecrtical
SUB TOTAL
E Instrumentation
SUB TOTAL
SUB TOTAL
TOTAL PROJECT COST
QUALITY 12ES001/18
MANAGEMENT CIVIL & STRUCTURAL WORKS
SYSTEM PAGE 1 OF 14
CONTENTS
1.0.0 SCOPE
2.0.0 CLASSIFICATION OF BUILDING AND GENERAL REQUIREMENTS
3.0.0 CODES AND DESIGN LOADS
4.0.0 SITE CLEARING, EARTH WOK, BACK FILLING
5.0.0 FOUNDATIONS
6.0.0 CONCRETE WORK
7.0.0 STRUCTURAL STEEL WORK
8.0.0 MASONRY WOK
9.0.0 ROOFING AND ROOFING TREATEMENT
10.0.0 DOORS, WINDOWS, VENTILATORS
11.0.0 FLOORING AND FLOORING FINISHES
12.0.0 FINISHING WORK
13.0.0 PROTECTIVE LINING
14.0.0 SANITARY AND WATER SUPPLY
15.0.0 ROADS
16.0.0 DRAINAGE SYSTEM AND CABLE TRENCHES
17.0.0 LIQUID RETAINING STRUCTURES
1.0.0 SCOPE
1.1.0 This document gives the engineering specification pertaining to Civil Engineering works.
This document is meant for attaching along with the turn key package for various works in
order to get uniform bid from the bidders to the extent possible. These specifications give the
general requirements for design and material classification for different works.
1.1.1 The specifications given are not conclusive an additions required in the specifications shall be
supplemented to suit to be project require meant by bidder mentioning the deviations and
additions in separate statement to be attached along with the bids.
1.2.0 The engineering specifications covered in this document are listed below.
1.3.1 Classifications of buildings and general requirements
1.3.2 Codes and design loads
1.3.3 Site clearing earth work, back filling
1.3.4 Foundations
1.3.5 Concrete works
1.3.6 Structural steel works
1.3.7 Masonry works
1.3.8 Roofing and Roofing treatment
1.3.9 Doors, Windows, Ventilators
1.3.10 Flooring and Flooring finishes
1.3.11 Finishing work
1.3.12 Protective lining
1.3.13 Sanitary and water
1.3.14 Roads
1.3.15 Drainage system and cable trenches
0 01/09/2018 Revised & Issued for ISO 9001:2015 HOD (C) GM (E) GM (F)
REV DATE REVISION DESCRIPTION PRPD CHKD APPRD

QUALITY 12ES001/18
SYSTEM PAGE 2 OF 14
1.3.16 Liquid retaining structures

1.4.0 The contractor shall be responsible for the complete design of all civil structures of the project
mentioned in the bid document. Issue these specifications do not absolve responsibility of the
contractor with respect of the structural stability a suitable adoption of the engineering
specifications.
1.5.0 A brief specialization of the work along the approximate bill of quantities of major items of
work viz. RCC, Brick and rubble masonry and concreting ,doors and windows etc are to be
submitted by the bidder along with the offer.
1.6.0 Whenever civil scope drawings are issued along with these specifications all designs shall be
carried out to suit the civil scope drawing in addition to the engineering specification
1.7.0 In case civil scope drawing details and engineering specifications differ the details given in the
civil scope drawings shall be followed for the design.
1.8.0 The specification for different work / structures pertaining to a particular project shall be
provided in the data sheet “civil and structural works” (Ref. format No.12FT018) and shall
attached.
2.0.0 CLASSIFICATION OF BUILDING AND GENERAL REQUIREMENTS

2.1.0 CLASSIFICATIONS OF BUILDING
2.1.1 Type A
RCC Framed structure with masonry walls
2.1.2 Type B
Building with RCC floor /roof supported on load bearing wall
2.1.3 Type C
Building with steel column steel roof trusses with AC sheet roofing Masonry walls etc.
2.1.4 Type D
As per Type a but with AC sheet cladding.
2.1.5 Type E
As per Type C but with RCC columns
2.1.6 Type F
As per Type C but with AC sheet cladding.
2.2.0 GENERAL REQUIREMENTS FOR BUILDINGS
2.2.1 The clear height of building shall not be less than 2.75 m generally. The size of a building
shall not be less than 9.50m² where there is only one room and where there are two rooms
one shall not be smaller than 9.50m² and other not less 7.50m². Minimum width shall be 2.4m.
2.2.2 The size of bath rooms shall not be less than 1.5m x1.20 or 1.8m² the combined bath room
and water closet shall have a floor area of not less than 2.80m² with a minimum width of 1.2
m a water closet area of 1.1 m². The height of bath room or water closet shall not be less than
2.2 m.
2.2.3 Every bath room or water closet shall have at least one wall open to external air and shall not
open in to a kitchen by a door or any other opening.
2.2.4 Rooms used as control rooms, MCC, compressor rooms etc. shall be provided with two doors
2.2.5 Minimum width of stairs shall be 1 m
2.2.6 The minimum width of treads without nosing shall be 25 cm for internal stairs.
2.2.7 Minimum rise for stairs shall be15cm for stairs of public building and residential building and
18 cm for stairs of plant buildings.
2.2.8 Minimum treads of stairs shall 30cm for public buildings and 25cm for plant buildings
2.2.9 The minimum clear head room in a passage under a stair case landing and the minimum
clear head room in stair case shall be 2.20m.
2.2.10 Hand rails shall be provided with in a minimum height of 100cm and shall be firmly supported
2.2.11 Sump, Tank, Pit, or openings in ground or in a floor shall be covered or fenced securely.

12FT012/18
QUALITY 12ES001/18
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2.2.12 Minimum width of steel ladder shall be 45 cm.

2.2.13 Maximum spacing of rungs for steel ladder shall be 200 mm.
2.2.14 where the height of steel ladder exceeds 2.4m cages shall be provided.
2.2.15 all rails on which a travelling crane moves shall be of proper size and adequate strength. The
rail shall have an even running surface .Every such rail or track shall be properly laid and
adequately supported.
2.2.16 General requirements of building are not conclusive and shall satisfy the prevalent
municipal/statutory bodies’.
3.0.0 CODES AND DESIGN LOADS

3.1.0 The design of structures foundations, etc. shall be as per latest relevant IS codes. Items not
covered in the IS codes can be designed based on other international codes like BS codes
American codes etc. or other accepted engineering practices some of the relevant IS codes
for designs are listed below.
1 Structural safety of buildings loading standards IS 875(Part I to IV)
2 Earthquake resistant design of buildings IS1893
3 Plain and Reinforced Concrete IS 456
4 Concrete structures for storage of liquid IS 3370(Part I to IV)
5 Design of reinforced concrete shell structures and folded plates IS 2210
6 Designs of reinforced concrete chimneys IS 4998
7 Design of reinforced concrete bins (silos) for Bulk food grain storage IS 4995
8 Structural safety of buildings masonry walls IS 1905
9 Structural safety of building foundations IS 1904
10 Design and construction of spread o foundation IS 1080
11 Design and construction of machine foundation IS 2974(Part I to V)
12 Design and construction of raft foundation IS 2950
13 Design and construction of pile foundation IS 2911 (Part I to IV)
14 Basic requirement of water supply, drainage and sanitation IS 1172
15 Water supply in buildings IS 2065
16 Design and construction of septic tanks IS 2470
17 Building drainage IS 1742
18 Structural steel in general building construction IS 801
3.2.0 The materials used, construction practices, testing procedures etc. shall also conform
relevant IS codes. Only tested quality material shall be used. Some of the relevant codes for
commonly used materials and construction practices are listed below.
1 earthquake resistant construction of building IS 4326
2 Cold twisted steel bars IS 1786
3 Mild steel and medium steel bar for reinforcement IS 432(Part I)
4 Fabric for concrete reinforcement IS 1556
5 Structural steel IS 226
6 Burnt clay building bricks IS 3495(Part I to IV)
7 Hollow light weight concrete block IS 2185(Part I)
8 Specifications for concrete masonry unit IS 2185 (Part II)
9 Construction of stone masonry IS 1597(Part I & V)
10 Brick work IS 2212
11 Preparation and use of masonry mortars IS 2572
12 Construction of hollow concrete bock masonry IS 2572
13 Plastic pipe work for water supply IS 7634(part I to III)
14 LDPE pipe for portable water supply IS 3076
15 HDPE pipe for portable water supply IS 4984

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16 Unplasticised PVC pipes for portable water supply IS 4985

17 Construction of refuse duct for malty storied Building IS 6924
18 Cement and cement lime plastic finishes IS 1661
19 Painting concrete masonry and plastered surface IS 2395(Part I & II)
20 Painting in ferrous metals in buildings IS 1477(Part I&II)
21 White washing & colour washing IS 6278
22 Laying in situ concrete flooring IS 2571
23 Selection of industrial floor finishes IS 4971
24 Aluminium doors, windows and ventilators IS 1948
25 Aluminium doors for industrial building IS 1949
26 Steel door, windows and ventilators IS 1038
27 Steel windows for industrial building IS 1361
28 Timber door, windows and ventilators frame IS 4021
29 Timber panelled and glazed shutters IS 1003 (Part I&II)
30 Acid resistant bricks IS 4860
31 Chemical resistant mortars IS 4832(Part I to II)
3.30 The list of given is not conclusive. Related codes and other relevant codes published by the
Burro of Indian standards shall be used along with the engineering specifications.
3.4.0 DESIGN LOADS
3.4.1 Design loads
In addition to dead ,live, wind or earth quake loads as per Indian standard codes, the building
and structures shall be designed for additional loads due to cranes mono rails equipment
(including impact and vibrations if any) platforms etc.., as per actual requirements.
3.4.2 Load combinations
Load combinations shall be as started in a relevant Indian standard and recommendations
and combinations specified by the equipment supply if any.
3.4.3 Wind and Earth quack loads
Unless otherwise specified wind and earth quack effect on structures on structures shall be
analysed based on relevant Indian standard codes and necessary modification factors may
be applied according to specific recommendations , if any
3.4.4 Dynamic loads
Whenever dynamic loads act on a structure the effect same shall be considered in the design
along with the static live and wind or earth quack load.
3.4.5 Analysis of Structures
Frame analysis shall be carried out for all framed structures. All connections shall be moment
connections. However bracing may be provided wherever deemed necessary incase of the
above.
3.4.6 In case of computer aided analysis /designs all relevant backups such as load calculation
flow charts , computer dates etc.., shall be furnished . Computer outputs shall be in clear
easily understanding able formats and shall be submitted in proper bound volumes.
4.0.0 SITE CLEARANCE, EARTH WORK AND BACK FILLING

The specification covers the requirements regarding site clearances, earth work back filling
etc. to be done at site.
4.1.0 Excavation shall be carried out to true line and levels in all type of soil except hard rock
requiring blasting.
4.2.0 When hard rock is encountered the surface shall be levelled/benched as directed by the
engineer- in- charge
4.3.0 All arrangements for drainage to keep the pits dry and required dewatering to be included in
the quoted rate.

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4.4.0 All shoring and strutting required for holding the size of excavation from collapse to be
included in the quoted rate
4.5.0 Removal of rubbish, slush, etc. from site to be included in the rate.
4.6.0 Back filling to be carried out using selected earth from excavation of good sand brought from
outside.
5.0.0 FOUNDATIONS
This specification covers the requirement governing design of foundations of varies
structures.
5.1.0 All designs shall be done based on relevant Indian standard codes.
5.2.0 All foundations shall be done designed to suit the soils conditions. For this purpose the bidder
may visit the site and get familiarized with soil conditions by conducting soil exploration work,
if necessary. When soil investigation reports are available, the design is to be done as
recommended in the report.
5.3.0 All underground pits, slumps, etc, shall be designed to take care of the uplift forces due to
buoyancy.
5.4.0 All foundations shall rest on firm original ground.
5.5.0 Unless otherwise recommended in the soil investigation report, all foundations shall extend
at least 60 cm below natural ground level. On rock or weather resisting natural ground,
removal of top soil may be all that is required. Foundations in any type of soil shall go below
the zone significantly weakened by root holes or cavities produced by burrowing animals or
worms.
5.6.0 If the sub soil is of aggressive nature sulphate resisting cement shall be used for
foundations/ underground structures.
5.7.0 The size, thickness and concrete mix for building and equipment foundations shall be
capable to transfer the load on the sub soil.
5.8.0 PCC 1:4:8 shall be used for leveling course, except for liquid retaining structures. The
thickness of leveling course shall be 80mm and minimum 150mm thick when used as
structural element. Leveling course below liquid retaining structures shall be of 1:3:6 mix
5.9.0 The minimum cover of 75mm shall be provided for foundations pockets to the edge of
foundations.
5.10.0 The foundations for machinery and allied equipment shall be designed as recommended by
equipment suppliers. Provision for isolation pads, vibration dampeners, bearing pads,
springs etc, shall be provided as per equipment manufacturers drawing.
5.11.0 For dynamic loaded foundations grouting shall be with non-shrink, high strength, free flow,
cementitious grout like Conbextra GP1, Shrinkkomp, etc. for static loaded foundation,
grouting shall be with cement grout or jelly concrete sand grout.
6.0.0 CONCRETE WORKS

This specification covers the requirements governing the design of concrete structures for
buildings, equipment foundations, storages, chimneys, etc.
6.1.0 All design shall be done based on the relevant Indian standard codes.
6.2.0 DESIGN CRITERIA
All design shall be carried out based on relevant IS codes and sound engineering practices.
The structure shall be designed based on the correct evaluation of all loads imposed on the
structure. The static equilibrium of the structure must be adequate against the different type
of loading.
6.3.0 MINIMUM THICKNESS AND DIMENSIONS
Minimum thickness of various components of the structure is given below.
Floor slabs including slabs on ground 10cms

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Column footing 15cms

Underground pit slab walls 50cms
Minimum dimension of beam / column 200mm
Levelling course 80mm
6.4.0 Minimum cover reinforcement shall be as per provisions in relevant IS codes. However for
works against earth faces, corrosive environment, etc., the cover shall be increased by
30mm than the code provisions.
6.5.0 MINIMUM HEIGHT OF PLINTH / PEDESTAL.
The minimum height of plinth / pedestal above finished grade or floor level shall be as
follows.
1. Building plinth 300mm above nearest road or pavement level
2. Pedestals / encasements for structural columns
Open area 300mm
Covered area 150mm
3. Pedestals for all equipment
Open area as required but not less than 300mm
Cover area as required but not less than 150mm
4. Stair pedestal 150mm
5. Ladder pedestal 150mm
6.6.0 GROUTING
6.6.1 For structural columns as required but not less than 25mm
6.6.2 For equipment as required but not less than 25mm
6.6.3 The specification for grout shall be either 1:1 cement grout or readymade non shrink grout to
suit the type of equipment to be grouted.
6.7.0 CONCRETE MIX
6.7.1 Levelling course of mix not leaner than1:4:3 shall be provided under foundations other than
water retaining structures.
6.7.2 M 15 or higher grade concrete shall be used for RCC works. When nominal mix is adapted
minimum concrete mix shall be1:2:4. Under any circumstances minimum cement content
shall not be less than 330 kg/m^3.
6.7.3 Richer concrete mix shall be adopted wherever required to suit the design requirement.
6.8.0 REINFORCEMENT RODS
6.8.1 The reinforcement rods for concrete shall be as follows.
Main bars in columns, footings, Cold twisted steel bars.
slabs, foundations, etc.
Lateral ties, stirrups, etc Cold twisted steel bars/mild steel
bars.
Reinforcement for floors Mild steel bars/steel fabric
6.9.0 EXPANSION JOINTS
6.9.1 Expansion joints in concrete structures shall be provided as per relevant IS code provisions
at suitable intervals. Bitumen impregnated fiber boards of approved manufacture as per IS
1838 shall be used as fillers for expansion joints. The gap between the expansion joints
shall be thoroughly cleaned and the bitumen fiber boards placed in position as per
manufacturer’s specification.
6.9.2 The expansion, contraction and construction joints, etc. for water retaining structures shall
be provided as per the codal provisions. All water bars specified shall be PVC.
7.0.0 STRUCTURAL STEEL WORKS.

This specification covers the requirements governing the design of steel structures.
7.1.0 All design shall be done based on the relevant Indian standard code.

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7.2.0 MINIMUM THICKNESS OF STEEL

For gussets, stiffeners, plate guides, etc. 8mm
For base plates 10mm
7.3.0 SLENDERNESS AND DEPTH RATIO.
The slenderness ratio of main members in tension and compression shall be in accordance
with IS 800. The following limiting ratios of depth to span shall be considered as general
guide.
Trusses 1/10
Rolled beams and girders for ordinary Floors and rafters 1/24
Supporting floor beams for vibrating Machinery 1/15
Roof purlins and girts 1/45
Cable columns 1/30
Gantry girders (rolled sections) 1/15
Gantry girders (built up) 1/12
7.4.0 CONNECTIONS
The connections shall be welded as far as possible. Field connections shall be made with
black bolts for ladders, hand rail posts, stair stringers removable members and floor plates,
platform forming members 200mm and under in size, purlins, girts and minor pipe support
members that require not more than three bolts per connection. The minimum size of bolts
shall be 16mm unless limited by the size of the connected parts.
7.5.0 MATERIAL
7.5.1 Unless otherwise specified, steel or hot rolled structural shapes and plates shall conform to
IS 226 / 2062.
7.5.2 Steel tubes for structural purpose shall conform to IS 1161.
7.5.3 High Strength bolts shall conform to IS 3757.
7.5.4 Bolts shall conform to IS 1367.
7.6.0 ERRECTION LOADS
All loads to be carried by the structure or any part if it due to storage or positioning of
construction material and erection equipment including all loads due to operation of such
equipment shall be considered as erection load. Proper provision shall be made including
temporary bracings to take care of stresses due to erection loads. The structure as a whole
and all part of the structure in conjunction with temporary bracings shall capable of
sustaining this erection load without exceeding the permissible stresses. Dead loads, wind
loads and all such parts of live load as would be imposed on the structure during the period
of erection shall be taken as acting together with the erection load.
7.7.0 TEMPERATURE EFFECTS
Expansion and contraction due to changes in temperature on the material of a structure
shall become decisive in design and adequate precautions shall be made for such effects.
7.8.0 FLOOR COVERING
Gratings or chequered plates shall be used for covering .gratings / chequered plates shall
be designed for a full live load plus a point load of 500kg minimum.
7.9.0 PAINTING, GALVANIZING, FIRE PROOFING
7.9.1 All fabricated structural steel, unless galvanized shall receive a shop coat of primer and
painted as per specification.
7.9.2 Steel which is to be fire proofed (marked FP on design drawings) shall be fabricated
unpainted and shall be given a coat of cement wash before encasement in fire proofing
material.
8.0.0 MASONRY WORKS

8.1.0 This specification covers the requirements governing design of masonry structures.

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8.2.0 All design shall be based on relevant Indian standard codes.

8.3.0 RANDOM RUBBLE MASONRY
8.3.1 The minimum thickness of wall / foundation shall be 38 cms.
8.3.2 The thickness shall be determined based on the loading and its slenderness ratio as per the
codal provisions.
8.3.3 The mortar for the masonry shall be 1:6 cement mortar.
8.3.4 All exposed faces of rubble masonry shall be pointed with cement mortar 1:3.
8.3.5 Wherever plastering is required the same shall be of cement plaster 1:4 mix, 15 mm thick.
8.4.0 BRICK MASONRY
8.4.1 The minimum thickness of wall shall be 20cm for load bearing walls and 10cm for partition
walls.
8.4.2 The thickness shall be determined based on the loading and slenderness ratio as per codal
provisions.
8.4.3 The mortar for the masonry shall be in cement mortar 1:6 for thickness 20cm and above and
1:4 for thickness 10cm.
8.4.4 All fair faces of masonry shall be plastered with cement mortar 1:4 mix 12mm thick and
rough surfaces with cement mortar 1:4, 15mm thick.
8.4.5 Minimum strength of bricks used shall be of class 35.
8.5.0 GENERAL REQUIREMENTS.
8.5.1 Points of concentrated stress involved such as corners, openings and interesting where
cracking is likely to occur shall be strengthened with steel reinforcement or PCC 1:2:4 mix.
The thickness of load bearing walls shall be sufficient at all points to keep the combined
stresses due to live, dead and other loads within permissible limits.
8.5.2 Where high strength bricks are used richer mix cement mortar shall be used.
8.5.3 All doors, windows and ventilator openings shall be provided with RCC lintels of required
thickness.
9.0.0 ROOFING AND ROOF TREATMENT.

This specification covers the specification to be followed for providing roofing ad roof
treatments for different structures.
9.1.0 ROOFING
9.1.1 RCC roof
Minimum thickness 10cm and grade M 15. Slope of 1/200 shall be provided for flat roofs. An
integral coat of cement plaster in cement mortar 1:3 average 6 mm thickness to be done on
the top of slab.
9.1.2 AC sheet roofing
Unless otherwise mentioned the thickness of roofing sheet shall be 6 mm. Slope of the roof
shall not less than 18 degrees. Half round a cave gutter with down shall be provided. Bolts
for fixing AC sheets shall be GI with rubber capping to prevent seepage. Wherever
necessary specials such as barge board, corner pieces apron piece, north light curve,
ventilation curve, etc., shall be provided. Where natural lighting is required not less than 2%
of the area shall be provided with translucent FRP sheets (1mm thick).
9.2.0 WATER PROOFING OR WEATHER PROOFING.
9.2.1 Type 1
Provide six course water proofing treatment using tar felt (type 3, gade1) and residual blown
bitumen and provided with 50 mm thick hollow clay tiles set in cement mortar and joints
sealed with bitumen compound grade A.
9.2.2 Type 2

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Water proofing treatment using admixtures like “ALGIPROOF” as per manufacturer’s

specification and provided with 50mm thick hollow clay tiles and joints sealed with bitumen
sealing compound.
10.0.0 DOORS / WINDOWS / VENTILATORS.

This section covers the specification to be followed for various types of Doors, Windows and
Ventilators.
10.1.0 STEEL DOORS, WINDOWS AND VENTILATORS.
10.1.1 This shall be made of standard section conforming to IS 1038 or hollow metal frames
sections confirming to IS 4351. Necessary fixtures such as mortice lock for door closers etc
shall be provided.
10.1.2 For control rooms like MCC, control room, etc., minimum 2 doors shall be provided on
opposite sides.
10.2.0 ALUMINIUM DOORS, WINDOWS AND VENTILATORS.
10.2.1 This shall be made of aluminum box or Z section confirming to relevant IS codes. The
sections used shall be of approved brand and design. Necessary fixtures like mortice lock,
handles, peg stays, floor spring, etc. shall be provided.
10.2.2 For control rooms, MCC and operations area like pump house, compressor house, DG set
room etc. glazing provided shall be of 5.5 mm thick wire glass.
10.2.3 For air conditioned rooms air lock facility shall be provided if specified.
10.3.0 ROLLING SHUTTERS.
10.3.1 For storage god owns, ware houses and plants where equipment are to be taken, steel
rolling shutters of required size confirming to IS 6248 shall be provided.
10.4.0 WOODEN DOORS, WINDOWS AND VENTILATORS.
10.4.1 The timber shall be used as specified. Only well-seasoned timber shall be used. The frames
shall be of minimum 100 x 70mm. The shutters used shall be one of the followings.
1. Panelled shutters for doors with 100 x 35 mm frames, 18 mm panel and bottom rail
with 150x35mm. There shall be a minimum of 5 panels per shutter.
2. Flush door shutter of block board core construction, 35 mm thick with teak veneered
face.
3. For windows and ventilators the shutter shall be glazed with 70 x 80 mm frames and
4 mm thick plain or ground glass. When specified, necessary window bars / grills of
approved design shall be provided.
4. For toilet PVC doors (PVC frames and shutter) of approved make or steel paneled
shutter doors shall be used as specified.
11.0.0 FLOORING AND FLOOR FINISHES.

This section covers the specification to be followed for different flooring and floor finishes
works.
11.1.0 Type 1
150 mm thick macadam sub base, over which 150 mm thick PCC 1:3:6 mix finished with
20mm cement mortar 1:3.
11.2.0 Type 2
150 mm thick macadam sub base over which 100 mm thick PCC 1:3:6 finished with 25 to 40
mm thick IPS.
11.3.0 Type 3
150 mm thick macadam sub base and 100 mm thick RCC floor with reinforcement of 20
kg/m^3 and finished with 6 mm integral coat of cement mortar 1:3.
11.4.0 Type 4
150 mm thick PCC 1:4:8 mix, finished with 20 mm thick plastering 1:3 and a floating coat.

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11.5.0 Type 5
100 mm thick PCC 1:4:8, finished with 20 mm thick. terrazzo tiles of approved design
(minimum mosaic thickness 6 mm) set in cement mortar 1:5, 18 mm thick.
11.6.0 Type 6
100 mm thick PCC 1:4:8 finished with 7 mm thick approved brand ceramic tiles set in
cement mortar 1:3 and using cement grout and joints finished with tile mate or equivalent.
11.7.0 Type 7
100 mm thick PCC 1:4:8 finished with 20 mm thick cement plaster in two coats mixed with
red oxide at 3.5 kg/bag of cement and polished.
12.0.0 FINISHING WORKS
This section gives the specification to be followed fir various finishing works.
12.1.0 PLASTERING
12.1.1 Type 1
Plastering to brick masonry, minimum 12 mm thick, using cement mortar 1:4.
12.1.2 Type 2
Two coats plastering to brick masonry works, minimum 20 mm thick and 3 mm second coat
12.1.3 Type 3
Plastering to underside of RCC with cement mortar 1:3, 10 mm thick
12.2.0 DADOING
7 mm thick ceramic tile dadoing over plastering for a height of 15 m from floor level using
approved brand tile.
12.3.0 PAINTING
12.3.1 Type 1
Painting with two or more coats of water proof cement paint approved brand and shade over
a coat of cement primer.
12.3.2 Type 2
Two coat of plastic emulsion paint (medium quality) of approved brand and shade over a
coat of primer.
12.3.3 Type 3
Two coats of oil bound washable distemper of approved brand and shade over a coat of
primer.
12.3.4 Type 4
Two or more coats of white washing / color washing with quick lime mixed with strainer.
12.3.5 Type 5
Two coats of Zinc chromate primer and two coats of approved quality and shade synthetic
enamel paint for steel structure.
12.3.6 Type 6
Two coats of Zinc chromate primer and two coats of approved quality and shade chemical
resistant enamel paint for steel structures.
12.3.7 Type 7
Two coats of Zinc chromate primer and two coats of approved quality and shade chlorinated
rubber paint for steel structures including surface preparation by sand blasting / rubbing with
emery paper.
12.3.8 Type 8
Two coats of approved quality epoxy paint over two coats of primer as per the
manufacturer’s specification for steel structure including surface preparation using sand
blasting / rubbing with emery paper.
12.3.9 Type 9
Two coats of approved quality wood primer and two coat approved quality and shade
synthetic enamel paint for wood work including surface preparation.

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12.3.10 Type 10
Two coats of poly Urethane (clear) mat finish over primer coat as per manufacturer’s
specification including surface preparation.
12.4.0 FALSE CEILING
12.4.1 Type 1
False ceiling using 4 mm thick plain AC sheets on steel frame work
12.4.2 Type 2
False ceiling using 4 mm thick plain AC sheet on Aluminum frame work
12.4.3 Type 3
False ceiling using 4 mm thick plain AC sheet on wooden frames
12.4.4 Type 4
False ceiling using 12 mm thick pre laminated phenol formaldehyde bonded particle board.
12.4.5 Type 5
False ceiling using enameled aluminium folded panels 5 mm thick using panel carries panel
clips, suspenders etc, of approved make like ‘LUXALOL’ and approved shape.
13.0.0 PROTECTIVE LINING

This section covers the specification for various types of protective linings used for different
purposes.
13.1.0 TYPE 1
40 mm thick acid/alkali resisting lining (class 2) over bitumen primer 10 mm mastic
membrane, potassium base silicate cement molten base and joints filled with phenolic resin
cement 20 mm depth.
13.2.0 Type 2
40 mm thick acid/alkali resisting lining (class 2) over bitumen primer 10 mm mastic
membrane, potassium base silicate cement molten base and joints filled with CNSL.
13.3.0 Type 3
Epoxy lining 3 mm thick with hardener resin filled mix of approved make as per
manufacturer’s specification
13.4.0 Type 4
50 mm thick mastic lining over bitumen primer
13.5.0 Type 5
Bitumen sand mix lining 25 mm to 50 mm thick using residual blown type bitumen and
course sand
14.0.0 WATER SUPPLY AND SANITARY WORKS.

This section covers the general requirements regarding the design of water supply and
sanitary works.
14.1.0 WATER SUPPLY
14.1.1 All external water lines shall be of HDPE class 4 quality with required fittings laid through
trenches with earth cushion.
14.1.2 All internal water lines shall be of PVC class 4 quality pipes. Wherever possible internal
water lines shall be concealed
14.1.3 The size of various pipes shall be designed taking n to account the water required, pressure
at supply point, minimum residual pressure at a discharge of (0.35 kg/cm^2), height of
building pressure drop due to various losses, etc. The C valve of the pipe may be taken as
per supplier’s specification.
14.1.4 Isolation valve, gun metal wheel valve, confirming to IS shall be provided for isolating the
water mains at branching points and at different floor levels so that repair works can be
attended by isolating such portion.

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14.1.5 When uninterrupted water supply is not available, overhead water tank (PVC) of required
capacity (minimum 1000 liters) shall be provided. Provision of scour, over flow, etc. shall be
provided.
14.1.6 Where sufficient pressure is not available for water necessary sump tank with pumping
arrangement shall be provided with overhead water tank.
14.2.0 SEWAGE LINES
14.2.1 All sewage lines outside the building shall be of glazed stone ware with a minimum diameter
of 100 mm.
14.2.2 Inspection chambers with RCC cover slabs shall be provided at all junctions.
14.2.3 The outlets for closets and urinals shall be connected to inspection chambers located as
close as possible to the building.
14.2.4 Building outlets from water closet and urinals only shall be taken to the septic tank.
14.2.5 Outlet from washbasins, sinks, bath rooms, etc. shall be connected to the drains through a
chamber.
14.2.6 When separate drainage scheme is provided all effluents can be connected to the same.
14.2.7 All internal outlets of washbasin, closets, sinks, etc. shall be of PVC Class 1 minimum 75
mm.
14.2.8 Necessary floor traps, gully traps (PVC shall be provided for all fittings like wash basin,
urinal, toilet, bath room, etc.)
14.2.9 Necessary ventilation pipe 75 mm dia. PVC with ventilating cowls and mosquito proof net
shall be provided.
14.2.10 External sewage lines shall be provided with manholes located not more than 30 m and at
all junctions/change of directions.
14.2.11 When the change of elevation is more than 1.5 m drop man holes shall be provided.
14.2.12 Wherever necessary septic tanks of required capacity provided as per the relevant IS codes
with provision for soak pit/dispersion trench.
14.2.13 All toilet fittings required like water closet, urinals, wash basin, low level flush tank, etc., shall
be of approved quality and make vitreous chinaware. Unless otherwise specified all fitting
shall be of white colour.
14.2.14 Necessary fittings such as pillar cock, stop cock, waste coupling of basin shower heads and
connection pipes with nuts shall be of best quality chromium plated brass.
14.2.15 Towel rails shall be of anodized aluminium.
14.2.16 Wash basin shall be provided with 4 mm thick mirror (size 450 mm x 300 mm) with plywood
backing.
14.2.17 Soap trays of vitreous china ware to be provided for bath rooms.
14.2.18 Urinals shall be of wall mounted front lipped urinal. Where urinal partitions are required it
shall be of marble slab 25 mm.
14.2.19 The finished floor level of toilet shall be kept 20 mm below the adjoining floor level by
providing necessary sunken slabs.
15.0.0 ROAD WORK

This specification covers the requirement governing the design and specification for roads.
All design shall be done based on the relevant Indian standard codes and high way
manuals.
15.1.0 ROAD DIMENSIONS
15.1.1 Width of primary roads : as specified
15.1.2 Width of secondary roads : as specified
15.1.3 Inside edge turning radius for primary roads : 6500 mm
15.1.4 Road camber
a IBM road 1/30 to 1/48

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b Bituminous road 1/48 to 1/60

c Concrete road 1/70 to 1/80
15.1.5 Maximum drop of from centre to edge : 150mm
15.1.6 Ruling gradient on plan ground : 1/30
15.1.7 Limiting gradient on plain ground : 1/20
15.1.8 In embankments RCC guards stone 250mm dia shall be provided on either side of the road
at minimum spacing of 3 meters.
15.1.9 Culverts shall be designed for IRC loading depending on the type of road.
15.2.0 WATER BOUND MACADAMSUB BASE (SOILING)
15.2.1 In filled up soil and black cotton soil WBM sub base shall be done using 90 mm to 40mm
size stone for a thickness of 230 mm
15.2.2 In cutting area where soil is loose WBM sub base shall be done using 90mm to 40mm size
stone aggregate for a thickness of 150 mm. WBM sub base need not be provided where soil
is ordinary rock/ hard laterite/hard rock.
15.3.0 WATER BOUND MACADAM BASE COURSE (METALING)
15.3.1 Provide and lay water bound macadam base course with stone aggregate 63mm to 40mm
including sorting spreading to template and consolidating with road roller complete including
spreading and consolidating blinding material 115 mm thick.
15.4.0 WBM BASE COURSE (REMATALLING)
Provide and lay WBM base course over scarified metalled surface with stone aggregate 50
mm to 20mm size, 75 mm thickness
15.5.0 BITUMEN SURFACE FINISHING
15.5.1 Bitumen concrete surfacing
Provide and lay 50 mm thick bitumen concrete surfacing using stone aggregate 4.8 m³
(60% 25 mm nominal size ) per 100m² and course sand 40% 20mm nominal size per 100
m² and course sand 2.4 m³ per 100m² provided. With host S90/A90 or equivalent bitumen
approved quality at 56 kg/m³ of stone aggregate and 128 kg/ m³ of sand over a tack coat
of 0.75kg/m³ including finishing, etc. complete.
15.6.0 CONCRETE SURFACE FINISH
The reinforced cement concrete surfacing shall be done using M15 mix concrete, 150 mm
thick. The concrete shall be reinforced using welded fabric if the width of the carriage way is
more than 4.5 the concreting shall be done strip viz a longitudinal joints shall be provided in
the centre. Along the length of the road joints shall be provided every 15 m. The joints shall
be20mm wide and shall be filled with the pre moulded expansion joints strips. A levelling
course of 80mmthick shall be provided below the reinforced slab using 1:4:8 concrete
mixes. The surface of the road shall be rough finished.
16.0.0 BUILDING AND STORM WATER DRAINAGE

16.1.1 The rain water collected from the roof shall be connected to the storm water drainage
system.
16.1.2 Sufficient number of down water pipes shall be provided to drain out the water from the roof
depending upon the roof area and intensity of rain fall.
16.1.3 The minimum diameter of down water pipes shall be 100mm and shall be of PVC.
16.1.4 Drains shall be laid under the building only in unavoidable circumstances.
16.1.5 Where it is necessary to lay drain under a building, following conditions shall be satisfied
A Pipe shall be of cast iron
B The drain shall be laid in a straight line at a uniform gradient
C Means of access in the form of materials shall be provided at each and immediately
outside the building.

12FT012/18
QUALITY 12ES001/18
16.1.6 All drain pipes shall be designed to discharge three times of the dry weather flow flowing
half full with a minimum self-cleaning velocity of 0.75 m/second.
16.1.7 Storm water drains outside the building shall be rubble or brick with 15 mm thick cement
plastering of 1:4 mix two coats for rubble masonry and 12 mm thick cement plastering of
1:4 mix two coats for brick masonry drains RCC drains of mix 1:2:4 can also adopted.
16.1.8 Effluent drains shall be suitably lined if required based on process requirement.
16.1.9 The minimum slope of drains shall be 1/300. Cover slabs with adequate thickness and
reinforcement shall be provided at road crossing and at places specified to suit project
requirement.
16.1.10 Reinforced cement concrete or cast iron pipe of suitable diameter with sufficient earth
custom can also be provided depending on the conditions outside the building.
16.2.0 CABLE TRENCHES
16.2.1 Cable trenches shall be provided inside the plant building and outside the plant buildings to
suit the Electrical requirements.
16.2.2 The cable trenches are usually constructed either in brick masonry or reinforced cement
concrete depending on the size of cable trenches and space availability. For brick masonry
cable trenches the bed slab shall be of cement concrete 1:3:6 mix 150mm thick.
16.2.3 For fixing cable racks in cable trenches 150 x 150 x 8 mm thick MS insert plate shall be
provided in the side wall of RCC cable trenches in brick masonry cable trenches the insert
shall be provided by giving by giving 200 x 200 mm size
16.2.4 Reinforced cement concrete cover slabs or chequered plate of suitable size and thickness
shall be provided as specified.
16.2.5 A bed slope of 1/400 provided
17.00 LIQUID RETAINING STRUCTURES

This section covers the requirements governing the specifications to be followed for design
and construction of liquid retaining structures
17.1.0 Design be conforming to IS 3370 Part I to IV (latest)
17.2.0 M20 grade concrete with minimum cement concrete of 363 kg/m³ or 1:1 ½:3 nominal mixes
shall be used.
17.3.0 for tanks resisting on grounds 1:3:6 mix levelling course shall be provided.
17.4.0 The provisions regarding expansion joints, construction joints bitumen painting above
levelling course etc. shall be made as per code.
17.5.0 PVC water bars 230 mm wide shall be used where ever necessary.
17.6.0 All embedded parts such as nozzles, pipes, bolts, etc shall be provided at the time of
concreting.
17.7.0 Plastering with cement mortar 1:4, 10 mm thick mixed with admixtures like impermo, acco
proof, etc shall be provided for inside hydro test only.
17.8.0 All leaks or wetting noticed during hydro test shall be rectified as per approved methods,
using approved materials.

12FT012/18
NOTES:-
32644-13-PS-001
TECHNICAL SPECIFICATION FOR ELECTRICAL INSTALLATION
PAGE 1 OF 1 R0
TPS NO. 32644 - 13 - PS - 001
STATUS ENQUIRY COMMITMENT
ORIGINATING DEPT. ELECTRICAL
P.O / W.O NO.
PROJECT Construction of Phosphoric Acid storage tank at Q10 berth W. Island
LOCATION WILLINGTON ISLAND
CLIENT M/s.FACT-CD
PURCHASER M/s.FACT-CD
VENDOR
ITEM: SUPPLY AND INSTALLATION OF ELECTRICS
0 06-06-2020 Original issue SM IK IK

00FT004 / 14

ELECTRICAL TECHNICAL SPECIFICATION FOR ELECTRICAL
DEPARTMENT INSTALLATION Page 1 of 2
Rev. No. with

No. of Issue
Pages
1 2 3 4
TECHNICAL
1.0
DOCUMENTS
Schedule of work- supply and installation of 1 1
1 32644-13-PS-001 SIW
electrics
2 32644-13-PS-001 SW Scope of work & special requirements 4 0
3 32644-13-PS-001 SPL Specification for erection, testing & commissioning 10 -
4 32644-13-PS-001-INS Scope of Inspection and Tests 4 0

5 00ES001/01 Vendor Data Submission Procedure 3 -
6 32644-13-PS-001-VDI Vendor Data Index 1
32644-13-TS-001-
7 Vendor Data Requirements 4 0
VDR ELEC
Engg Specification – General Requirements for
8 13ES900/14 4 -
Electrics
9 32644-13-DA-90001 Data sheet – General Requirements for Electrics 1 0
10 13ES924/14 Engg Specification-Electric for Turnkey Installation 10 -
11 32644-13-DA-924-01 Data Sheet- Turnkey installation 5 0
Technical particulars- Electric for Turnkey
12 32644-13-TP-924-01 6 0
installation
Engg Specification – Medium Voltage 16 -
13 13ES906/14
Switchboards
14 13ES 930/14 Engineering Specification-Cables 2 -
15. 13ES 911/14 Engg. Specification-Push button station 3

Engg. Specification-Medium Voltage Induction 6 -
16. 13ES910/14
Motor
Engg specification for fabrication of cable trays 2 0
17 13ES914/14
and structural steel
18 13ES915/14 Engg. Specification – Cabling Installation 4 -
19 13ES916/14 Engg. Specification – Earthing 4 -
20 13ES927/14 Engg. Specification-Lighting Installation 6 -
21 32644-13-PS-001 SV Sub Vendor List 2 0
22 32644-13-PS-001 CS Compliance Statement 1 -
0 06.06.20 ORIGINAL ISSUE SM IK IK

00FT011 / 14

ELECTRICAL TECHNICAL SPECIFICATION FOR ELECTRICAL
DEPARTMENT INSTALLATION Page 2 of 2
2.0 Drawings
1 32644-13-SD-00101 Single Line Diagram of Power Distribution(typical) 1 1
2 32644-13-PL-00501 Overall Power Layout (typical) 1 1
3 32644-13-GE-00251 Typical arrangement of cable riser 1 0
4 32644-13-GE-00252 Typical arrangement of over head cable tray 1 0
5 32644-13-GE-00253 Typical arrangement of earthing junction plate 1 0
6 32644-13-GE-00254 Typical details of buried cables 1 0
7 32644-13-GE-00255 Typical details of cable trench section 1 0
8 32644-13-GE-00256 Earthing connection details(typical) 2 0
Arrangement of canopies for outdoor devices 2 0

9 32644-13-GE-00257
(Typical)
Typical arrangement of copper bonded electrode 1 0
10 32644-13-GE-00258
earth pit

ELECTRICAL SCHEDULE OF ITEMS OF WORK
DEPARTMENT
TECHNICAL SPECIFICATION FOR ELECTRICAL INSTALLATION 32644‐13‐PS‐001SIW R0
SL No DESCRIPTION OF ITEM QTY UNIT AMOUNT

Rate Amount IGST Total
(₹) (₹) (₹) Amount(₹)
1.0.0 ELECTRICAL
Supply, Erection, Testing, Commissioning and Handing over of following electrical equipment
as per scope of work detailed below.
1 415V,35MVA.TPN, Motor Control Centre(MCC)
1 LS
2 415V, 4Way 3phase Lighting Distribution board in cast aluminum enclosure, light fittings
including all accessories and welding socket outlets 1 LS
3 Local Control Stations for ON/OFF control of MV motors in , weather proof, cast Aluminium
1 LS
enclosure with canopies .
4 Cables and Cabling 1 LS
5 Earthing and lightning protection
1 LS
6 GRP/FRP cable trays and structural steel items 1 LS

7 Excavation and back filling for cable trenches and supply of brick and sand for cable laying
1 LS
purposes.
8
Miscellaneous items like GI pipes, insulation mats , danger notice plates, resuciation charts 1 LS
cable router marker testing of motors,cutting of roads, concrete, etc
TOTAL
Say
0 06.06.20 SREENATH.M-DM(Elec)
FACT ENGINEERING AND DESIGN
INDULEKHA.K-DGM(Elec) INDULEKHA.K-DGM(Elec)
ORGANISATION
REV DATE PREPARED CHECKED APPROVED
Page 1 of 1 FACT ENGINEERING AND DESIGN ORGANISATION
32644-13-PS-001SW R0
ELECTRICAL SCOPE OF WORK & SPECIAL REQUIREMENTS
Page 1 of 4
DEPARTMENT
1.0 INTRODUCTION
1.1 M/s.Fertilizers and Chemicals Travancore Ltd (FACT) a Govt. of India Undertaking is planning for
constructing two numbers of Phosphoric acid tanks and associated facilities at Q10 berth area
Willington Island.This requisition is issued for the supply and installation of electrics envisaged for
above work
2.0 SCOPE OF WORK
2.1 The scope of work of this requisition covers the design, and detailed engineering, procurement,
manufacturing, testing at works, supply, dispatch, storage, handling erection, testing and
commissioning of all electrics required for the package, fully conforming to standards and
specifications.
Scope of work shall also cover preparation and submission of documents and handing over of the
installation as per enclosed details, specifications, data sheets, schedule of items of work,
drawings, etc. Power supply at 415V,250A,TPN,50Hz will be made available by the client at the
existing MCC/ MV Switch board located in the substation building. Further distribution of power
supply shall be carried out by the contractor. Cables shall be laid though over head GRP cable
trays inside substation building. Cables shall be laid through GRP cable trays wherever pipe
supports,building walls etc are available. Cables shall be laid through buried cable trenches
wherever pipe bridges are not available. Cables to drive motors shall be taken through GI conduits
in paved area.RCC hume pipes shall be used for laying cables at road crossings.MV switch
board/MCC under the scope of contactor shall be located in the Heavy equipment workshop.Drive
motors for acid transfer pumps and sump pump,feeders for lighting and two numbers of welding
socket outlets for tank area etc. shall be fed from above switch board.ON,OFF and trip indications
of pumps shall be made available at the existing control room.
Bidder shall furnish Load list, single line diagram of power distribution, cable schedule, cable sizing
calculations, power layout, earthing layout and lighting layout drawings etc for the approval of
consultant/client.
All the drawings shall be submitted to Owner/ Consultant for approval. However, approval of the
drawing shall not relieve the LSTK contractor from its responsibility of delivering the project as per
tender terms & conditions.
Weather proof and acid resistant well glass LED type light fittings shall be provided for the stairs
and hand rails of tanks.WP and acid resistant type LED flood lights shall be provided on the top of
the tanks for illuminating area around dyke wall and roads.
Two numbers of copper bonded type earth electrodes shall be provided near heavy equipment
workshop for earthing MV switch board and lighting distribution boards.Local Control stations ,drive
motors ,Junction boxes etc shall be earthed in duplicate and shall be connected to earthing system
. All steel structures, tanks, vessels, pipes, pipe joints, valves etc. shall be earthed against
static charge accumulation .Separate earth pits shall be provided for tanks.Earth pits shall
be interconnected and shall be connected to nearest existing earth pits using 150 sq.mm
PVC covered Aluminium conductor cable. Hoods (using aluminium sheet) shall be
provided for drive motors and local control station located in outdoor area as per the
drawing enclosed with the tender documents.
2.2 The Electrics include the following but not limited to the following
0 2-6-‘20 ORIGINAL ISSUE SM IK IK

32644-13-PS-001SW R0
Page 2 of 4
DEPARTMENT
Supply and installation of MV switch boards/MCC.

Testing and commissioning of MV motors
Supply and installation of Local control stations (push button stations), welding receptacles etc.
Supply and installation of 650/1100V,XLPE insulated,PVC sheathed armoured,FRLS aluminium &
650/1100V,XLPE insulated PVC sheathed armoured FRLS copper cables ,
Earthing and lightning protection
Lighting including supply and installation of lighting fixtures, DBs etc.
Supply and installation of GRP cable trays and steel structural supports
Miscellaneous civil works
Supply and installation of miscellaneous items
Providing service personnel
Preparation of detailed drawings and documents for approval
Furnishing vendor drawings for approvals for supply items
Preparation of drawings
Site test reports
Rendering necessary assistance and preparation of documents for statutory approval covering all
Electrical installation
2.3 Installation work is inclusive of supply of erection materials, hardware, consumables and sundry
items required for the installation.
It is the responsibility of the bidder to supply and install all items, that are incidental and
necessary for the completion of the installation, whether specifically mentioned or not, so that
the installation complies with the standards and regulations specified.
2.4 Associated civil and structural works such as chipping, plastering, grouting, minor brick and
concrete works, excavations, fabrication, painting and any other work necessary for completion
of the installation shall be included in the scope of work. Separate charges shall not be applicable
for the above unless otherwise indicated in Schedule of items of Work.
2.5 The bidder shall furnish all labour (supervisory, skilled, unskilled and administrative), transport
vehicles, generator sets, welding machines, gas cutters, erection tools and tackles, cleaners,
crimping devices, blow lamp, handling equipment, testing equipment, etc, and any other
such equipment necessary for installation, testing and commissioning, at no extra cost to the
purchaser.
2.6 It is the responsibility of the bidder to pay wages and salaries to the persons employed and ensure
that all labour rules and acts are complied with. Contributions, fees, etc. necessary in this
regard shall be paid and the bidder shall maintain all necessary records.
2.7 All consumable materials such as insulation tape, cleaning and paint brushes, welding
electrodes, rust preventive materials, jute, cotton waste, hacksaw blades, bolts, nuts,
corrosion inhibitive grease, fuel, lubricants, etc and any other material required for carrying out
the work shall be included in the scope of the bidder.
2.8 Work shall be started and carried out in accordance with the terms and conditions, approved
drawings, specifications and requirements as set forth in this document and instructions of the
purchaser or his authorised representative from time to time.
2.9 Where supply of materials are involved, the scope shall include design, manufacture, assembly,
testing, and inspection at works, packing and delivery at site.
2.10 Testing and commissioning works include calibration, all pre-commissioning tests, checking of all
wiring and connections for power, control, metering,
protection, alarm, annunciation, lighting, and earthing. Testing and commissioning of all the
equipment covered in this contract shall be carried out as per relevant standards or as directed by
the purchaser.
2.11 Bidder shall carry out clearing of all construction waste materials and loose earth, which might

32644-13-PS-001SW R0
Page 3 of 4
DEPARTMENT
have collected in and near the work site consequent to execution of the work under this
contract. Also all temporary structures erected by the bidder shall be removed.
3.0
STATUTORY APPROVAL
3.1 It shall be the responsibility of the bidder to ensure that complete installation supplied and/or
erected by him fully meets with the relevant standards, Acts, Rules, Regulations, etc applicable.
Also it shall be the responsibility of the bidder to obtain approval of statutory authorities like
Electrical Inspectorate.
3.2 Preparation of any additional drawings/documents required for obtaining statutory approvals
including those of Electrical Inspectorate, Central Electrical Authorities(CEA,Chennai), etc other
than what is supplied along with this specification shall be included in the scope of the bidder.
Any major deviation in the power distribution scheme envisaged for the project, which may not be
acceptable for the statutory bodies, shall be pointed out in the offer submitted.
3.3 Any modification/rectification required by the Purchaser/ Electrical Inspectorate resulting from the
improper installation by the bidder or to make the same in full conformity with the relevant
standards, Acts, Rules, Regulations, etc applicable for the installation shall be carried out by the
bidder, without any extra cost to the Purchaser.
4.0 DRAWINGS AND DETAILS ENCLOSED WITH THE TENDER
4.1 The drawings enclosed are only typical for the guidance of the bidder to formulate the bid and to
furnish his rates and prices
4.2 Preparation, completion and handing over the documents and updating the drawings to "AS BUILT"
status as per requirement and direction of purchaser/Engineer-In-Charge shall be included in the scope
of bidder
4.3 All the available data have been furnished in this requisition. If any other data is additionally
required, the bidder shall obtain the same from purchaser
5.0 CONSTRUCTION POWER
5.1 The bidder shall make their own arrangement for construction power, unless otherwise stated
elsewhere.
6.0 CONTRACTOR'S LICENSE
6.1 The bidder shall possess a valid and competent Electrical Contractor License (class
A)issued by the State Electricity Licensing Board for carrying out electrical installation
works in the State where project site is situated.
6.2 True copies of the relevant pages of the Electrical Contractor License possessed by the
Bidder shall be furnished along with the technical offer for substantiating the validity and
scope of the license.
6.3 The license shall be produced for verification on request by the purchaser.
6.4 All wiremen, electricians, and supervisors engaged by the bidder for the above work shall
possess necessary valid license issued by State Electricity Licensing Board. These shall be
made available for scrutiny of the Purchaser.
7.0 SPECIAL NOTES
7.1 All exposed MS parts included in the supply scope of the bidder shall be painted with two coats of
epoxy based paint over suitable primer at no extra cost to the purchaser.
7.2 The scope of work shall include painting feeder names, equipment numbers, circuit numbers,
etc., with suitable sized characters as directed by the Site-In-Charge on equipment,

32644-13-PS-001SW R0
Page 4 of 4
DEPARTMENT
devices associated with this work at no extra cost. All materials required for the above
shall be supplied free of cost by the bidder.
7.3 All mounting hardwares and external hardwares of electrical item shall be of stainless steel
considering installation in corrosive/saline atmospere near sea shore.

ELECTRICAL 32644-13-PS-001SPL
SPECIFICATION FOR ERECTION TESTING AND
DEPARTMENT COMMISSIONING Page 1 of 10
1.0 SCOPE
1.1 This specification covers the engineering requirements for erection/installation,
testing and commissioning of electrical equipments/items and its associated works.
2.0 STANDARDS
Erection, testing and commissioning of the equipment covered shall be done as per
standard codes of practice and shall comply with requirements of following Indian
standards and other relevant standards. Indian Electricity Rules and acts and also to
the regulations that are in force at the place of installation.
IS:335 : Specification of new insulating oil
IS :900 : Code of practice for installation and maintenance of induction motors
IS: 1255: Code of practice for installation and maintenance of power cables up to and
including 33KV rating
IS: 1866: Code of practice for maintenance and supervision of mineral insulating oil
In equipment.
IS: 5216 : Guide for safety procedures and practices in Electrical work
IS: 6792: Method for determination of electric strength of insulating oil.
IS: 9124: Code for maintenance and field testing of electrical relays.
IS:10028: Code of practice for selection ,installation and maintenance of
Transformers-part-2 installation
IS:10118:Code of practice for selection ,installation and maintenance for switch gear
And control gear-part-3 installation.
IS: 13408: Code of practice for the selection, installation and maintenance of
Electrical apparatus for use in potentially explosive atmospheres (other than
mining application of explosives Processing and manufacture).
3.0 REFERENCES
3.1 Following documents shall be read in conjunction with this specification:
- Scope of work and special requirements
- Engineering specification and Data Sheets of General Requirements
of Electrics.
- Engineering specification and Data Sheets of Cabling and earthing installation,
installation of outdoor switchyard equipments.
- Engineering specification of Lighting Installation and fabrication of cable trays and
structural steel.
- Drawing and other documents enclosed with the specification.
4.0 GENERAL
4.1 The erection/installation testing and commissioning shall be carried out in accordance
with specifications ,data sheets, drawings, manufacturer’s recommendations, relevant
standards or as directed by Owner/Engineer-in-Charge. Requirements regarding
erection/installation, testing and commissioning of switch boards, transformers, motors,

REV. DATE DESCRIPTION PRPD. CHKD. APPRD.
FACT ENGINEERING DESIGN ORGANISATION

00F121A/14
push button stations, battery and battery charger etc. are generally explained herein. It
is the responsibility of the contractor to supply all equipments, items, accessories,
materials, tools, tackles, transporting and lifting vehicles, consumables etc. required for
unpacking, checking, transportation, storage, safe custody, installation, erection,
testing, commissioning, return of unused equipment/items which are supplied from
owner’s stores and handing over of the electrics to the entire satisfaction of the owner.
4.2 The erection scope shall include supply of all hardwares and accessories such as bolts,
nuts, washers, gaskets, cable termination accessories, lugs, paint, primer, sand etc.
required for completeness of the work. All consumable materials such as insulation
tape, cleaning and paint brushes, welding electrodes, rust preventive materials, jute,
cotton waste, hack saw blades, bolts, nuts, inhibitive grease, fuel, lubricants, etc. and
any other material required in carrying out the work but not for incorporation in to the
permanent work, shall also be included in the scope of contractor.
4.3 The equipment/items erected shall be handled with care by experienced riggers under
the guidance of a competent supervisor. Proper handling and transporting equipments
are to be used and dragging is to be avoided.
4.4 The equipment/items supplied by the Owner shall normally be kept at their stores. The
contractor shall inspect these items at the stores by unpacking the containers, if
necessary. Damages and short supplied items, if any found shall be reported to the
Owners representative in writing prior to taking delivery. The responsibility of safe
custody of these items after taking delivery and till handing over shall rest with the
contractor. Unused materials and containers shall be returned to the stores.
4.5 The items supplied by the Owner shall be transported from the point of storage to the
point of erection/installation using proper capacity transporting vehicles. The scope
shall include unpacking the containers, assembling parts, fixing loose items,
components, etc.
4.6 Materials supplied by the contractor or issued by the Owner shall be given suitable
protection against weather, dust and vermin. In storage places, equipments shall be
placed over wooden sleepers to keep them above ground.
4.7 Before carrying out erection/installation works of any item, proper care regarding
levelling, alignment, access to working parts, facilities for removing the items for repair,
statutory clearance, etc. shall be taken.
4.8 Foundation bolts, nuts, lock nuts, washers, etc. will normally be supplied by the
equipment supplier. Any further requirement of these items shall be under the scope of
contractor. The equipment shall be installed on the foundation bolts firmly such that
there will not be any vibration during operations.
4.9 The push button stations, power junction boxes, switches, isolators, etc. if any, shall be
mounted at convenient places like walls, columns, pedestals, cable rack supports, etc.
Pedestals where ever required shall be fabricated from the steel sections used for
fabrication of cable supports, racks, etc. and installed.
4.10 For mounting of equipment/items on the walls/columns/ supports, suitable MS/GI
brackets shall be fixed/ grouted.
4.11 Electrical connections shall be done with great care using spring washers, bimetallic
strips, conducting grease , etc. wherever required to ensure good contact without
creating undue stresses. Copper busbar joints shall be made after tinning the contact
13F121A/14

area. Supply of all required accessories or electrical connections shall be included in

the contractor’s scope.
4.12 Discrepancies if any found between drawings/statutory requirements and actual
conditions at the site, shall be immediately brought to the attention of owners
representative.
4.13 If any modification is found required in the wiring or to suit site condition the same shall
be carried out as per the instruction of the Engineer-in-Charge without any extra cost.
4.14 All equipments under erection shall be kept properly cleaned and free of dust, vermin,
moisture, etc.
4.15 After erection it shall be ensured that no foreign materials, tools or tackles are left in the
equipment. All unused cable entries, cutouts, etc. shall be sealed properly. For
hazardous area blanking plugs suitable for the area classification applicable shall be
used.
4.16 All tests shall be carried out in the presence of Owner’s representative and test shall be
recorded on an approved proforma duly certified. The records of all tests shall be
submitted to the purchaser’s representatives.
4.17 All interconnected wiring shall be checked thoroughly for correct connection with the
wiring, and schematic drawings of the manufacturer and the drawings supplied by
owner before energising.
4.18 All power and busbar connection shall also be thoroughly inspected and checked for
connections, foreign materials, tightness, etc. before energising the equipments.
4.19 All components within the main equipment shall be tested for proper performance and
correct operation before commissioning the equipment.
4.20 All labelling shall be checked for correctness.
4.21 All nuts, bolts, clamps, joints, connections, etc. shall be checked for tightness and
tightened wherever required.
4.22 All moving parts shall be checked for its correct movement and proper lubrication.
Apply lubrication wherever required.
4.23 All equipment containing liquid shall be checked for correct quantity filling and all
gaskets, walls, etc. shall be checked for leak proofness. Oil filling, if found required,
shall be done dry and clean oil. Gaskets shall be replaced if found required. The
condition of the oil shall be tested in accordance with I.S. 335.
4.24 It shall be ensured that all CT leads are loaded or shorted prior to testing and
commissioning.
4.25 Insulation tests shall be carried on all electrical devices, whether specifically mentioned
or not, as per this work after properly cleaning these devices.
4.26 All the relays and its settings after commissioning shall be furnished to owner detailing
relay type no., panel no. etc.
4.27 In case of any component of an equipment supplied by the owner is found to
faulty/unsuitable, the same shall be replaced by the new one issued by owner.
4.28 Parts of relays blocked for transportation should be released according to
manufacturer’s instruction.
13F121A/14

4.29 All relays, before installation, the rating, range and auxiliary supply voltages for the
relay should be checked against drawings/schematic/schedule.
4.30 Relays shall be checked and tested for insulation, pickup value, dropout value, timing,
polarity, directional unit sensitivity, stray torque check, slop characteristic, etc.
4.31 Local control stations, Distribution Boards (DBs), welding receptacles, etc. shall be
mounted at a height of 1.5M from operational floor, on pedestals/walls/structures etc.
by grouting/fixing suitable frames.
4.32 Polarisation test shall be conducted, wherever specified. The polarisation index is the
ratio of the 10 minutes resistance value to the 1 minute resistance value.
5.0 CIVIL AND STRUCTURAL WORKS
5.1 Miscellaneous civil works associated with the erection/ installation work such as
excavation, dewatering and refilling of earth work for earth pits and cable trench,
chipping, grouting, small cutting, etc on floors/walls/columns/structures and bringing
back the same to original finish, grouting of supports, providing suitable fixing
arrangements for cables, push button stations, DBs etc shall be included in the
rates quoted for erection of the respective items, unless specifically excluded in the
‘Schedule of Items of Work’.
5.2 All structural works associated with cabling, earthing, lighting, equipment erection
and supporting arrangements shall be included in the scope of the contractor. All the
welding and cutting works shall be carried out by certified welders.
5.3 Painting shall be done on all MS materials provided by the contractor such as base
channels, frames, supports, pedestals, cable trays/racks/risers, enclosures,
boxes, conduits, chequered plates, etc. Before painting the surface should be
thoroughly scrapped and cleaned to remove dust, grease, plaster or any other
foreign materials. It is the responsibility of the contractor to supply and install all
the required materials for painting including paint.
5.4 Cement concrete footing shall be provided for push button stations, cable
trays/racks/risers, pedestals, supports, etc. Footing shall be provided using 1:2:4 PCC
with 20mm broken stone. It is the responsibility of the contractor to supply and install all
materials such as cement, river sand, reinforcement rods, 20 mm broken stone, etc
without any extra cost to owner.
5.5 All concrete works and grouting shall be cured for a minimum period of 48 hours.
5.6 Necessary MS plate inserts will generally be provided by the purchaser on walls,
concrete slabs, beams columns, etc. Any additional requirement of MS plate inserts,
as required by Owner, on walls, concrete slabs, beams, columns, etc shall be under
the scope of the contractor. The inserts shall be provided by using MS plates properly
hooking using MS rods of sufficient diameter and welding this to the reinforcement
rods of concrete slabs, beams, columns, etc., as the case may be.
5.7 Chipping, grouting, etc., as recommended shall be done for completion and
installation work on the finished floor, wall, roof, etc. It is the responsibility of the
contractor to supply all necessary materials and to bring the disturbed surface to
the original finish.
5.8 Touch up painting of scratches found on equipment, other painted metallic surfaces,
galvanised structures, etc associated with this work is also included in the
scope of the contractor without any extra charge for same. Base steel structures shall
13F121A/14

be painted with 2 coats of epoxy primer and 2 coats of epoxy paint.

6.0 TRANSFORMERS
6.1 While taking delivery, transformers shall be examined for any sign of damage in transit.
Also ensure that all nuts/clamps are tightened properly. Transformers shall be handled
carefully. Transportation shall be done either by truck or trailer of sufficient capacity.
6.2 The transformers installation shall be carried out in accordance with IS:10028.
Transformer foundation/plinths will be constructed by purchaser/owner. Loose items
supplied along with the transformer shall be fixed in position as per manufacturer’s
drawings/documents/instruction manuals.
6.3 The transformer shall be transported or erected only with suitable capacity
vehicles/equipments. While lifting a transformer, ensure proper balance and that lifting
change does not interfere with any part of the transformers.
6.4 The transformer shall never be placed directly on the ground nor left without putting in
wheel stoppers.
6.5 The transformer shall be installed on the channels/plates/racks grouted to the floor.
6.6 The transformer shall be levelled, aligned and checked for free movement on the
wheels and stoppers shall be fixed to stop further free movement.
6.7 Verify whether all accessories supplied loosely are fitted up as per manufacturer’s
recommendations. Fix up loosely supplied CTs, if any as part of REF protection,
Earth leakage, etc. while fixing the cooling tubes, ensure that these tubes are flushed
with hot oil.
6.8 Whenever blanking plates are removed to fix detached parts such as bushing,
components, etc. a new gasket shall be used while fixing the same.
6.9 When the oil is despatched to site separately, it is usually in sealed drums. At the time
of filling the oil, it shall be ensured that the oil is filtered, clean and dry. The oil used for
filling or topping up shall comply with IS:335.
6.10 The condition of oil should be checked before use. Samples of oil from the
transformers should be taken from the bottom of the tank. When samples are taken
from drum, they should be taken from the bottom after the oil has been allowed to settle
at least for 24 hours.
6.11 Test the oil contained in the transformer and extra oil supplied for topping up for
dielectric strength and acidity as described in IS:335 and IS:6792.
6.12 Top of the transformer without the oil getting contaminated with dust and
moisture. Oil filling shall be done through the bottom drain valve with all air vents
opened to prevent formation of air pockets. The oil shall be filled through a stream
line oil filter using flexible metallic hoses. Flow of oil shall be reduced towards the final
stage to prevent internal pressure build up. After completion of oil filling, sufficient time
shall be allowed for the oil to spread all over and air bubbles to escape.
6.13 Ensure the electrical and earth connection are proper, Whenever gasketted flanges
are provided earth connection between flanges shall be provided to by pass fault
current flow.
6.14 Ensure that the valves in the oil path are open and drain valves are closed.
6.15 Ensure that Buchholz, temperature and level protections are operative and
13F121A/14

settings are proper.

6.16 Measure IR values of Transformer windings and control circuits using suitable Megger.
6.17 Identify the vector group of transformer, if necessary.
6.18 Conduct polarity test, insulations test, dielectric test, volume resistivity, acidity and
water content test, ratio tests on all tap positions, load tests, magnetic balance test, etc.
6.19 Measure polarisation index for transformers.
6.20 Conduct simulation test on Buchholz, temperature, oil level trip/alarm circuits.
6.21 Verify calibration of temperature and oil level indicators.
6.22 Complete details regarding the preparation of the transformer before initial charging
shall be supplied by the transformer manufacturer and design has to be strictly followed
by contractor. Transformer rated above 1MVA, when energised for the first time the
voltage should be built up gradually.
6.23 After energisation of the transformer, the following observation shall be made/recorded
for 24 hours on hour basis at no extra cost.
1. Current and voltage for each phase.
2. Over heating of any part of transformer
3. Abnormal noise or humming
4. Events of alarm and trip
5. No load and magnetising in rush current
6.24 If the transformer oil is found to have poor dielectric strength, the oil shall be
dried out as described in IS 10028. Normally the streamline filter shall be used for
drying up. The curve, Insulation Resistance and Temperature vs Time shall be
furnished. Before drying out check any oil leakage through bushings and radiators,
transformer tank is connected to earth temperature indicators are suitably calibrated,
capillary tube connection made to respective temperature indicators, etc. The dielectric
strength of oil should be tested using a standard oil test kit. The oil should withstand at
least 40 KV for one minute with the spear gap of 4mm as per IS:335. If the dielectric
strength is less than that specified above, oil should be cleaned, heated, filtered and
reconditioned properly till the above result is archived. Charges for filtering specified
“schedule of items of work” shall included charges for filtering unit provided by
contractor at site.
7.0 SWITCHBOARDS
7.1 The details of switch boards such as, appropriate overall dimension and weight etc. are
specified in the “Schedule of items of work”.
7.2 For convenience of packing and transportation, switch boards are sent from
manufacturer’s works in convenient shipping sections. Breakable items like meters,
relays etc. are sent separately. The contractor shall list out the items received and
listing out any damaged or short supplied items and furnish the same to
owner/Engineer-in-charge.
7.3 Grouting pockets are generally provided on the respective floors by owner. The
channels/bolts shall be rigidly grouted on the pockets of floor by contractor. Necessary
chipping, grouting, filling, painting etc. shall also be done by the contractor. Where
grouting pockets are not provided by the owner required pockets shall be made by
13F121A/14

contractor by chipping the floor at no extra cost.

7.4 The switch boards shall be installed on the foundation firmly such that there is no
vibration during tripping or closing of breaker/isolating devices. Interconnect the
terminals of cubicles/shipping section. Cable glands holes shall be drilled if required.
Blocking of moving parts provided for transportation shall be removed.
7.5 Great care shall be taken to ensure that the equipment has been installed correctly and
levelled properly before the holding down bolts are grouted to, thereby ensuring correct
operation of isolation mechanisms and jointing together the bus bars of the various
shipping sections.
7.6 The base channel required for mounting the panels shall be levelled and grouted to the
floor by chipping the floor to make a proper bonding surface, if required.
7.7 The switch boards shall be placed on the base channel, assembled, aligned and
levelled, so that bus bar jointing, breaker operation, inter-panel bolting, etc., can be
carried out freely. The fixing /grouting of the bolt shall be carried out only after
alignment and levelling. The foundation bolts shall be either grouted in the pocket
holes or tightened to the groove provided on the base channels as per manufactuer’s
recommendations.
7.8 Fix all loosely supplied components. Plug cut outs/opening in panels and seal off all
gaps by way of vermin proofing. All joints and connections shall be tightened.
7.9 All moving parts where required shall be lubricated. Petroleum jelly shall be applied to
all electrical contact surface at connection.
7.10 On no account should a power operated mechanism be operated by power until
operation by hand has proved it completely satisfactory.
7.11 While making connection to terminals, care should be taken to avoid undue strain on
insulators, bushings, etc. Joints and connections shall be checked for tightness and
tightening, if required. During connection, check should be made to ensure that the
ratings of current transformers and ratings of meters and relays should match. If
required necessary multiplying factor shall be stenciled on meters and adjustment of
setting made on the core of instrument transformers.
7.12 Verify name plates, wiring and components with drawings/bill of materials.
Discrepancies if any noticed shall be brought to the attention of the Engineer-In-
Charge.
7.13 Check breaker operation mechanism for proper operation. Circuit breaker
mechanism should be checked against manufactures drawing to ensure that the setting
at works have not been distorted during transportation.
7.14 Internal cleaning of all panels and chambers of switch board thoroughly with the help of
vacuum cleaners and blowers.
7.15 Continuity of wiring, phase sequence and polarity of CTs and PTs shall be checked and
verified.
7.16 Wiring shall be checked thoroughly and done, if required, for correct connection with
wiring/schematic drawings of manufacturer/purchaser. Minor modifications, if any,
required in feeder wiring, providing shorting wires for unused remote stop/interlock
terminals etc. as per individual feeder interconnection wiring diagrams shall be done, at
no extra cost.
13F121A/14

7.17 All components including relays shall be tested for proper performance and correct
operation.
7.18 Test continuity, insulation, primary and secondary injection test on metering
instruments, protective relays, auxiliary contacts, etc. and calibrate meters according to
the instruction of the Engineer-in-Charge. Services of Testing Engineers, if required by
owner, shall be made available by contractor without any extra
7.19 Conduct primary injection test on Over current, Earth fault, REF, Differential Protection,
etc.
7.20 Conduct simulation tests on all protection, alarm, annunciation, interlock, breaker
and motor control circuits.
7.21 Megger test bus bars, breakers, insulators, PTs, control wiring, etc. using suitable
meggers.
7.22 High voltage tests on HV breakers and switchboards as per relevant IS.
7.23 If the insulation resistance value of switchboards are found to be lower than
acceptable limits dry out the switchboards in accordance with IS 10118 till the IR value
improves to safe value.
7.24 Set all the relays properly as per setting furnished by the Engineer-in-Charge.
7.25 Ensure that all the equipment has checked for assembly of circuit breaker and
mechanism, alignment of the complete unit, grouting of foundation, fixing of loose
instruments, adjustment of circuit breaker, contact travel, connection of interlocks, main
circuit and earth connection, wiring, etc. and its insulation thoroughly dried before
commissioning and energising.
8.0 MOTORS
8.1 Unless otherwise specified elsewhere, motors will be erected by other agencies.
8.2 Ensure that all accessories supplied along with the motors such as Temperature
sensors, Temperature indicators, Speed sensors, limit switches, pressure switches,
etc. are properly fixed and Ventilation and Cooling System of the motor are working
smoothly.
8.3 Conduct Mechanical and Electrical checks as per IS:900
8.4 As the motors are idle for a long period, the bearing covers should be removed and
grease in the housing pressed with thumbs between the racers of the bearing. If the
deterioration of greases is found, old grease should be removed and new grease
pressed in the bearing housings.
8.5 The contractor shall test the insulation resistance of the motor winding and direction of
rotation in the presence of Engineer-in-charge and ensure they are as per
requirements. Insulation resistance, currents on coupled and decoupled runs shall be
measured and recorded.
8.6 If motors are found to have low insulation value, the following methods shall be adopted
as instructed by Engineer-in-Charge, for improving the resistance value.
a) By applying low voltage with rotor locked
b) By blasting hot air from external source
8.7 Set right the motor protection relay correctly.
13F121A/14

8.8 Run motors on no load for a period of 4 hours or as instructed by the Engineer-In-
Charge. During no load run record voltage, current, bearing temperatures at one-hour
intervals. The starting current shall be also be recorded.
8.9 If the no load runs are found satisfactory, run the motor on load and record
observations as mentioned above for 8 hours or as instructed by the Engineer- In-
Charge. In case of variable speed motors, variation of speed shall be checked and
regulation of speed noted. In case of motor operated valves (MOV’s), control panel
and all checking, testing, etc. shall be for the total unit as per manufacturer’s instruction
manual.
8.10 On completion of installation, the contractor has to submit a completion report as per
proforma given in Annexure-E of IS:900.
8.11 Any other test recommended by the manufacturers for special type of equipment like
variable speed motors, etc. shall be done.
8.12 All HV motors and MV motors rating 37 KW and above are provided with space
heaters, unless otherwise specified. HV motors are provided with main and star
terminal boxes. Motors rating 55KW and above are provided with star delta
starting/auto transformer starting.
8.13 For special type of equipment like variable speed motors, motor operated valves, etc.
any other special test and commissioning by the manufacturers shall be done without
extra cost to the owner.
8.14 Polarisation index test shall be conducted on HV motors.
9.0 BUS TRUNKING
9.1 The details of Bus Trunking such as rating, numbers off, etc. are specified in the
‘Schedule of items of work’. The details such as accessories, weight, etc. also
specified unless the supply of same is covered in contractor’s scope.. Bus trunking
shall be erected, tested and commissioned as per manufactures instruction manual or
as directed by their service engineers, as the case may be without any extra cost to
owner.
9.2 Bus trunking shall be supported from walls/roof slabs using hanger supports, tie rods,
wall brackets etc. Ensure proper supporting and levelling by checking with spirit level
and pendulum weight.
9.3 The bus duct shall properly meggered before starting installation.
9.4 Necessary cutout on walls, if required, shall be under the scope of the contractor. After
installation bus duct entry shall be completely sealed off.
9.5 Earth loops/earth coupler plates shall be provided between flanges/matting surfaces to
allow fault current to freely flow.
10.0 BATTERY SET & BATTERY CHARGERS/UPS SYSTEM
10.1 The battery erection scope shall include assembling the mounting frame, fixing
batteries, battery interconnections, etc.
10.2 Each shell shall be inspected for any damage of its positive plates, negative plates,
containers, etc. Cell shall be cleaned, properly reused with distilled water.
10.3 All the inter cell/inter tier connections, contact surfaces shall be applied with petroleum
jelly.
13F121A/14

10.4 The testing and commissioning of the battery set shall include filling of electrolyte,
charging discharging, etc. as per manufacture’s recommendations.
10.5 Erection, testing and commissioning of UPS panels, battery charger panels, distribution
panels, etc. shall be carried out generally as per the requirements furnished for switch
boards.
10.6 Necessary distilled water required during charging to be supplied by the contractor.
10.7 All necessary safety precautions shall be taken while preparing electrolyte, ie. Goggle,
rubber, apron, gloves, etc.
10.8 Battery should discharged at specific rate after initial charging and recharge the battery
there after. Lamp load/resistance bridge required for discharge shall be under
contractor’s scope. Record all battery voltage of each cell, specific gravity,
temperature, current during charging/discharging, after final charging the battery shall
be put on float charge. All the batteries shall numbered serially on the surface of
container with suitable red colour paint./acrylic sheet with black numbers engraved.
10.9 During the period of charging, unit shall not be overloaded and cells must be topped up
as often as necessary to prevent the electrolyte falling below.
10.10 The manufacturer will supervise testing and commissioning if so mentioned elsewhere
as desired by owner.
11.0 OTHER EQUIPMENTS
11.1 Other equipment such as capacitors, reactors, control panels, push button stations,
NGR, EHV switchyard equipments, circuit breakers, Isolators, Current Transformers,
Potential Transformers, Lightning Arresters .etc. shall be installed listed and
commissioning as per manufacturer’s instructions
13F121A/14

TECHNICAL 32644-13-PS-001INS
PROCUREMENT
SCOPE OF INSPECTION AND TESTS
SPECIFICATION (ELECTRICAL) Page 1 of 4 R0
TPS NO: 32644-13-PS-001
ITEM : Construction of Phosphoric Acid storage tank at Q10 W. Island
EQPT. NOS.:
The following inspection and test shall be conducted and records submitted
Sl. Ins./test Witness
Description Remarks
No. Reqd. Reqd.
Routine tests at Manufacturer’s works on all electrics (Motors,

1.0 cables,MV Switchboard/ Control panel,LCS etc) as per relevant Reqd Reqd
standards.
Physical verification at Manufacturer’s works for compliance with
2.0 purchase order specifications and approved drawings/ Reqd Reqd
documents
3.0 Verification of CMRI certificates for electrics of Hazardous area Reqd
4.0 Tests at site
Pre-commissioning tests and commissioning tests as per
4.1 Reqd Reqd
relevant standards
4.2 Insulation Resistance test Reqd Reqd
4.3 Primary and secondary injection tests on CTs and Relays Reqd Reqd
4.4 Checking power, control and earthing system and connections. Reqd Reqd
5.0 Other specific tests
5.1 Checking The Lightning Protection System Reqd Reqd
0 06.06.20 ISSUED FOR ENQUIRY SM SM IK

13FT924D/14

TECHNICAL 32644-13-PS-001 INS
PROCUREMENT SCOPE OF INSPECTION AND TESTS
TPS NO. 32644-13-PS-001
ITEM : MEDIUM VOLTAGE SWITCH BOARDS
EQPT. NOS.:

Description Remarks
No. Reqd. Reqd.
Physical verification for compliance with P.O. spec., scope,

1.0 Reqd Reqd
approved drawings & BOM
2.0 Routine tests Reqd Reqd
2.1 Power frequency Voltage dry tests on main circuits. Reqd Reqd
2.2 Voltage tests on control and auxiliary circuits Reqd Reqd
2.3 Measurement of resistance of main circuit Reqd Reqd
2.4 Mechanical operation test Reqd Reqd
2.5 Tests of auxiliary electrical and pneumatic devices Reqd Reqd
2.6 Verification of wiring Reqd Reqd
2.7 Electrical operation test Reqd Reqd
2.8 Megger test Reqd Reqd
Safety interlocks and protection against electric shock and short
2.9 Reqd Reqd
circuits
2.10 Verification of CT ratio and polarity of CTs Reqd Reqd
2.11 Verification of nameplate information & marking Reqd Reqd
2.12 Relay operation tests
Primary and secondary injection tests on panels and protective
2.13 Reqd Reqd
gears
Separate testing of breaker operating mechanism and other
2.14 Reqd Reqd
accessories
Type test certificates to
3.0 Type tests
be furnished
3.1 Impulse voltage dry test
3.2 Power frequency voltage dry test
3.3 a) Temperature rise tests of Switchboard
b) Temperature rise tests of Circuit breaker
0 02.06.2020 ISSUED FOR ENQUIRY SM IK IK

REV. NO DATE DESCRIPTION PREPARED CHECKED APPROVED

TECHNICAL 32644-13-PS-001 INS
TPS NO. 32644-13-PS-001
ITEM : MEDIUM VOLTAGE SWITCH BOARDS
EQPT. NOS.:
Description Remarks
No. Reqd. Reqd.
3.4 Verification of dielectric properties
3.5 Verification of making and breaking capacity of breaker
3.6 Verification of temp. limits and characteristics of relays
3.7 Short time current tests on main circuits
3.8 Short time current test on earthing circuits
3.9 Mechanical operation test
3.10 Verification of degree of protection

TECHNICAL 32644-13-PS-001INS
SPECIFICATION Page 4 of 4
TPS NO.. 32644-13-PS-001
ITEM : MEDIUM VOLTAGE INDUCTION MOTOR
EQPT. NOS.:

Description Remarks
No. Reqd. Reqd.
1.0 Physical verification for conformity with P.O. specifications and approved drawings
2.0 Routine test (as per IS), including the following:
2.1 Insulation resistance test Reqd

2.2 High voltage test Reqd
2.3 No load running test Reqd Required test
certificates shall be
2.4 Locked rotor test Reqd furnished
2.5 Reduced voltage running test at no load Reqd
2.6 Measurement of resistance of windings of stator Reqd
2.7 Open circuit voltage ratio test - -
3.0 Type tests Required test certificates shall be furnished
3.1 Dimensional check
3.2 Measurement of stator resistance and rotor resistance
3.3 No load running test at rated voltage
3.4 Open circuit voltage ratio test
3.5 Reduced voltage running test at no load
3.6 Locked rotor test
3.7 Full load running test
3.8 Temperature rise test
3.9 Momentary overload test
3.10 Over speed test
3.11 Tan delta test & polarization index test
3.12 Vibration & noise measurements
3.13 High Voltage test
4.0 Special tests (optional)

13FT910D/14

TECHNICAL 00ES001 / 01
PROCUREMENT VENDOR DATA SUBMISSION PROCEDURE
SCOPE
This document together with “VENDOR DATA REQUIREMENTS (VDR)” defines FEDO’s requirements for
vendor drawing and data for any enquiry, work order or purchase order.
Bidders unable to comply with these requirements must detail all exceptions in their proposal. The timely
delivery of quality drawings and data is as crucial as delivery of the equipment itself and hence the same shall
be strictly adhered to after commitment.
Failure to provide adequate preliminary data / drawing may render a proposal non-responsive and hence may
be rejected. After commitment failure to provide documents as per purchase order may delay progressive
payments and adversely affect future invitation to bids.
VENDOR DATA REQUIREMENTS (VDR)
FEDO will provide a partially completed VDR form along with each enquiry. This form explains group code of
the document, quantity of each document required and lead time for submission. Columns are available for the
vendor to fill in his deviations, if any, from FEDO’s requirements.
The vendor shall forward a filled-in VDR form along with his offer, if he has got any deviation from FEDO’s
requirements. In the absence of a filled-in VDR form along with the offer, it will be presumed that the vendor is
accepting FEDO’s requirements specified in the VDR.
CLASSIFICATION OF DOUCMENTS
Documents are classified based on their status and nature of content.
Status of documents:
Preliminary documents required along with the offer.
Documents to be submitted after commitment.
Final documents.
3.2.0. The documents are further classified into Groups A,B and C, depending on the nature of the
documents as explained below.
Group A requirements
These documents are urgent in nature and contains information that are required for proceeding with the
detailed engineering of surrounding/down stream equipments in the plant and hence are to be submitted on
priority basis.
Group B requirements
These documents are to be reviewed by FEDO for compliance with the purchase order / work order
specifications but are not essential for other engineering activities of FEDO.
Group C requirements
Documents in this group contains data / information / records which are final in nature and that are required for
the equipment user and need not be reviewed by FEDO.
PRPD.BY: CHKD BY: APPRD BY: ISSUED ON : SEPT

03

VENDOR DATA INDEX (VDI)
Vendor shall forward a filled up and updated VDI along with each vendor data transmittal. VDI shall list out all
documents that are being prepared for the particular order, their current revision status and indicate the
documents included in the present transmittal. A blank VDI is attached along with this document which shall be
used for this purpose.
QUALITY OF VENDOR DRAWINGS
vendor drawing and data shall be supplied in full size drawings, reproducibles and CDs as specified in the VDR.
All drawings / documents shall be clear, legible, right reading and made out of originals prepared in black ink.
English language and metric units shall be used for the preparation of all documents.
The documents shall be prepared n any of the following standard sizes.
A1: 594 mm x 840 mm

A2: 420 mm x 594 mm
A3: 297 mm x 420 mm
A4; 210 mm x 297 mm
All documents submitted to FEDO shall be folded into A4 size (210 x 297 mm) except originals/ reproducibles
which may be rolled. All reproducibles shall be in high quality polyester films. Soft copies shall be furnished in
CD for final drawings/documents.
Each drawing / document shall have a title block at the right hand bottom corner with the following information.
Name of Vendor.
Name of Project, Owner and location.
Name of Consultant: FEDO
FEDO Purchase Order Number.
Equipment name and number.
Drawing title.
Drawing number, revision and page number.
All drawings shall be drawn to some standard scales only and the same shall be indicated in the drawing.
The status of the document like “PRELIMINARY, FINAL, FOR REVIEW” etc. shall be stamped on all copies
forwarded to FEDO.
All documents shall have a block of 100 mm x 100 mm space left vacant for FEDO to put their stamp after review.
All drawing/document shall have a revision block explaining revision number, revision description, data of
revision, revision authorization etc. When the revised drawings are submitted all currently revised area shall be
clearly demarcated by clouding. Any revisions made on other parts of the documenting will not be reviewed by
FEDO.
When drawings are received back from FEDO with comments, vendor shall incorporate all the comments and
resubmit the same. If the vendor is not in a position to incorporate certain comment made by FEDO, then the
reason for such deviation shall be highlighted in the forwarding letter to FEDO.

PAGE 3 OF 3
SPECIFICATION
The respective engineering specification and other purchase order spec. will explain
the minimum data / details required in various drawings. In the absence of any such information
in the purchase order documents, vendor shall follow the standard good engineering practices
in detailing the drawing.
CONDITIONS OF FEDO REVIEW
FEDO and / or its client reserve the right to review the vendor documents. FEDO’s REVIEW WITH OR
WITHOUT COMMENTS OF THE VENDOR DOCUMENTS SHALL NOT RELIEVE THE VENDOR OF
RESPONSIBILITY TO COMPLY WITH ALL PURCHASE ORDER TERMS AND CONDITIONS, including
all implied requirements relating to fitness for service and good engineering practices. Approval or
acceptance does not imply or infer any determination relating to compliance by the vendor with its full
responsibilities under the purchase order.
FEDO’s comments are limited to identifying requirements within the scope of the purchase order or
failure by the vendor to comply with the requirements of purchase order, as revealed by the limited
review. Oversights in the above limited review cannot be taken as approval for the vendor to deviate
from the purchase order conditions. FEDO reserve the right to point out any such deviations at any
stage of the order execution. The vendor shall comply with all such requirements without any price /
delivery implications.
FEDO review will be authorized by an official stamp as given below, properly filled and signed by the
concerned. Comments if any will be indicated in red ink or clouded in the case of copies of commented
drawings.
Appropriate comment in the ‘comments’ column and ‘status of review’ column will be marked.
Comment Status of Review
As noted Revise and resubmit for review
No comments Proceed as noted and submit revised docs.

For records
Not reviewed No further review required
Forward final docs. as per P.O.
All documents received in FEDO shall be dispatched after review within 15 days from the date of receipt.
Vendor shall notify FEDO of non receipt of reviewed documents in time immediately, to take corrective
actions.
The delivery of the equipment shall in no case be linked with the review of the vendor drawings and data
by FEDO. It is the sole responsibility of the vendor to execute the job as per the purchase order
conditions. If required the vendor shall depute his technical personnel to FEDO after submission of
documents for timely finalisation of documents.

32644- 13 - PS - 001 VDI
VENDOR DATA INDEX
PAGE 1 OF 1 R0
PROJECT: Construction of Phosphoric Acid storage tank at
PROJECT NO. : 32644 VENDOR:
Q10 W. Island
ITEM: P.O NO.: DATE:
Sl. Rev. 0 Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 Relevant to
No. Doc. / Drawing No. Description This issue
Date Date Date Date Date Date
ISSUE NO.
DATE
SIGNATURE
00FT020/14

TECHNICAL 32644-13-PS-001 VDR-ELEC
SPECIFICATION Page 1 of 4
PROJECT: Construction of Phosphoric Acid storage tank ITEM: ELECTRICS FOR TURNKEY
at Q10 W. Island INSTALLATION
CLIENT : M/s. FACT-CD TPS. NO: 32644-13-PS-001

PO NO:
STATUS : ENQUIRY COMMITMENT
VENDOR:
@@
Offer After commitment
Final
Sl. Group
Description Lead time in weeks
No. code
Qty. Qty. Re @ Qty.
Agreed
qd Proposed
1.0 A Item wise deviations, if any, from specification. 1S+1P
2.0 A Technical particulars as per prescribed proforma 1S+1P 1S+1P 4 4P+1S
3.0 A Single Line diagram of Power Distribution 1S+1P 1S+1P 4 4P+1S
List of Electrical loads with rating (kW/Amps) and
4.0 A 1S+1P 1S+1P 4 4P+1S
quantity
General layout of the system indicating location
5.0 B 1S+1P 1S+1P 4 4P+1S
of all electrics and substation building
6.0 B Harmonics calculations for VFD 1S+1P
Dimensioned foundation plan showing floor cut
7.0 B 1S+1P
outs for cable for major electrical equipments.
Technical literature, installation ,operation and
8.0 C maintenance manual of major electrical 1S+1P
equipments.
9.0 C Power Layout 1S+1P 4 4P+1S
10.0 C Cable Schedule 1S+1P 4 4P+1S
11.0 C Earthing Layout 1S+1P 4 4P+1S
12.0 C Dimensioned GA drawing of individual electrics 1S+1P 4 4P+1S
Schematic wiring diagram of controls of the
13.0 C 1S+1P 4 4P+1S
,HV/MV switch boards MCC
Schematic wiring diagram of controls and
14.0 C 1S+1P 4 4P+1S
interlocks for HV/MV motors if any
Bill of Materials for all electrics indicating make,
15.0 C 1S+1P 4 4P+1S
type, quantity, rating, catalogue ref details etc.
16.0 C Manufacturer’s Routine test certificates 1S+1P 4 4P+1S
17.0 C Manufacturer’s Type test certificates 1S+1P 4 4P+1S
Legend: Group code: A-For review and detailed Engineering, B-For review, C- For information and record
Document type: R-Reproducible, P-Print, S-Soft copy in properly secured media.
Notes: 1. @ Vendor shall fill in proposed lead time if different from the required lead time.
2. @@ Each set of final documents shall be submitted in a folder. Two such folders shall be
packed and dispatched with the equipment.
0 06.06.20 Original Issue SM IK IK

13FT924C/14

DATA 32644-13-PS-001 VDR-ELEC
SHEET VENDOR DATA REQUIREMENTS
Page 2 of 4
CIMFR certificates for electrics in hazardous

18.0 C 1S+1P 4 4P+1S
areas.
List of spares for two years trouble free operation
19.0 B 1S+1P 1S+1P 4 4P+1S
of major electrical equipments.
Design calculations of Electrical system including
20.0 B 1S+1P 4 4P+1S
cable sizing, earthing, lighting, etc.
13FT924C/14

TECHNICAL 32644-13-PS-001-VDR
PROJECT: Construction of Phosphoric Acid storage tank

ITEM: MEDIUM VOLTAGE SWITCH BOARDS
at Q10 W. Island
CLIENT :M/s FACT-CD TPS. NO: 32644-13-PS-001
STATS : ENQUIRY COMMITMENT P.O. NO.:
@@
Final
Sl. Grp. Lead time in weeks
Description
No. code
Qty. Qty. Req @ Qty.
Agrd.
d. Propd
Duly filled in Technical particulars of Medium 1S+1P
1.0 B 1S+1P 4 1S+4P
voltage switch boards , as per format attached
Foundation plan, showing cutouts/ floor 1S+1P 1S+4P
2.0 A openings, foundation pockets, etc. along with out 4
line dimensions and static & dynamic loading
Dimensioned general arrangement drawing - 1S+1P 1S+4P
3.0 A 4
internal & external, including busbar disposition
1S+1P 1S+4P
4.0 A Sectional view showing fixing details 4
Drawing of Bus trunking flange, with complete 1S+4P
5.0 A dimensions including bolt hole locations & sizes
and bus bar arrangement
1S+1P 1S+4P
6.0 A Single line diagram of switch boards 4
Schematic diagram and wiring diagrams 1S+1P 1S+4P
(including inter panel wiring diagrams), with
7.0 B 4
ferrule nos, terminal nos, arrangement of
terminals, etc.
Schedule of materials / components, with 1S+1P 1S+4P
8.0 B 1S+1P 4
quantity, rating, type, make, etc.
Relay coordination details, with recommended 1S+4P
9.0 B
settings, calculation etc
1S+1P 1S+4P
10.0 B Calculation sheet proving busbar capacity 4
Calculation sheet proving capacity of control 1S+1P 1S+4P
11.0 B 4
transformers
Certificates / records of routine & type tests 1S+1P 1S+4P
12.0 B 4
conducted as per scope of Inspection and tests
Legend: Group code: A - For review and detailed Engineering, B - For review, C - For information and
record
Document type: R -Reproducible, P - Print, S- Softcopy in properly secured media
Notes: @ Vendor shall fill in proposed lead time if different from the required lead time.
@@ Each set of final documents shall be submitted in a folder. Two such folders shall be packed and
despatched with the equipment.
0 02.06.2020 Issued for Enquiry SM IK IK

13FT906C/14

TECHNICAL 32644-13-PS-001-VDR
ITEM: MEDIUM VOLTAGE SWITCH BOARDS

@@
Final
Sl. Grp. Description Lead time in weeks
No. code
Qty. Qty. Req @ Qty.
Agrd.
d. Propd
Type test certificates of breakers, switches, 1S+1P 1S+4P
13.0 B 4
MCCB etc.
1S+1P 1S+4P
14.0 B Certificate of short circuit rating of breakers 4
CPRI test certificate for similar switchboard 1S+4P
15.0 B
assembly
Test Certificates of brought out items like 1S+4P
16.0 B
protective relays, CTs, energy meters, etc.
Characteristic curves of fuses and thermal 1S+1P 1S+4P
17.0 B 4
overload relays, with range of adjustment relays.
Technical literature / catalogues of relays, MCCB 1S+1P 1S+4P
18.0 C KWH / KW / PF meters, etc. With its wiring 4
diagrams.
Technical catalogue & internal wiring diagrams of 1S+1P 1S+4P
19.0 C 4
circuit breakers
Technical literature, pamphlets and brochures 1S+1P 1S+4P
20.0 C 4
relating to the various equipment used.
Erection , Operation & Maintenance manuals of 1S+4P
21.0 C
breakers and complete switchboard
22.0 B Spare parts list
Duly filled and signed Compliance statement as
23.0 B
per format attached
24.0 B Unpriced copy of price bid
1S+1P
25.0 B Testing procedure for temperature rise test
1S+1P
26.0 C Quality Assuarance Plan (QAP)

SPECIFICATION
GENERAL REQUIREMENT OF ELECTRICS
Page 1 of 4
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
3.0.0 COMPLETENESS OF CONTRACT
4.0.0 COMPONENTS AND CONSTRUCTION
5.0.0 STANDARDS & REGULATIONS
6.0.0 SERVICE CONDITIONS
7.0.0 EARTHING
8.0.0 POWER SUPPLY DETAILS
9.0.0 NAME PLATES
10.0.0 PAINTING
11.0.0 INTER CHANGEABILITY
12.0.0 DANGER NOTICE PLATES
13.0.0 TOOLS AND APPLIANCES
14.0.0 SERVICES OF MANUFACTURER’S TECHNICAL EXPERTS
15.0.0 TRAINING
16.0.0 PERFORMANCE OF EQUIPMENT
17.0.0 TESTS
18.0.0 DOCUMENTS
19.0.0 INSTRUCTIONS TO THE BIDDER
1.0.0 SCOPE
1.1.0 This specification covers the general requirements for supply and installation of all electrical items
as applicable.
2.0.0 REFERENCE
2.1.0 The following documents shall be read in conjunction with this specification:
2.1.1 Data sheet of General Requirements for Electrics.
2.1.2 Engineering specifications, Data sheets and Technical Particulars of individual equipment / items.
2.1.3 Scope of work, Scope of Inspection and Tests, Special requirements of the project, Vendor Data
Requirements, etc attached with the Technical Procurement Specifications.
3.0.0 COMPLETENESS OF CONTRACT
3.1.0 The electrics supplied / installed shall be complete with all accessories for the safe, smooth and
efficient operation of the system. Such parts shall be deemed to be within the scope of this
specification whether specifically mentioned or not.
4.0.0 COMPONENTS AND CONSTRUCTION
4.1.0 Each and every component shall be of reputed make and be of proven design for best
performance, reliability and durability. They shall be brand new. Workman ship shall be of the
highest grade and the entire construction shall be in accordance with the best modern
engineering practice.
5.1.0 All electrical equipment / installations shall fully comply with the requirements laid down in the
00FT006
following rules / regulations / acts / standards / codes as amended up to date.
PRPD. : CHKD. : APPRD. : ISSUED ON SEPT 2014

SPECIFICATION
Page 2 of 4
5.1.1 Indian Electricity Rules.
5.1.2 Indian Electricity Act.
5.1.3 Indian Electricity Supply Act.
5.1.4 Indian Factories Act.
5.1.5 Fire Insurance Act.
5.1.6 Petroleum Rules.
5.1.7 OISD Standards.
5.1.8 Pollution control norms as per Environmental Regulations.
5.1.9 Standards / regulations of statutory bodies applicable for the place of installation.
5.1.10 Relevant Indian / International standards and in their absence, the standards of the country of
manufacture.
5.2.0 Vendor shall furnish all necessary assistance & documents for obtaining approval from statutory
bodies. Making whatever additions/ modifications considered necessary by the Electrical
Inspectorate and other authorities to bring the equipment / installation in conformity with the
above rules, Regulations, acts and standards shall be in the scope of the vendor.
5.3.0 All equipment shall be of tropical design according to relevant Indian / International Standards.
5.4.0 All electrics shall be suitable for the hazardous / non-hazardous area involved and /or specified.
Electrics suitable for the hazardous area involved shall be selected as per the relevant Indian
Standards and shall be of proven design approved by CIMFR / relevant statutory bodies. In such
cases copies of relevant certificates shall be furnished for Purchaser’s approval.
6.1.0 All equipment shall be suitable for the service conditions specified in the Data sheet of General
Requirements for Electrics attached.
7.0.0 EARTHING
7.1.0 Duplicate earthing terminals, suitable for terminating earthing conductors of sizes indicated in the
data sheets of individual equipment, shall be provided on the body of the equipment apart from
those, if any, provided inside the terminal boxes.
8.0.0 POWER SUPPLY DETAILS
8.1.0 The equipment shall be suitable for the power system details furnished in the Data sheet of
General Requirements for Electrics unless otherwise specified in the data sheets of individual
equipment.
8.2.0 The equipment shall perform satisfactorily even with variation in supply voltage and frequency as
detailed in the data sheets. The equipment shall operate at the specified rating without exceeding
the permissible temperature rise as per the relevant I.S. in spite of the variation in supply voltage
and frequency.
00FT006

SPECIFICATION
Page 3 of 4
9.0.0 NAME PLATES
9.1.0 Necessary nameplates, conforming to standards, giving relevant details of the equipment, shall
be provided on individual equipment. Any additional details shall also be indicated in the
nameplate, if so specified in the specifications / data sheets of individual equipment.
10.0.0 PAINTING
10.1.0 Unless otherwise specified in the specifications / data sheets of individual equipment / items,
painting procedure described in this clause shall be adopted.
10.2.0 All exposed metal parts shall be subjected to at least the following pretreatment before painting to
suit the material and environment involved.
10.2.1 De-greasing.
10.2.2 Rust removing.
10.2.3 Phosphating/ equivalent chemical treatment.
10.2.4 Giving two coats of corrosion resistant primer suitable for final coating.
10.3.0 Two coats of anticorrosive painting shall be given after the above process so as to render the
materials suitable for the highly corrosive environment specified.
10.4.0 Final Colour and finish of the equipment shall be Dark Admiralty Grey (shade no: 632) as per
IS: 5 unless otherwise specified in the data sheet for individual equipment/item.
10.5.0 Vendor shall furnish detailed painting procedure proposed, along with the bid.
11.0.0 INTER-CHANGEABILITY
11.1.0 All similar parts shall be inter-changeable with each other.
12.0.0 DANGER NOTICE PLATES
12.1.0 Danger Notice plates conforming to IS: 2551 and other statutory requirements shall be affixed on
equipment wherever required.
13.0.0 TOOLS AND APPLIANCES
13.1.0 The vendor shall supply one set of special tools and appliances that may be required for carrying
out the maintenance, special inspection etc. of the equipment offered, without any extra cost.
13.2.0 Vendor shall also furnish list of tools and appliances required for the maintenance of different
equipments.
14.0.0 SERVICES OF MANUFACTURERS’ TECHNICAL EXPERTS
14.1.0 Services of the manufacturer’s technical experts shall be made available to the Purchaser, if
found necessary, during erection, testing, and commissioning and during the guarantee period.
15.0.0 TRAINING
15.1.0 The vendor shall render all facilities free of cost for imparting training to purchaser’s technical
personnel at manufacturer’s works, if required, for the proper assembly, installation, testing,
00FT006
commissioning, operation and maintenance of the equipment supplied. The travel and living
expenses of the personnel deputed for training will be borne by the Purchaser.

SPECIFICATION
Page 4 of 4
16.0.0 PERFORMANCE OF EQUIPMENT
16.1.0 Duly filled in Technical Particulars of individual equipment / item shall be furnished as per
formats attached. Performance figures of the equipment as per Technical Particulars furnished
along with the offer shall be guaranteed.
17.0.0 TESTS
17.1.0 All the tests specified in Scope of Inspection & Tests attached along with the Technical
Procurement Specification shall be performed.
18.0.0 DOCUMENTS
18.1.0 Drawings and documents shall be furnished as per Vendor Data Requirements (VDR) attached
with Technical Procurement Specification.
19.0.0 INSTRUCTIONS TO THE BIDDER
19.1.0 All the drawings and documents as per Vendor Data Requirements shall be furnished along with
the offer. Offers without these details will be treated as incomplete and are liable for rejection.
19.2.0 In the absence of clearly spelt-out item wise deviations from purchaser’s specification, it will be
presumed that the equipment offered are in conformity with the specification.
19.3.0 The Vendor shall supply all equipments and items of make specified in the vendor list attached
with the specification. The Vendor shall obtain Purchaser’s approval before placement of
purchase order for electrical items / components wherever makes are not specified in the
respective data sheets.
00FT006

32644-13-DA-90001
GENERAL REQUIREMENT FOR
DATA SHEET
ELECTRICS Page 1 of 1 R0
Construction of Phosphoric Acid storage tank at Q10 W.

1.0 Project
Island
2.0 Owner FACT-CD
3.0 Location Willington Island, Kochi
4.0 Service conditions
4.1 Altitude < 1000m above mean sea level

4.2 Humidity Min 64%
4.3 Humidity max. 93%
0
4.4 Humidity design 100% at 40 C
0
4.5 Ambient temperature C-Min. 19.2
0
4.6 Ambient temperature C-Max. 34.3
0
4.7 Ambient temperature C-Design 40
4.8 Rain fall – Max . Record in an hour 40mm
4.9 Rain –fall Max record in 24 Hours 169.5mm
5.0 Environment Coastal area. Presence of salts and corrosive gases
6.0 Wind velocity for structural design 124 km/h

7.0 Seismic factor for design Within seismic Zone 3 as per IS 1893
8.0 Soil data
8.1 Soil resistivity
8.2 Type of soil (hard / loose)
9.0 Power system
9.1 Voltage (V) & Variation (± %) 433V +/- 10%

9.2 Frequency (Hz) & Variation (± %) 50Hz +/- 5%
9.3 No of phases Three
9.4 No. of wires Four
9.5 Fault level (MVA) 31/15
9.6 Method of neutral earthing Solid earthing
Construction of Phosphoric Acid

PROJECT
storage tank at Q10 W. Island
CLIENT FACT-CD
P.O. NO.
0 06-06-20 SM IK IK
VENDOR
REV. DATE PRPD. CHKD. APPRD.
13FT900A/14
SPECIFICATION
ELECTRICS FOR TURNKEY INSTALLATION
Page 1 of 10
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
3.0.0 STANDARDS
4.0.0 GENERAL REQUIREMENTS
5.0.0 MOTORS
6.0.0 VARIABLE SPEED DRIVES
7.0.0 M.V.SWITCHBOARDS/ MOTOR CONTROL CENTRES (MCC)
8.0.0 LOCAL CONTROL STATIONS
9.0.0 CABLES AND CABLING
10.0.0 EARTHING
11.0.0 SAFETY ITEMS
12.0.0 HAZARDOUS AREA CLASSIFICATION FOR SELECTION OF ELECTRICS
13.0.0 ERECTION, TESTING AND COMMISSIONING
14.0.0 APPROVAL FROM ELECTRICAL INSPECTORATE
15.0.0 LIGHTING
16.0.0 MAKE OF ELECTRICAL EQUIPMENT/ ITEMS
1.0.0 SCOPE
1.1.0 This specification covers the requirements for design, engineering, supply, receiving materials at
site, inspection at site, storage, transportation at site, erection, testing and commissioning of all
electrics required for the safe, efficient and smooth running of the turnkey installation / package.
2.0.0 REFERENCE
2.1.0 The following documents shall be read in conjunction with this specification
2.1.1 Engineering specification and Data Sheet of General Requirements for Electrics
2.1.2 Data Sheet of Electrics for Turnkey Installation.
2.1.3 Technical Particulars of Electrics for Turnkey Installation.
3.0.0 STANDARDS.
3.1.0 Requirements laid down in the latest revisions of the following Indian Standards and other relevant
standards shall be strictly adhered to.
IS: 325 Three phase Induction Motors.

IS/IEC:60034 Rotating Electrical Machines.
IS/IEC:60947 Low voltage switchgear and control gear.
IS: 8623 Low voltage switchgear and control gear assemblies
IS: 1248 Direct acting indicating analogue Electrical measuring instruments and
accessories
IS: 2705 Current transformers.
IS: 13703 Fuses for voltages not exceeding 100V AC or 1500V DC
IS: 10118 Code of practice for selection, installation and maintenance of switchgear and
control gear.
IS: 732 Code of practice for electrical wiring installation.
IS: 694 PVC insulated cables for working voltage upto and including 1100 volts.
IS: 1554 PVC insulated (Heavy duty) Electric cables.
IS: 3043 Code of practice for earthing.
IEC:62305-P-1 to 4 Protection against lightning.
IS: 7689 Guide for control of undesirable static electricity.

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SPECIFICATION
Page 2 of 10
IS: 5571 Guide for selection of electrical equipment for hazardous areas.
IS: 5572 Classification for hazardous areas (other than mines) for electrical
installations.- Part 1 - Areas having flammable gases and vapors.
IS:12615 Energy Efficient Induction Motors- Three Phase Squirrel cage
4.1.0 The scope of work for electrics shall be complete in all respects and shall include necessary Medium
Voltage switchboards / Motor Control Centres, Motors, Local Control Stations, Cables, Earthing
Materials, Safety items and interlocks, Cabling, Earthing, Lighting, etc. required for the installation,
as specified in the data sheets.
4.2.0 The Purchaser will be providing adequate power supply at 415 Volts, 50 Hz, 3 phase and neutral
A.C. to the MV switch boards / Motor control centres provided by the vendor. The incoming cables
shall be connected to the MV Switchboard / MCC by the purchaser. Voltage and frequency variation
shall be +10%and +5%, unless otherwise specified in the Data Sheet.
4.3.0 For Motors/Equipments suitable for voltage rating above 415Volts, purchaser will arrange power
supply through purchaser’s circuit breakers. Necessary power cabling upto the motors /equipments
and control cabling upto the local control stations of motors as well as termination of the above
cables at both ends shall also be arranged by the purchaser in such cases. The interconnecting
cabling for protection/ alarm required, between HV motors and purchaser’s HV switch board is
included in the scope of purchaser.
4.4.0 The purchaser will be terminating the main earth bus at single point within battery limit (size and
material of main earth bus shall be as per Data Sheet). Further earthing within battery limit shall be
included in the scope of the vendor.
5.0.0 MOTORS.
5.1.0 All drive motors required for the system shall be included in the scope of the vendor unless
otherwise specified in the Data Sheet.
5.2.0 Motors shall be suitable for the voltage ratings indicated in the Data Sheet and shall conform to the
following specifications.
5.2.1 Motors provided shall have adequate performance characteristics such as starting torque pull out
torque, etc. and rating for meeting the driving and starting duty of the driven equipment.
5.2.2 All motors shall be squirrel cage induction type with insulation Class B / F with temperature rise
limited to Class B and totally enclosed fan cooled enclosure with IP 55 / IPW55 degree of protection;
except in cases of special types of motors such as slip- ring motors, variable speed motors, etc.
required to meet special drive requirements, and environmental conditions. In all such cases,
motors with necessary special features shall be provided and approval for the same shall be
obtained from the purchaser. Degree of protection for the enclosure shall be as specified in the Data
Sheet.
5.2.3 Motors shall be provided with 240V,50Hz, single phase anti- condensation heaters, if so specified in
data sheet and shall be wired up to separate terminal box with cable glands suitable for the cable
sizes specified in Data Sheet.
5.2.4 Motors shall be provided with terminal boxes (where in all six winding ends are brought out), cable
glands, etc. suitable for the type and sizes of cables selected by vendor. In addition, the motor shall
have the largest terminal box possible in the frame size.
5.2.5 All motors are envisaged to be started on Direct-On-Line unless otherwise specified in the Data
00FT001
Sheet.
5.2.6 All motors shall be suitable for number of starts specified in the Data Sheet.

SPECIFICATION
Page 3 of 10
5.2.7 Motor frame sizes shall be in accordance with IEC recommendations / relevant Indian Standards.
5.2.8 For unidirectional motors, the direction of rotation shall be clearly marked on the body of the motor.
5.2.9 Motors shall have a starting time, which is less than hot locked rotor withstand time of motor by at
least two seconds at the rated conditions of voltage and frequency specified with driven machine
coupled.
5.2.10 Motors shall be suitable for starting at 80% of the rated voltage against torque speed characteristics
of the driven equipment.
5.2.11 The terminal box of Medium Voltage motors shall be capable of withstanding the calculated fault
level in terms of the let through energy of combination starter unit at the place of installation.
5.2.12 An indelible warning inscription shall be provided on the motor to indicate that switching of
anticondensation heater supply shall also be ensured before carrying out any work on the motor.
5.3.0 In addition to the above requirements high voltage motors shall conform to the following:
5.3.1 Ensure that starting current is not more than 600% of full load current at rated voltage and
frequency.
5.3.2 All the six winding ends shall be brought out and marked, three to one terminal box for power supply
connections and three to another terminal box on the opposite side for star connection. Further main
terminal box shall be phase segregated type and terminal boxes shall be suitable for system fault
level for 0.25 seconds or as indicated in the Data Sheet.
5.3.3 If temperature detectors / oil level indicators etc. are provided as per Data Sheet, the same shall be
wired upto a terminal box with cable gland suitable for the cable sizes indicated in the Data Sheet.
5.3.4 Additional protection features such as zero speed switches for loads with high starting time,
embedded resistance temperature detectors for windings and bearings, oil temperature detectors
and level indicators (with alarm and trip contacts) for oil lubricated bearings etc. shall be provided, if
specified, in the Data Sheet. For resistance type winding / bearing temperature detectors suitable
temperature scanner / monitoring relays with alarm and trip contacts shall be provided, in a weather
proof enclosure, if specified in the data sheet.
6.0.0 VARIABLE SPEED DRIVES
6.1.0 The Variable Speed Drive System shall be suitable for the load characteristics and operation duty of
the driven equipment, the equipment shall be suitable for continuous operation.
6.2.0 The converter design shall impose minimum harmonics on the electrical power system in
accordance with the relevant standards and shall be acceptable to the Owners electrical network.
6.3.0 The Converter Vendor shall advise the percentage of current harmonics over the full range of
frequencies. Filters shall be fitted within the converter to minimise harmonic currents.
6.4.0 The converter shall incorporate a programmable microprocessor based control system allowing
updating / modifying of the logic functions of the converter by a simple programme procedure using
a control panel keypad/ and panel display.
6.5.0 The converter shall be provided with self-check facilities including failure reporting and signalling.
The programme shall be protected against loss of supply voltage with back-up for the programme
memory and the fault diagnostic and indication shall be equipped with a memory function to
00FT001
retain information with regard to tripping of the Converter.

SPECIFICATION
Page 4 of 10
6.6.0 If requested in the requisition, the converter shall be able to communicate with a remote
control/diagnostic system by means of a serial communication interface
6.7.0 The converter shall accurately control the driven equipment speed and torque of any standard
induction motor and shall be suitable for pump, fans, mixers, agitator applications etc., as specified
in the requisition.
6.8.0 A reference signal of 4mA shall correspond with the minimum operational speed and the reference
signal of 20mA shall correspond with the maximum speed.
6.9.0 The Variable Speed Drive System shall be capable of running through voltage dips of up to 20% and
equipped with an automatic restart facility which will restart the system with voltage dips greater than
20% less than 4 seconds. Restart shall only take place with voltage recovery greater than 90%.
Upon restart the converter shall be capable of synchronising onto rotating motor “flying restart” and
develop full acceleration torque.
6.10.0 If the speed exceeds 105% of the maximum operational speed the VSDS shall trip, if the speed
reduces to 95% of minimum speed for more than 10 seconds the VSDS shall trip. The converter
shall have available critical speed function where it is necessary to avoid certain speeds due to
mechanical resonance problems.
6.11.0 Speed control will be carried out either manually for maintenance, or automatically via 4-20mA
signal from the process control.
6.12.0 Depending on operational requirements the motor start/stop will be either carried out manually by
push buttons or automatically via the process control system.
6.13.0 Emergency stop located at each motor shall trip the supply contactor, removal of power by an
emergency shall not cause damage. All stop buttons shall operate at all times.
6.14.0 When the converter is switched on, the drive shall breakaway at a minimum frequency consistent
with the slip of the motor. Once motor rotation is established the drive shall ramp up to the set point
speed at a controlled rate. Set point speed having been established, change of set point speed shall
also be at a controlled rate superimposed on the rate of change demanded by the operator or
controller.
6.15.0 During all starting operations, the rate of increase of torque, up to the maximum limited by the
protection, shall also be at a controlled rate. The drive shall be suitable for a "windmilling" start with
the motor being rotated by the driven equipment in either direction.
6.16.0 Programmable converter relay outputs shall be included with volt free contacts for control and alarm
functions.
6.17.0 VFD’s shall comply with IEEE 519 for total harmonic distortion calculation and measurement. If
harmonic filters are required to meet this specification, the VFD manufacturer must provide the filter
and is fully responsible for the design, manufacturing and installation of the filter as an integral part
of the VFD package.
6.18.0 The variable frequency drive shall provide near sinusoidal voltage and current waveforms
to the motor at all speeds and loads. Output current THD shall be less than 5%. Standard
induction or synchronous motors shall not require derating or upgraded turn-to-turn
insulation and shall not require additional service factor.
6.19.0 Variable frequency drive induced torque pulsations to the output shaft of the mechanical
system shall be less than 1% to minimize the possibility of exciting a resonance.
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7.0.0 M.V. SWITCHBOARDS / MOTOR CONTROL CENTRES (M.C.C.)

SPECIFICATION
Page 5 of 10
7.1.0 The control gear for all Medium Voltage loads shall be housed in centralized MCC's installed in a
suitably located electrical room.
7.2.0 MCC's shall be rated for minimum 25 MVA symmetrical fault level with switch fuse/ MCCB incomers
and shall conform to the following stipulations:
7.2.1 Number of MCCs shall be selected in such a way to limit the incomer rating to 630 Amps, unless
otherwise specified in the Data Sheet.
7.2.2 MCC shall be of self-standing, dust, damp and vermin proof construction in fully compartmentalized
cubicle type execution. The MCC shall be single / double front, draw out / non draw-out type as
specified in Data Sheet. The enclosure shall be of folded sheet steel construction. Thickness of
sheet steel shall not be less than 2 mm except for certain non load bearing members like instrument
mounting plates, partitions, doors, etc. for which a minimum thickness of 1.6 mm shall be ensured.
7.2.3 The construction of MCC shall be in such a way that each vertical row of modules shall have
separate vertical bus bars, vertical bus bar chamber and cable alleys. The width of the cable alley
shall be sufficient to accommodate all the cables and shall have free access for cable terminations
and in any case shall not be less than 150 mm.
7.2.4 For draw out type MCC the following stipulations shall also be adhered to:
(i) Power and control contacts shall be of fully draw out, self aligning type which get automatically
disconnected when the module is withdrawn.
(ii) A distinct and stable “TEST” position for each module shall be provided. Test push button for
checking the control circuitry shall be provided, if specified in Data Sheet.
(iii) Identical feeder types shall be interchangeable with each other. Also all modules shall carry labels
identifying KW rating & type of control wiring.
(iv) Necessary earthing arrangements shall be provided for the draw out module in TEST and SERVICE
positions.
7.2.5 The bus bar supports shall be of non-hygroscopic glass reinforced plastic material with anti-tracking
features.
7.2.6 Bus bars shall be provided with insulating sleeves and bus bar joints shall be shrouded.
7.2.7 MCC including dropper bus bars to each module shall be rated for the minimum symmetrical short
circuit level of 25 MVA at 415V.
7.2.8 MCC shall be provided with incoming feeders comprising of suitably rated AC 22 duty switch fuse
units/ Moulded Case Circuit Breakers, voltmeter with 3 way and off selector switch & fuses
(connected on the incoming cable side) , CT fed ammeter with necessary CTs & 3 way and off
selector switch and CT operated KWh meter. CTs & meters shall be of accuracy class 1.5 and
meters shall be of size 96mm x 96mm.
7.2.9 Outgoing motor starter feeders shall comprise of suitably rated AC 23 duty load break
switches/MCCBs, HRC fuses, 100% capacity AC 3 category Air break contactors and bimetal
overload relays. Feeder switches shall have AC 23 rating corresponding to the full load current of
the motors connected. Rating of load break switch shall not be less than the rating of the HRC
fuses.
7.2.10 The bi-metal overload relays shall be manual / auto reset type as specified in the data sheet. For
manual reset type, reset push button shall be provided on the door. These relays shall have single
phasing protection feature. If built-in feature is not available, separate current operated type single
phasing preventor shall be provided.
00FT001
7.2.11 Overload relays for motor of blowers, fans, agitators, compressors, crushers & mills shall be of
heavy-duty - delayed action type to allow more starting time.

SPECIFICATION
Page 6 of 10
7.2.12 Ammeters shall be provided for outgoing feeders, if so specified in the Data Sheet.
7.2.13 CTs of ratio and VA capacity suitable to connect remote ammeters (in one phase) shall be provided
for all motor feeders of 15 kW and above unless otherwise specified in the Data Sheet. Secondaries
of these CTs shall be of 1A rating. Minimum VA capacity shall be 7.5 and class of accuracy 1.5
unless otherwise specified in Data Sheet.
7.2.14 Control supply for the motor starters shall be 110V AC, 50 Hz, single phase AC unless otherwise
specified in Data Sheet. In case of 240 V control supply, each circuit shall be provided with
individual control fuses and links.
7.2.15 For control voltages less than 240 volts separate control transformers (cast resin insulated type) for
each modules or common for each bus section shall be provided as specified in the Data Sheet. In
case common control transformer for each bus section is envisaged, it shall have adequate capacity
and provisions to feed entire control loads of both bus sections of switchboard, when required. The
control transformer shall have +5% taps on primary side and with center tap of secondary winding
earthed & having fuse protection on primary side and double pole MCB on secondary side.
Common control transformers shall also have suitable switch fuse unit on primary side and
additional tapping of +2.5% on secondary side. It shall be ensured that control supply of each feeder
gets isolated automatically when power supply to that particular feeder is switched off.
7.2.16 If anti-condensation heaters are provided for motors, provision shall be made to feed the same
through isolator with HRC fuse protection/ MCB and NC contact of Main contactor of respective
motor starter.
7.2.17 All power and control fuses shall be of the HRC link type, with operation indicators.
7.2.18 In each motor feeder module, at least one Normally Open and one Normally Closed auxiliary contact
shall be wired up to the terminal block as spare. The terminal block shall have at least 10% spare
terminals, subject to a minimum of two.
7.2.19 All feeders controlled by contactors shall be provided with OFF buttons. Indicating lamps and Reset
button shall be provided, if specified, in the Data Sheet.
7.2.20 Providing pressure switches, limit switches, safety switches etc. wherever required for the safety of
the equipment and facilitating interlocking shall be the responsibility of the supplier. Interlock defeat
switches, as required shall be provided on the control panel (where such panels are provided) or on
local control station near the motor and not on the MCC.
7.2.21 All outgoing switch fuse feeders shall be provided with AC 22 load break switch, HRC fuses and
neutral link.
7.2.22 The incomer switch fuse unit shall have single phasing annunciators wired up to a terminal block, if
so specified in the Data Sheet.
7.2.23 In MCCs having two incomers each shall be of 100% capacity. Interlocks shall be provided
between incomers / bus coupler to prevent paralleling.
7.2.24 Facility shall be provided for padlocking feeder switches in the OFF position.
7.2.25 Necessary switch-to-door interlock shall be provided in all compartments so that the door of a
compartment can be opened only when the switch is in OFF position.
7.2.26 Space heater/ anti condensation heaters (suitable for 240 V, single phase AC) shall be provided for
each vertical panel if so specified in the Data Sheet. For double front MCC's space heaters shall be
provided on both fronts. Space heaters shall be controlled through isolator with HRC fuse protection
00FT001
/ MCB, thermostat etc.

SPECIFICATION
Page 7 of 10
7.2.27 Continuous earth bus of 70 sq. mm. bare Copper Conductor, or 120 sq. mm. bare Aluminium
conductor or 240 sq. mm. GI strip or as specified in the Data Sheet shall be provided for the entire
length of the MCC. Duplicate earth terminals shall be provided for external connection.
7.2.28 Maximum allowable current density for bus bar sizing shall be 1.25 Amps/ sq. mm for copper or 0.78
Amps /sq. mm for Aluminium.
7.2.29 Horizontal busbars shall be of uniform cross section throughout the length of the switchboard.
Vertical busbars of all vertical panels of the switchboard shall also be of uniform cross section.
7.2.30 Power wiring shall be carried out with PVC insulated, stranded copper / aluminium conductors of
650 Volts grade having adequate current carrying capacity. Minimum size of conductor for power
wiring shall be 4Sq.mm copper. Control wiring shall be carried out with 650 V grade, PVC insulated,
copper conductor of size not less than 2.5 Sq.mm.
7.2.31 For draw out MCC, provision of control supply in the test position of draw out modules shall be
available. In draw out switchboards with module control supply, required test control supply feeder
(complete with switch fuse/ and test control supply transformer with double pole MCB on secondary,
centre tap of secondary winding earthed, etc. as in clause 6.2.15 above), associated test supply bus
/ wiring, etc. shall be provided.
7.2.32 The feeder arrangement shall be such that the operating height (ie. operating handle, switches,
push buttons, etc.) lies within 1828 mm, but above 300mm, from the floor level.
7.3.0 MOULDED CASE CIRCUIT BREAKERS
7.3.1 Where moulded case circuit breakers are used for feeder circuit protection, rating and
characteristics shall be chosen in such a way as to ensure proper discrimination with other upstream
and downstream protective devices within the assembly.
7.3.2 The MCCB should be current limiting type with trip time of less than 10 milli second under short circuit
conditions. The MCCB should be either 3 or 4 poles as specified in data sheet.
7.3.3 MCCB shall comply with the requirements of the relevant standards IS13947 – Part 2 and should
have test certificates for Breaking capacities from independent test authorities CPRI / ERDA or any
accredited international lab.
7.3.4 MCCB shall comprise of Quick Make -break switching mechanism, arc extinguishing device and the
tripping unit shall be contained in a compact, high strength, heat resistant, flame retardant, insulating
moulded case with high withstand capability against thermal and mechanical stresses
7.3.5 The breaking capacity of MCCB shall be as specified in the schedule of quantities. The rated service
breaking capacity (Ics) should be equal to rated ultimate breaking capacities (Icu). MCCB’s for motor
application should be selected in line with Type-2 Co-ordination as per IS 13947-2. The breaker as
supplied with ROM should meet IP54 degree of protection.
8.0.0 LOCAL CONTROL STATIONS
8.1.0 Each motor shall be provided with a local control station near motor. The enclosure shall be of Cast
Iron or Cast Aluminium construction with IP-55 / IPW 55 degree of protection, as specified in the
Data Sheet.
8.2.0 Local control stations for M.V motors shall be provided with ‘ON’ push button (Green) and 'OFF'
push button (Red).
00FT001
8.3.0 Local control station for H.V Motors shall be provided with 'ON' push button (Green), 'OFF' push
button (Red), Ammeter and five numbers Indication lamps. (viz 'ON'-Red , 'OFF'-Green, 'Tripped
on fault' - Amber, 'Ready for start' -Clear, 'Space heater ON' - Yellow.).

SPECIFICATION
Page 8 of 10
8.4.0 For all motors of 15 kW and above or as specified in Data Sheet, suitable ammeters shall be
provided in the local control stations. Ammeters shall have an accuracy class of 1.5 unless
otherwise specified in Data Sheet and shall have a suppressed end scale to suit the starting current.
8.5.0 The OFF push button shall be lockable with a pad-lock in pressed 'OFF' position.
8.6.0 If starting of motors / equipment are envisaged from more than one location or Auto / manual
operation is envisaged, necessary Local - Remote or Auto-Manual switches shall be provided either
in the Local Control Station or in the Instrument Control panel, if any. Stop facility shall be available
from any location irrespective of the position of selector switches.
8.7.0 All spare contacts shall be wired up to the terminal block. The terminal block shall have 10% spare
terminals subject to a minimum of two.
8.8.0 Nameplates in white perspex acrylic sheet with letters engraved in black shall be provided for each
control station indicating the service.
8.9.0 Circuit breaker contactors controlling motor feeders shall have rating at least 125% of the maximum
continuous rating of connected motors.
9.0.0 CABLES AND CABLING.
9.1.0 All power cables shall be PVC insulated, armoured and PVC sheathed with Aluminium conductor
unless otherwise specified in Data Sheet.
9.2.0 All control cables shall be PVC insulated, armoured and PVC sheathed with Copper conductor .The
control cable shall be laid segregated from the power cables.
9.3.0 The sizes of cables shall be so chosen that they are rated to carry the full load current continuously
after allowing for necessary derating factors for the service conditions of installation, and also that
the voltage drop in cables does not exceed 3% for full load running. For motor starting, voltage drop
up to 15% shall be permitted.
9.4.0 M.V power cables of 400 sq mm and above shall be laid with a clearance of 70 mm in between and
shall be clamped individually. Other cables can be laid touching and clamped in groups.
9.5.0 Cables shall be clamped at every 1500 mm interval on the horizontal trays / racks and at 750 mm
interval on the vertical trays / risers, at 400 mm interval for cables laid on walls, columns and other
structural works, and at bends and take off points.
9.6.0 A clearance equal to one diameter of the bigger cable shall be maintained between two adjacent
power cables buried underground and no such clearance need be provided for control and lighting
cables.
9.7.0 All fixing materials shall be given coatings of anticorrosive paint. Cable tags made of Aluminium
sheet shall be provided at every 10M interval. The purchaser will furnish the identity numbers of
cables after submission of the cable schedule by the supplier. All the cable racks in trenches and
overhead structure shall be bonded for continuity.
9.8.0 Selection of the size of cables for motors shall be done from the table indicated in the Data Sheet.
However, higher sizes may be used if warranted by voltage drop consideration in individual cases.
9.9.0 Wherever cables pass through masonry or concrete work, they shall be taken through suitable PVC
/ GI pipes. For road crossing suitable GI or concrete pipe shall be provided.
00FT001
9.10.0 After drawing the cables in GI / PVC pipes, the ends shall be sealed with cable compounds.
9.11.0 The size and minimum number of cores in control cables shall be as specified in the Data Sheet.

SPECIFICATION
Page 9 of 10
9.12.0 Type of cabling shall be overhead / buried in ground / through pipes / through permanently
constructed trenches with RCC / CI chequered plate covers as specified in Data Sheet.
10.0.0 EARTHING.
10.1.0 All electrical equipment shall be provided with duplicate earthing in conformity with relevant
standards / regulations applicable. The main earth bus shall be of bare / insulated aluminium or
copper or galvanized iron strip as specified in the Data Sheet and earthing of individual equipment
shall be done with conductors of type, sizes & material specified in the Data Sheet.
10.2.0 Earthing cables / strips shall be taken along with the power cables on the cable trays / racks / risers /
GI pipes / non-metallic pipes or buried. Earthing cables shall be clamped at intervals same as that of
power cables. Bare earthing strips shall be clamped at 3000 mm interval on horizontal trays / racks,
1500 mm interval on vertical trays / risers, 800 mm interval on walls, columns, and at bends / take
off points.
10.3.0 Metallic cable trays / risers shall be earthed at both ends. Electrical continuity of earthing throughout
the tray shall be ensured.
10.4.0 Earthing of equipment, vessels, pipe lines etc. if required towards protection against static electricity,
shall be done in conformity with relevant standards / regulations applicable.
10.5.0 Earthing system for protection of building and structures against lightning shall be provided if so
specified in Data Sheet in conformity with relevant standards / regulations applicable.
11.0.0 SAFETY ITEMS
11.1.0 Safety items required as per statutory regulations such as danger notice plates, rubber mat in front
of switch boards, fire extinguishers, resuscitation charts and fire buckets shall be supplied by the
vendor, if specified in Data Sheet.
12.0.0 HAZARDOUS AREA CLASSIFICATION FOR SELECTION OF ELECTRICS.
12.1.0 All electrics and their installation shall be suitable for the hazardous/ Non-hazardous area involved
and / or specified in the Data Sheet. Electrics suitable for the hazardous area involved shall be
selected as per the relevant Indian Standards and shall be of proven design approved by CIMFR /
relevant statutory bodies. In such cases copies of relevant certificates shall be furnished for
Purchaser’s approval.
13.0.0 ERECTION, TESTING AND COMMISSIONING.
13.1.0 Supply of all erection materials required for the erection of electrical equipments supplied by vendor
shall be the responsibility of the vendor. These items shall include all accessories for cable-jointing,
cable terminations/ cable tray/ racks, supporting steel structures, pipes, clamps, bricks, sand,
cement, rubble, compression type cable glands, insulating materials etc. Necessary grouting, fixing
etc. also shall be arranged by the vendor.
13.2.0 It shall be the responsibility of the vendor to supply and install all items that are incidental and
necessary for the completion of the installation, whether specifically mentioned or not, so that the
installation complies with relevant standards and regulations, at no extra cost to the purchaser.
13.3.0 Commissioning works includes all precommissioning tests, checking of all power, control & earthing
connections, testing and commissioning of all equipment / system supplied, erected and / connected
by the vendor, as per relevant standards and as directed by purchaser.
00FT001
13.4.0 The electrical installation work shall be carried out only through a contractor possessing valid and
competent electrical contractors license issued by the State Electricity Licensing Board for carrying
out electrical installation work in the place of installation.

SPECIFICATION
Page 10 of 10
13.5.0 All equipments which do not come under a roof shall be provided with weather proof features, and
be suitably protected using hoods /canopies
14.0.0 APPROVAL FROM ELECTRICAL INSPECTORATE.
14.1.0 It shall be the responsibility of the vendor to ensure that the complete installation supplied and / or
erected by him fully meets with relevant standards / Acts / rules / Regulations applicable and duly
got approved by statutory authorities like Electrical Inspectorate.
14.2.0 Any modifications / rectification required by the owner / Electrical Inspectorate resulting from
improper installation by the vendor or to make the same in full conformity with the relevant standards
/ Rules / Acts / Regulations applicable for the installation shall be carried out by the vendor without
any extra cost to the purchaser.
15.0.0 LIGHTING.
15.1.0 If lighting is included in the scope of the vendor, the same shall conform to specifications for the
lighting installation attached.
16.0.0 MAKE OF ELECTRICAL EQUIPMENT / ITEMS
16.1.0 Make of Electrical equipment / items shall be as specified in Data Sheet / Sub vendor list attached.
16.2.0 Approval shall be got from the Purchaser for the individual makes of the different electrical items,
wherever makes are not specified in the Data Sheet, before placement of purchase order.
00FT001

TECHNICAL
PROCUREMENT ELECTRICS FOR TURNKEY 32644-13-DA-92401
SPECIFICATION INSTALLATION -DATA SHEET Page 1 of 5 R0
1.0 Power supply voltage (clause 4.2.0/ 4.3.0) 1. 415V± 10%, 50 Hz ±5%, 3 Phase & neutral
AC at the substation
1.1 All Electrics shall be suitable for corrosive atmosphere due to the presence of acid
2.0 MOTORS
2.1 Scope of supply of vendor (clause 5.1.0) Squirrel cage induction motors –energy efficient –class
IE3
2.2 kW range and voltage ratings of motors (clause 5.2.0)
a) Type of motor Squirrel cage induction motor –energy efficient
b) Motors of rating upto and including 150kW 415V ± 10%, 50 Hz ±5%, 3 Phase AC
c) Motors of rating above 150kW upto and 3.3kV ± 10%, 50 Hz ±5%, 3 Phase AC
including 1000 kW
2.3 Class of Insulation (Clause 5.2.2) Class F with temperature rise limited to Class B
2.4 Degree of Protection (Clause 5.2.2) a) IP55 for Indoor
b) IPW55 weatherproof for Outdoor
2.5 Enclosure for (Clause 5.2.2
a) Non Hazardous area Shall be suitable for corrosive atmosphere(phosphoric
acid)
b) Hazardous area NA
2.6 Anti condensation heaters (Cl. 5.2.3) Required for motors of rating 37 KW & above
2.7 Method of Starting (Clause 5.2.5) Direct On Line or VFD as per the process requirement
2.8 Number of Starts (Cl. 5.2.6)
a) Number of consecutive cold starts 3
b) Number of consecutive hot starts 2
c) Number of equally spaced starts/hr. 4
2.9 Fault withstand time at terminal box 50kA
a) Starting Current (Cl. 5.3.1) As per IS
b) Main terminal box (Phase segregated) Required
(Cl. 5.3.2)
c) Star terminal box (Cl. 5.3.2) Not Required
d) Zero speed switches for motors of high
starting time required. (Cl. 5.3.2)
e) Winding temperature detectors (Cl. 5.3.3)- Not Required
RTD
f) Bearing Temperature detectors (Cl. 5.3.3) - Not Required
RTD
PROJECT Phosphoric Acid Tank
CLIENT M/s.FACT-CD
P.O. NO.
0 08-06-‘20 SM IK IK
VENDOR
13FT924A/14

TECHNICAL ELECTRICS FOR TURNKEY 32644-13-DA-92401
PROCUREMENT INSTALLATION
SPECIFICATION DATA SHEET Page 2 of 5 R0
g) Oil temperature detectors (Cl. 5.3.3) Not Required

h) Oil level indicator (Cl, 5.3.3) Not Required
i) Temperature scanner / Monitoring relays Not Required

with alarm and trip contacts for
winding/bearing RTD
j) Foundation bolts for motors Required
3.0 MV SWITCHBOARDS / MOTOR CONTROL CENTRES (MCC)
3.1 Incomer rating 200A MCCB
3.2 Number of Incomers in each MCC One (one from Client’s switchboard at substation)
Multi-Function meters shall be provided for incomer.
3.3 Enclosure IP 52
3.4 Number of Bus coupler in each MCC -
3.5 Type of MCC (Clause 6.2.2) a) Single front
b) Draw out
3.6 Cable entry Bottom
3.7 Material of Bus bars PVC sleeved Aluminium/ Copper
3.8 Test Push Button (Cl. 6.2.4) Not Required (but test facility for control circuit
required)
3.9 Type of overload relay reset (Clause 6.2.10 & Thermal overload(bimetal) relay -manual with reset
6.2.19) button. CT operated motor protection relay shall be
provided for motor feeders 22kW and above
3.10 Ammeters for outgoing feeders (Clause 6.2.12)
a) For Switch fuse/ MCCB feeders Not Required
b) For motor feeders Required
3.11 Current transformer for remote ammeter (Cl.6.2.13)
a) For motor feeders Required for motors of rating 15kW and above
b) Class of Accuracy 1.5
3.12 Control supply (Cl. 6.2.14) 110V AC
3.13 Control voltage Transformer (Cl. 6.2.15) Required for each module
3.14 Indication lamps on Motor feeders (Clause
6.2.19)
a) Motor ON (red) Required
b) Motor OFF (Green) Required
c) Overload Tripped (Amber) Required
d) Voltage rating for indication lamps 110V AC, with LED lamps.
3.15 Short circuit rating of MCCB 50KA for 1 sec
3.16 Single phasing annunciator for incomer (Cl. Thermal bimetallic overload relays provided for motor
6.2.22) feeders shall have integral / built in single phasing
preventing feature
3.17 Panel anti-condensation heaters (Clause Required
6.2.26)
13FT924A/14

3.18 Earth bus for MCC(Clause 6.2.27) Suitable for 50kA/1sec

3.19 Other requirements 1) Outgoing feeders as required for the acid pumping
system including lighting and one numbers welding
socket outlets. Spare feeders minimum one number for
each rating shall be provided. All out going feeders
shall be SFU type.
3.20 Type of motor starter DOL type. SFU shall be provided for all motor feeders
as overload protective device. Type of co-ordination
between contactor, overload protective device and
short circuit protective device shall conform to Type II
as per relevant standards. ON,OFF and trip indications
of pumps shall be made available at the existing
control room.
Note: Incomer feeder for the MCC shall be made available by the client at the outgoing feeder of
existing MV switch board located in the substation building.MCC for phosphoric acid tanks shall be
located in heavy equipment work shop building. Cables and cabling from substation building to Heavy
equipment workshop shall be included the scope of work of contractor.
4.0 LOCAL CONTROL STATIONS (Required for motors )
4.1 Material of construction (Clause 7.1.0) Cast Aluminium
4.2 Enclosure and degree of protection (Cl. 7.1.0)
a) Non Hazardous IP 55 weather proof for outdoor
b) Hazardous NA
4.3 Ammeter (Cl. 7.4.0) Required for motors rated 15KW and above
4.4 Accuracy class (Cl.7.4.0.0) Class 1.5
4.5 Local/Remote selector switch shall be provided
4.6 Indication lamps – cluster type LED lamps Not required
4.7 Foundation bolt for LCS Required
5.0 CABLES & CABLING
5.1 Type of cable and material of conductor (Cl. 8.1.0 & 5.2.4)
a) Power cables - MV Aluminium conductor with XLPE insulated ,PVC inner sheathed,armoured
PVC FRLS outer sheathed for cable sizes above 4sqmm. Cable sizes
4sqmm and below shall be Copper conductor, XLPE insulated, PVC inner
sheathed armoured PVC FRLS outer sheathed as per IS:7098
b) Control cables Copper conductor with XLPE insulation, PVC inner sheathed, armoured,
PVC outer sheathed FRLS type as per IS:7098
All cables for Instrumentation interface shall be stranded 1.5Sq.mm copper
cable.
5.2 Table of minimum cable sizes of Power cables (Cl. 8.8.0) Vendor shall provide adequate cable sizes to
limit the running voltage drop to 3%).Sizes indicated are for Aluminium cables .Equivalent size of
copper cable can be provided.
Motors ≤ 3.7 kW 1 # of 3 x 4 sq.mm Cu
Motors>3.7kW ≤7.5 kW 1 # of 3 x 6 sq.mm .Al
Motors>7.5kW ≤11 kW 1 # of 3 x 10 sq.mm Motors>75kW ≤90 kW 1 # of 3 x 240 sq.mm
Motors>11kW ≤15 kW 1 # of 3 x 16 sq.mm Motors>90kW ≤110 kW 1 # of 3 x 300 sq.mm
13FT924A/14

Motors>15kW ≤22 kW 1 # of 3 x 25 sq.mm Feeders 32A 4 x 10 sq.mm Al.

Motors>22kW ≤30 kW 1 # of 3 x 35 sq.mm Feeders 63A 3.5 x 35 sq.mm Al
Motors>30kW ≤37 kW 1 # of 3 x 50 sq.mm Feeders 100A 3.5 x 70 sq.mm Al.
Motors>55kW ≤60 kW 1 # of 3 x 150 sq.mm Feeders 400A 2RX3.5 x 240 sq.mm
Al.
Motors>60kW ≤75 kW 1 # of 3 x 185 sq.mm Feeders 800A 4RX3.5 x 400 sq.mm
Al.
5.3 Minimum sizes of control cables (Cl. 8.11.0)
a) Size in sq.mm 2.5
b) Minimum No. of cores for MV Motors (for LCS) As reqd. with 1 core, spare
c) Minimum No. of cores for HV Motors ( for LCS) -
d) Interlock/ Interconnection cables to control Upto 7 core – 1 core spare, More than 7 core – 2
panels/ eqpt etc. cores spare
5.4 Type of cabling (Cl. 8.12.0) 1) Cabling inside substation building -

a) MV equipment through over head GRP cable trays.
2) Cabling outdoor area - through over
head GRP cable trays where pipe
bridges/supports are available.Cables
shall be laid through GI pipes in paved
area.In other area where pipe bridges are
not available cables shall be laid through
buried trenches.RCC hume pipes shall be
provided for road crossings
6.0 EARTHING
6.1 Main incoming earth bus (Cl. 4.3.0)
6.2 Plant main earth bus if any (Cl. 9.1.0) * Vendor to furnish
6.3 Equipment earthing (Cl. 9.1.0)-Type & material
6.4 Equipment earthing (Cl. 9.1.0)-Table of minimum sizes
MCC / Switchboards, 2R 120sq.mm Al. cable Static Earthing of 1Rx120Sq.mm Al
fuse/ current limiting type Process cable.
MCCB protected equipment/Tanks
Motors ≤ 30KW & local 2Rx16 sq.mm Al
control stations
Motors >30KW, ≤37KW 2Rx35 sq.mm Al
Motors >37KW, ≤55KW 2Rx50 sq.mm Al
Motors >55kW, ≤65kW 2Rx 70Sq.mm Al
Motors>65kW, ≤75kW 2Rx120Sq.mm Al
Motors rated 75 KW 2Rx150Sq.mm Al
and above
6.5 Size of static earthing minimum (Cl. 9.4.0) 16 sq mm Aluminium cable
13FT924A/14

6.6 Lightning protection (Cl. 9.5.0) -
Two numbers of earth pits( Maintenance free copper bonded earthing electrodes approved by Kerala
state Electrical Inspectorate, comprising of 3 m long, dia. not less than 17 mm, earth electrode of low
carbon steel with 250 micron copper bonding on outer surface and having terminals to connect the
conductor) shall be provided for earthing MCC . Local Control stations ,drive motors ,Junction boxes
etc shall be earthed in duplicate and shall be connected to earthing system . All steel structures,
tanks, vessels, pipes, pipe joints, valves etc. shall be earthed against static charge
accumulation. Separate earth pits shall be provided for tank earthing .Inter connection of earth pits
with the nearest existing earth pit at two points shall be carried out with 150sq.mm PVC covered Al.
cable
7.0 SAFETY ITEMS (CLAUSE 10.0.0)

7.1 Danger Notice plates Required
7.2 CO 2 Fire Extinguisher (4.5kg) Required
7.3 Insulation mat in front of MCC/ switchboards 1.1 kV grade insulation mat as per IS 15652:2006
of thickness not less than 2.5 mm and 1000 mm
width shall be provided
7.4 Fire buckets ( 1 gallon) -
7.5 Resuscitation charts Required
8.0 Area Classification (Cl. 11.0.0) Safe area
9.0 Weatherproof protection (hood) for outdoor Required with Aluminium sheet
equipment (Clause 12.5.0) Motors & PB stns.
10.0 Responsibility of getting approval from Electrical Vendor shall be responsible for getting approval
Inspectorate (Cl. 13.1.0) from Electrical Inspectorate(CEA)
11.0 Lighting (Clause 14.0.0) Well glass , acid resistant ,weather proof LED
type light fittings shall be provided at srairs and
hand rails of tanks. Weather proof ,acid resistant
LED type flood light fittings shall be provided at
the top of the tanks for illumination of dyke wall
area and nearby roads .
12.0 Painting (Deviations if any on those specified in Epoxy painting
13ES900)
13.0 MAKE (Cl. 15.0.0) Refer sub vendor list (Electrical)
14.0 OTHER REQUIREMENTS
13FT924A/14

TECHNICAL ELECTRICS FOR TURNKEY 32644-13-TP-924-01
PARTICULARS INSTALLATION Page 1 of 6
1.0 MOTORS
1.1 Make
1.2 Equipment No. / Name
1.3 Type of Motor
1.4 Motor rating
1.5 Speed in RPM (Syn.)
1.6 Frame size
1.7 Class of Insulation
Enclosure, Degree of Protection & Type of
1.8
cooling
1.9 Direction of rotation
1.10 Full load current (Amps)
1.11 Starting Current (%FLC)
1.12 Slip (Percentage) at Full load
1.13 Efficiency (%) and power factor
a) At full load
b) AT ¾ load
c) At ½ Load
1.14 Locked rotor withstand time
a) Hot (seconds)
b) Cold (seconds)
1.15 Starting time of motor on DOL with driven equipment coupled
a) At 100% voltage
b) At 80% voltage
Minimum voltage required for starting with
1.16 the equipment and corresponding starting
time
1.17 Allowable number of starts with driven equipment coupled
a) Consecutive cold starts
b) Consecutive Hot starts
c) Equally spaced starts/Hr.
Guaranteed temperature rise under worst
1.18
conditions of voltage and frequency
1.19 Speed Vs. Torque curve
1.20 Current Vs. time curve
1.21 Current Vs. Speed curve
Thermal withstand characteristics (hot &
1.22
cold)
1.23 Start withstand time
PROJECT Phosphoric Acid tank
CLIENT M/s.FACT-CD
P.O. NO.
VENDOR
13FT924B/14

a) Hot (seconds)
b) Cold (seconds)
Margin between starting time and locked
1.24 Rotor withstand time hot (Clause 5.3.1 of
13ES924)
1.25 CIMFR Certificate (for Flame-proof motors)
1.26 Bearings
a) Drive end bearing No. & type
b) Non-drive end bearing No. & type
c) Make of bearings
1.27 Lubricant
a) Make
b) Type
c) Lubrication Schedule of motor
1.28 Weight of Motor
2.0 LOCAL CONTROL STATIONS
2.1 Maker’s Name
2.2 Works at which units will be fabricated
2.3 Material of construction
2.4 Enclosures & Degree of protection
2.5 Technical details, leaflets etc
2.6 Standards applicable
2.7 Ammeter range & Accuracy class
2.8 CIMFR certificate for flame proof equipment
2.9 Type of Local control stations
3.0 CABLES
3.1 Make
3.2 Type & Material
Power Cable
Control cable
Power cable
Control cable
4.0 EARTHING CONDUCTORS
4.1 Make
4.2 Type & Material
5.0 OTHER DETAILS
13FT924B/14

6.0 MOTOR CONTROL CENTRES

6.1 Number of MCCs
6.2 Incomer Rating
6.3 Maker’s name
6.4 Works at which the boards will be fabricated
6.5 Type of switchboards
6.6 Max. Temperature rise over ambient
6.7 Sizes of phase and neutral bus bars of the following ratings along with supporting calculations
a) 100A
b) 200A
c) 400A
d) 630A
e) 800A
Short time (1 sec.) rating of bus bars in
6.8
KA(Rms)
6.9 Type, make, ratings/range/ratios and relevant details of individual components
6.10 Technical details, leaflets and type test certificates for the following items.
a) Heavy duty type switches
b) Air Break contactors (Power &Auxiliary)
c) HRC link type fuses (Power and Control)
d) Bus bars
e) Current transformers
f) Bimetallic thermal overload relays
g) Meters
h) Indicating lamps
i) Timers
j) Single phasing annunciators
Overall dimensions in mm of each
6.11
switchboard
Weight of each switchboard in Kg. (Dynamic
6.12
loading if any shall be furnished)
6.13 Material and area of cross section of conductors of
a) Bus bars to switch of each rating
b) Switch to fuses of each rating
Material and voltage class (grade) of

6.14
insulation of above conductors if insulated
13FT924B/14

6.15 COMPONENT / FEEDER DETAILS

Over Size of wire
Motor Rating of terminals in
Full Mod- HRC Fuse Contactor load used in
KW/ Switch/MCCB Amps.
Load ule relay modules
Fdr. AC22 AC23 Therm- Let Therm- AC3 1sec.
Amps size range Draw-
rating Type rating rating al rating through Type al rating rating Rating Power Control Fixed Outgoing
(A) (A) (A) energy (A) (A) (A) (A) out
0.25
0.37 1.2
0.55 1.6
0.75 1.8
1.1 2.6
1.5 3.5
2.2 5.0
3.7 7.5
5.5 11
7.5 14
9.3 19
11 21
15 28
18.5 35
22 40
30 55
37 66
45 80
55 100
75 135
90 165
110 200
132 230
150 275
63
Switch fuse/MCCB
100
200
250
feeder
400
630
13FT924B/14

7.0 VARIABLE FREQUENCY DRIVES

7.1 Make
7.2 Model Number
7.3 Country of manufacture
7.4 Type of reference
7.5 Standards to which the VVFD conforms to
7.6 Weight
7.7 Drive type
7.8 Dynamic Response
a) Speed fluctuation band
b) Speed recovery time after 100% torque
step
c)Type of feed-back for speed control
d)Speed control accuracy
Waveform distortion factor (% harmonics) in
output / input waveform
7.9
(Number of harmonics and magnitude of
each harmonic generated shall be furnished)
7.10 Rating expressed at (torque)
7.11 Speed control range
7.12 Overload capacity
7.13 Rating declared at (temp.)
7.14 Switching frequency at declared rating
7.15 Overload capability of converter
a) 115% In( for variable torque) for
7.16 Overall efficiency of drive (excl. motor) at
a) 100% load
b) 75% load
c) 50% load
7.17 Overall power factor of drive (excl. motor) at
a) 100% load
b) 75% load
c) 50% load
7.18 Control mode
7.19 Acceleration time (Adjustable)
7.20 Deceleration time (Adjustable)
7.21 Operation mode
7.22 Speed reference signal
7.23 Braking
7.24 Frequency setting
7.25 Communication protocols
7.26 PID function
7.27 Type of power converter
7.28 Type of cooling system provided
7.29 Type of output filter provided
13FT924B/14

7.30 Panel Construction

a)Material of construction
b)Thickness
c)IP Rating
7.31 Cooling
i) Type
ii) Redundancy in cooling units
7.32 Panel space heater rating
Maximum noise level from the drive at 1-
7.33
meter distance
7.34 Dimensions
a) Length
b) Height
c) Depth
d) Weight of cubicle
7.35 Earth bus
7.36 Size
7.37 Minimum fault current capacity
13FT924B/14

SPECIFICATION
MEDIUM VOLTAGE SWITCH BOARDS
Page 1 of 16
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCES
3.0.0 STANDARDS
5.0.0 CONSTRUCTION&GENERAL REQUIREMENTS
6.0.0 BUS BARS
7.0.0 FEEDER ARRANGEMENT
8.0.0 CABLE COMPARTMENTS
9.0.0 CABLE TERMINATION
10.0.0 WIRING
11.0.0 INSULATION
12.0.0 EARTHING
13.0.0 NAME PLATE
15.0.0 FEEDER LOAD-BREAK SWITCHES
16.0.0 MINIATURE CIRCUIT BREAKERS
17.0.0 FUSES
18.0.0 STARTER-CONTACTORS
19.0.0 OVERLOAD RELAYS
20.0.0 CURRENT TRANSFORMERS
21.0.0 RELAYS
22.0.0 CONTROL TRANSFORMERS
23.0.0 INDICATING INSTRUMENTS
24.0.0 INDICATING LAMPS, PUSH BUTTONS, CONTROL SWITCHES, ETC
25.0.0 ANTI-CONDENSATION HEATERS
26.0.0 DRAWOUT SWITCHBOARDS
27.0.0 MEDIUM VOLTAGE CIRCUIT BREAKERS
1.0.0 SCOPE
1.1.0 This specification covers the general requirements for design, manufacture, testing and supply of
Medium Voltage Switch boards like Power Control Centres (PCC), Motor Control Centres (MCC),
Power cum Motor Control Centres (PMCC), Auxiliary switch boards, Lighting Switchboards, etc.
2.0.0 REFERENCES
2.1.0 Following documents shall be read in conjunction with this specification:
2.1.1 Engineering specification and Data sheet of General requirements for Electrics
2.1.2 Data sheet of Medium Voltage Switchboards
2.1.3 Technical Particulars of Medium Voltage Switchboards
3.0.0 STANDARDS
3.1.0 Requirements laid down in the latest revisions of the following Indian Standards and other relevant
standards & regulations shall be strictly adhered to:
IS: 8623(Part I) Specification for Low- Voltage Switchgear & Control gear Assemblies
IS/IEC60947-1 Low voltage switch gear and control gear :part 1-General rules
IS/IEC60947-3 Low voltage switch gear and control gear :part 3-Switches, disconnectors,Switch
disconnectors and fuse combination units
PRPD.: CHKD.: APPRD.: ISSUED ON: SEPT 2014
00FT001

SPECIFICATION
Page 2 of 16
IS: 5578 Guide for marking of insulated conductors
IS: 11353 Guide for uniform system of marking and identification of conductors and apparatus
terminals
IS: 10118 Code of practice for selection, installation, and maintenance of switchgear and control
gear
IS: 13118 Circuit breakers
IS:13703 Specification of low voltage fuses for voltages not exceeding 1000V-AC or1500V-DC
IS:13947:part4:sec:1 Specification for low voltage switchgear and control gear -Part 4;Contactors
and motor starters-Sec-1:Electro mechanical contactors and motor starters
IS: 2705 Current Transformers

IS: 4201 Application guide for CTs
IS: 3231 Electrical relays for power systems protection
IS: 3842 Application guide for electrical relays for ac systems
IS:13947:part5:sec:1 Specification for low voltage switchgear and control gear -Part 5-control circuit
devices and switching elements-sec1:Electromechanical control circuit
devices
IS:8828 Electrical accessories- Circuit breakers for over current protection for house hold and
similar installations
IS: 1248 Direct acting electrical indicating instruments

IS: 13010 A C watthour meters class 0.5,1.0 and 2.0- Specification
IS: 13779 AC static watthour meter ,class 1.0 and 2.0- specification
IS: 8530 Maximum demand indicators , class 1.0
IS: 14415 Volt ampere hour meter for restricted power factor range- specification
IS: 14390 Volt ampere reactive hour meter, class 3.0
IS: 14372 Volt ampere hour meter for full power factor range
IS: 1901 Visual indicator lamps
IS: 2551 Danger notice plates
IS: 732 Code of practice for electrical wiring installations
IS: 900 Code of practice for installation and maintenance of induction motors
IS: 3043 Code of practice for earthing
4.1.0 The equipment shall be designed to operate satisfactorily at rated load under the service conditions
and power supply conditions specified in the data sheet of “ General requirements for electrics” and
data sheet of “Medium voltage switch boards”.
5.0.0 CONSTRUCTION & GENERAL REQUIREMENTS
5.1.0 All switchboards shall comply with the requirements of IS:8623 applicable for Low-Voltage Switchgear
and control gear assemblies.
5.2.0 The switchboard shall be of folded sheet steel construction, fully compartmentalized, floor mounted,
free standing type and dust, damp &vermin proof. The degree of protection shall be as specified in the
data sheet. Vertical units shall be assembled to form a continuous line up of uniform height and front
line up.
5.3.0 Thickness of sheet steel shall not be less than 2 mm except for certain non load bearing members like
instrument plates, partitions, doors, etc. for which a minimum thickness of 1.6 mm shall be ensured.
5.4.0 Doors and openings shall be provided with neoprene gaskets. All hardware shall be corrosion
00FT001
resistant.
5.5.0 All doors shall be hinged at one end and shall be bolted (knob type) on other end. All hinges shall be
of concealed design for elegant appearance.

SPECIFICATION
Page 3 of 16
5.6.0 Adequate lifting facilities shall be provided on each section. Lifting eyes may be of removable/foldable
design. When removed, these shall not leave any openings on the boards.
5.7.0 All barriers used shall be manufactured from non-inflammable material.
5.8.0 Bus bars shall be housed in separate metallic compartment (horizontal bus bar chamber & vertical
bus bar chamber) and shall be accessible for inspection only with special tools.
5.9.0 Individual feeder modules shall be housed in independent and separate enclosed compartments
separated from each other by metallic barriers. Each vertical row of modules shall have independent
vertical bus bars, vertical bus bar chambers, and cable alleys.
5.10.0 The design of the switchboard shall be such as to allow for extension of vertical panels at both the
ends. The ends of the busbars shall be suitably drilled and the side covers of the horizontal bus bar
chambers at extreme ends shall be provided with opening, which shall be covered with a gasketted
plate screwed to the panel.
5.11.0 In the case of single front panels without rear access (as specified in the data sheet), access to all
components, cable connections, bus bars, etc. shall be from the front only.
5.12.0 The equipment shall be designed to ensure complete safety during operation, inspection, connection
of cables, relocation of outgoing circuits and maintenance even with the bus bar system energized.
Features which prevent shorting of power and / or control terminals due to accidental dropping of
maintenance tools etc., inside the switchboard shall be provided. Checking and removal of
components shall be possible without disturbing adjacent components. All auxiliary equipment /
components shall be easily accessible.
5.13.0 All exposed live terminals in the cable alley and incomer terminals inside modules shall be covered or
shrouded to prevent accidental contact.
5.14.0 The incoming power connection shall be through bus trunking or cables as specified in the data sheet.
Ample space for connection of these cables / bus trunking shall be provided.
5.15.0 For lighting and auxiliary switchboards, the neutral conductors & bus bars shall have the same current
carrying capacity as that of the phase conductors & busbars.
5.16.0 Mechanical castle key interlocks and electrical interlocks shall be provided between the incomers and
bus couplers to prevent paralleling of incoming feeders, if specified in the data sheet.
5.17.0 Necessary foundation bolts, nuts and washers shall be supplied along with the equipment.
5.18.0 For additional / special requirements of Drawout switch boards (non breaker panels) refer clause
24.0.0 and for requirements of Circuit breaker panels refer clause 25.0.0below.
5.19.0 Temperature rise test if specified (in Scope of inspection and tests / Data sheet), shall be conducted
on one unit of each type of MV switchboard, before despatch. Test shall be conducted for the
specified full load rating of the bus bars. Test shall be done for both power and neutral bus in both
horizontal and vertical bus bar system. Diversity factor given in Table 1 of IS:8623 shall not be
applicable. Tests shall comply with he requirements of IS:8623,Clause 8.2.1, verification of
temperature rise limits. Testing procedure to be adopted shall be furnished in the bid. Bus bar
o
temperature rise shall be limited to 40 C. Tests shall be conducted in the presence of FEDO/ owner
representatives.
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6.0.0 BUS BARS
6.1.0 Busbars shall be of high conductivity aluminum/copper as specified in the data sheet. Insulating
sleeves complete with necessary joint shrouds shall be provided for bus bars, if specified in the data
sheet.

SPECIFICATION
Page 4 of 16
2 2
6.2.0 Maximum allowable current density for busbars shall be 1.25 A/mm for copper and 0.78 A/mm for
Aluminium.
6.3.0 The horizontal and vertical bus bars shall be rated for the same fault level specified in the data sheet.
6.4.0 Horizontal busbars shall be of uniform cross section throughout the length of the switchboard. Vertical
busbars of all vertical panels of the switch board shall also be of uniform cross section.
6.5.0 The bus bars and bus bar supports shall withstand the dynamic, thermal & magnetic stresses and
strains due to the maximum short circuit current corresponding to the fault level indicated in the data
sheet, without any deformation, deterioration or damage.
6.6.0 Rigid insulating barriers / protection guards /wire meshes shall be provided between the group of live
bus bars and other parts, so as to eliminate danger to personnel due to accidental contact.
6.7.0 The bus bar supports shall be of non-hygroscopic material with anti tracking features to prevent
flashovers. These shall have high tracking index and be mechanically strong. Hylam is not
acceptable.
6.8.0 Appropriate identification shall be provided on the busbars for distinguishing the various phases,
neutral and control / auxiliary buses.
7.0.0 FEEDER ARRANGEMENT
7.1.0 Feeder module / compartment sizes shall be integral multiples of one or two basic sizes.
7.2.0 Indicating lamps, meters and push buttons shall be mounted flush with the front-hinged cover.
7.3.0 The control components, except those coming on doors, shall be mounted on a base plate, fixed on
the frame of the module.
7.4.0 The incoming feeder shall be arranged preferably in the middle of each group of feeders, in such a
way that loads are distributed equally on either side.
7.5.0 The feeder arrangement shall be such that the operating height (ie. operating handle, switches, push
buttons, etc.) lies within 1828 mm, but above 300mm, from the floor level.
8.0.0 CABLE COMPARTMENTS
8.1.0 Cable compartments / cable alleys shall be provided for easy termination of all incoming and outgoing
cables. The width of this cable alley shall be sufficient to accommodate all the cables and shall have
free access for cable terminations and in any case shall not be less than 150mm. Cable alleys shall
be provided with suitable doors. It shall be possible to carry out maintenance work safely on cable
connections to anyone circuit, with the bus bars and adjacent circuit live.
8.2.0 Adequate supports and facilities for clamping shall be provided for cables, wherever necessary.
8.3.0 A horizontal wire way, extending over the entire length, shall be provided at the top / bottom for inter
panel wiring.
8.4.0 Removable gland plates, having a minimum thickness of 2mm, shall be provided. Gland plates for
glanding for single core cables shall be made of nonmagnetic material.
00FT001
8.5.0 Cable glands shall be supplied loose along with the equipment for fixing them at site, if specified in the
data sheet.
9.1.0 All terminal blocks shall have adequate current carrying capacity, heavy duty & break resistant.

SPECIFICATION
Page 5 of 16
9.2.0 Terminals shall be compact and shall have high dielectric strength so as to prevent flashover and
have thermal strength to prevent deterioration. All terminals shall be mounted on aluminium rails, with
provision for addition of terminals.
2
9.3.0 Direct conductor termination type terminals of approved make will be acceptable up to 10mm size.
Bolted type terminals with crimping type lugs shall be provided for all cable connections greater than
2
10mm .
9.4.0 Sufficient clearances shall be available between terminals when terminal lugs are fitted to them.
9.5.0 Not more than two wires (one incoming & one outgoing) shall be connected per terminal.
9.6.0 Minimum 10% spare terminals shall be provided on each control terminal block, subject to a minimum
of two.
9.7.0 Shorting links shall be provided for CT terminals.
9.8.0 Identification numbering / lettering shall be provided for each terminal.
9.9.0 Necessary hardware required for cable termination like nuts ,bolts, washers, spacers etc. for incoming
and outgoing feeder shall be fitted and supplied.
10.0.0 WIRING
10.1.0 The switchboard shall be completely pre-wired and ready for external connections at site.
10.2.0 All control wiring shall be carried out through common wire ways. These shall not cross the bus bar
chamber. All control wiring shall be easily accessible for maintenance.
10.3.0 Necessary colour codes shall be adopted for power and control wiring for easy identification.
10.4.0 Power wiring shall be carried out with PVC insulated, stranded copper conductors of 650 Volts grade
2
having adequate current carrying capacity. Minimum size of conductor for power wiring shall be 4mm
copper.
10.5.0 Control wiring shall be carried out with 650 V grade, PVC insulated, copper conductor of size not less
2 2
than 1.5 mm . Circuits involving current transformers shall have 2.5mm ,1100 V grade conductors.
10.6.0 Wiring shall be terminated in easily accessible terminal blocks. The wires shall be arranged neatly and
the two ends of each wire and terminal block shall bear identification number/letter using unbreakable
ferrules.
10.7.0 Control wiring wherever terminated shall be in single layer formation.
10.8.0 All inter panel control wiring shall be taken through PVC sleeves and this shall be done by the switch
board manufacturer with the identification of wires and terminals for interconnection.
11.0.0 INSULATION
11.1.0 All insulating materials shall be non-hygroscopic, mould proof and treated with suitable varnishes.
Hylam shall not be used.
00FT001
12.0.0 EARTHING
12.1.0 A continuous earth bus as specified in the datasheet shall be provided for the entire length of the
switchboard.
12.2.0 A minimum of 2 terminals shall be provided on the bus for external connection to earth grid.

SPECIFICATION
Page 6 of 16
12.3.0 All panels shall be properly connected to the earth bus.
12.5.0 All non-current carrying metallic parts of the equipment shall be earthed.
12.6.0 All hinged doors and covers shall be provided with suitable flexible earthing connections.
13.0.0 NAME PLATE
13.1.0 A nameplate with the switchboard designation shall be fixed at the top of the central panel. Separate
nameplates, giving feeder designation shall be provided on each compartment.
13.2.0 Necessary functional nameplate shall be provided for each component such as lamps, PBs, relays,
switches, etc. mounted on the panel front.
13.3.0 Nameplates shall be of Non corrosive metal like stainless steel with letters engraved in it.
13.4.0 The component nos. shall be painted / suitably identified inside the panel at appropriate points to give
a permanent marking.
14.1.0 Where moulded case circuit breakers are used for feeder circuit protection, rating and
characteristics shall be chosen in such a way as to ensure proper discrimination with other upstream
and downstream protective devices within the assembly.
14.2.0 The MCCB should be current limiting type with trip time of less than 10 milli second under short circuit
conditions. The MCCB should be either 3 or 4 poles as specified in data sheet.
14.3.0 MCCB shall comply with the requirements of the relevant standards IS13947 – Part 2 and should
have test certificates for Breaking capacities from independent test authorities CPRI / ERDA or any
accredited international lab.
14.4.0 MCCB shall comprise of Quick Make -break switching mechanism, arc extinguishing device and the
tripping unit shall be contained in a compact, high strength, heat resistant, flame retardant, insulating
moulded case with high withstand capability against thermal and mechanical stresses
14.5.0 The breaking capacity of MCCB shall be as specified in the schedule of quantities. The rated service
breaking capacity (Ics) should be equal to rated ultimate breaking capacities (Icu). MCCB’s for motor
application should be selected in line with Type-2 Co-ordination as per IS 13947-2. The breaker as
supplied with ROM should meet IP54 degree of protection.
15.0.0 FEEDER LOAD BREAK SWITCHES
15.1.0 The switches shall be of air break type, AC22 /AC23 utilization category as per IS. MinimumAC22
rating of the switch used shall be 63 A.
15.2.0 The switches shall have a quick-make, quick-break, fault-make, load-break mechanism operated by
an external insulated earthed handle, complete with ON-OFF position indicator/ dial plates.
15.3.0 Load break switches of motor starter feeders shall have AC23 rating corresponding to full load current
of the motor connected. Also theAC22 rating of the switches used shall not be less than the rating of
the HRC fuses in the feeder.
00FT001
15.5.0 The switch fuse feeders shall be provided with load break switches of AC22 utilization category.
15.6.0 Bolted type removable copper links of adequate size shall be provided for neutral, in all incomer
feeders and outgoing feeders with TPN switch fuse units.

SPECIFICATION
Page 7 of 16
15.7.0 The cubicle door shall be interlocked with the switch mechanism so that the door cannot be opened
unless the switch is in the OFF position.
15.8.0 Padlocking facility in OFF position shall be provided for feeder switches.
15.9.0 In the event of an independent control circuit supply to the coils of the contactors, the main switch shall
be provided with necessary auxiliary contacts to disconnect this control supply as well, when the
switch is turned to ‘OFF’ position for isolating the main supply.
16.0.0 MINIATURE CIRCUIT BREAKERS (MCB)
16.1.0 Miniature Circuit Breaker shall comply with IS-8828. Miniature circuit breakers shall be quick make
and break type for 240/415 VAC 50 Hz application with magnetic thermal release for over current and
short circuit protection.
16.2.0 The breaking capacity shall not be less than 10 KA at 415 Volts AC. MCB’s shall be DIN mounted.
The MCB shall be Current Limiting type (Class-3). MCB’s shall be C Type as per their Tripping
Characteristic curves defined by the manufacturer, unless otherwise specified in the data sheet.
16.3.0 The MCB shall have the minimum power loss (Watts) per pole defined as per the IS/IEC and the
manufacturer shall publish the values. MCB shall ensure complete electrical isolation & downstream
circuit or equipment when the MCB is switched OFF.
16.4.0 The housing shall be heat resistant and having high impact strength. The terminals shall be protected
against finger contact to IP20 Degree of protection. All DP, TP, TPN and 4 Pole miniature circuit
breakers shall have a common trip bar independent to the external operating handle.
17.0.0 FUSES
17.1.0 All fuses shall be HRC link type , suitable for industrial application conforming to IS: 13703 Part II.
17.2.0 Selection of fuses for motor feeders shall be as per IS: 900.
17.3.0 All power and control fuses shall be provided with distinct operation indicators, to show whether they
have operated or not.
17.4.0 For all fuses provided in the fuse holders, necessary viewing aperture shall be provided on the fuse
holder for locating the blown out fuses.
17.5.0 Fuse holders and fuse bases shall be made of unbreakable non-inflammable and non-hygroscopic
material, preferably of phenolic mouldings.
17.6.0 Fuse pullers of different sizes required for inserting and removing HRC fuses shall be supplied for each
switchboard.
18.0.0 STARTER-CONTACTORS
18.1.0 Starter contactors shall be electromagnetic, air break type, suitable for uninterrupted duty and of AC3
/ AC4 utilization category as specified in data sheet, conforming to relevant standards.
18.2.0 The operating coil shall be vacuum impregnated, with special varnish, to remove all traces of air and
moisture. Alternatively, it can be of resin cast material as well.
00FT001
18.3.0 The holding coils shall be rated for the control voltage specified in the data sheet.
18.4.0 If specified in data sheet, the holding coils shall be provided with delayed (up to 5 seconds) under
voltage release features.
18.5.0 Contactors shall preferably have switching position operation indicator.

SPECIFICATION
Page 8 of 16
18.6.0 A minimum of 1 N/O and 1 N/C spare auxiliary contacts, in addition to those required for control
circuits, shall be available for each contactor. (If necessary, add on blocks or auxiliary contactor can
be provided.)
18.7.0 Wherever control voltage is DC, necessary series economy resistors shall be provided in the control
circuits, to reduce the DC load on the battery / rectifier.
18.8.0 Type of co-ordination between contactor, overload protective device and short circuit protective device
shall conform to Type II as per relevant standards.
19.0.0 OVERLOAD RELAYS
19.1.0 All overload relays shall be designed to nullify the effects on settings due to changes in ambient
temperature and humidity and they shall have adjustable accurately calibrated settings.
19.2.0 Overload protection shall be available for all the phases.
19.3.0 The over load relay shall be manual / auto reset type as specified in the data sheet. For manual reset
type, reset knob / push button shall be provided on the cubicle door, if specified in the data sheet.
19.4.0 Overload relays shall be either direct connected or CT operated, depending on the rating of motor. In
the case of CT operated relays, cast resin insulated CTs shall be included in the scope of supply of
vendor.
19.5.0 Thermal bimetallic overload relays provided for motor feeders shall have integral / built in single
phasing preventing feature. If built in feature is not available, separate current operated type single
phasing preventor shall be provided.
19.6.0 If separate single phasing preventor (SPP) is provided, the same shall be fail safe type and shall
function without any external power supply. In case of failure of internal wiring, the relay shall trip the
motor. The SPP shall be suitable for protection of the nonreversible as well as reversible motors.
19.7.0 Thermal over load relays for motor feeders of blowers, fans, agitators, crushers, compressors and
mills shall be of heavy duty, delayed action type to allow for more starting time. If required heavy-
duty overload relays are not available, necessary bypass contactor & timer arrangement circuit shall
be provided to allow for more starting time.
19.8.0 Contactor and overload relay shall be selected so as to withstand the let through energy of the
connected HRC fuse and MCCB’s in the feeder, and consequent thermal and dynamic effects.
20.0.0 CURRENT TRANSFORMERS
20.1.0 Current Transformers (CTs) shall be of cast resin insulated type, and shall conform to relevant
standards like IS: 2705 & IS: 4201.
20.2.0 Ratings of CTs provided shall match the specific requirements of the meters and protective relays
involved.
20.3.0 CTs provided in circuit breaker panels shall withstand the maximum short circuit current for a
minimum of 1 second. However for motor feeders the minimum duration can be 0.6seconds.
20.4.0 Separate CTs / cores shall be used for metering and protection. Dual purpose CTs are not
00FT001
acceptable.
20.5.0 CTs for metering purposes shall have adequate capacity to cater for 130% of full load conditions.
Metering CTs shall have an Instrument Security Factor not more than 5 and an accuracy class not
more than 1.5 unless otherwise specified.

SPECIFICATION
Page 9 of 16
20.6.0 CTs for protection purposes shall have sufficient accuracy, burden and accuracy limit factor for
necessary coordination / discrimination for clearing faults. Accuracy limit factor for protection CT shall
not be less than 10 and accuracy class shall be 5 P. CTs for differential / REF protection shall be of
class ‘PS’.
20.7.0 All CT terminals and terminals to remote meters shall be provided with links to facilitate shorting as
and when required.
20.8.0 CTs shall be provided with polarity markings adjacent to terminals, both for primary and secondary.
These shall be legible even after years of service.
20.9.0 1 No. current transformer with 1 Amp secondary rating shall be provided for each motor feeder having
a motor rating of 15 KW and above, unless otherwise specified in the data sheet, for remote
ammeter. Burden of this CT shall be sufficient to compensate for the lead burden and for the burden
of remote ammeter. As per data sheet, if same CT is used for local and remote meters, it shall have
adequate burden to meet the total requirement.
20.10.0 If standby earth fault protection (earth leakage protection) and / or restricted earth fault protection are
provided on incoming breaker panels, one number ground CT with suitable VA and ratio for standby
earth fault protection and one number ground CT with suitable ratio, knee point voltage and exciting
current for restricted earth fault protection, shall be supplied loose, per incomer, in weatherproof
enclosure fitted with cable glands.
21.0.0 RELAYS
21.1.0 Relays shall conform to IS 3842 & IS 3231.
21.2.0 Protective relays shall be flush mounted drawout type. The type and manufacture of the relays shall
be approved by the buyer.
21.3.0 All relays shall have hand reset type operation indicators and initiating contacts. Indicators shall be
visible from front side of the panel. It shall be possible to reset them without opening the relay case.
21.4.0 Protective relays shall be suitable for the CT secondary current.
21.5.0 The relay shall have provision for insertion of test plug at the front for testing and calibration
purposes. It shall be possible to test the relays without disconnecting the wiring and without
withdrawing the relay. The insertion of the test plug shall automatically short circuit the CTs and
permit extension of external power supply to the relay.
21.6.0 Circuit breaker feeders with protective relays shall be provided with high speed master tripping
relay of the lock out type with hand reset feature and coil cut off contact.
21.7.0 It shall be ensured, by checking with the relay manufacturer, that with the accuracy limit factor of
current transformer provided, the thermal withstand capability of relays will not get exceeded for the
fault level prescribed.
21.8.0 If composite motor protection relays are prescribed in the data sheet for motor feeders, thermal
withstand characteristics of motors will be furnished on receipt from motor manufacturer. Selection of
most suitable version of motor protection relay based on the motor characteristics, to provide
adequate protection to the motor, shall be the responsibility of the switchboard supplier. Necessary
application checks shall be carried out by vendor in consultation with the relay manufacturer and
recommended settings along with calculations shall be submitted.
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21.9.0 Vendor shall furnish complete relay coordination details applicable. This is required to check the
adequacy of CT ratios, VA ratings, relay types and characteristics, etc. and to determine the optimum
settings to be adopted for ensuring selectivity and backup protection. While selecting the settings,
manufacturing tolerances of devices shall be considered. Settings for all adjustable devices shall be

SPECIFICATION
Page 10 of 16
tabulated. Graphs shall also be drawn to match motor characteristics with motor protection relay
characteristics.
22.0.0 CONTROL TRANSFORMERS
22.1.0 Control transformer shall be provided on each module unless otherwise specified in the datasheet,
wherever control voltage specified / required is different from the mains voltage.
22.2.0 Control transformer shall be cast resin-insulated type.
22.3.0 Control transformer shall have ± 5% voltage tappings on the primary side and with center tap of
secondary winding earthed. Where common control transformer is specified in data sheet for bus
section additional tappings of ± 2.5% shall also be provided.
22.4.0 All Control transformers shall have HRC fuse protection on primary side and double pole MCB on
secondary side. Where common control transformer’s are specified in the data sheet for bus section,
suitable switch fuse unit shall be provided on the primary side.
22.5.0 Control transformer provided in individual module shall have adequate capacity to feed the control
loads of the feeder as well as the inrush VA of the contactors & relays of the feeder.
22.6.0 Where common control transformers are specified in the data sheet for each bus section, each unit
shall have adequate capacity to feed all control loads (including those of spare panels) of particular
bus section and any one of the adjacent bus sections as well as the inrush VA of contactors & relays
applicable. In the event of failure of the control transformer of one bus section, control transformer
feeding any one of its adjacent bus sections shall be capable of feeding the same also, in addition to
its own loads, by temporary interconnection.
22.7.0 Where control transformers are provided bus section wise, the compartment housing the control
transformer shall preferably be located towards the bottom of the switchboard, to facilitate
maintenance and replacement.
22.8.0 Wherever module control transformers are envisaged in draw out switchboards, a separate control
transformer (complete with switch fuse on primary, double pole MCB on secondary and centre tap of
secondary winding earthed) for test supply shall be provided along with associated wiring and
accessories.
22.9.0 Where common control transformers are provided, the control supply to module shall get
automatically isolated when the feeder switch is switched OFF.
23.0.0 INDICATING INSTRUMENTS
23.1.0. Meters shall be flush mounted and of a type and make approved by the buyer.
23.2.0 All meters shall be square type of size 96mm x 96 mm unless otherwise specified in the datasheet.
Dials shall be white with black numerals and letters.
23.3.0 A moving iron voltmeter having a range of 0-500Volts AC shall be provided, along with a suitable
selector switch, to read all line to line voltages on the incoming side of incoming feeders. The selector
switches shall have 3 way and OFF positions. Necessary facia plates to denote switch positions shall
be provided. Necessary control fuses shall be provided in the voltmeter circuit.
23.4.0 Voltmeter shall be of Class 1.5 accuracy as per IS and shall have suppressed scale for the lower
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values in the range.
23.5.0 Ammeters shall be of accuracy Class 1.5 as per IS unless otherwise specified.
23.6.0 Ammeter having suitable range shall be provided along with ammeter selector switch to read line
currents in the incomer feeders. The selector switches shall have 3 way and OFF position. Necessary

SPECIFICATION
Page 11 of 16
facia plates to denote switch positions shall be provided. These ammeters shall have approximately
uniform scale up to about full load current and suppressed end scale from 100% to at least for 150%
full load.
23.7.0 Ammeter, if provided for motor feeders as per data sheet, shall have suppressed overload range
(cramped end scale), to read the starting current of 600-800% and 200-400% of normal full load
current of motors for DOL starting and for star delta starting respectively.
23.8.0 A red mark shall be provided on the ammeter dial, corresponding to the full load current.
23.9.0 All ammeters shall be operated through current transformers and not directly connected. Calibration of
the ammeters shall tally with the ratio of the current transformers.
23.10.0 Cushion stoppers and zero correction screws shall be provided for all meters.
23.11.0 Energy meter, kilowatt meter and power factor meter, if provided as per data sheet, shall be operated
through current transformer only. The rating shall correspond to full load requirements. The
multiplication factor, if any, shall be furnished and exhibited by the side of the meter.
23.12.0 All lighting feeders shall be provided with CT operated ammeter with selector switch and energy meter
suitable to measure unbalanced loads on a 3-phase 4 wire system.
23.13.0 All selector switches shall be of rotary type, spring loaded and of robust construction. The operating
handle of these switches shall be knob type and of black colour.
23.14.0 Digital type meters shall be provided wherever specified in the data sheet.
23.15.0 All auxiliary equipment such as shunts, transducers, CTs, VTs, etc. that are required shall also be
included in the supply of the switchboard.
24.0.0 INDICATING LAMPS, PUSH BUTTONS, CONTROL SWITCHES, ETC.
24.1.0 INDICATING LAMPS
24.1.1 Indicating lamps shall be of long life LED type and shall be indigenously available..
24.1.2 Necessary preventive measures shall be ensured to avoid any malfunction of the connected circuit
in the case of any fault in the indicating LED’s.
24.1.3 All signaling lamps must have clarity of colour .The colour shall be in LED and not as an applied
coating
24.1.4 Necessary protective fuses shall be provided for the lamp circuit in breaker feeders with shunt trip
arrangements.
24.2.0 PUSH BUTTONS
24.2.1 Number of PBs like START, STOP, REVERSE etc. required are given in the data sheet. Colour of
push buttons knobs shall be as per relevant IS.
24.2.2 All push buttons shall have 1 N/O + N/C contacts, unless otherwise required.
24.2.3 All push buttons shall be provided with legend plates to identify the function or operation.
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24.3.0 Local / Remote change over switch shall be provided, if specified in the data sheet, when starting is
envisaged from more than one location.
24.4.0 All Control switches shall be preferably of rotary type with operating knob. They shall have proper
designation plates.

SPECIFICATION
Page 12 of 16
25.0.0 ANTICONDENSATION HEATERS
25.1.0 Anti condensation heater of adequate capacity, rated for 240 V AC, shall be provided in every vertical
panel, in easily accessible position. For double front switchboards, heaters shall be provided on both
the fronts.
25.2.0 Necessary two pole ONOFF switch with HRC fuse & neutral link (or two pole MCBs) shall be provided
for each anti condensation heater circuit along with suitable thermostat for automatic temperature
control.
25.3.0 Heater supply to individual panel heaters in each bus section shall be availed through a separate
switch fuse feeder complete with suitably rated two pole switch, HRC fuse, neutral link, associated
heater supply bus/wiring, etc.
25.4.0 Wiring of anti condensation heaters shall be isolated or separately bundled from other internal wiring ,
preferably using a different colour.
25.5.0 If anti condensation heater is specified in data sheet, space heater supply shall be taken from the
outgoing end of motor isolator and shall be wired through an MCB and separate auxiliary contactor,
coil supply of it shall be through the NC contact of the main contactor.
26.0.0 DRAWOUT SWITCHBOARDS
26.1.0 The feeders shall be fully draw out type.
26.2.0 All draw out modules shall have distinct and stable TEST position, SERVICE position & ISOLATED
(WITHDRAWN) position.
26.3.0 All power contacts (both on bus bar side and cable side) shall be of fully draw out, self aligning, plug
in design, which get automatically disconnected when the draw out module is withdrawn from the
connected (SERVICE) position. Removable male and female contacts preferred.
26.4.0 Wiring for neutral may be in the fixed portion of the compartment. Where neutral connection is
required for control purposes within the module, they shall be through draw out contacts providing full
draw out facility.
26.5.0 All control contacts also shall be fully draw out self aligning type which get automatically connected/
disconnected depending on the circuit requirements, when draw out module is withdrawn to TEST /
ISOLATED positions.
26.6.0 Manual plug-in plug-out arrangement for control contacts is not acceptable.
26.7.0 The design of the contacts shall be such as to increase the contact pressure during starting and short-
circuiting conditions.
26.8.0 Necessary separation barriers shall be envisaged between pairs of power contacts to prevent
flashovers.
26.9.0 Draw out arrangement shall be designed in such a way that withdrawing and plugging in of the trolley
are achieved with smooth and reliable operation and without causing any damage or thrust to the plug
in type contacts.
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26.10.0 Withdrawable trolley/ chassis shall be preferably with screw cranking arrangement and/or guide
vanes, such that trolley movement is positively guided and self aligning type. The trolley must move
on low friction rolling mounts.
26.11.0 Trolley pad locking switch and latch /trolley clamping captive screw shall be provided for the fully
inserted position.

SPECIFICATION
Page 13 of 16
26.12.0 There shall be positive indication for the various positions of the trolley.
26.13.0 Wiring for components within the draw out module shall be identical in layout, ferrule numbering,
sequencing of secondary isolating contacts, colouring etc. to achieve maximum interchangeability.
26.14.0 In the case of double front panels, the module trolleys shall be interchangeable from one front to
another front in such a manner that direction of rotation of motors are kept unaltered. Such
interchanging shall not require rearranging /connecting cables.
26.15.0 Identical feeder types shall be interchangeable with each other. Also all modules shall carry labels
identifying KW rating & type of control wiring
26.16.0 Necessary earthing arrangements shall be provided for the truck in the‘ TEST’ and‘ SERVICE’
positions. The earth connection shall make before the main power and control contacts make and
break after the power and control contacts are disconnected. Earthing connection through manual
plug & socket connection will not be acceptable.
26.17.0 Provision of control supply in the test position of draw out modules (feeders which require control
supply) shall be available. In draw out switchboards with module control supply, required test control
supply feeder, associated test supply bus/ wiring, etc. shall be provided.
27.0.0 MEDIUM VOLTAGE CIRCUIT BREAKERS
27.1.0 GENERAL & CONSTRUCTIONAL FEATURES
27.1.1 Circuit Breakers, if any, shall conform to IS: 13118.
27.1.2 All CBs shall be suitable for uninterrupted duty as per IS.
27.1.3 CBs provided for control of motors, capacitors, etc. shall be suitable for the specific duty involved.
27.1.4 If different ratings of circuit breakers are used in the switch board, they shall preferably belong to the
same family. The individual units of same ratings in a continuous switchboard shall be
interchangeable.
27.1.5 Circuit breaker enclosure shall be same as that of main equipment.
27.1.6 Circuit breaker shall be of forward draw out construction. The cradle shall be so designed and
constructed as to permit the smooth withdrawal and insertion of the breaker into it. The movement
shall be free of jerks, easy to operate and shall preferably be on steel balls / rollers and not on flat
surfaces. Horizontal draw out type truck is preferred.
27.1.7 Each CB shall be housed in a separate compartment and shall be enclosed on all sides. Adequate
provision shall be made for escape of hot gases by providing louvers. The louvers shall be covered
with perforated sheets and shall be so located as to direct the hot gases away from the operating
personnel. Multi-tier arrangement can be provided, if adequate space for maintenance is ensured.
27.1.8 Sheet steel barriers shall be fitted between the tiers in a vertical section and between two vertical
sections in the breaker compartment.
27.1.9 The hinged lockable door of the draw out type of CB shall not form an integral part of the draw out
portion, so that entry of foreign materials / things into the cubicle is not possible when the CB is drawn
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out.
27.1.10 The door shall be of such a design that it shall allow the breaker to be kept withdrawn up to the ‘TEST’
and ‘ISOLATED’ positions with the CB door closed.

SPECIFICATION
Page 14 of 16
27.1.11 The CB door shall be interlocked with the breaker positions such that:
a) The door cannot be opened unless the breaker is in ISOLATED position and
b) The breaker cannot be racked into the SERVICE position unless the door is closed.
27.1.12 The following four positions of the CB shall be distinctly marked and locking arrangements shall be
made:
a) SERVICE position:
The main disconnecting contacts shall be fully gripped on both sides, namely the bus bar side
and the load side (both main and secondary isolating contacts in service).
b) Test position:
The truck shall be perfectly isolated from the live busbars in order to test for proper performance
(main isolating contacts separated and secondary isolating contacts in service / test position).
c) ISOLATED position:
It shall be able to withdraw the truck from the cubicle for inspection and maintenance (both main
and secondary isolating contacts isolated).
d) MAINTENANCE position:
It shall be possible to draw out / take out the circuit breaker fully outside the cubicle for
maintenance purposes.
27.1.13 The above first three positions of the CB shall be positive, achieved only through the turning /racking
motion of the draw out mechanism and not by trial and error. There shall be an indicator clearly
showing the first three positions listed above, and the same shall be visible from the front without
opening the front door.
27.1.14 It shall not be possible to close the CB unless it is positively in one of the following positions:
a) Truck in ‘SERVICE’ position

b) Truck in ‘TEST’ position
c) When the truck is in completely ‘ISOLATED’ position.
27.1.15 The interlocks mentioned above are the minimum requirement. Manufacturers shall include any other
safety interlocks, which may be required by the particular design feature of the switchgear offered.
27.1.16 Necessary earthing arrangements shall be provided for the truck in the‘ TEST’ and‘ SERVICE’
positions. The earth connection shall make before the main power and control contacts make and
break after the power and control contacts are disconnected. Earthing connection through manual
plug & socket connection will not be acceptable.
27.1.17 Separate and adequate accommodation shall be provided for instruments / meters, indicating lamps,
auxiliary contactors, timers, control fuses, CTs, VTs, protective and auxiliary relays, auxiliary switches,
control transformers if any, etc. These shall be easily accessible for testing and maintenance, without
any danger of accidental contact with live parts of the CB. All the above accessories, bus bar
connections, wire ways, cable space, painting and other general requirements of CB shall conform to
relevant clauses mentioned elsewhere in this specification.
27.1.18 Truck/trolley shall be provided for handling the circuit breaker
27.2.0 CIRCUIT BREAKER CONTACTS
27.2.1 CB contact assemblies shall include easily replaceable arcing contacts. Main current carrying
contacts shall be of low resistance, arc resistant and adjustable to compensate wear.
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27.2.2 Contact fingers shall be spring loaded to reduce contact bounce.
27.2.3 The isolating contacts shall be self-aligning and able to carry rated short circuit current, without any
tendency for the contacts to ‘blowoff’.

SPECIFICATION
Page 15 of 16
27.2.4 In case of air circuit breakers, the arc chutes shall be removable for routine inspection of the contacts.
27.2.5 In case of air break contacts, the arcing contacts shall have anti-sticking and burn resistant properties.
27.2.6 Wiring and termination of secondary isolating contacts shall be interchangeable in all identical
breakers.
27.3.0 OPERATING MECHANISM
27.3.1 It shall be possible to close and trip the circuit breaker without opening the CB compartment door. The
operating handle and the mechanical trip push button shall be at the front of the breaker and integral
with it. Arrangements with operating handle fitted on the door independently of the breaker, and
connected through a set of links to the breaker, are not acceptable.
27.3.2 CB shall be fitted with hand / direct motor / motor charged spring / solenoid closing mechanism, as
specified in the data sheet. Whatever be the mode of operation of the breaker, it shall have hand
closing provision to be operated in emergencies and during testing.
27.3.3 Operating mechanism shall be mechanically and electrically trip free in all positions of CB.
27.3.4 It shall be possible to mechanically trip the CB mechanism by a distinctively marked push button.
27.3.5 In “manually operated breaker”, the design of the handle and operating mechanism shall be such as
not to require large open slots in the front door for the movement of the handle. Manual closing
mechanism shall be of independent manual type.
27.3.6 In “electrically operated breakers”, remote closing facility shall be provided. The type of electrically
operated mechanism and the voltage of operation shall be as indicated in the data sheet.
27.3.7 The breaker shall be provided with suitable anti pumping feature to ensure that it does not reclose
automatically after a tripping, even if the closing impulse is maintained.
27.3.8 When the breaker is in the closed position, a closing operation of an initiating control device shall not
result in further operation of the breaker closing mechanism or discharging of the closing spring.
27.3.9 Closing of CB shall be prevented, unless the spring is fully charged.
27.4.0 OTHER REQUIREMENTS
27.4.1 The auxiliary wiring between the switchgear receptacle and the truck unit shall be established by
means of a plugging / sliding unit, consisting of minimum 10 pairs of contacts rated for 10A, 650V
grade, which get automatically disconnected when the drawn out module is withdrawn from the test
position.
27.4.2 A mechanical ON-OFF indicator, appropriately marked, shall be provided at the front of the CB.
27.4.3 A mechanical interlock shall be provided between the circuit breaker and isolator, if any, directly
connected to CB to prevent operation of the isolator when the CB is in closed position.
27.4.4 The closing coils and other auxiliary devices shall operate satisfactorily at all voltages between85-
110% of the rated control voltage specified in the data sheet. Trip coils shall operate satisfactorily at
all voltages between70-110% of the rated trip voltage mentioned in the data sheet.
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27.4.5 Auxiliary power supply for control, indication and space heaters shall be as indicated in the datasheet.
For auxiliary power supply, necessary control switch fuse / MCB of required ratings shall be provided,
unless otherwise specified in the data sheet.

SPECIFICATION
Page 16 of 16
27.4.6 Releases:
Releases shall be provided, if specified in the data sheet. Type of releases provided and their
characteristics shall be furnished by the vendor. If provided, the releases shall have the following
features:
a) The overload release shall be provided with a setting range of 70% to 110% of the breaker rated
current or as specified in the data sheet.
b) The short circuit release shall be provided with minimum two settings corresponding to 750% and
1000% of the rated current, with adjustable time delay range of 25ms to350 ms or as specified in
the data sheet.
c) Earth fault releases shall be provided with a setting range of 10% to 40% of the rated current, or
as specified in the data sheet.
d) In PCCs/ PMCCs, where two breakers are connected in series they shall be fitted with releases
permitting discrimination.
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SPECIFICATION CABLES
Page 1 of 2
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
3.0.0 STANDARDS
4.0.0 GENERAL CONSTRUCTIONAL REQUIREMENTS
5.0.0 DRUM LENGTHS
6.0.0 TOLERANCES
7.0.0 METHOD OF INSTALLATION
8.0.0 CABLE DRUMS
1.0.0 SCOPE
1.1.0 This specification covers the requirements for design, manufacture, testing at Works and supply of
cables.
2.0.0 REFERENCE
2.1.0 The following documents shall be read in conjunction with this specification.
2.1.1 Engineering specification and Data Sheet of General requirements for Electrics
2.1.2 Data sheet of Cables
2.1.3 Technical particulars of Cables
3.0.0 STANDARDS
3.1.0 Cables shall comply with the requirements laid down in the latest issues of following standards
wherever applicable along with other related standards.
IS 694 PVC Insulated Cables for working voltage up to and including 1100V
IS 1554 (Part I & II) PVC Insulated (Heavy Duty) Electric Cables
IS 7098 (Part I & II) Cross-linked Polyethylene Insulated PVC Sheathed Cables
IS 10418 Drums for Electric Cables
IS: 5831 PVC insulation and sheath of Electric Cables.
IS:8130 Conductors for insulated Electric cables and flexible cords.
IS:3975 Mild steel wires strips and tapes for armouring of cables.
IS: 10810 (part 41) Methods of test on cables. Mass zinc coating on steel armour.
IS:209 Zinc ingot
IS:3961(Part 2) Recommended current rating for cables. Part 2: PVC insulated and PVC
sheathed heavy duty cables
IS:10810(part 58) Oxygen index test
IS:10810( Part 61) Flame retardant test.
IS:10810( Part 62) Fire retardant test for bunched cables.
IS:13573 Joints and terminations for Polymeric cables for working voltages from 6.6kV
upto and including 33kV performance requirements and type tests
IEC60331 Fire resisting characteristics of Electric cables
IEC-60332-2 Test on Electric cables under fire conditions-Part: 2 Test for vertical flame
propagation for a single small insulated wire or cable
IEC-60332-3 Test on Electric cables under fire conditions-Part: 3 Test for vertical flame
spread of vertically mounted bunched wires or cables
IEC-60502 Extruded solid dielectric insulated power cables for rated voltages from 1kV
upto 30kV
IEC- 540&540A Test methods for insulation and sheath of electric cables and cords.
ASTM: D2863 Standard method of flammability of plastics using oxygen index method.

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SPECIFICATION
CABLES
Page 2 of 2
ASTM: D2843 Standard Test Method for Density of Smoke from the Burning or
Decomposition of Plastics
IEC: 60754-1 Test on gases evolved during combustion of materials from cables – Part 1:
Determination of the halogen acid gas content
4.0.0 GENERAL CONSTRUCTIONAL REQUIREMENTS
4.1.0 Outer sheath of all PVC and XLPE cables shall be black in colour and minimum oxygen index shall
0
be 29 at 27±2 C. Suitable chemicals shall be added into PVC compound of the outer sheath to
protect the cable against rodent and termite attack.
4.2.0 All cables covered in this specification shall be flame retardant (FR) unless specified otherwise in
data sheet. The outer sheath of PVC and XLPE cable shall posses flame propagation properties
meeting requirements as per the IS:10810(Part 62).
4.3.0 Sequential marking of the length of the cable in metres shall be provided on outer sheath at every
one meter interval. This embossing/engraving shall be legible and indelible.
5.0.0 DRUM LENGTHS
Unless otherwise specified in the Data Sheet of Cables, Cables shall be supplied in standard drum
lengths as follows:
5.1.1 Medium Voltage power cables upto and including 6Sq.mm - 1000metres
5.1.2 Medium Voltage power cables from 10Sq.mm to 400Sq.mm - 500 metres
5.1.3 Control cables upto and including 27 Core- 1.5Sq.mm/ 2.5sq.mm - 1000 metres
5.1.4 3.3/6.6/11kV(E) upto3x400 sq.mm - 500 metres

5.1.5 3.3/6.6/11kV(E) Upto 1x630Sq.mm - 1000 metres
5.1.6 33kV (E) Upto 3x400Sq.mm - 250 metres

5.1.7 33kV(E) Upto 1x400Sq.mm - 1000 metres
5.2.0 Cable quantities less than one full standard drum length shall be supplied in single length.
5.3.0 Specific requirements if any, regarding drum lengths / single lengths etc. indicated in the data sheet
shall be complied with.
6.0.0 TOLERANCES
6.1.0 Drum lengths: Maximum tolerances permissible on the drum lengths shall be +5% or -2%, when
more than one drum length is ordered.
6.2.0 Ordered quantity: Maximum tolerances permissible on the total ordered quantity item wise shall be
+ 2% or -2%.
7.0.0 METHOD OF INSTALLATION
7.1.0 The cables are proposed to be laid on overhead racks exposed to weather or on racks in the cable
trenches or buried directly in ground. The supplier shall furnish the rating factors for the different
methods of installation.
8.0.0 CABLE DRUMS
8.1.0 Cable drums are proposed to be stored in the OPEN store yard where it will be exposed to rain, sun
and other climatic variations. The wooden drums shall not deteriorate and collapse during the
storage for at least two years.
8.2.0 PVC /Rubber end cap shall be supplied free of cost for each drum with a minimum of eight per
thousand meter length. The ends of the cables shall be properly sealed with caps to avoid ingress of
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water during transportation and storage.

SPECIFICATION
PUSH BUTTON STATION
Page 1 of 3
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
3.0.0 STANDARDS
4.0.0 GENERAL DESCRIPTION
5.0.0 CONSTRUCTION
6.0.0 WEATHER PROOFING
7.0.0 PUSH BUTTONS
9.0.0 AMMETERS
10.0.0 NAME PLATE
1.0.0 SCOPE
1.1.0 This specification covers the requirements for design, manufacture, testing and supply of push button
stations.
2.0.0 REFERENCE
2.1.1 Engineering specification and and Data Sheet of General requirements for electrics
2.1.2 Data sheet of Push button station.
2.1.3 Technical particulars of Push button station.
3.0.0 STANDARDS
3.1.0 All push button stations shall comply, wherever applicable, with the latest issues of the following
standards and other relevant standards.
IS: 2419 Indicating instruments

IS: 1248 Direct acting electrical instruments
IS: 1901 Indicating Lamps
IS/IEC60079-11 Electrical apparatus for explosive gas atmospheres: part 11-Equipment protection by
intrinsic safety"I"
IS:13947 Specification for low voltage switchgear and control gear
IS: 7118 Direction of movement of control devices
IS/IEC60947-1 Low voltage switch gear and control gear :part 1-General rules
4.0.0 GENERAL DESCRIPTION
4.1.0 Push button stations shall be designed in such a way that the equipment unit is suitable for mounting
on pedestal as well as on wall/surface. Fixing screws with cadmium / nickel plating shall be supplied
with each unit.
4.2.0 Push button stations for hazardous area shall be of a design for which approval has been obtained
from the Central Mining and Research Institute, Dhanbad, for use in the division of hazardous area
specified. The details of such approval shall be given on the name plate. The approval / certification
shall be relevant and valid.
4.3.0 All materials shall be selected, fabricated and painted to withstand / resist the environmental and
service conditions specified in Data sheet of General requirements for electrics, attached.
5.0.0 CONSTRUCTION
5.1.0 Material of construction of enclosure shall be as specified in the data sheet such as cast iron / cast
aluminum alloy / higher impact strength glass polyester material. If aluminum is used it shall be
copper free. The glass polyester if used shall not get affected due to ultra violet rays over its life span.
PRPD. : CHKD. : APPRD. : ISSUED ON: SEPT 2014
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SPECIFICATION
PUSH BUTTON STATION
Page 2 of 3
5.2.0 The enclosure shall be as specified in the data sheet, like IP55 / IP55 weather proof (IP55WP) / flame
proof (FP) / flame proof weather proof (FPWP).
5.3.0 Compression type cable glands suitable for the cable sizes given in the data sheet shall be provided.
5.4.0 Cable glands provided for flameproof push button stations shall be flameproof double compression
type, approved by C.M.R.I., Dhanbad.
5.5.0 All necessary terminals shall be wired up to a terminal block for easy connection of external cables.
The terminals shall be suitable for connection of 2.5mm2 copper conductor unless otherwise
specified in the data sheet.
5.6.0 The cable entry shall be from the bottom unless otherwise specified in the data sheet.
5.7.0 The pushbutton station shall have four legs for mounting. The lugs shall be offset, so that the rear
surface of the unit stays at least 5mm away from the surface. On lugs two holes shall be circular and
two oblong, to facilitate correct positioning of the unit.
5.8.0 20% of the terminals with a minimum number of two shall be provided as spare.
5.9.0 All components shall be base mounted unless otherwise specified in the data sheet.
5.10.0 All hardware such as nuts, bolts, washers etc. shall be nickel / cadmium plated SS.
5.11.0 Two Nos. external earth terminals shall be provided on the body of the push button station.
5.12.0 The push button station shall be wired as per requirement specified in the data sheet / typical
drawings attached.
5.13.0 The internal wiring shall be carried out using PVC insulated multi strand copper wires of 1.5mm2
5.14.0 Warning inscriptions “Isolate elsewhere before opening” shall be prominently marked on the top of
the push button station.
6.0.0 WEATHER PROOFING
6.1.0 Push button stations specified with weatherproof enclosures shall be suitable for outdoor operation
and shall subject to direct sun and rain without further protection like canopy, hood etc.
7.0.0 PUSH BUTTONS
7.1.0 Number of push buttons like ‘ON’, ‘OFF, ‘REVERSE’ etc. required are specified in the data sheet.
7.2.0 Number of Normally Open (N/O) contacts and Normally Closed (N/C) contacts to be actuated by
each push button are indicated in the data sheet. Push buttons shall be momentary actuated type
unless otherwise indicated in data sheet.
7.3.0 Push buttons shall have padlocking facility for the ‘OFF’ position (lockable in the pressed ‘OFF’
position). The locking links shall be of simple but robust and rigid construction. It shall not be
possible to lock in the normal position of ‘OFF’ button.
7.4.0 Push button unit shall be rated for 10 A, 500 V unless otherwise specified in the data sheet.
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7.5.0 Auto - manual / local- remote selector switches shall be knob type having stay put type contacts of
same rating as that of push buttons and shall have distinct ‘OFF’ position unless otherwise specified
in the data sheet.

SPECIFICATION
PUSH BUTTON STATION
Page 3 of 3
8.1.0 Indicating lamps shall be provided if specified in the data sheet.
8.2.0 Indicating lamps shall be of long life LED type and shall be indigenously available.
8.3.0 Indicating lamps for “SPACE HEATER ON” indication shall be rated for 240V, single phase AC
8.4.0 Lamps must have the clarity of colour. Lamps shall be so designed to prevent glare from the bulb
and shall permit visibility from all directions.
9.0.0 AMMETERS
9.1.0 The ammeters in the push button stations shall be moving iron type with Class-1.5 accuracy
conforming to IS:1248, suitable for 1A secondary current of Current Transformer. The burden shall
not exceed 3 VA. The normal range shall be suitable for full load current of motors as indicated in
the data sheet. The exact ranges/scales shall be furnished along with the order. The ammeter shall
have compressed end scale (suppressed overload range) for at least 6 to 7 times the values of
normal range. Cushioned stoppers shall be provided at the end of scale to stop the pointer during
starting kicks. Full load shall be indicated on the scale with a red mark.
9.2.0 The size of the ammeter shall be 72 x 72 mm2 unless otherwise specified in the data sheet.
10.0.0 NAME PLATE
10.1.0 Name plates in white Perspex acrylic sheet engraved in black / stainless steel plate with 5 mm
letters as specified in the data sheet, shall be provided, indicating the service.
10.2.0 The function of each push button /lamp /switch shall be clearly marked below the respective
components in anodized aluminum plate having letters of a minimum 3mm height unless otherwise
10.3.0 Nameplates shall be fastened by SS screws only.

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13ES910/14
ENGINEERING
SPECIFICATION MEDIUM VOLTAGE INDUCTION MOTOR
Page 1 of 6
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCES
3.0.0 STANDARDS
5.0.0 STARTING CURRENT AND TORQUE
6.0.0 NUMBER OF STARTS
7.0.0 INSULATION
8.0.0 CONSTRUCTION
9.0.0 VENTILATION
10.0.0 BEARINGS AND LUBRICATION
11.0.0 WEATHER-PROOFING
12.0.0 TERMINAL BOXES AND TERMINATIONS
13.0.0 EARTHING
14.0.0 NAME PLATES
15.0.0 LIFTING FACILITIES
16.0.0 COUPLINGS
18.0.0 PROTECTION
19.0.0 RECIPROCATING COMPRESSOR FACTOR
20.0.0 MOTOR SUPPLIED AND ORDERED ALONG WITH THE DRIVEN MACHINE
21.0.0 ADDITIONAL ACCESSORIES / REQUIREMENTS
22.0.0 DESPATCH
1.0.0 SCOPE
1.1.0 This specification covers the general requirements for design, manufacture, testing and supply of
medium voltage induction motors.
2.0.0 REFERENCE
2.1.1 Engineering specification and Data Sheet of General requirements for electrics
2.1.2 Data sheet of Medium Voltage Induction Motors
2.1.3 Technical particulars of Medium Voltage Induction Motors
3.0.0 STANDARDS
3.1.0 All motors shall comply, wherever applicable, with the latest issues of the following Indian Standards
and other relevant standards.
IS: 325 3 Phase Induction Motors

IS: 1231 Dimensions of 3 phase foot mounted Induction Motors
IS: 1271 Classification of insulating materials
IS/IEC60079-0 Electrical apparatus for explosive gas atmospheres: part 0-General
requirements
IS/IEC60079-1 Electrical apparatus for explosive gas atmospheres: part 1-Flame proof
enclosures ”d”
IS/IEC60079-2 Electrical apparatus for explosive gas atmospheres: part 2-Pressurized
enclosures ”p”
IS/IEC60079-7 Electrical apparatus for explosive gas atmospheres: part 7-Increased safety”e”
IS/IEC60079-15 Electrical apparatus for explosive gas atmospheres: part 15-construction
test and marking for type of protection "n"
IS: 2223 Dimensions of flange mounted AC Induction Motors

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SPECIFICATION
MEDIUM VOLTAGE INDUCTION MOTORS
Page 2 of 6
IS: 2253 Designations for types of construction and mounting arrangements of rotating electrical
machines
IS: 2254 Dimensions of vertical shaft motors for pumps
IS: 4029 Guide for testing three phase induction motors
IS: 4691 Degrees of protection provided by enclosure for rotating electrical machinery
IS: 4722 Rotating electrical machines
IS: 4728 Terminal markings and direction of rotation for rotating electrical machinery
IS: 4889 Methods of determination of efficiency of rotating electrical machines
IS: 6362 Designation of methods of cooling of rotating electrical machines
IS: 6381 Construction and testing of electrical apparatus with type of protection"e"
IS: 7389 Pressurized enclosures of electrical apparatus for use in explosive atmospheres
IS: 8789 Values of performance characteristics for 3 phase induction motors
IS: 12065 Permissible limits of noise levels for rotating electrical machines
IS: 12075 Mechanical vibration of rotating electrical machines with shaft heights from 56 &
higher measurement, evaluation and limits of vibration severity
IS: 12615 Energy efficient motors
4.1.0 All machines shall be continuous maximum rated (Class S1 as per IS:325) under the operating
conditions specified in the data sheet, and shall be suitably protected for operation under the service
conditions stated in data sheet.
4.2.0 Motors for hazardous areas shall be of a design for which approval has been obtained from the
Central Mining and Research Institute (CMRI), Dhanbad, for use in the particular hazardous area
specified. All motors approved as above, shall have a separate nameplate carrying the details of
such approval, fixed on the body adjacent to the main nameplate. The approval / certification shall
be latest/relevant.
4.3.0 The motor coupled to its driven machine shall start and operate successfully under full load even if
the voltage at the motor terminals is lowered to 80% of rated voltage for 30 seconds.
4.4.0 Critical speeds should be either well below or well above the normal running speeds of the motor.
4.5.0 Slip at rated load shall not exceed 3% at rated voltage and frequency.
4.6.0 The motors shall be liberally designed as regards their pullout torque, pullout voltage and their ability
to ride through voltage dips during system disturbances. They should, if required, be suitable for
automatic restart under full load after a momentary lack of supply voltage, with the possibility of the
restored supply voltage being out of phase with respect to the motor residual voltage. The extent to
which the motor has to withstand out of phase residual voltage (in percentage) shall be as specified
in the data sheet.
5.0.0 STARTING CURRENT AND TORQUE
5.1.0 All motors are envisaged to be started direct on line across full line voltage unless otherwise
specified in the data sheet. The rotor shall be squirrel cage type unless otherwise specified in the
data sheet. The rotor shall be dynamically balanced with fan and half key on the rotor shaft.
5.2.0 The starting characteristics of the machine shall be carefully selected as to:
5.2.1 Satisfy the torque requirements of driven machine, even where reduced voltage starting is specified
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in the data sheet.
5.2.2 Have starting time which is less than locked rotor withstand time (hot) of the motor by at least two
seconds, at the rated conditions of voltage and frequency specified, with driven machine coupled.
5.2.3 Ensure that starting current is not normally more than 600% of full load current at the rated voltage
and frequency (subject to IS tolerance) unless otherwise specified in the data sheet.

SPECIFICATION
Page 3 of 6
5.2.4 Ensure that accelerating torque is not too large to cause stressing of the transmission elements and
the driven machine
5.2.5 Ensure that motor is suitable for starting at 80% of the rated voltage against torque speed
characteristics of the driven equipment.
6.0.0 NUMBER OF STARTS
6.1.0 The motor shall be suitable for the number of starts specified in the data sheet. If nothing is specified
in data sheet, then the motor should be suitable for Direct-on-line starting with minimum number of
starts stated below:
a) Three successive cold starts
b) Two successive hot starts
c) Four uniformly spaced starts per hour
7.0.0 INSULATION
7.1.0 Insulation class shall be class F with temperature rise limited to class B
7.2.0 Motor winding shall be done using copper conductor only
7.3.0 The winding shall be tropicalised.
7.4.0 All windings shall be treated with humidity, acid and alkali resisting protective coating like epoxy gel
to withstand service conditions in an industrial atmosphere described in data sheet.
8.0.0 CONSTRUCTION
8.1.0 The motor shall be able to withstand the corrosive atmosphere mentioned in data sheet. External
screws and bolts shall be protected particularly against corrosion by passivation.
8.2.0 The enclosure shall be provided with the required degree of protection, viz IP 55 (Indoor) / IPW55
(Outdoor) / Flameproof / Flameproof weatherproof, etc. as specified in the data sheet.
8.3.0 Vibration and noise levels shall not exceed those given in the relevant IS.
8.4.0 Motor frame sizes shall be in accordance with IEC recommendation in the absence of Indian
Standards. For a particular motor, required frame sizes as per IS / IEC or higher frame size shall
only be supplied.
8.5.0 The shaft shall be generously proportioned for transmitting continuous full load torque and any
specified overload or duty, which may be created by the driven machine. In designing the motor
shaft and bearing systems, the manufacturer shall take full account of the characteristics, thrust,
shaft system and bearing system of the driven machine and also the type of coupling proposed, so
as to give a completely satisfactory shaft and bearing system.
8.6.0 The motors shall be suitable for connecting capacitor at the motor terminals, if required in data
sheet. Rating of capacitor shall be as indicated in the data sheet. If there is any limitation/
inadequacy with regard to the rating of the capacitor that can be connected to the motor, the findings
shall be clearly substantiated in the Technical Particulars.
8.7.0 Condensate drains shall be provided where water may collect. Drain holes shall also be provided,
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wherever required.
8.8.0 Foundation rails if any, foundation bolts, nuts; washers, etc. shall be supplied.
8.9.0 All motors shall be capable of standing idle for long periods without damage to the bearings.

SPECIFICATION
Page 4 of 6
9.0.0 VENTILATION
9.1.0 Motors shall be self-ventilated.
9.2.0 Materials of construction of fans, tubes, etc. used shall be suitable for the environment specified in
the data sheet.
9.3.0 Motors shall be bi-directional, i.e. suitable for rotation in clockwise and anti-clockwise directions.
10.0.0 BEARINGS AND LUBRICATION
10.1.0 The bearings shall be of reputed manufacturer and of a type interchangeable with bearings from
other makes.
10.2.0 The method and type of lubrication shall be selected by the manufacturer and shall be suitable for
the rating (kW), speed and duty involved.
10.3.0 Excess grease escape devices shall be provided.
10.4.0 Grease migration to winding shall be prevented.
10.5.0 Necessary grease nipples for online lubrication from outside shall be provided for both Drive End
and Non-Drive End bearings. Whenever grease nipples are provided, these shall be associated,
where necessary, with appropriately located relief devices to ensure passage of grease through the
bearings.
10.6.0 Name and grade of lubricant shall be given in the motor nameplate.
10.7.0 Lubrication schedule for the motors shall be indicated in the nameplate or shall be furnished
separately in the maintenance manual.
10.8.0 Details of bearing shall be furnished in the test certificates, to facilitate ordering of spares.
11.0.0 WEATHERPROOFING
11.1.0 If Outdoor service is specified in the data sheet, the motors shall be suitable for operation in direct
sun and rain, without further protection (like canopy, hood, etc.) from weather. However, vertical
motors shall be provided with a hood over the fan cover, as an integral part of the motor.
12.0.0 TERMINAL BOXES AND TERMINATIONS
12.1.0 The motors shall be complete with compression type cable glands suitable for the armoured PVC
/XLPE main power cables, as specified in the data sheet.
12.2.0 All the six winding ends shall be brought out and marked to one terminal box for power supply
connections.
12.3.0 The terminal boxes shall be suitable for the system fault level for 0.25 seconds or as indicated in
data sheet. The terminal boxes shall be amply sized to accommodate the cable sizes specified in
data sheet. The terminal box shall be provided with pressure relief device if necessary.
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12.4.0 It shall be possible to rotate the terminal box in steps of 90 degrees to enable cable entry from any
direction.
12.5.0 Live terminals shall be insulated from the frame with material resistant to tracking.

SPECIFICATION
Page 5 of 6
12.6.0 Flameproof double compression type cable glands shall be provided for flameproof motors approved
by CMRI, Dhanbad.
12.7.0 For anti-condensation heater, thermistor, etc. separate terminal boxes shall be provided, with cable
glands, suitable for the cable sizes specified in data sheet. These terminal boxes shall be flame
proof for flameproof motors.
12.8.0 Main terminal box shall be located on the right hand side of the motor, when viewed form its drive
end, unless otherwise specified in the data sheet.
12.9.0 In case star delta starting is envisaged / capacitors are to be connected to the motor terminals, the
terminal box shall be of special design by which sufficient creepage space between terminals is
available. The terminal box shall be provided with two / three sets of cable glands as specified in the
Data Sheet.
13.0.0 EARTHING
13.1.0 All motors shall have two suitable earth studs, capable of withstanding the fault level, integral to the
motor frame for motor earthing. The studs should be adequate for accepting lug of the earthing
conductor size specified in the data sheet.
14.0.0 NAME PLATES
14.1.0 Two stainless steel nameplates shall be supplied and fastened by SS fasteners. In addition to the
data required to be furnished on the name plate as per IS, locked rotor current, temperature rise,
type of enclosure, direction of rotation (if unidirectional), weight, grade of lubricant, bearing sizes and
ambient temperature for which the motor is designed shall also be indicated.
14.2.0 A stainless steel warning label with indelible red inscription shall be provided on the motor to
indicate that isolation of main power supply alone is not sufficient and that space heater supply shall
also be isolated before carrying out any work on the motor.
15.0.0 LIFTING FACILITIES
15.1.0 Provision for lifting the motor shall be provided on the motor.
16.0.0 COUPLINGS
16.1.0 The motor shall be supplied with bare, single shaft extension and key. The couplings shall be
supplied and fitted by the driven machine supplier.
17.1.0 The motors of rating 37 KW and above shall be provided with anti condensation heaters to prevent
condensation when the motor is kept idle for long periods. The anti-condensation heaters shall be
rated for single phase 240 V, 50 Hz. power supply, unless otherwise specified in the data sheet.
18.0.0 PROTECTION
18.1.0 Embedded temperature detectors or thermistors, hot air thermostats, etc. shall be provided in the
motor if specified in the data sheet. Where thermistors are provided, thermistor control relay shall be
supplied loose in a suitable weatherproof enclosure of cast aluminium.
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19.0.0 RECIPROCATING COMPRESSOR FACTOR
19.1.0 Supplier of motors for driving reciprocating compressors shall liaise with the purchaser and the
compressor manufacturer to ensure that the compressor factor chosen is sufficient to have a
satisfactory degree of current pulsations.

SPECIFICATION
Page 6 of 6
20.0.0 MOTOR SUPPLIED ALONG WITH THE DRIVEN MACHINE
20.1.0 When a motor is supplied as a combined unit with the driven machine, the driven machine supplier
shall ensure proper co ordination in the selection of motor and its characteristics. The driven
machine supplier is also responsible for the suitability of the motor for the equipment and shall
guarantee a reasonable defect liability period.
20.2.0 The driven machine supplier shall also ensure the correctness of the motor test certificates,
suitability of couplings etc.
21.0.0 ADDITIONAL ACCESSORIES / REQUIREMENTS
21.1.0 The motors shall be provided with additional accessories / requirements, if any, specified in the data
sheet
21.2.0 Where any special requirement such as degree of protection to enclosures, thermal cutout, special
cable boxes, extra starting torque, supply of half coupling, etc. are specified, these details shall be
clearly recorded in the test certificates or in an attached supplement.
22.0.0 DESPATCH
22.1.0 Before despatch, opening in the motor like cable entry should be sealed to prevent entry of moisture
and dust during transit and storage.
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FABRICATION AND INSTALLATION 13ES914/14
ENGINEERING
SPECIFICATION
OF CABLE TRAYS AND OTHER
Page 1 of 2
STRUCTURALS FOR ELECTRICS
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
3.0.0 STANDARDS AND REGULATIONS
4.0.0 STANDARD REQUIREMENTS
1.0.0 SCOPE
1.1.0 This specification covers the standard requirements for fabrication and installation of cable trays/ racks
/risers, frames, supports etc. as per drawings / data sheet enclosed for supporting the electrical items
like cables, push button stations, distribution boards, switch boards, lighting fixtures, etc.
1.2.0 Supply of required steel sections for fabrication of the above structures shall be included in the scope
of the contractor, only if specifically indicated in the data sheet / price data sheet.
1.3.0 The scope shall also include painting of all mild steel structurals installed as per this specification.
2.0.0 REFERENCE
2.1.2 Data sheet of Fabrication and Installation of cable trays and other structurals for Electrics
3.1.0 Fabrication, installation and painting of cable trays/racks / risers, supports, frames, etc. shall be as per
standard codes of practice and shall fully comply with the requirements of the Indian Electricity Rules
& Acts and also to the Regulations / Standards that are in force at the place of installation.
3.2.0 The steel sections supplied if any, shall confirm to relevant Indian standards.
4.1.0 CABLE TRAYS
4.1.1 Cable trays shall be ladder type, fabricated using mild steel sections as per typical drawings
applicable, unless otherwise specified in the data sheet.
4.1. 2 The cable trays are to be connected at joints & bends and fixed to the tray supports by welding/ bolting
as specified in the data sheet / drawings.
4.2.0 CABLE TRAY SUPPORTS / RISERS/ CABLE RACKS
4.2.1 The cable trays shall be supported at proper intervals by tray supports / risers as per typical drawings
applicable. The cable tray supports / risers with necessary cross arms shall be fabricated using MS
sections as per the drawings applicable.

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FABRICATION AND INSTALLATION 13ES914/14
ENGINEERING
SPECIFICATION
OF CABLE TRAYS AND OTHER
Page 2 of 2
STRUCTURALS FOR ELECTRICS
4.2.2 Wherever cable racks (direct cable supports without cable trays) are envisaged the same shall be
fabricated using suitable MS sections as indicated in the drawings / data sheet. These cable racks
shall be made continuous by running a suitable MS section welded to all the racks.
4.3.0 PEDESTALS / FRAMES / SUPPORTS
4.3.1 Pedestals, frames, supports, etc. required for mounting of push button stations, panels, switch boards,
fire buckets, distribution boards, light fixtures etc. shall be fabricated, if required, using suitable mild
steel sections and fixed at relevant places indicated in the drawings.
4.4.0 PAINTING
4.4.1 All fabricated mild steel sections shall be treated properly for removal of rust, dirt, dust, grease etc.
before application of primer. After completion of surface cleaning, all MS surfaces shall be applied with
a coat of primer suitable for anti corrosive paint specified in the data sheet. Two coats of anticorrosive
paint shall be applied over the primer coat. The required quantity of primer and paint shall be supplied
by the contractor.
4.4.2 The two coats of paint shall preferably be of two different shades.
5.1.0 The cable trays/racks / supports/ risers have to be fabricated considering the sizes of cable trenches,
number and size of cables proposed in the route, etc, wherever detailed drawings are not furnished.
5.2.0 The owner will provide necessary embedded M.S. plate inserts for welding cable racks / supports, etc.
at fixed intervals on the walls of the cable trenches, below the roofs, on the walls, columns, beams,
etc. wherever cable route has been finalized by him or if the contractor informs such requirements in
advance/before commencement of civil works, to the owner. However, wherever M.S. plate inserts are
not available, the contractor shall provide the same for fixing of cable racks / supports, etc. with
necessary chipping and replastering the surface concerned.
5.3.0 Where more than one layer of cable trays/ racks are used the spacing between them shall be 150 mm
or more depending on the cable sizes.
5.4.0 Necessary holes (with threads wherever necessary) on the steel sections required for fixing of bolts,
nuts etc. for cable clamping and mounting of equipment shall be provided before welding and fixing
the same.
5.5.0 The welding shall be carried out as per standard codes of practice. All joints shall be full welded.
5.6.0 The contractor shall supply all the necessary consumables including welding rods, gas, etc. and make
his own arrangement for welding equipment.
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13ES915/14
ENGINEERING
SPECIFICATION
CABLING INSTALLATION
Page 1 of 4
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
5.0.0 GENERAL
6.0.0 TESTING OF CABLES
1.0.0 SCOPE
1.1.0 This specification covers the standard requirements for erection, testing and commissioning of
cabling installation as per the drawings, specification, data sheets and other details enclosed.
1.2.0 Supply of required cables shall also be included under the scope, only if specifically indicated in the
data sheet for cabling.
1.3.0 The term cable shall mean power / control / lighting cable for this specification.
2.0.0 REFERENCE
2.1.2 Data sheet of Cabling installation.
3.1.0 Cabling installation shall be carried out in accordance with the latest editions of relevant Indian
Standards and the installation shall fully comply with the requirements of the Indian Electricity Rules
& Acts and other Statutory Regulations that are in force at the place of installation.
4.1.0 HANDLING & LAYING OF CABLES
4.1.1 When unloading cable drums, they shall be carefully lifted and placed on the ground. For removing
the cable from the drums, the drum should be properly mounted on jacks on a cable wheel, making
sure that the spindle is strong enough to carry the weight without bending and that it is lying
horizontally in the bearings so as to prevent the drum creeping to the one side or the other while it
is rotating. The drums should be carefully rolled down from a suitably arranged ramp or rails in the
direction of arrow marked on the drum. Under no circumstances should a drum be dropped to the
ground as the shock may cause heavy damages to the inner layers of cable.
4.1.2 On transporting over a long distance from stores to work spots, the drums should be placed on
cable drum wheels strong enough to carry the weight of the drums which are pulled by means of
ropes, or alternatively they may be placed on a trailer or a vehicle with a low loading platform for
transporting to the destination.
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4.1.3 Cable rollers shall be used for laying of cables and cables shall be properly handled while laying to
avoid any damages.

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13ES915/14
ENGINEERING
SPECIFICATION
Page 2 of 4
4.1.4 Cables shall be cut to required lengths only after assessment of correct lengths required by actual
measurement at site. The contractor shall ensure that wastage of cables is minimum by resorting to
most economical cable cutting schedules prepared by the contractor.
4.1.5 The cables shall be laid on trays, racks, risers, walls, structures, etc. and in trenches as shown in
the Power lay out (cable layout) drawings.
4.2.0 CLAMPING
4.2.1 Power and Control cables shall be properly segregated while doing the laying and clamping.
4.2.2 MV power cables of 400 sq.mm and above and H.V. cables shall be laid with a clearance of 70mm
in between and shall be clamped individually. Other cables can be laid touching and clamped in
groups.
4.2.3 Cables shall be clamped at every 1500mm interval on the horizontal trays / racks and at 750mm
interval on the vertical trays/ risers, bends, at take off points, and at 400mm interval for cables laid
on walls, columns and other structural works.
4.2.4 Cables leading to cable box of an equipment shall be supported at a distance of 450mm from cable
gland / cable box.
4.2.5 Cables shall be clamped only after the cables are neatly laid, dressed and kept in position.
4.2.6 Types of cable clamps, fixing bolts / nuts / washers and materials of cable clamps shall be as
specified in the data sheet for cabling.
4.3.0 CABLES IN PIPES
4.3.1 Wherever cables are taken through GI pipes, suitable bushes shall be provided at both ends to
avoid sharp edges of the pipes damaging the cables.
4.3.2 Wherever cables pass through masonry or concrete work, they shall be taken through suitable PVC
/ GI pipes. For road crossings GI/ Hume pipes of suitable size shall be provided.
4.3.3 After drawing the cables in the GI / PVC pipes, the ends shall be sealed with cable compound.
4.4.0 CABLE LAYING DIRECT IN GROUND
4.4.1 For laying cables direct in ground, suitable trenches shall be excavated in the soil to the required
sizes and at location shown in drawings attached / applicable. Cables shall be laid directly in the
excavated trench on the sand bed. After laying cables as per cable/ power layout drawings, the
excavated trenches shall be back filled with layers of sand, well burnt bricks and riddled soil
respectively as shown in the cross sectional details given in the drawings attached.
4.4.2 A clearance equal to one diameter of the bigger cable shall be maintained between two adjacent
power cables buried underground and no such clearance need be provided for control and lighting
cables, unless otherwise specified in the data sheets / drawings.
4.4.3 There shall not be any cross over of cables when laid in the ground.
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4.4.4 Inspection chambers constructed from brick and masonry complete with suitable RCC slab cover
shall be provided for all power and control cable joints in the through run of the cables. Jointed
cable shall be looped in the inspection chamber to provide extra length of cable for the purpose of
rejoining in future in case original cable joint fails. Cable identification tags shall be provided inside
the cable chamber.

13ES915/14
ENGINEERING
SPECIFICATION
Page 3 of 4
4.4.5 Wherever buried cable enters the building the same shall be taken through PVC / GI pipes
embedded at the entry portion. After taking cables through the above pipes, the same shall be
sealed by using suitable compound so as to avoid ingress of water.
4.4.6 Necessary cable marker plates made out of Cast iron shall be fixed at every 15Metres interval and
at all bends along the route of buried cable trench at central line of the trench. Voltage rating of the
cables shall be engraved on the marker plates.
4.4.7 The depth of cable laying shall be as per clause 6.3.2 of IS:1255
4.4.8 The minimum segregation for direct buried cables from other services shall be as given in the table
below:-
MINIMUM CLEARANCE
11/66kV Circuits 6.6kV Circuits 415V Circuits 240V Circuits
Instrument, communication and 4000mm 1250mm 750mm 500mm

other low signal cables.
600/1000V cables 300mm 300mm None None
All piped services below ground 500mm 300mm 300mm 300mm
and Hot pipe services above
ground
4.5.0 LAYING OF SINGLE CORE CABLES
While designing layout with single core cable installations following factors shall be
considered
4.5.1 Cables shall be laid as a general practice in trefoil formation touching each other or flat formation
with spacing as per requirement.
4.5.2 When cables are laid in a flat formation, the individual cable fixing clamps, and spacers shall be of
non magnetic material.
4.5.3 As a general practice, the sheath of single core cables shall earthed to keep sheath at earth
potential. However depending on the current the cable has to carry, the feeder length and
permissible sheath potential, various methods of sheath bonding are employed, viz. single point
bonding, bonding at middle, sectionalised bonding etc., for which cable manufacturers
recommendations shall be followed.
4.6.0 CABLE JOINTING

4.6.1 During the preliminary stage of laying the cable, consideration should be given to proper location of
the joint position so that when the cable is actually laid, the joints if any, are made in the most
suitable places. Joints shall not be made at passageways and at road crossings.
4.6.2 In cable trenches or in any other cable route where there are two or more cables laid together, the
joints, if any shall be arranged to be staggered by two or more metres so as to reduce the
possibility of one joint failure affecting the other.
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4.6.3 Before jointing is commenced the insulation resistance of both section of the cable to be jointed
shall be measured using suitable megger.
4.6.4 In jointing of armoured PVC cables, hot pouring compound shall not be used. Only cold sealing
compound shall be used.

13ES915/14
ENGINEERING
SPECIFICATION
Page 4 of 4
4.6.5 Individual conductors in cables shall always be jointed number-to-number or colour to colour of the
insulation over the conductors.
4.6.6 All materials required for cable jointing such as jointing kit, compounds, insulation tapes, cable lugs,
glands, fittings etc. and other consumable materials shall be supplied by the contractor wherever
necessary.
4.7.1 Cable glands necessary for cable termination on the equipment will be supplied along with
equipment. However, the contractor shall supply suitable glands for all other requirements.
4.7.2 Wherever necessary holes are not drilled on the gland plate of the switch boards or on the cable
boxes of the equipment for fixing of cable gland, suitable holes shall be drilled at convenient
locations by the contractor for fixing the cable glands.
5.0.0 GENERAL
5.1.0 Lighting cables shall be installed in compliance with engineering specification for lighting installation
also, if attached.
5.2.0 The armour of the PVC-A-PVC cables shall be effectively earthed at both end terminations through
separate earthing of cable glands.
5.3.0 As far as possible, joints at intermediate points in the through run of the cable should be avoided.
5.4.0 The power, control and lighting cables shall be provided with identification tags fixed to them at
every 10 m interval. The tags shall be made from full hard aluminum discs not less than 3mm, thick
and of size 50mm x 75mm for all cables of size 400mm2. and above and proportionately smaller
sizes of tags ( but 3mm thick ) for all other sizes of cables. Tags shall have 4 holes, 2 holes on
either side for tying around the cable by using suitable binding wire. The cable numbers assigned in
the cable schedule and circuit numbers for lighting distribution cables shall be punched on these
tags.
6.0.0 TESTING OF CABLES
6.1.0 All cables shall be tested before and after jointing/ termination as per relevant Indian Standards.
Jointing/termination shall be redone, if found unsatisfactory without any extra cost to the owner.
6.2.0 All cables shall be megger tested, and H.V. cables shall be pressure tested (HV dielectric test) in
addition to megger test, before commissioning.
6.3.0 The cable cores should be tested for continuity, absence of cross phasing, insulation resistance to
earth and insulation resistance between conductors.
6.4.0 All tests shall be carried out in the presence of owner’s representatives and tabulations of
observations shall be furnished.
6.5.0 The contractor shall make his own arrangement for necessary testing meters and equipments.
00FT001

SPECIFICATION
EARTHING
Page 1 of 4
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
5.0.0 LIGHTNING PROTECTION
6.0.0 EARTH PITS
7.0.0 JOINTS / TERMINATIONS
8.0.0 TESTING OF EARTH CONDUCTORS/ ELECTRODES.
1.0.0 SCOPE
1.1.0 This specification covers the standard requirements for supply of earthing materials and
accessories and erection, testing and commissioning of Earthing system, as per the drawings and
data sheets for earthing.
1.2.0 If design of earthing system is also included in the scope of vendor, the same shall be as per
details in the Data sheet of Earthing and relevant design calculations shall be furnished by
vendor for purchaser’s approval.
2.0.0 REFERENCE
2.1.2 Data sheet of Earthing
2.1.3 Technical particulars of Earthing
3.0.0 STANDARDS AND REGULATIONS.
3.1.0 Earthing shall be carried out in accordance with the latest edition of following standards and shall
fully comply with the requirements of the Indian Electricity Rules , Indian Electricity Act, Petroleum
rules (where applicable), and also to the Regulations laid down by CEA/ Electrical Inspectorate,
OISD, Central/state/ local/ insurance authorities, that are in force at the place of installation.
IS: 3043 Code of practice for Earthing

IS: 7689 Guide for control of undesirable static electricity
IS: 2309 Protection of Buildings and allied structures against Lightning- Code of
practice
IS: 732 Code of practice for Electrical wiring installations
OISD110 Recommended practices on Static Electricity
OISD 147 Inspection and safe practices during Electrical installations
OISD149 Design aspect for safety in Electrical system
OISD173 Fire prevention and protection system for Electrical installations
OISD180 Lightning Protection
Where conflict exists between standards and codes, the more stringent shall govern.
4.1.0 Duplicate earthing (two separate and distinct connection with the earth) shall be employed for all
electrical equipments. The plant earthing system shall have an earthing network with
required number of earth electrodes connected to it. The following shall be earthed:
 System Neutral
 Current and potential transformer secondary neutral.

00FT001
SPECIFICATION
EARTHING
Page 2 of 4
 Metallic non-current carrying parts of all electrical apparatus such as transformers,
Switchgears, motors, lighting/power panels, terminal boxes, control stations,
lighting fixtures, receptacles etc.
 Steel structures, loading platform etc.
 Cable trays and racks, lighting mast and poles.
 Storage tanks, spheres, vessels, columns and all other process equipment.
 Electrical equipment fencing ( e.g transformer yard etc.)
 Cable shields and armour.
 Flexible earth provision for wagon,truck.
 Pump handling Hydrocarbon if it’s base plate is separate from motor’s base plate.
 Turbo driven pump handling Hydrocarbon.
4.2.0 Earthing cables / strips shall be taken along with the power cables on the cable trays / racks /
risers. All earthing shall be done on the body of the equipment and not on the detachable part.
4.3.0 Earthing cables shall be clamped at every 1500mm. interval on the horizontal trays / racks,
750mm interval on vertical trays / risers, 400mm interval on walls / columns / on structural using
spacers, and at bends / take off points. Bare earthing strips shall be clamped at 3000mm interval
on horizontal trays / racks, 1500mm interval on vertical trays / risers, 800mm interval on walls /
columns, and at bends / take off points.
4.4.0 Metallic cable trays / risers shall be earthed in duplicate. Continuity of earthing throughout the tray
shall be ensured. GI strips, if used for cable tray earthing, shall not be welded to trays, to prevent
corrosion.
4.5.0 Wherever insulated earth conductors are taken out from the cable trenches, walls / through floor,
etc. they shall be taken through non-metallic or GI pipes. In the case of bare earth conductors,
non-metallic pipes shall be used.
4.6.0 Wherever earth conductor crosses the road, it shall be taken through GI pipes / non-metallic
pipes / formed cable trenches. In the case of bare earth conductors metallic pipes shall not be
used.
4.7.0 At all terminations of earth conductors on equipment, sufficient length shall be left for easy
movement of the equipment from its position for alignment purposes.
4.8.0 Wherever not detailed, the route of the conductor and location of the earth pit shall be arranged,
so as to avoid obstructions, crossing, etc. according to convenience at site and shall be got
approved by the Engineer in charge at site or his representative.
4.9.0 Wherever required, earthing cables / strips shall be buried along with power cables.
4.10.0 Earthing cables / bare earth strips used for interconnection of earth pits, run as ring main shall be
buried in ground at a depth of 500 mm below finished grade level.
4.11.0 Wherever looping earth connections are envisaged between motor and local push button
stations, the same shall be done using common lug at motor end as shown in IS: 3043.
4.12.0 Unless adequately connected to earth elsewhere, all utility and process pipelines should be
bonded to a common conductor by means of earth bars or pipe clamps and connected to the
earthing system at a point where pipelines enter or leave the hazardous area except where
conflicting with the requirements of cathodic protection.
4.13.0 Steel pipe racks in the process units and offsite area shall be earthed at every 25
00FT001
metres.

SPECIFICATION
EARTHING
Page 3 of 4
4.14.0 Tanks, piping and process vessels and equipment containing flammable liquids or gas shall be
earthed by a connection to the earth network, or by bonding to an earthed metal structure for
protection against static electricity.
4.15.0 The sheath of single core cables shall earthed to keep sheath at earth potential.
However depending on the current the cable has to carry, the feeder length and
permissible sheath potential, various methods of sheath bonding are employed, viz.
single point bonding, bonding at middle, sectionalised bonding etc., for which cable
manufacturers recommendations shall be followed.
5.0.0 LIGHTNING PROTECTION
5.1.0 Lightning protection shall be provided for the equipment, structures and buildings as per
the requirements of IS: 2309.
5.2.0 An independent earthing network shall be provided for lightning protection and this shall
be bonded with the main earthing network below ground, minimum at two points.
5.3.0 Lightning protection for the plant structures, storage tanks and columns in the
hydrocarbon industry shall be carried out as per OISD 180.
5.4.0 An earth electrode should be connected to each down conductor. Each of these earth
electrode should have a resistance not exceeding the product given by 10 Ohm
multiplied by the number of earth electrodes to be provided. The whole of lightning
protective system including any earth ring shall have a combined resistance to earth not
exceeding 10 ohm without taking account of any bonding.
6.0.0 EARTH PITS
6.1.0 The arrangement of earth pit shall be as given in IS: 3043 unless otherwise specified in the data
sheet. Necessary provisions for terminating main earth conductors on to the earth electrodes
shall be ensured.
6.2.0 All accessories required for the earth pits such as electrodes, clamps, clips, bolts, nuts, washers,
GI pipes, funnel, valve and the masonry works of the pits including supply of necessary
materials, cement and excavation and refilling of soil for providing earth pits shall come under the
scope of the contractor.
6.3.0 Water supply for watering of earth pits will be given by Purchaser at one point. Common valve for
isolating and 1" distribution pipe to earth pits shall be provided by the contractor. Individual taps
shall be provided for each earth pit, if specified in the data sheet.
7.0.0 JOINTS / TERMINATIONS
7.1.0 The joints of bare earth strip shall be bolted/ riveted / brazed / welded as stipulated in IS: 3043.
All such joints shall be given necessary coatings of suitable compound to prevent corrosion.
7.2.0 In the case of PVC insulated earth conductors proper joints shall be made and the entire joint
shall be fully sealed by suitable compound so that no metallic part is exposed.
7.3.0 Crimping type of lugs shall be used for termination of earth conductors. However in the case of
bigger size of earth conductors where crimping type of terminations are not feasible, soldering
type of lugs may be used.
00FT001

SPECIFICATION
EARTHING
Page 4 of 4
7.4.0 The contractor shall make his own arrangement for the necessary equipment, drilling / welding
machines and all other tools and tackles which are necessary for completing the installation.
8.0.0 TESTING OF EARTH CONDUCTORS / ELECTRODES.
8.1.0 All earth conductors shall be tested before and after jointing / termination as per relevant Indian
Standards. Jointing / termination shall be redone, if found unsatisfactory, without any extra cost to
the purchaser.
8.2.0 Earth pits shall be checked & tested for proper connections / terminations.
8.3.0 Each Earth electrode shall be tested as per relevant Standards and results tabulated.
8.4.0 Effective resistance of the earthing system shall be tested and tabulated.
8.5.0 All tests shall be carried out in the presence of Engineer -in- charge or his representative and
tabulations furnished.
8.6.0 The contractor shall make his own arrangement for the meters and equipments necessary for the
testing.
00FT001

SPECIFICATION
LIGHTING INSTALLATION
Page 1 of 6
CONTENTS
1.0.0 SCOPE
2.0.0 REFERENCE
5.0.0 WIRING
6.0.0 EARTHING
7.0.0 TESTING
1.0.0 SCOPE
1.1.0 This specification covers the general requirements for erection, testing and commissioning of
lighting system as per the Schedule of items of work/ drawings/ documents/ data sheets and
general conditions of contract, including supply of required materials and accessories.
2.0.0 REFERENCE
2.1.1 Engineering specification and Data Sheet of General requirements for Electrics.
2.1.2 Data sheet of Lighting Installation
2.1.3 Technical particulars of Lighting Installation
3.0.0 STANDARDS
3.1.0 Lighting installation shall fully comply with the requirements of the Indian Electricity Rules,
Regulations, Acts and other statutory regulations that are in force in the place of installation and
also carried out in accordance with the latest editions of relevant Indian Standards, particularly the
following.
IS: 732 Code of practice for electrical wiring installations

IS: 6665 Code of practice for industrial lighting
IS: 3043 Code of practice for earthing
IS: 1554(Part I) PVC insulated (Heavy duty) electric cable.
IS: 694 PVC insulated cables
IS: 1293 Plugs & socket outlets
IS: 3854 Switches for domestic and similar purposes
IS: 371 Ceiling roses
IS: 2412 Link clips for electrical wiring
IS: 3837 Accessories for rigid steel conduits for electrical wiring
IS: 3480 Flexible steel conduits for electrical wiring
IS: 3419 Fittings for rigid non-metallic conduits
IS: 9537(Pt II &III) Conduits for electrical installations
IS: 1332 Precast reinforced concrete street lighting poles
IS: 2193 Precast prestressed concrete street lighting poles
IS: 2713 Tubular steel poles
IS: 2551 Danger notice plates
IS:4736 Hot dip Zinc coatings on mild steel tube
IS:14768 Conduit fittings for Electrical installations
OISD 149 Design aspect for safety in Electrical system

00FT006
SPECIFICATION
Page 2 of 6
4.1.0 Scope of work shall include installation of lighting fixtures, fans, plug socket outlets, distribution
boards (DB) etc. with all associated accessories and materials required to make the installation
complete in all respects even in cases when such items are specifically not mentioned. Cost of all
such miscellaneous items shall be included in the price of installation quoted, unless specifically
excluded from the scope.
4.2.0 All items shall be of makes specified in the data sheet. Wherever makes are not specified, the
items offered shall be of reputed make and got approved by purchaser/ engineer in charge at site,
before ordering.
4.3.0 Wherever cables/ wires are to be passed through masonry works, road crossings, cement floors
etc. they shall be protected by taking through GI pipes/ conduits (metallic/ PVC). After wiring up,
the walls, floorings etc. shall be restored to the original condition.
4.4.0 All exposed metal parts are to be coated with primer and paint as specified in the data sheet.
4.5.0 Utmost care shall be taken to avoid scratches kinks and cuts on the conductor while transporting
the wires/ cables to site during installation. Suitable inhibiting grease shall be liberally applied to
bare Aluminium conductors, before connecting them up.
4.6.0 The junction boxes, cable end boxes etc. wherever provided shall have sufficient wiring space in
relation to the size of cable/ wire specified. Items supplied shall be complete with cable glands,
cable boxes, conduit entries, terminals etc. and other accessories, which are necessary for the
satisfactory installation/ operation of the lighting system.
4.7.0 Cables to and from lighting switchgear/ distribution board shall be laid in trenches/ racks/ trays
available along with power cables. In other areas cables shall be clamped properly on steel surface
using MS spacers. (MS spacers shall be welded to the surface). On concrete surface cable shall be
directly clamped. Cables leaving or entering cable trenches other than buried shall be taken
through GI pipes to 1.2m above ground/ floor level. The cables taken over walls/ columns/ racks
shall be properly clamped using Aluminium clamps of 16SWG sheet, with width varying from 12.5
to 25mm.
4.8.0 The contractor should possess a contractor’s license (valid up to date) issued by the State
Electricity Licensing Board. The work should be got carried out only by licensed wireman under the
supervision of licensed supervisors.
4.9.0 Wooden materials shall be coated with good quality varnish.
4.10.0 Sufficient number of earth pits shall be provided if found necessary or if specified in the
drawing/data sheet and interconnected so as to have the resistance of the earthing installation
within the limits as per relevant Indian Standard.
4.11.0 All distribution boards shall be marked LIGHTING or POWER as the case may be and also marked
with the voltage and number of phases of the supply. Each DB shall be provided with the drawing
giving details of each circuit with its control, the current rating of the circuit, the rating of the fuse
elements/ MCBs and all-important details given in the circuit diagram. The drawing shall be made
on durable material like PVC and pasted inside the front cover of the DB.
4.12.0 Locations of lighting fixtures, ceiling fans, plug sockets etc. shown in the drawing are indicative.
They shall be located to suit the site conditions subject to the approval of purchaser’s engineer in
charge.
00FT006
4.13.0 All switches and plug socket outlets shall be mounted at a height of 1.5m above floor level unless
otherwise specified in the drawing.

SPECIFICATION
Page 3 of 6
4.14.0 All emergency DBs shall have the words “ Emergency AC/ DC” (as the case may be) painted on it
in large letters in RED paint. Emergency lighting fixtures shall be marked “E” in RED.
4.15.0 Serial numbers if any allotted to each DB in the drawing shall be painted on it in RED for
emergency DBs and in WHITE for other DBs.
4.16.0 Respective circuit numbers shall be painted on the lighting fixture at a conspicuous place if so
4.17.0 All fuses shall be of HRC type unless otherwise specified in the drawing/ data sheet.
4.18.0 The scheme followed for circuit numbering is as given below unless otherwise specified.
4.18.1 First two digits indicate the serial number of the DB

4.18.2 Third digit indicates the serial number of the circuit (way) in each phase.
4.18.3 The letter after the digit indicates the phase of the circuit.
4.19.0 DBs, main switches etc. shall be mounted on painted MS angle frames or MS boxes.
4.20.0 Where ceiling fans are provided, lighting fixtures shall be suspended by means of conduits such
that the fan blades and lighting fixtures are at the same level.
4.21.0 On walls/ columns/ handrails, lighting fixtures shall be mounted on suitable GI pipes/ MS angle
frames. On ceilings the fixtures shall be mounted on suitable MS brackets, wooden blocks etc.
4.22.0 Fan hooks shall be provided on RCC slabs/beams by chipping the concrete and hooking to the
reinforcing rod if indicated in the drawing. The slab /beam surface shall be restored to the original
condition after providing the hook.
4.23.0 Similar parts of all switches, lamp holders, distribution fuse boards, ceiling roses brackets,
pendants, fans and all other fittings shall be so chosen that they are of the same type and
interchangeable in each installation.
4.24.0 Lighting installation in oil and gas installations shall be as per OISD 149.
4.25.0 Aviation warning lights shall be in accordance with the convention of the International Civil Aviation
Organisation (ICAO) Publication Annex 14 and to Indian standards, together with the approval of
the local aviation authority.
5.0.0 WIRING
5.1.0 GENERAL
5.1.1 Looping back system of wiring shall be adopted. Looping of cables shall be carried out only from
control gears / junction boxes / ceiling roses and not from lighting fixtures.
5.1.2 Control switches and plug socket outlets shall be mounted on painted MS box / PVC box as
indicated in the data sheet. Front plate of these boxes shall be of the material specified in the data
sheet.
5.1.3 Junction boxes shall be of PVC/ painted MS box/ cast aluminium as specified in the data sheet.
5.1.4 Flush type ceiling roses shall be provided if indicated in the drawings. Ceiling roses shall have
terminals for connecting 3-core cable.
00FT006
5.1.5 More than two wires shall not be connected to a terminal of ceiling rose/ switch/ plug socket outlet
etc.

SPECIFICATION
Page 4 of 6
5.1.6 The number of stranded conductor cables drawn into or laid into an enclosure of a wiring system
shall be such that no damage is caused to the cable or to the enclosure during their installation.The
maximum number of stranded conductor cables that can be drawn through a conduit shall be as
per IS:732
5.2.0 CABLE WIRING
5.2.1 Use 1.1kV grade heavy duty PVC-A-PVC Aluminium/ Copper cable of size and number of cores
indicated in the drawing for circuit mains (ie. from DB to control gear/ junction box of the first point
in the circuit) and distribution (ie from control gear/ junction box of the first point to the control gear/
junction box of the adjacent point in the circuit and so on). 3 core 1.5 sq mm PVC insulated and
sheathed unarmoured stranded copper cable shall be used for connecting fans / non flameproof
lighting fixtures to the control gear/ junction box. In the case of flameproof lighting fixtures 1.5 sq
mm PVC-A-PVC copper cable shall be used.
5.2.2 In the case of street light fixtures mounted on concrete/ steel poles, wiring from DB to the junction
box provided at the bottom of the pole and looping back to the junction box of the adjacent pole in
the circuit shall be done using 1.1kV grade PVC-A-PVC Aluminium/ Copper cable of size indicated
in the drawing. The incoming cable shall be connected to a terminal block to be provided in the
junction box by the contractor. Wiring from the terminal block to the lamp shall be done through a
2A HRC fuse using 3core 1.5 sq mm PVC insulated and sheathed stranded copper cable. (The
third core is used for earthing the fixtures)
5.2.3 240V, 15/5A, 3 pin plug socket outlets shall be wired using 1.1kV grade 3 core PVC-A-PVC
Aluminium/ Copper cable of size indicated in the drawing.
5.2.4 Armoured cables shall be terminated using flameproof cadmium plated brass cable glands in the
case of flameproof equipment and ordinary cable glands in the case of non flameproof equipment.
2
Crimping type tinned copper lugs shall be used for conductors of 6mm and above.
5.2.5 Lighting cables shall be identified by providing tags (Aluminium discs 3mm thick) at 10m intervals.
Circuit numbers indicated in the circuit diagram shall be punched on these tags.
5.3.0 CONDUIT WIRING
5.3.1 Rigid/ flexible PVC conduits or rigid steel conduits or rigid flow-coat metal conduits with ISI mark
and of suitable sizes shall be used as specified in the data sheet.
5.3.2 Use PVC insulated single core Aluminium/ Copper cable of size and number of cores indicated in
the drawing for circuit mains (ie. from DB to control gear/ junction box/ ceiling rose of the first point
in the circuit) and distribution (ie from control gear/ junction box of the first point to the control gear/
junction box/ ceiling rose of the adjacent point in the circuit and so on). Use 3 core PVC insulated
and sheathed unarmoured 24 strand (each strand having 0.2mm dia. minimum) copper cable for
connecting lighting fixture/fan to ceiling rose.
5.3.3 240V, 15/5A, 3 pin plug socket outlets shall be wired using single core PVC insulated Aluminium/
Copper wires of sizes specified in the drawing.
5.3.4 Circuits of different phases shall not be drawn in the same conduit. However balanced 3-phase
circuit and neutral can be drawn in the same circuit.
5.3.5 The entire system of metallic conduit work, including the outlet boxes and other metallic
accessories, shall be mechanically and electrically continuous by proper screwed joints, or by
double check nuts at terminations. The conduit shall be continuous when passing through walls or
floors.
00FT006

SPECIFICATION
Page 5 of 6
5.4.0 TRUNKING CABLE MANAGEMENT SYSTEM
5.4.1 Adaptable trunking shall be used for power cables and data cables to run parallel in two different
compartments with partition.
5.4.2 PVC insulated cables and / or other approved insulated cables to IS: 694-1990 shall be used in this
type of work.
5.4.3 Preferred size of the mini trunking (Casing wiring) should be 25x16 mm, 32x16 mm, 40x25 mm,
40x40 mm and for adaptable trunking it should be 100x34 mm or 100x50 mm or 160x50 mm or
200x50mm for making upto four isolated compartments.
5.4.4 Trunking should be equipped with rail on its surface on which clip-on partition can be clipped which
should accept frames/plates for wiring devices upto 6/8 modules.
5.4.5 The mini trunking and adaptable trunking shall be of the same material, viz. either PVC or anodized
aluminium in extruded sections.
5.4.6 The mini trunking shall have a square or rectangular body. The trunking cover shall be “CLIP-ON”
type with double grooving in the case of PVC wire-ways, and CLIP-ON type for the metallic wire
ways. All surfaces shall have smooth finish inside and outside. The top of the side walls of the body
shall be suitable for the above types of fixing arrangement of trunking. PVC trunking or Aluminium
trunking should have uniform thickness throughout its length and shall be of factory finish. The
thickness of the mini trunking & adaptable trunking shall be 1mm minimum.
5.4.7 The mini trunking and adaptable trunking shall be fixed by means of suitable screws to approved
type of asbestos or fiber fixing plugs, at intervals not exceeding 60 cm for all sizes for mini trunking.
In case of Adaptable trunking, the screwing distance shall be such that the weight of the trunking &
cable hold firmly on the wall or ceiling. On either side of the joints, the distance of the fixing
arrangement shall not exceed 15 cm from, the joint.
6.0.0 EARTHING
6.1.0 All DBs shall be provided with an earth bus of the same size in addition to three buses for the
phases and one for the neutral, which shall be connected in duplicate to the main earthing system
using PVC insulated/ bare Aluminium/ Copper conductor of size indicated in the data sheet.
6.2.0 All DBs and main switches shall be earthed in duplicate using PVC insulated/ bare Aluminium/
Copper conductor of size indicated in the data sheet.
6.3.0 Lighting fixtures, E point of plug socket outlets, control switches junction boxes etc. shall be
earthed using conductors specified in data sheet.
6.4.0 Where 3 core cables are specified for wiring, the third core shall be used for earthing.
6.5.0 All earth wires shall be connected to the main earthing system. If earth pits are provided specifically
for the lighting installation in the drawings, they shall be interconnected using conductors specified
in the data sheet and also linked to the main earth system.
6.6.0 A protective (earth continuity) conductor shall be drawn inside conduits and trunking for earthing of
all metallic boxes of the installations as well as for connections to the earth pin of the socket
outlets.
00FT006

SPECIFICATION
Page 6 of 6
7.0.0 TESTING
7.1.0 The following tests shall be conducted satisfactorily, by the contractor at his own cost, in the
presence of the purchaser’s representative; test results shall be submitted and results got
approved.
7.1.1 Insulation test
7.1.2 Earth resistance test
7.1.3 Earth continuity test
7.1.4 Continuity test.
7.1.5 Operation of ELCB.
00FT006

TECHNICAL SUB VENDOR LIST (ELECTRICAL) 32644-13-PS-001 SV
PROCUREMENT FOR PHOSPHORIC ACID STORAGE
SPECIFICATION TANK Page 1 of 2 R0
5.4 INDUCTION MOTORS – LV (415 V) (SAFE / HAZARDOUS AREA)

1 ASEA BROWN BOVERI LTD. INDIA
2 FUJI ELECTRIC SYSTEMS CO. LTD. JAPAN
3 SIEMENS LTD. INDIA
4 TOSHIBA CORPORATION JAPAN
5.6 HT / LT POWER & CONTROL (11 KV, 6.6 KV & 415V) POWER CABLES
1 NICCO CORPORATION LIMITED INDIA
2 TORRENT CABLES LIMITED INDIA
3 UNIVERSAL CABLES LTD. INDIA
5.8 SWITCHBOARDS – LV (415 V) (MCC / PCC / PMCC)
1 ABB LTD. INDIA
2 LARSEN & TOUBRO LTD. INDIA
3 SIEMENS LTD. INDIA
5.17 FLAMEPROOF / HOSEPROOF LOCAL CONTROL STATION, JUNCTION BOX,
LIGHTING FITTING, PLUG, SOCKET, HAND LAMP, ACCESSORIES
LIGHTING, DISTRIBUTION BOARD & CONTROL PANEL
1 BALIGA LIGHTING EQUIPMENTS LTD. INDIA

2 FCG FLAMEPROOF CONTROL GEARS PVT. LTD. INDIA
3 FLAMEPROOF EQUIPMENTS PVT. LTD. INDIA
4 R. STAHL INDIA/GE
RMANY
5.18 STREET / FLOOD LIGHTING FIXTURES
1 PHILIPS INDIA LTD. INDIA
5.19 LIGHTING POLES
1 BAJAJ ELECTRICALS LTD. INDIA
2 CROMPTON GREAVES LIMITED INDIA
3 PHILIPS INDIA LTD. INDIA
5.20 FLAMEPROOF / HOSE PROOF INDUSTRIAL LIGHTING FIXTURES
1 BALIGA LIGHTING EQUIPMENTS LTD. INDIA
2 FCG FLAMEPROOF CONTROL GEARS PVT. LTD. INDIA
3 FLAMEPROOF EQUIPMENTS PVT. LTD. INDIA
0 06-06-2020 Original issue SM IK IK

00ft024/14

TECHNICAL SUB VENDOR LIST (ELECTRICAL) 32644-13-PS-001 SV
PROCUREMENT FOR PHOSPHORIC ACID STORAGE
SPECIFICATION TANK Page 2 of 2 R0
4 R. STAHL INDIA/GERMANY
5.23 DISTRIBUTION BOARDS
1 CONTROLS & SWITCHGEAR CO. LTD. INDIA
2 ELECMECH CORPORATION INDIA
3 INTRELEC INDIA
4 LOTUS POWERGEAR PVT. LTD. INDIA
00ft024/14

32644-13-PS-001CS
PROCUREMENT
SPECIFICATION
COMPLIANCE STATEMENT
PAGE 1 OF 1 R
TPS No. 32644-13-PS-001
We state that our Quotation No……….……………….………….. is in full compliance with the documents
issued against the Enquiry No. …………….………………..….. except for the deviations listed below.
LIST OF DEVIATIONS
S. No. Description Reasons for Deviation
Name of Vendor:
Date: Name & Designation Seal & Signature

00FT014/14

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LEGEND
SYMBOL EXPLANATION SYMBOL EXPLANATION
-fl- � INDICAllON IAIIPS
MAGNETIC
A
�
B CONTACroR, MICRO PROCESSOR VOI.TMEIER
B
� :i� PROT. REIAY I VJ
PUSH BUTTON STATION WITH
ON OFF BIITTON & AMMEIER
3 PHASE SQUIRREL
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~- MINIAl\JRE CIRCUIT BREAKER � VOLTMEIER SELECTOR SWITCH
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t- CURRENT lRANSFORMER -,!,- E:ARTH CONNECTION
'v CABLE TERMINAllON ........ DRAW OUT F£Al\JRE
- ji SWITCH FUSE
,__
PROJECT NAME: PROJECT NO:

1 EW PA TANK A T Q10 BERTH-W.ISLAND 32644
A NO.
0 PRELIMINARY
DESCRIPTION
Soman SM
DRAWN CHKD
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APPRD. DATE
03.06.'20 TITLE
SINGLE LINE DIAGRAM (TYPICAL) - -
0 A
SC ALE: -- I SHEET 1 OF 1
DRG. NO. 32644-13-SD-00 101 REV.
CLIENT: M/s. FACT-CD
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CABLES IN CABLE TRAY □ N PIPE BRIDGE/
------
·----·
BUILDING \,/ALLS/DYKE \,/ALL, ETC.
CABLES BURIED UNDER GROUND
CABLES THROUGH G.I PIPE BURIED
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PRELIMINARY
THIS DRAWING IS THE PROPERTY OF FACT ENGINEERING AND
SCALE
DATE
I 1:750
05.06.'20
FACT ENGINEERING
THE FERTILISERS AND CHEMICALS TRAVANCORE LTD 11�
& DESIGN ORGANISATIOl'-1 II FEDO
DESIGN ORGANISATION AND IS TO BE USED ONLY FOR THE
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PURPOSE OF WHICH IT WAS LENT AND MUST NOT BE USED
nRAWN
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PROJECT NO: 32644
IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE CHE�:KED
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COMPANY AND IS SUBJECT TO RETURN ON DEMAND II I I

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t---+--------+-----+--+-- PROJECT NAME: PROJECT NO:
---+-----1 NEW PA TANK AT Q10 BERTH-
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DRAWN CHKD APPRD. DATE
DETAILS (TYPICAL) O A
SHEET 1 OF 1
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APPRD. DATE TYPICAL ARRANGEMENT OF CANOPIES
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L_J
HOOD FOR MOTOR L_J L_J B
NOTES:-
1. AFTER FABRICATION THE HOOD SHALL BE
PAINTED WITH EPOXY PAINT WITH SUITABLE
PRIMER.
2. THE SIZE OF THE HOOD SHALL BE SUCH THST
THERE WILL BE A CLEARANCE OF THE MINIMUM VIEW FROM A
30mm FROM THE MOTOR, ON ALL SIDES.
+---+----------+---+-----+---+------< PROJECT NAME: PROJECT NO:

+---+----------+---+-----+---+------< NEW PA TANK AT Q10 BERTH-W. ISLAND 32644
:1- SM IK 04.06.'20 TITLE

DRAWN CHKD APPRD. DATE TYPICAL ARRANGEMENT OF CANOPIES
SHEET 2 OF 2 FOR OUTDOOR DEVICES 0 A
DRG. NO. 32644-13-GE-00 257 REV.
4 3 2
TECHNICAL
32664-14 -PS-001
PROCUREMENT INDEX
TPS No. 32664-14 -PS-001
Sl. Rev. No. with issue

Doc. No. Description No. of
No. pages 1 2 3 4
1 32664-14-PS-001 SW INST SCOPE OF WORK 1 0
2 32664-14-PS-001 SIT INST SCOPE OF INSPECTION AND TESTS 2 0
3 32664-14-PS-001 VDR INST VENDOR DATA REQUIREMENTS 4 0

SPECIAL REQUIREMENT OF THE
4 32664-01 -PS-001 SPL INST 3 0
PROJECT
5 32664-14-PS-001 SV INST SUB VENDOR LIST 3 0
ATTACHMENTS
FIELD INSTRUMENT ERECTION
1 14ES008/15 30 0
SPECIFICATION
2 32664-14-CL-00001 OVERALL CABLE LAYOUT 1 0
3
2
1
00FT011/00
0 6/6/2020 FOR COMMENTS DCK MKZ MS

REV. DATE DESCRIPTION PRPRED CHKED APRVD

INSTRUMENTATION
DEPARTMENT SCOPE OF WORK 32664-14 -PS-001 SW INST
Page 1 of 1 R0
PROJECT: NEW PA TANK AT WI

CLIENT: FACT-CD
FACT
ITEM: INSTRUMENTATION SYSTEM FOR NEW PA TANK AT WI
STATUS ENQUIRY/ COMMITMENT
PO NUMBER -
The scope of work include the following
Sl.No Description Required Remarks
1. Supply of hardware
(Field instruments, Erection material, Spares)
2. Inspection, testing and quality assurance services
3. Erection, integration to
o existing facility and commissioning
4. Documentation
Note:- The above mentioned scope is only for preliminary understanding only.
only Detailed
scope is mentioned in subsequent documents and attachments of this tender document.
14FT660/15
0 06/06/20 FOR CLIENTS COMMENTS DCK MKZ MS


INSTRUMENTATION SCOPE OF INSPECTION AND 32664-14-PS-001 SIT INST
DEPARTMENT TESTS Page 1 of 2 R0

ITEM : As indicated below
EQPT NO.
The following inspection and test shall be conducted and records to be submitted
Sl.No Description Inspection. Witness Remarks

Required Reqd
RADAR LEVEL TRANSMITTERS/ LEVEL
SWITCH
1.0 Visual inspection $ $
2.0 Dimensional inspection $ $
3.0 Performance test accuracy $ $
4.0 Material test certificate $ *
5.0 Certificate for electric code $ *
6.0 Hydraulic test $ $
7.0 Weather proof certificate $ *
8.0 SIL certificate - -
9.0 W&M India certificate
10.0 IBR certificate (If applicable- for guided $ *
wave)
11.0 Functional test- Alarm contacts, $ $
communication with host/ accessories etc
CABLES
3.0 Performance/ insulation resistance $ $
Routine tests as per national/ international $ $
4.0
standard referred in the data sheet/ QAP
5.0 Type test report $ *
ELECTRICAL FITTINGS AND JUNCTION

BOXES
3.0 Certificate for electrical code $ *
4.0 Weather proof certificate $ *
5.0 Type test report $ *
6.0 Routine test $ $
PRESSURE GAUGES
1.0 Calibration Certificate $ *
14FT942/15

INSTRUMENTATION SCOPE OF INSPECTION AND 32664-14-PS-001 SIT INST
DEPARTMENT TESTS Page 2 of 2 R0
Sl.No Description Inspection. Witness Remarks

Required Reqd
2.0 Material Test certificate (For diaphragm $ *
seal, thermowell)
3.0 Weatherproof certificate $ *
$ - Manufacturer shall conduct their standard inspection as part of their 'quality assurance'
program and shall furnish inspection reports for review. If required, witness inspection will
be conducted by purchaser's representative.
*Report review
Note –1 ID of ferrule by GO/NOGO gauge, pipe thread by plug and ring gauge,
interchangeability of ferrule nut.
Note-2 Also ferrule tightening test to be carried out.
14FT942/15

INSTRUMENTATION 32664-14-PS-001 VDR
DEPARTMENT VENDOR DATA REQUIREMENTS INST
Page 1 of 4 R0

CLIENT: M/s FACT- CD
ITEM: Package items
STATUS ENQUIRY/ COMMITMENT
PO NUMBER
OFFER AFTER COMMITMENT FINAL
SL GRP. Lead Time In
DESCRIPTION
NO CODE QTY QTY Weeks QTY
Req. Prop Agrd
A From package vendor
1. B Deviation list 1P+1S
2. C Documents and drawings 1P+1S 2 3P+1S
index
3. B Bidder’s checklist- Filled ( If
attached with tender)
4. B Control system Architecture
5. B Instrument schedule
6. B Spare parts list 1P+1S 6 3P+1S
7. B Instrument specifications 1P+1S 4 3P+1S
8. B Instrument design
philosophy
9. B Instrument installation 1P+1S 4 3P+1S
diagram (loop schematic
diagram)
10. B Instrument location & cable 1P+1S 4 3P+1S
panel arrangement/wiring
drawings
11. B Bill of material 1P+1S 4 3P+1S
12. B Control panel & inter lock
panel arrangement/wiring
drawings.
13. B Marshalling box(termination 1P+1S 8 3P+1S
box) drawings
14. B Junction box schedule/ 1P+1S 6 3P+1S
connection drawings
15. B Cable schedule 1P+1S 4 3P+1S
14FT910/15

INSTRUMENTATION VENDOR DATA REQUIREMENTS 32664-14-PS-001 VDR INST
DEPARTMENT Page 2 of 4 R0
16. B Interlock scheme &write up

17. B Control room layout
18. B IO List of PLC
19. B Grounding details
20. B Air distribution drawings
21. B Instrument hookup drawings 1P+1S 6 3P+1S
(Process Hookup, Electrical
hookup, Pneumatic Hookup)
22. B Instrument/ junction box 1P+1S 6 3P+1S
installation drawings with
supports and canopy
23. B Test procedures for 1P+1S 6 3P+1S
instrument, lines etc
24. B Pre-commissioning and 1P+1S 10 3P+1S
commissioning checklist,
Procedure etc
25. C Loop folders (All connected
drawings of every instrument
loop in a folder in a
dedicated CD/DVD)
26. C All documents and drawings 1S 2$ 1S
in CDs/DVDs (Editable copy)
27. C As built drawings 1P+1S 4$ 3P+1S
Group code:
A- For review and detailed engineering,
B- For review,
C- For information and record document type:
R- Reproducible,
P- Print,
M- Microfilm
S- Soft (CD/DVD)
$- Counts from Date of Startup
Notes:
@ Vendor shall fill in proposed lead-time if different from the required lead-time.
@@ Each set of final documents shall be submitted in a folder. Two such folders shall be
packed and dispatched with the equipment.
14FT910A/15

SL GRP. DESCRIPTION OFFER AFTER COMMITMENT FINAL

NO CODE QTY QTY Lead Time In QTY
Weeks
Req Prop Agrd
B Vendor data requirement
from instrument
manufactures
1. C Manufactures catalogue with 1P+1S 12 3P+1S
model code no.
2. B Manufactures technical 1P+1S 12 3P+1S
specification indicating range,
material, utility requirements
3. B Quality assurance plan 1P+1S 12 3P+1S
4. B FAT/ SAT Procedure for
DCS/PLC
5. B Control valve sizing & noise
level calculations
6. B Thermowell wake frequency
and sizing calculation
7. B Flow element sizing
8. B Dimensioned outline 1P+1S 14 3P+1S
drawings for instruments/
Junction boxes, panel etc
9. B Control panel/ interlock panel 1P+1S 14 3P+1S
drawings
10 B Wiring drawings 1P+1S 14 3P+1S
11 B Control panel/ interlock panel
detail fabrication drawing
12 B Termination, wiring & power 1P+1S 12 3P+1S
supply distribution drawings
13 B Instrument assembly drawing 1P+1S 14 3P+1S
14 B Performance curves/test 1P+1S 2BD 3P+1S
certificates M
15 C Third party (IBR, CMRS etc) 1P+1S 2BD 3P+1S
certificates M
16 C Detailed spare parts manual 1P+1S 12 3P+1S
17 C Operation, installation, 1P+1S (1) 3P+1S
maintenance, service manual
for each instrument
18 B Material test report 1P+1S 2BD 3P+1S
M
19 C Weather proof Certificates 1P+1S 2BD 3P+1S
M
20 C Hydro test certificates, 1P+1S 2BD 3P+1S
14FT910A/15
Leakage test certificates M

21 B General Arrangement
drawings of panels
22 C All documents and drawings 1S 4$ 1S
in CD
(1)-dispatched along with instrument/ system
BDM- Before dispatch of material
Note: All the above indicated submission time is typical and shall be optimized (Early
submission) to complete the project within time schedule indicated in NIT if required.
14FT910A/15

TECHNICAL SPECIAL REQUIREMENT OF THE 32664-01-PS-001 SPL
PROCUREMENT PROJECT (INST)
SPECIFICATION (INSTRUMENTATION) Page 1 of 3 R0
1.0. INTRODUCTION
M/s FACT intends to install two nos of new Phosphoric acid Tanks at Willington
Island, Kochi at its existing raw material handling site on LSTK basis. The
following covers the special requirements and scope of work related to
instrumentation for the project.
2.0. DEFINITIONS
Client/ Owner M/s FACT CD
PMC M/s FEDO
LSTK Lump sum Turn Key
Vendor LSTK Contractor / its sub contractor as the case may
be
3.0. SCOPE OF WORK
The contractor’s scope of work is inclusive of but not limited to the following:
3.1. Design and detailed engineering of total instrumentation required for the tank
and its interfacing to existing control room.
3.2. Supply of instrument erection material like cable tray, cable, cable glands,
junction box, structural steel, consumables etc, erection, commissioning.
3.3. Testing, calibration, painting etc.
3.4. Documentation and as built preparation
3.5. Scope of anticipated work with quantity is detailed in instrumentation schedule
of work. Note that being a LSTK work, the work mentioned in schedule of work
is to be treated for reference.. Major items and services only are listed in this
document. The supply, erection and integration of instrumentation for the safe
operation of the system shall be in the scope of the LSTK contractor.
4.0. FACILITY DESCRIPTION

4.1. As part of the new Tanks, one no of radar type level transmitter shall be
mounted on each tank. These transmitters shall be interfaced to a local field
indicator also supplied by the Radar OEM and shall be wired in series to the
control room wiring. Necessary looping shall be implemented in a junction box.
4.2. All these level instrument shall be connected to a single junction box and wired
till control room through overhead cable tray routed alongside the pipe rack for
14FT660/15

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

acid pipelines. Necessary structural work shall be included in scope of

instrumentation.
4.3. New Junction box and cable tray work is included in scope of contractor. Note
that, existing cable tray shall be used wherever it is available to control room in
cable route as indicated in cable routing drawing.
5.0. GENERAL
5.1. All the cables inside the dyke wall shall be routed at an elevation greater than
the height of dyke wall. For this purpose, concrete footing and additional
structural work if required shall be included in scope of work.
5.2. Vendor shall supply all instruments and erection material from attached vendor
list only. Supply of material from any other vendor is subject to PMC/ Owner
approval.
5.3. Vendor shall submit QAP, test certificates of all instruments and erection
material as per vendor data requirements for PMC approval.
5.4. Vendor shall execute all site related jobs as per sound engineering practice and
to the satisfaction of site in charge of client/PMC.
5.5. All instruments and junction boxes shall be protected against direct sunlight and
rain by installing canopies of 20 AWG aluminium sheet. Instrument and junction
box tag numbers shall be painted on support. All steel structural’s used for
instrument/junction box/cable tray shall be painted. Cables shall be tagged with
SS plates.
5.6. General instrument erection guide lines are attached in 14ES010/15. Irrelevant
sections in the document may be ignored.
5.7. Relevant erection tools of good quality and repute shall be provided to workers
during instrument erection.
5.8. All the instruments supplied shall be covered under guarantee/ warrantee for a
period of 12 months from the date of erection or 18 months from the date of
supply.
5.9. Contractor shall maintain good cleanliness at site during instrument erection. All
scrap or waste materials shall be disposed to designated scrap yard at site.
5.10. If there is any conflict in the specifications or in scope of work, PMC’s
authorised site engineer shall be consulted for the resolution and his decision
shall be final and binding on contractor.
5.11. If necessary bidder shall conduct site visits for data collection before quoting.
14FT660A/15
5.12. Mandatory Instrument spares are also included in the instrument schedule of
work. Commissioning spares shall be included in contractor scope for

replacements if any due to damage/ maintenance requirements arising out of

pre-commissioning/ commissioning activities.
5.13. Main cable routing drawing is attached in 32664-14-CL-00001. All minor cable
routing including the cable laying from tank side indicator to JB, Instrument to
JB are also in the scope of contractor. Junction box and tank side indicator
shall be mounted in easily accessible locations at 1.5m height.
6.0. CLIENT’S OBLIGATION

6.1. The control room receiver instruments shall be supplied and erected by the
client (Push button, Lamps, Recorders or display units etc.). The contractor
scope is limited to cabling to control room, glanding, termination, testing (in
coordination with client) etc
14FT660A/15

32664-14-PS-0001
DATA SV INST
SUB VENDOR LIST
SHEET
PAGE 1 OF 3 R0
The make of instrumentation items shall be as per the following list.

a. GENERAL INSTRUMENTS CONSORTIUM
b. H GURU INSTRUMENTS (SI) P LTD
c. MANOMETER (INDIA) PVT LTD
d. ODIN INDIA PRIVATE LIMITED
PRESSURE & DIFFERENTIAL e. PREMIER INSTRUMENTS & CONTROLS
PRESSURE GAUGES LTD
f. BLUE BELLS CONTROL SYSTEMS PVT LTD
g. WIKA INSTRUMENTS (I) PVT. LTD.
h. WAAREE INSTRUMENTS LTD.
i. BUDENBERG GUAGE CO. LTD.
a. KEI INDUSTRIES LTD.
b. ASSOCIATED CABLES PVT LTD, MUMBAI
c. GENERAL INSTRUMENTS CONSORTIUM
d. UNIVERSAL CABLES LTD.
CABLES
e. TOSHNIWAL CABLES
f. POLYCAB WIRES PVT. LTD.
g. DELTON CABLES LTD.
h. BROOKS CABLE WORKS LTD.
a. CHEMTROLS SAMIL (INDIA) PVT LTD
b. GENERAL INSTRUMENTS CONSORTIUM
SWITCHES-LEVEL (FLOAT c. INSTRUMENTATION LTD
TYPE)
d. MOTOYAMA ENGINEERING WORKS LTD
e. TRANSDUCERS & CONTROLS P LTD
4 NEW PA TANK AT WI
14FT703/15
PROJECT
3
M/s FACT CD
2 CLIENT
1 P.O. NO
0 06/06/20 DCK MKZ MS
VENDOR
REV DATE PRPD CHKD APPRD
FACT ENGINEERING AND ORGANISATION

32644-14-PS-0001
DATA LIST OF SUB VENDORS FOR PACKAGE SV INST
SHEET INSTRUMENTS
PAGE 2 OF 3 R0
f. TOKYO KEISO CO LTD

g. ISA CONTROLS FRS LTD
h. SAKURA ENDRESS C/o ITOCHU
CORPORATION
i. MAGNETROL INTL INC
j. LEVCON CONTROLS PVT. LTD.
k. PEPPERL+FUCHS INDIA PVT LTD
a. ENDRESS + HAUSER (I) PVT LTD
b. EMERSON PROCESS MANAGEMENT
(INDIA) PVT LTD
c. MAGNETROL INTL INC
LEVEL TRANSMITTER
GUIDED WAVE/NON d. KHRONE-MARSHALL PVT LTD
CONTACT TYPE RADAR e. ABB LIMITED
f. HONEYWELL AUTOMATION INDIA LIMITED
g. YOKOGAWA INDIA LIMITED
h. SIEMENS Ltd
a. BALIGA LIGHTING EQUIPMENTS PVT LTD
b. CROMPTON GREAVES LTD
c. EX-PROTECTA
JUNCTION BOX d. FLEXPRO ELECTRICALS PVT LTD
e. FLAMEPROOF EQUIPMENTS PVT LTD
f. FLAMEPACK (MANIPAL)
g. ALSTOM T&D INDIA LIMITED
a. BLUE STAR LTD
b. ALWAYE ENGINEERING WORKS
c. INDIANA GRATINGS PVT LTD
CABLE TRAY d. STEELITE ENGINEERING LTD

14FT703A/15
e. VENUS STEEL PRODUCTS

f. VINAY STEEL SYSTEMS
g. CHELUR CORPORATION

32644-14-PS-0001
DATA LIST OF SUB VENDORS FOR PACKAGE SV INST
SHEET INSTRUMENTS
PAGE 3 OF 3 R0
a. FCG FLAMEPROOF CONTROL GEARS PVT.

LTD
b. FLEXPRO ELECTRICAL PVT LTD
c. EXPROTECTA
CABLE GLAND
d. BALIGA LIGHTING EQUIPMENTS PVT LTD
e. MULTI PRESSINGS
h. CEAG FLAMEPROOF CONTROL GEARS(P)
LTD
14FT703A/15

SPECIFICATION FIELD INSTRUMENT ERECTION SPECIFICATION
Page 1 of 30
CONTENTS NOTE:
PART A – GENERAL The description under scope of supply
1.0.0 SCOPE OF WORK will be general in nature and covers
2.0.0 CONTRACTOR’S OBLIGATIONS most of the prevalent types of
3.0.0 OWNER’S SUPPLY instruments, some of which may not be
required for this particular project.
PART B- TECHNICAL Hence only the applicable items shall
REQUIREMENTS be referred to. For actual list of
4.0.0 INSTRUMENT INSTALLATION instruments, refer schedule of work.
5.0.0 ONLINE INSTRUMENTS
6.0.0 FIELD MOUNTED PRIMARY PART A- GENERAL
MEASURING INSTRUMENTS 1.0.0 SCOPE OF WORK
7.0.0 FIELD MOUNTED TRANISMITTERS The scope of work shall include but not be
8.0.0 FIELD MOUNTED CONTROLLER limited to: -
9.0.0 FIELD MOUNTED GAUGES 1.1.0 Unpacking, checking, cleaning and
10.0.0 FIELD MOUNTED SWITCHES withdrawal of instruments, instrument
11.0.0 ANALYSERS accessories and erection materials at
12.0.0 MISCELLANEOUS INSTRUMENTS owner’s stores and /or from places of
13.0.0 JUNCTION BOXES, PDB’S, MB’S storage anywhere within the boundary
14.0.0 CONTROL PANELS wall of project and existing factory. Return
15.0.0 FABRICATION WORK AND MOUNTING of leftover materials to owner’s stores.
OF INSTRUMENTS 1.2.0 Transportation and handling of
16.0.0 GENERAL NOTES FOR INSTRUMENT instruments, instrument accessories and
PIPING AND TUBING erection materials at owner’s stores and
17.0.0 GENERAL NOTES ON TERMINATION /or from places of storage anywhere
ELECTRICAL INSTALLATION AND within the boundary wall of project to work
GROUNDING site and /or contractors stores.
18.0.0 GENERAL NOTES ON CABLE TRAY, 1.3.0 Installation of field mounted instruments
DUCTS AND CONDUIT INSTALLATION such as pressure/vacuum gauges, dial
19.0.0 CIVIL WORKS thermometers, pressure switches, blind
20.0.0 CALIBRATION AND FUNCTIONAL switches, manometers, differential
CHECK pressure indicators, local flow indicators/
21.0.0 TESTING AND LOOP CHECKING recorders, local indicating controllers, flow
transmitters, pressure transmitters
PART C – JOB COMPLETION differential pressure transmitters,
REQUIREMENTS temperature transmitters, rotameters etc.
22.0.0 COMPLETION OF ERECTION JOB 1.4.0 Installation of vessel mounted instruments
23.0.0 COMMISSIONING AND START –UP such as level gauge glass, magnetic level
24.0.0 BILL OF QUANTITIES AND MATERIALS gauges, bi-colour level gauges, torque
tube level instruments, level switches, dial
PART D- PROCEDURES AND thermometers, pressure gauges etc.
STANDARDS 1.5.0 Installation of instruments on vendor’s
25.0.0 GENERAL REQUIREMENTS AND equipment such as Speed Indicators,
RECOMENDEDATION FOR PIPE Speed Controllers, Vibration/Axial
WELDING Displacement/ axial Thrust Monitoring
26.0.0 SPECIFICATION FOR PAINTING Systems, Ammeters, Anti surge Controls
WORK etc.
27.0.0 INSPECTION AND TEST PROCEDURE 1.6.0 Supervision of installation of on-line
FOR INSTRUMENT INSTALLATION instrument (by other contractors) such as
WORK. Orifice Flow Element, Control Valves, PD/
28.0.0 APPLICABLE STANDARDS
14 ES008 /15
Turbine Meters, Rotameters etc.

1.7.0 Installation of analytical instruments such
PART E- ATTACHMENTS as Infrared Analysers, Paramagnetic
29.0.0 DRAWINGS-ANNEXURE I Analysers, Thermal conductivity
30.0.0 SCHEDULE OF WORK – ANNEXURE II Analysers, NOX analyser, H2S analysers,
31.0.0 ITEMS TO BE SUPPLIED BY silica analysers, Density Analysers, PH
CONTRACTOR- ANNEXURE III
PRPD BY: CHKD BY: APVD BY ISSUED ON:

Page 2 of 30
analysers, Electrical Conductivity conduit pipes, fittings and flameproof

Analysers, Dissolved Oxygen analysers, boxes.
Online gas Chromatographs, oxygen 1.22.0 Any civil job involved in the installation of
analysers etc supports, mounting stands, control
1.8.0 Installation of miscellaneous instruments panels, junction boxes, relay boxes, air
such as Belt weighers, flame safe guard piping, tubes etc.
instruments, pneumatic change over 1.23.0 Cleaning and blowing of main air header
switches, air sets, thermocouple and distribution lines, pneumatic tubing,
assemblies, thermo resistance impulse piping and sample lines for
assemblies, purge type liquid level analysers etc.
measuring systems, volume tanks for 1.24.0 Testing of main air header distribution
double acting piston actuators etc. lines, pneumatic tubing etc, for any
1.9.0 Installation of local panel mounted leakage and proper connections.
instruments such as receiver indicators, 1.25.0 Hydraulic/ pneumatic testing of impulse
indicating controllers, pneumatic/ piping and sample lines.
electronic receiver recorders, manual 1.26.0 Testing of electrical cables, compensating
loaders, ratio control stations, computing/ cables, and special cables for proper
selector relays, temperature indicators/ connections, continuity and insulation,
recorders, receiver switches, alarm together with other contractors as
annuciators, timers, analyser recorders, required.
etc. 1.27.0 Testing of complete instrument loops for
1.10.0 Interconnecting field & panel mounted proper connections and functioning,
instruments. together with automation contractor.
1.11.0 Cutting gasket of various materials to 1.28.0 Steam tracing of impulse lines wherever
suitable sizes and fixing the same along necessary and final connections to steam
with the fitting or flanged connections. jacketed instruments. Piping connections
1.12.0 Any modifications jobs during installation for internal washing of instruments and
of instruments. purging of instrument casing.
1.13.0 Erection and interconnection of control 1.29.0 Cleaning and painting of frames,
panels, cubicle boards, control desks etc. supports, clamps, mounting stands and
locally and in the control rooms. racks etc, as per painting specifications.
1.14.0 Fabrication and installation of frames, 1.30.0 Testing, calibration and functional
supports, mounting stands, clamps, checking of all the instruments and
brackets, cable racks, cable tray and accessories.
bends, tees and crossings etc. for the 1.31.0 TIG welding, stress relieving and dye
racks and trays. penetrant tests wherever required.
1.15.0 Fabrication and installation of instrument Welding of IBR impulse pipes (CS),
protective boxes (Canopy). SS316 and 316L impulse pipes.
1.16.0 Laying and supporting of cable tray and 1.32.0 Sealing of cable entries into control
ducts. panels /room after laying of all cables and
1.17.0 Laying and supporting of instrument air tubes.
headers and distribution lines. 2.0.0. CONTRACTOR’S OBLIGATIONS
1.18.0 Laying and support of multi run tubing and The contractor’s obligations shall include:
single run tubing on racks and their 2.1.0 Arrangement and supply of required tools
termination. and tackles such as electric welding sets,
1.19.0 Laying and support of multicore and gas welding sets, gas cutting sets, hydro
single pair electrical cables, multicore and testing pumps, trailer, forklifts, crane,
single pair compensating cable and any jumbo trucks, pipe and tube benders,
other special cables on racks/ trays and drilling equipments, multi-meters, ferrule
their terminations. printers etc and all other tool necessary
1.20.0 Fabrication, laying and supporting of for the installation of instrument
14 ES008 /15
impulse piping and sample lines for according to good international practice.
analyzer and for laboratory. 2.2.0 Arrangement and supply of consumables
1.21.0 Fixing in position electrical junction boxes, like welding electrodes, industrial gases,
distribution boxes and relay boxes- in the cleaning fluids such as kerosene,
field and behind the control panel-, insulation tapes, sealing compounds, all
clamping materials for cable/tube trays

Page 3 of 30
and racks, impulse piping and air header pair and multipair compensating cables
such as bolts, nuts, M.S. clamps (straight two core and multi-core electrical/
pin type)/ U type lugs of 1.5 mm Sq./ electronic cables etc (except those
2.5mm Sq. size in required quantity, SS/ included in contractor’s scope.)
aluminium tag plates, PVC cable marking 3.2.0 Supply of all pneumatic, electrical,
ferrules etc. and all other consumables electronic and analytical instruments,
necessary for execution of the job. special sampling systems, resistance
2.3.0 Arrangement and supply of testing thermometers, dial thermometers,
equipments and other instruments such thermocouples, bimetallic
as dead weight tester (weight in kg/cm thermometers, thermo wells, all the
.Sq) manometer, portable pneumatic switches for alarm and shutdown,
/electronic calibrator, standard test pressure and vacuum gauges, air filter
gauge, thermocouple test kit, D.C regulators, solenoid valves, output
potentiometer, whetstone bridge, decade gauges, analyzer cabinets etc except
resistance box, temperature bath with those included in the contractor’s scope.
thermostatic control, oscilloscope, 3.3.0 Supply of water free of cost and
telephone sets, signal generator, electricity on chargeable basis.
megger, vacuum pump, hydraulic pump 3.4.0 Cranes, jumbo trucks, forklifts etc will be
avometer, digital multimeter, testing spared by the owner on chargeable basis
/calibrating facilities for panel mounted (only if available) otherwise contractor
indicators, recorders, controllers, has to make his own arrangements.
computing relays, counters, turbine flow
meters, transmitters , electro pneumatic PART B- TECHNICAL
converters etc. REQUIREMENTS
2.4.0 Planning and maintaining of all activities 4.0.0 INSTRUMENT INSTALLATION
of the contract as per PERT chart 4.1.0 The instrument contractor shall ensure
approved by owner. Arranging staff like that the instruments are received in good
supervisory staff, skilled and unskilled condition and shall report defect if any to
labour forces etc as required for timely the engineer in charge. The contractor
completion of the entire job. will be responsible for safety of all
2.5.0 Maintaining records on daily basis of all instruments thereafter till the
the works as per approved schedule, commissioning of the plant. Any loss or
calibration and inspection reports as per damage of instruments while in his
the advice of OWNER. custody shall be chargeable to the
2.6.0 Making arrangements for distribution of contractor. Contractor shall be
electricity and water from supply point to responsible for supply and cost of all
work spots. replacement material and labour
2.7.0 Co-ordination with other contractors’ necessary to rectify faults which occur
works as required by OWNER to during instrument installation or testing
complete the instrument erection work. period due to reasons such as falls or
2.8.0 Security arrangement for contractor’s due to faulty work man ship or faulty
office and stores to ensure safety of all material in the contractor’s supply.
equipments and all free issue materials 4.2.0 All the instruments are to be checked for
supplied by the OWNER. their calibration prior to installation in the
2.9.0 Clearing of site after completion of work. field and shall be corrected for any
2.10.0 Return of OWNER’S surplus and free calibration misalignments that would
supply materials and other excess have occurred during transportation or
materials included in work order to subsequent handling.
OWNER after accounting. 4.3.0 All the installation works shall be done as
3.0.0 OWNER’S SUPPLY per released construction drawings,
Owner’s obligations shall include: - instrument installation drawings and
14 ES008 /15
3.1.0 Supply of all pipes, pipe fittings, cable manufacturer’s instruction manuals that
trays and ducts, valves, flanges, junction will be supplied after the contract is
boxes, control panels, gauge boards two finalized.
core and multi-core control/ power/ 4.4.0 If the area in which the installation are to
shielded cables, three core and multicore be carried out are partially hazardous [as
resistance thermometer cables, single per area of classification] and partially

Page 4 of 30
general purpose then the instrument 5.2.8. Concentricity of orifice bore with pipe I.D.
erection contractor shall execute all the shall be ensured.
electrical works in accordance with 5.3.0 INTEGRAL ORIFICE TRANISMITTERS
applicable codes of Indian standards for 5.3.1. Transmitters shall be installed in co-
electrical installation and owners safety ordination with piping contractor with
regulations. correct flow direction along with the
4.5.0 Contractor shall handover/ report all straight pipe pieces adjacent to flow
faulty instruments or any defects found, transmitter.
which may arise due to design omission 5.3.2. In the case of pneumatic transmitter,
or discrepancies, which would impede connect receiver gauge and air set with
the proper functioning of instruments/ proper air and signal tubing. Tubing
system must be brought to the notice of wherever required shall be done with
engineer in charge without undue delay. necessary slopes as stipulated in the
5.0.0 ONLINE INSTRUMENTS installation standards.
Instrument contractor shall supervise and 5.3.3. In the case of electronic transmitters,
ensure correct installation of on-line twisted pair screened armored cable
instruments, by piping contractor. It will /cables as specified shall be glanded and
be the responsibility of the instrument terminated as per termination details.
contractor to see that the following are 5.4.0 ROTAMETER, PURGE ROTAMETER &
accomplished as per specifications and ROTAMETER TRANISMITTER
drawings. Contractor shall supervise &ensure the
5.1.0 FLOW TUBES (Venturi, nozzle etc) following while piping is in progress.
5.1.1. The flow tube shall be installed in 5.4.1 Verticality of meter
pipeline with arrow aligned in the 5.4.2 The float which is removed for the
direction of flow. purpose of transportation shall be kept in
5.1.2. The straight pipe lengths adjacent to flow position before installation.
tube shall conform to vendor drawings 5.4.3 Proper gaskets are used.
/standards. 5.4.4 Rotameter scale clearly visible from the
5.1.3. Tapping & fittings shall be as specified in operation platform. Reducer pairs
the instrument process piping drawings. supplied with meter to be installed by
5.1.4. Measurements of I.D, length shall be piping contractor shall be supervised by
done in order to ensure that correct unit instrument contractor.
is installed for each line. Change in I.D if 5.4.5 After installation, proper air & signal
any, shall be reported to site Engineer. connections shall be made through
5.1.5. Ensure that no weld deposit is junction box & to control room. [tubing
projecting inside the pipeline. &tube connections are covered
5.1.6. Gasket used shall be that specified for separately in section 16.0.0]
duty and shall not project inside the pipe 5.4.6 Air set if supplied loose shall be installed
beyond the limits specified by standards. as per instrument pneumatic diagram.
5.2.0 ORIFICE PLATE 5.5.0 TURBINE /MAGNETIC /VORTEX/
5.2.1. Orientation of tapping & necessary POSITIVE DISPLACEMENT/
straight length upstream and down ULTRASONIC/ MASS FLOW METER
stream of orifice. The flow meter is to be mounted, wired
5.2.2. Proper gasket (gasket shall not project and tubed as mentioned below: -
inside the pipe and shall be within the 5.5.1 Flow meter shall be installed, in co-
limit specified in orifice plate ordination with the piping contractor, on
specification.) pipeline with arrow aligned in the
5.2.3. Proper direction of orifice plate. direction of flow.
5.2.4. No weld materials shall project inside the 5.5.2 The straight pipe lengths adjacent to flow
pipeline near the orifice. meter shall be 10xD upstream 5xD
5.2.5. Location of tapping shall be at proper downstream or as recommended by the
14 ES008 /15
distance from orifice plate. manufacturer.

5.2.6. Correct orifice plate /unit is installed for 5.5.3 Care shall be taken to ensure correct
each line. alignment of flow meter with in mating
5.2.7. The drain/ vent hole in the orifice plate pipe work.
shall be located as per specification. 5.5.4 Electrical connection from the flow meter
to the secondary instruments shall be

Page 5 of 30
made. Do not run the signal leads in the will be provided by the electrical
same conduit/ tray as that for power contractor. Instrument contractor shall
supply. [Cable wiring & conduit work are ensure that proper earthing of the valve
covered separately] body is made by the electrical contractor
5.5.5 The complete installation shall be carried before commencing any work on the
out in accordance with the instruction valve. Also instrument contractor shall
manual supplied by vendor. ensure proper functioning of limit
5.5.6 The flow meter shall not have any strain switches, open, close commands,
on its body from adjacent pipes. continuous position feedbacks, other
5.6.0 CONTROL VALVES, DAMPERS, contacts if any.
PRESSURE REDUCING VALVES, 5.8.0 SOLENOID VALVES
DESUPERHEATERS Work involves installation of solenoid
The instrument contractor shall ensure valve on pneumatic signal lines to control
the following while the control valve is valve/ damper actuator, and termination
being installed by the piping contractor. of electrical cables. All necessary
5.6.1 Control valve is installed in the correct electric & pneumatic connections shall be
direction. done by instrument contractor, [tubing &
5.6.2 The control valve is not under wiring conduit work etc are covered
mechanical strain after erection. separately under sec. 16.0.0& 17.0.0].
5.6.3 Proper gaskets are used for the purpose.
5.6.4 In the case of butterfly valve the vane 6.0.0. FIELD MOUNTED PRIMARY
shall not be obstructed by any piping MEASURING ELEMENTS
parts and shall be free to rotate. 6.1.0. ANNUBAR FLOW ELEMENTS/ PITOT
5.6.5 The air supply to the control valve and TUBE
the signal line from the respective 6.1.1. Elements shall be so installed that it can
controller to the valve positioners /valve be inserted or withdrawn from the
shall be made by the instrument pressurized pipe lines under flow
contractor. conditions without interruption of service.
5.6.6 Signal tubing, instrument piping etc are 6.1.2. Annubar installation shall be as per
covered separately. instrument process piping drawings and
5.6.7 For valves with air filter set and instruction manual supplied by the
positioner, contractor shall ensure that vendor.
the valve positioner & the associated 6.1.3. All the process piping connections shall
linkages are physically and functionally in be given by the contractor [piping
good condition. covered under 16.0.0].
5.6.8 When solenoid valve is mounted on the 6.2.0. TEMPRATURE ELEMENTS [T/C & RTD]
valve, the air connections would be 6.2.1. T/C shall be installed at proper locations
provided by the valve supplier. along with specified thermo well.
Contractor shall give all electrical 6.2.2. T/W shall be screwed or flanged type and
connections through required fittings. shall be adequately tightened with use of
5.6.9 Instrument contractor shall ensure the proper gasket, nuts & bolts, which will be
proper installation of the pressure control supplied by the owner.
valve by piping contractor with respect to 6.2.3. Each T/C shall be connected by proper
direction and other aspects for control signal /extension cable using proper
valves. The backpressure tappings from glands from individual temperature
the downstream/ upstream piping shall element to junction boxes.[cables are
be properly connected by the instrument included separately under 18.0.0]
contractor. 6.3.0. MULTIPLE T/C ASSEMBLIES
5.6.10 Calibration of control valve shall include Work involved is same as above.
all testing and calibration of all the 6.4.0. RTD ELEMENTS [FOR BEARING
accessories such as limit switches, TEMPRATURE]
14 ES008 /15
continuous position feedback etc. R.T.D elements are already wired up to

5.7.0 MOTOR OPERATED VALVES local junction boxes by the equipment
The instrument contractor shall ensure vendors. Contractor shall connect these
proper installation of motor operated from junction boxes through the multicore
valve while it is being erected by piping leads with the corresponding instrument
contractor. The electrical connections point. [The cabling is included separately

Page 6 of 30
under 18.0.0]. The RTD elements are The work involved is identical to item
already installed on machinery / 7.1.0 except that there will be only one
equipment. In case these instruments are impulse tapping.
not installed by the vendor in the field, 7.4.0. DISPLACEMENT TYPE LEVEL
instrument contractor shall arrange to TRANISMITTERS WITH AIR SET
install these instruments as per 6.0.0. 7.4.1. The displacement type level transmitters
6.5.0. VIBRATION PROBES, AXIAL with air set shall be fitted in such a way
DISPLACEMENT PROBES & DRIVE that it is subjected to minimum vibration
SPEED PROBES 7.4.2. The installation shall be carried out using
All the probes are already mounted on necessary pipes, isolation valves & other
the machinery /equipment by the vendor fittings as specified in the instrument
and wired up to junction box and process piping drawings.
terminated. Instrument contractor shall 7.4.3. Connections of air supply lines- free of
provide the electrical connection from the oil, water &dust -at constant pressure of
junction box to control panel. In case 1.4 kg/cm.sq.
these were not installed by the vendor in 7.4.4. Calibration &checking should be carried
the field, instrument contractor shall out in co-ordination with piping group.
arrange to install these probes as per [Installation of valves, pipes& tube are
drawings. covered in section 16.0.0].
7.0.0. FIELD MOUNTED TRANISMITTERS 7.4.5. The air filter set shall be installed as
PNEUMATIC specified in instrument pneumatic tubing
7.1.0. D/P TRANISMITTER FOR FLOW, diagram.
LEVEL, DENSITY ETC ELECTRONIC TRANISMITTERS
Mounting of differential pressure The details in item 7.1.0 to 7.4.0 under
transmitters, air filter regulator, locally pneumatic transmitters will be applicable
fabricated suitable stands /supports, to electronic transmitters except that
tubing them from the first isolation valves cabling is involved instead of tubing.
with the 3 valve manifold, giving 7.5.0. ELECTRO MECHANICAL LEVEL
necessary slopes as stipulated in the TRANISMITTERS
installation diagrams. Provide air supply Mounting the instrument on the vessel
using 6mm OD SS tubes; connect ¼” OD nozzle/ flange using proper gaskets,
copper tube [output], to a receiver gauge nuts, bolts and connecting the power
or to the secondary local instrument or to /signal cables.
junction box as the case may be. Install 7.6.0. RADIO ACTIVE LEVEL
air filter set. [Tubing, process piping TRANISMITTERS
supports etc are covered separately Installation of the radioactive source, line
under sec 16.0.0]. detector and point detectors as per the
7.2.0. LEVEL TRANISMITTER- FLANGE details provided by the manufacturer and
MOUNTED strictly following the government
7.2.1. FLUSH /EXTENDED DIAPHRAM TYPE regulations.
Mounting of the transmitter on the vessel 7.7.0. TANK LEVEL TRANISMITTERS (FLOAT
nozzle /isolation valve using proper nuts, AND TAPE TYPE)
bolts, gaskets, receiver gauge, air set Installation of float and tape, guide wires,
and pneumatic tubing shall be installed protector pipe with V– seal and mounting
as per 7.1.0. the transmitter on suitable supports. The
7.2.2. FLUSH /EXTENDED DIAPHRAM TYPE protector pipe shall be properly
WITH REMOTE SEAL–FOR LEVEL supported and signal cable shall be
AND DENSITY terminated.
Work involved is identical to item 7.1.0 7.8.0. TEMPRATURE TRANISMITTERS
except that instead of impulse tubing, 7.8.1. The installation shall be carried out as
capillary tubing with flanged diaphragm to per instruction manuals of vendors.
14 ES008 /15
be mounted on to the vessel nozzle/ 7.8.2. The thermo well with bulb shall be fixed
isolation valves the capillary tube shall be [screwed or flanged] on the pipeline
supported properly. using proper thread sealant or nut, bolt,
7.3.0. GAUGE/ ABSOLUTE PRESSURE gaskets as the case may be as per 6.2.2.
TRANISMITTERS 7.8.3. Integral type temperature transmitters
shall be mounted on the thermo well

Page 7 of 30
head. Signal Cable shall be glanded and (The details for piping fittings and valves
terminated. are covered separately.).
7.8.4. Remote mounted transmitter shall be 9.3.0 LEVEL GAUGE [REFLEX TYPE]
separately mounted on a pedestal with Each level gauge shall be fitted with a
proper accessibility and the cable to pair of gauge cocks, the piping
temperature element and signal cable to connections & fittings shall be carried out
control room shall be glanded and as per the instruction given by the
terminated to the transmitter. supplier and as per the instrument
8.0.0. FIELD MOUNTED CONTROLLERS installation diagram.
8.1.0. INDICATING CONTROLLERS- 9.4.0 MAGNETIC LEVEL GAUGES
PNEUMATIC Work involved is same as item 9.3.0
The work involves mounting the except that care shall be taken to handle
transmitter/ controller on proper support it properly so that the magnetic float is
Suitable piping connections, air supply not damaged.
connections, and signal lines shall be 9.5.0 BOILER LEVEL GAUGES
provided as specified to correct final 9.5.1 The high pressure level gauge shall be
control element. The piping & tubing fitted with proper gaskets & weather
shall be as specified in the process proof one end open hood and suitable
piping diagrams. [The details for supports illuminator.
tubing’s &piping are covered under 9.5.2 Process piping connections & complete
16.0.0]. installation shall be in accordance with
8.2.0. DISPLACEMENT TYPE LEVEL instruction manual supplied by vendor.
TRANISMITTER + CONTROLLER WITH Supply using cables shall be connected
AIR SET to the illuminator from the near by switch
Work involved is a combination of 7.4.0 provided by the electrical contractor. [The
and 8.1.0. details for piping and fixing valves
8.3.0. ELECTRONIC CONTROLLERS conduit &wiring etc. shall be covered
Field mounted electronic controllers are separately.]
either mounted inside local control rooms 9.6.0 BOILER LEVEL GAUGE WITH REMOTE
or in local control panel. The installation INDICATION
of the controller inside the room shall be 9.6.1 This shall include the erection of
in a panel with suitable size cut out. The condensate chamber.
panel cutting and complete installation 9.6.2 Process connections &complete
and wiring of the controller shall be as installation should be carried out in
per manufacturer’s instruction manuals accordance with instruction manual
and shall be done by the contractor. supplied by the vendor, while piping work
Wherever local panel mounted is in progress.
controllers are used, mounting of the 9.7.0 TANKAGE SYSTEMS
panel on its foundation, purging 9.7.1. ELECTRONIC TANK GAUGING
connections, all wring and termination, SYSTEM
canopy for the local panel etc will be in 9.7.1.1. The tankage system, including servo and
contractor’s scope. radar type level instruments with
9.0.0 FIELD MOUNTED GAUGES associated instruments such as pressure
9.1.0 PRESSURE GAUGES /single element temperature transmitter/
Installing pressure gauge using suitable multiple temperature element
connecting tubes /vent/ drain/valves /etc transmitters, tank side indicators, junction
from the first isolation valve provided on boxes etc shall be mounted and wired as
ducts/ pipes/ vessels/ pumps etc. per vendor’s installation manual and
9.2.0 MANOMETER wiring drawings.
Scope includes: - 9.7.1.2. Connection to control room and
9.2.1. The installation of instruments with commissioning of the system shall be
14 ES008 /15
proper supports. under the supervision of the tank gauging

9.2.2. Filling with proper manometer fluid. vendor.
9.2.3. Connecting all the piping and valves as 9.7.1.3. The control room panel erection,
per the drawings. necessary inter-panel wiring, cold loop
9.2.4. Providing final connections using a checking of field cables etc of the system
flexible hose. is also under the scope of the vendor.

Page 8 of 30
9.7.2. FLOAT AND TAPE METHOD valves instead of pneumatic copper

9.7.2.1. Contractor shall ensure that the tubing from transmitters.
instrument is located in an easily 10.2.2. Pressure switches shall be installed
accessible place. Location shall also be rigidly to avoid vibration.
such that ambient temperature is within 10.3.0. DIRECT CONNECTED DIFFRENTIAL
the specified limits as given by the PRESSURE SWITCH
vendor. Work involved is same, as 10.2.0 except
9.7.2.2. For float and tape measurement, that impulse tubing shall be provided.
contractor shall install measuring tape, 10.4.0. DIRECT CONNECTED LEVEL SWITCH
float, protector pipe, local indicator and [INTERNAL/ EXTERNAL/ FLOAT TYPE]
supports as per hookup drawings or Scope includes the installation of level
vendor drawings. switches on vessel, making necessary
9.7.2.3. Contractor shall fix the channel steel or electrical connections using armored
pipe vertically, which does not bend due cable [scope for wiring is covered
to its weight, under the sidewall of tank, separately under 16.0.0& 17.0.0].
for accurate measurements. 10.5.0. LEVEL SWITCH
9.7.2.4. The float and tape shall not be subjected TUNING FORK TYPE, PADDLE TYPE,
to sudden, abnormal vibrations, due to a CAPACITANCE TYPE [WITH OR
violent stream of feed fluid or while WITHOUT EXTERNAL CHAMBER]
erecting the same. Scope of work is same as item 10.4.0
9.8.0 DIAL TYPE INDICATING 10.6.0. TANK LEVEL SWITCHES [FLOAT AND
THERMOMETERS TAPE TYPE]
The work involves installing of Installation of float, tape and guide wires,
thermometers and thermo-wells mounting the switch on the vessel flange,
(threaded or flanged) on pipes/ vessels connecting the cable and termination.
using proper nuts, bolts &gaskets 10.7.0. TEMPRATURE SWITCH
provided by piping group. The threaded The scope of work includes mounting
thermo well shall be fitted using Teflon temperature switch with thermo well on
tapes or pipe ‘dopes’ as the case may the vessel/ pipe line, cabling and
be. termination etc.
9.9.0 TEST THERMOWELLS 10.8.0. DIRECT CONNECTED FLOW SWITCH
Mounting of thermo well on the pipes/ Scope of work includes, mounting the
vessels using proper nuts, bolts and flow switch on the pipe line, cabling and
gaskets termination.
9.10.0 DIFFRENTIAL PRESSURE INDICATOR 10.9.0. LIMIT SWITCH
Work involved is same as per 9.1.0 Electrical connection to be made to the
except that there are two tapping. limit switches mounted on control valves,
9.11.0 THERMOMETER –CAPILARY TYPE actuators etc.
Work involved is same as per 9.7.0, 11.0.0. ANALYSERS
except that the capillary tube shall be Manufacturer’s instruction manuals shall
supported by tray / structural. be strictly followed for proper installation
10.0.0. FIELD MOUNTED SWITCHES and functioning of analyser.
10.1.0. RECIEVER PRESSURE SWITCH 11.1.0. PH ANALYSERS
(PNEUMATIC) 11.1.1. IMMERSION TYPE
The pressure switches shall be mounted Mounting the electrode with holder using
on suitable supports. Necessary the mounting hardware provided,
pneumatic tubing and electrical installing the analyser transmitter and JB
connections shall be made. The on 2” pipe pedestal and termination.
pneumatic signal shall come from 11.1.2. FLOW THROUGH TYPE
corresponding transmitter. [Pneumatic Contractor shall supervise and ensure
tubing and electrical wiring are covered the proper installation of the electrode
14 ES008 /15
separately under 16.0.0 & 17.0.0] chamber on the pipe line by piping group.
10.2.0. DIRECT CONNECTED PRESSURE Analyser transmitter and JB shall be
SWITCH mounted on 2” pipe pedestal and the air
10.2.1. Work involved is same as 10.1.0 but supply tubing, cabling and termination
impulse tubing shall be connected from shall be done.
pipelines /vessels using proper isolation 11.1.3. PH- ANALYSER, CABINET MOUNTED

Page 9 of 30
Installation of the analyser cabinet, air field, and inter-connecting cable to be

supply tubing, interconnecting cabling terminated.
and termination. 11.9.0 TERMAL CONDUCTIVITY ANALYSER
11.2.0. CONDUCTIVITY ANALYSERS Installation of the sampling cabinet,
Contractor shall supervise and ensure analyser cabinet at locations shown in
the proper installation of the electrode the layout drawings, connecting the
chamber on the pipe line by piping group. sample tubing as per the drawings, and
Analyser transmitter and JB shall be terminating the cables etc shall be done.
mounted on 2” pipe pedestal and the Manufacturer’s instruction manuals shall
interconnecting cabling and termination be strictly followed for the installation and
shall be done. functioning of the analyser.
11.2.1. CONDUCTIVITY ANALYSER WITH 11.10.0 INFRARED ANALYSERS.
SAMPLING RACK Work involved is same as item 11.9.0
Installation of the analyser sampling rack, 11.11.0 PARA MAGNETIC O2 ANALYSERS
impulse tubing for sample inlet and Work involved is same as item 11.9.0
outlet/ drain, cooling water inlet and 11.12.0 NOX ANALYSERS
outlet, interconnecting cabling and Work involved is same as item 11.9.0
termination etc shall be done. 11.13.0 SO2 ANALYSER
11.3.0. DISSOLVED O2 ANALYSERS Work involved is same as item 11.9.0
Mounting the electrode with holder using 11.14.0 ZIRCONIA PROBE FOR O2 ANALYSER
proper support, installing the analyser Work involved is same as item 11.8.0
amplifier and JB on 2” pipe pedestal, 11.15.0 ONLINE GAS CHROMATOGRAPHY
mounting the power supply converter and Work involved is same as item 11.9.0
inter connecting cabling and termination 12.0.0 MISCELLANEOUS INSTRUMENTS
etc. 12.1.0 HYDROCARBON DETECTOR
11.4.0. PROCESS TITRATORS 12.1.1. The scope includes fixing of the detector
Installation of the process titrators inside on a pedestal downstream of local wind
the local control room and the connected direction such that the gases to be
cabling and tubing/ piping, as per detected are facing to the element. The
installation details provided by the installation of canopy shall not keep the
manufacturer shall be done. wind away from the detecting assembly.
11.5.0. DENSITY ANALYSER (VIBRATION The associated cabling and termination
TYPE) shall be as per the drawings released by
Mounting the analyser sampling rack and FEDO.
cabling and termination etc shall be 12.1.2. The elevation of the detector shall be
done. such that for detection of heavier gases
11.6.0. DENSITY ANALYSER (FLOAT TYPE) (Compared to air) the instrument shall be
Contractor shall supervise and ensure located above the point of leak source.
the proper installation of the density Similarly, for detection of lighter gases,
analyser on the pipe-line by piping group. the instrument shall be mounted below
Pneumatic to electronic converter shall the point of leak source.
be mounted on 2” pipe pedestal, air 12.1.3. Where line of sight gas detectors are
supply /signal tubing, cabling and specified, their installation, alignment etc
termination etc to be done. shall be strictly as per vendor’s
11.7.0. MOISTURE ANALYSERS instruction manual. For transmitter-
The analyser probe shall be mounted on receiver type or transmitter-reflector type
the flange provided on the pipe line using instrument, the line of view shall be free
proper gasket, nuts and bolts which will of obstructions and frequent passage
be supplied by the owner. The signal ways of man/ machinery. The cabling of
cable shall be connected to the probe both the transmitter and receiver will be
and terminated. in the scope of the contractor.
14 ES008 /15
11.8.0. OLEUM ANALYSER 12.1.4. For detection of toxic gases, the

Work involved is same as item 11.7.0. In instrument shall be located as near to the
addition to the above, contractor shall point of source as possible for faster
mount the analyser transmitter and detection of leaks.
junction box on suitable support in the 12.2.0 HEAT/ SMOKE DETECTOR

Page 10 of 30
12.2.1. These types of instruments are normally 12.5.2. Instrument erection contractor shall
located inside buildings. The installation install the operation box properly on a
of these instruments shall be as per suitable structure nearby using brackets
relevant NFPA standards. The scope if required. Provide termination of all
shall be generally same as in 12.1.0 incoming and out going cables to the
except that these instruments are either operation box as per the wiring scheme
ceiling/ wall mounted. of bagging machine supplier.
12.3.0 FLAME DETECTORS 12.8.0 MOTION DETECTOR
12.1.1. Fixing the detecting element in such a This is Small electronic instrument
way that direct flame and heat will not provided with mounting socket, similar to
damage the instrument. a relay. Contractor shall mount the
12.1.2. Mounting the preamplifier/ relay units motion detector inside a housing
inside a dust tight metal enclosure or provided by purchaser and terminate all
local panel supplied by others. incoming and outgoing cables as per
12.1.3. Interconnecting cabling between the manufacturer’s wiring scheme.
detecting element and the relay. 12.9.0 I/P CONVERTERS + POSITIONERS &
12.4.0 VANE ACTUATORS E/P POSITIONERS
12.2.1. Supervision of installation of the vane Mounting I/P converters on separate
actuator carried out by mechanical supports wherever necessary, making
contractor and to ensure that the same the electrical and pneumatic connections.
installed as per manufacturer’s 13.0.0 JUNCTION BOXEs, PDBs, MBs
recommendations. 13.1.0. ELECTRICAL JUNCTION BOXES,
12.2.2. Termination of tubing and wiring on to PDB’S, MB’S AND TERMINATION
the positioners, air set, I/P converter etc BOXES
of the actuator. 13.1.1. Fabrication of necessary supports and
12.5.0 SUCTION PYROMETERS welding it on the available structures or
12.3.1. To install the suction pyrometer grouting on to the floor including the civil
assembly on to the flange nozzle of the work connected with it. Mounting the
furnace using proper gaskets, bolts and junction box, connecting the individual
nuts, supplied by the owner. cables and multicore cable using cable
12.3.2. This is to be connected by proper glands and terminating the wires. All the
compensation/ extension cable up to the electrical wires shall be identified using
junction box. the cable marking ferrules. For
12.3.3. Provide necessary tubing with required termination boxes, only one cable entry
fittings for air connection to the ejector of and outlet is required. All other holes
the suction pyrometer. shall be blinded with suitable plugs.
12.3.4. Cabling for suction pyrometer will be 13.1.2. Where cable runs are underground,
similar to thermocouple. junction boxes, marshalling boxes etc
12.6.0 ACTUACTOR OF CONTROLLED shall be mounted above grade at
VOLUME PUMPS convenient height for easy access.
12.4.1. The control volume pump will be installed 13.1.3. If the wiring is over-head, JBs/ PDBs/
by machinery contractor. Instrument marshalling boxes shall be mounted a
contractor shall supervise the installation few feet above grade for easy access.
work and ensure that the same is Care shall be taken to ensure safe
installed as per manufacturer’s working conditions.
instructions/ recommendations. 13.1.4. Where wiring must enter the top of JBs/
12.4.2. Provide the termination of signal cable PDBs/ marshalling boxes, it shall be
(4-20 mA signals) and also tubing for all brought near the bottom of the box and
connection to the positioners unit and the then back up to terminals. Forming a drip
actuator. loop near the bottom of the JBs/ PDBs/
12.4.3. Generally the scope of work will be marshalling boxes.
14 ES008 /15
similar to control valve. 13.1.5. JBs/ PDBs/ Marshalling boxes shall be

12.7.0 OPERATION BOX mounted suitably such that they do not
12.5.1. This is required for the local operation of hinder works like movement of personal
bagging machines etc. This houses the around the plant, removal of equipments
push buttons and lamps required for the like heat exchanger shell tubes .etc.
operation of bagging machine. 13.2.0. RTD JUNCTION BOXES

Page 11 of 30
Work involved is same as item 13.1.0 when ready for installation. Hooks shall
13.3.0. TERMOCOUPLE JUNCTION BOXES be used while lifting and moving the
Work involved is same as item 13.1.0, panel. Welding shall not be done on the
except that compensating cables are panel at site for supports etc. Panels
used instead of electrical cables. shall not be used as earth as it may
13.4.0. A.C. POWER DISTRIBUTION BOXES damage the electronic instrument.
Work involved is same as item 13.1.0, Proper earthing for the panel shall be
except that the distribution box houses provided separately; otherwise it shall be
isolation switches and fuse units for connected to the main earth of the plant.
distributing 110VAC power to field 15.0.0 FABRICATION WORK AND
instrument. MOUNTING OF INSTRUMENTS
13.5.0. ENCLOSURE FOR INTRINSIC SAFE 15.1.0 FABRICATION WORK.
BARRIERS 15.1.1. Instrument contractor shall fabricate
Work involved is same as 13.1.0, except different steel structures supplied to him
that the contractor shall mount I.S as per drawings. Unit rates shall be
barriers inside the enclosure and the applicable as shown in bid item. Minor
incoming and outgoing cables are to be civil works like chipping, grouting, etc,
glanded and terminated. shall form part of fabrication job.
14.0.0 CONTROL PANELS Consumables like welding rods and gas
14.1.0. The control panel is pre-wired, and pre- shall be included in the fabrication cost.
tubed, all the wire and tubes being 15.2.0 INSTRUMENT AIR LINES
terminated to the respective terminal 15.2.1. Piping contractor will terminate main
blocks, and bulkheads respectively. instrument air header lines on the pipe
Instrument contractor shall undertake the bridge with first isolation valve for branch
installation of panels, mounting the lines for instrument air distribution.
instruments on the panel and execute all The fittings will be welded type and pipes
the termination of wiring & tubing at the will be galvanized carbon steel type.
back of the panel. Contractor’s scope includes installing,
14.2.0. Instrument erection contractor’s scope testing and commissioning of these lines.
shall include but not be limited to the 15.2.2. 316L PIPES /316SS PIPES, CARBON
transportation, calibration / testing, loop- STEEL PIPES
checking etc, of all the panel mounted Welding of instruments’ impulse lines
instruments. However, if the contractor using pipes shall be done by qualified
has to under take some of wiring and welders as per the standard welding
tubing which are found necessary at a procedure.
later stage for which they have to NOTES ON MOUNTING OF
indicate the cost of the wiring / tubing per INSTRUMENTS
meter basis the materials will be supplied (a) Mounting of all accessories of field-
by the purchaser. mounted instruments such as manifolds,
14.3.0. The local control panels shall be air sets, condensate pots etc wherever
mounted as per instrument location and applicable, are included in the installation
cable routing diagrams, IADs/ GADs. All of the instruments and no extra shall be
the wires and tubes shall be terminated paid for their accessories.
as per instruction manual from (b) No field mounted instrument shall be
manufacturer. Foundation for panels and installed with support from impulse
racks shall meet the requirements of the piping/ signal lines.
equipment vendor’s specifications. (c) Hand rails shall never be used for
14.4.0. Panel shall be located to allow easy mounting or supporting instruments.
access and operation and to permit (d) Instruments shall be mounted on
operator to survey the maximum panel pedestal fabricated using base plate and
area, panels shall be arranged and 2” pipe of about 1.5meter height.
14 ES008 /15
located for easy reading, servicing and (e) All field mounted instruments shall be
maintenance of equipments and panels/ mounted at grade or on platform.
cubicles. Air purging shall be used (f) If pedestal is installed at paved area, it
whenever necessary for environment shall be fixed to the concrete paving with
reason as well as electrical safety. anchor bolts
Panels shall be removed from racks only

Page 12 of 30
(g) If ground is unpaved, a concrete base 16.12.0. Instrument connection block valves on
shall be provided for the pedestal. lines, orifice flanges, vessels and
Pedestals mounted on the top of equipment are to be in accordance with
platforms or process piping shall be the specification of the line, vessels or
removable. equipment to which they connect and
(h) The instruments shall be mounted on that are furnished by the piping division.
pedestals using “U” clamps, nuts and 16.13.0. Field contractor shall relieve strain from
bolts or as per installation drawings given all connections by properly supporting all
by engineering department or vendor. pots, leads and instruments. Refer to
(i) Pedestal shall be painted to protect from “typical instrument support details” and
corrosive atmosphere and weather standard drawings attached.
conditions. 16.14.0. Instrument pressure leads and flow
16.0.0. GENERAL NOTES FOR INSTRUMENT meter leads are to be sloped 1 in 12
PIPING AND TUBINGS minimum in horizontal runs, except that
16.1.0. The sizes of the piping /tubing and also long pressure instrument leads carried
their materials of construction are on racks through the yard may be run
decided by the designer of the horizontally, but without pockets,
instrumentation and control system. together with pneumatic leads.
16.2.0. Instrument tubing (mainly SS) shall be 16.15.0. When a pressure lead rises above the
cut using only the standard cutter. Use pressure connection and the instrument it
only fine sand–paper for polishing the serves a minimum slope of
outer edge of the tubes after cutting. approximately 1 in 12 from high point of
Never use a file or grinder. Any burr or the lead toward the pressure connection
scratch will not make a good tight–fit and the instrument must be maintained.
when joining the tube with compression 16.16.0. ‘Field’ contractor shall provide sufficient
type couplings. After tightening, softly flexibility for pressure leads and
remove the joint and inspect for the pneumatic leads to allow for thermal
uniform closure of the ferrule on the expansion of vessels, lines or equipment
fitting. to which they connect.
16.3.0. Where tubing is adjacent, clearance 16.17.0. Use bends in all pressure leads and keep
between them near the coupling portion threaded joints to a minimum.
shall be at least 10cm for easy 16.18.0. Bends in tubing for pneumatic leads are
maintenance. to be kept to the absolute minimum
16.4.0. The pipes shall be supported on angles required.
using proper U-clamps. 16.19.0. All pressure leads and pneumatic leads
16.5.0. Pipe lines (for impulse lines) shall be to and from instruments are to be
bent only after sand filling and heating thoroughly cleaned of burrs and foreign
and using a bending tool, otherwise, it matter before being put into operation.
will kink and become weak. 16.20.0. All pressure/ level instruments in wet
16.6.0. Always avoid sharp bends. Use only service are to be corrected for liquid
smooth bends wherever necessary. head pressure.
16.7.0. Give proper support for the piping for 16.21.0. Instruments, instrument pressure leads,
drawing out purpose. flow meter leads and pneumatic leads
16.8.0. When using pipe connector or couplings, shall not be mounted on, nor supported
adequate space for spanner head shall from platforms, railings, steel supports,
be provided. equipment and process or utility lines
16.9.0. When brazing or welding two pipe ends, that are subject to abnormal vibrations,
care shall be taken to see that the particularly vibrations caused by
adjacent pipes/ vessels are not affected reciprocating machines, unless
by this heating. absolutely necessary. Additional bracing
16.10.0. For ‘reference drawings’ list refer to and / or supports shall be provided for
14 ES008 /15
document control index. instrument and instrument leads to

16.11.0. All instruments on instrument piping assure rigidity under such abnormal
details and other instrument drawings are conditions.
shown symbolically. For true picture and 16.22.0. Where rack is not provided, pneumatic
location of connection refer to vendor’s leads [generally 3 or less] shall, be
drawings. strapped to air headers or branches.

Page 13 of 30
16.23.0. Elevation shown in instrument locations low point(s) in the system to provide
and air supply header drawings are to drainage.
bottom of piping unless otherwise noted. 16.38.0. No bends, scratches or cuts shall be
16.24.0. The quantities given in the bill of made on any of the enclosed tubes, as
materials for pipes and tubes are for these will be points of potential failure.
straight pieces only. Installation of fittings 17.0.0 GENERAL NOTES ON TERMINATION,
like elbows, tees, valves condensate pots ELECTRICAL INSTALLATION AND
etc. shall be included in the cost of GROUNDING
erection and no separate charges will be 17.1.0 TERMINATION
applicable for these items. 17.1.1 Wires of cable shall be cut as it comes
16.25.0. Locations and facing of instruments shall off the reel at location free from sharp
be adhered to as closely as possible. objects.
16.26.0. Air supply piping will be supported on 17.1.2 Jacket shield material shall be terminated
existing steel. ‘Field’ contractor shall without cutting insulation underneath. If
provide additional steel wherever no pair jackets is used and pair are
required. individually shielded then insulating tape
16.27.0. ‘Field’ contractor shall provide all or sleeving shall be applied to exposed
materials required for mounting and shielded in order to protect accidental
supporting instruments, Instrument pots, grounds.
piping etc. Refer to “typical instrument 17.1.3 All cable ends shall be protected against
support details” drawings. moisture entry prior to connecting the
16.28.0. Unless otherwise noted, pedestal type cables to its permanent terminations.
mounted transmitters, indicators, 17.1.4 Stripping of insulations from wire shall be
recorders and controllers shall be located done without cutting the conductor.
with the center line of the instrument Standard stripping tools of proper design
1.3M above grade or platform. shall be used.
16.29.0. All elevations given are based on the 17.1.5 Screws shall be torqued adequately to
grade elevation indicated on the lay out get good contact with wires inserted
drawings. under the screw.
16.30.0. All tube fitting shall be used as specified 17.1.6 Proper compression of terminal screws
in instrument hook up &layout drawings. shall be done to prevent corrosion which
The contractor shall ensure material, may later cause poor continuity, galvanic,
dimension and physical condition of all or rectification action .High quality-
items before putting them into service. terminal strips and insulating materials
16.31.0. For D/P transmitters with capillary shall be used.
extension, the capillary tube shall be 17.1.7 All wires or leads terminated at
insulated using glass wool with aluminum connection shall have sufficient slack to
cladding as indicated in the instrument reduce the effect of vibrations.
application diagrams. 17.1.8 Necessary cable supports shall be
16.32.0. Welding as per the standard procedure provided to avoid having cable weight
/specifications shall be followed. Any pre support from wire terminations.
heating/ post-weld heat treatment shall 17.2.0 ELECTRICAL INSTALLATION
be done wherever required as per 17.2.1 The equipment erection and their
standards. installation shall confirm to the latest
16.33.0. All pipe lines shall be thoroughly checked Indian electricity rules and Indian
for cleanliness and moisture before and Factories Act, as regards safety, earthing
after installation. and other essentials provisions specified
16.34.0. After testing, all C.S pipes shall be epoxy therein form installation and operation of
painted. the electrical part of the instrumentation
16.35.0. The take off points shall be from top of loop.
the header. 17.2.2 Fittings switches, distribution boards,
14 ES008 /15
16.36.0. While brazing or welding two pipe ends, junction boxes etc for electrical lines shall
care shall be taken to see that adjacent be installed at places indicated in
pipes /vessels do not get affected due to drawings.
heating. 17.2.3 The cable termination shall be done
16.37.0. Even when dryers are supplied to keep using solderless crimping type closed
the air dry, a drain shall be installed at eyelet connectors [contractor’s supply].

Page 14 of 30
17.2.4 Cables carrying 110 volts or above shall 17.2.16 All sealing fittings shall be dammed with
not run in same conduit, metal or PVC fiber and filled with sealing compound
ducting, trunking or trays as cables carry after wiring is completed.
lower voltage. 17.2.17 The 24V/ 110V alarm, control and
17.2.5 Cables carrying alternative current shall instrument power wiring shall be run in
not be run in the same conduit, metal or conduit/ cable trays from local
PVC ducting trunking or trays, as cables instruments to centrally located terminal
carrying direct current unless agreed to boxes. Wires shall be copper single
the owner in writing. There shall be a conductor, PVC insulated rated 600 V.
minimum separation of 200mm between 17.2.18 Conduits/ cable trays in main runs shall
trays carrying these signals. be supported on a suitable steel rack.
17.2.6 Laying of earth, conductors fixing on 17.2.19 Minimum size of conduit shall be 20 mm
cable duct /tray structural, clamping/ and that of cable tray shall be 50mm.
jointing by brazing wherever necessary, 17.2.20 All the spares wire shall be tagged and
testing and commissioning including placed in convenient place or terminated
supply of earth conductors, crimping suitably.
lugs, bolts, nuts, washers etc and supply 17.2.21 All cables shall be tagged with Aluminium
and installation of earth pits as per laminating plates at every 30m, at every
drawings. crossings (Pipe bridges/ walls) etc.
17.2.7 Where cables are run through pipes, the 17.3.0 GROUNDING
entry to and exit from pipes shall be 17.3.1 All exposed metallic parts that could
smooth and free from burrs. Cables shall become energized with hazardous
be pulled into such pipes in such a way potentials shall be reliably connected to
that there is no damage to the cable. the equipment grounding circuits.
17.2.8 Where space is left in pipes for cables to 17.3.2 On complex inter-connected
be pulled in at a later date, a galvanized instrumentation networks caution shall be
draw wire of adequate size shall be left in exercised when grounding the circuit to
the pipes. ensure that multiple grounds are not
17.2.9 There shall be no intermediate joints in established.
any cable. Joints shall be made only at 17.3.3 Cable screen shall be earthed at only
terminals in instruments or approved one point near the control room.
equipment. 17.3.4 All instrument grounds shall be checked
17.2.10 Temperature compensation cables, for same potential if tying between
alarm and trip system wires shall be run instrument circuit grounds to the same
in conduit or on cable tray as specified on earth electrode beds that are used for
drawings. power grounding is done.
17.2.11 Elevations shown for horizontal conduit 17.3.5 All the spares conductors in a multicore
/tray runs are the elevations of the cable shall be grounded to avoid
platforms, steel or piping from which induction of large voltage surges on
these are to be supported. Contractor signal circuits when near by lightning
shall provide any additional supports if strikes occur.
required. 17.3.6 Shields or signal wires shall never be left
17.2.12 Vertical conduit /tray runs at structures unconnected, grounded indiscriminately,
shall be supported from ladders unless connected to their signal pair at two more
otherwise noted. points or tied to other signal leads.
17.2.13 Location and elevation of conduit /cable 17.3.7 Instruments, junction boxes, cable gland
tray run may be changed when plates shall be properly earthed
necessary to avoid interference. whenever applicable.
17.2.14 Cables shall be located at minimum 18.0.0 GENERAL NOTES ON CABLES ON
distance of 300 mm from hot piping or TRAYS, DUCTS AND CONDUIT
equipment. INSTALLATION
14 ES008 /15
17.2.15 Vents and drains shall be furnished at 18.1.0 Changes in direction of cable trays/ cable
high and low points in conduit runs. ducts shall be achieved by use of cable
Conduit shall be sloped towards drain tray bends and tee pieces or by efficient
fittings. clampings. For cable trays, generally
available supports will be used for
routing. But whenever it is not available.

Page 15 of 30
Contractor shall make necessary 18.10.0 All underground runs in process plants
supports for routing the cable trays/ shall be clearly marked for run location
cables ducts and identified using pointer marks and
18.2.0 Main cables shall be laid through cable service identification signs as per the
ducts. Contractor shall provide proper installation standards.
covers after installation of all the cables 18.11.0 Cable conduit shall be supported from at
inside the duct. In case of new cables least every 1.5 meters. Supports shall be
are laid in existing ducts, contractor shall tack welded to conduits.
uncover and re-fix the covers as 18.12.0 Conduits shall not be supported from
necessary. piping -that may have to be replaced or
18.3.0 All pneumatic tubing and electrical cables removed for inspection-, or from high
shall be clamped on the cable tray at temperature piping.
intervals of not more than 500mm. 18.13.0 Conduit runs shall be solidly connected
18.4.0 Grease shall be applied to all machine to assure continuity in their entire length.
bolts before tightening. Necessary Ground jumbers shall be installed where
grease shall be supplied by contractor. physical condition cast any doubt as to
Cable tray &cable ducts shall be fixed on the required electrical continuity.
structural supports fabricated at site by 18.14.0 All underground conduits shall be
contractor. arranged in banks and should have
18.5.0 Contractor shall fabricate at site, suitable protection and identifying concrete
bends, tees, crossings etc and shall envelop.
supply/ fabricate required clamps from 18.15.0 Conduit banks shall be installed about 2
sheets/ strips for the trays and ducts feet below grade, 12” below drainage
wherever required according to the ditches in process areas, or below the
routing requirement. The cables taken frost line, whichever is deeper.
along trays /angles alone will have to be 18.16.0 The ends of cables shall be properly
clamped. The cable inside the duct shall sealed before pulling, to prevent moisture
be neatly arranged. This shall also and damaging substances from entering.
include laying under ground cables 18.17.0 Cables normally shall be pulled directly
through the trench wherever required. from a shipping reel placed on a cable
18.6.0 The quantity given in the bill of puller into position in the tray. Cables
materials for cable trays, cable conduits shall be taken out from drums using
and cable ducts are for straight pieces cable puller only, to avoid twisting and
only. Installation of fittings like bends, subsequent damage of outer sheath of
tees, reducers etc shall be included in the cable. The cable puller shall be either
cost of erection and no separate charges fabricated or supplied by the contractor.
will be applicable for these fittings. Fire Small, cables (2’and smaller in diameter),
resistant materials/ coatings as specified can be laid with a basket grip. The pulling
shall be applied on the cable trays/ ducts tension shall not exceed the cable
at locations where fire proofing is manufacturer’s recommendations. Pulley,
required. rollers, etc shall be used to guide the
18.7.0 Trays are not designed as walkways or cables into positions in the tray.
hoisting beams and persons shall be 18.18.0 Specific care shall be taken while
advised not to use them as such. installing special cables like co-axial
18.8.0 All runs of ducting and conduits shall be cables as electrical characteristics may
mechanically and electrically continuous. change due to improper handling.
Running threads shall be secured by lock 18.19.0 Care shall be taken to see that there are
nuts. no kinks or loops that may scrape the
18.9.0 Underground conduit banks which cross edges of conduit fittings, cover plate
beneath roadways, railways or other surfaces and edges etc and result in
areas subject to heavy loading or having damaged insulation and even broken
14 ES008 /15
poor soil conditions shall be adequately wire.

supported or the envelope reinforced 18.20.0 Covers on tray shall be used to prevent
using concrete cover slabs to prevent accumulation of dirt, debris, snow, ice,
shearing, crushing or damage from etc.
uneven settlement. 18.21.0 A minimum of 5 feet clearance shall be
present between noise generating

Page 16 of 30
equipments and cable tray on which pneumatically 1.5 times maximum

signal cables will be laid. working pressure and isolated from the
18.22.0 Cable trays shall be run with the breadth source of pressure. The pressure shall
of the tray in a vertical plane. Where not fall by more than 0.1Kg/cm2 in ten
FEDO’s site engineer agrees that a minutes.
vertical run is not possible, a short 20.4.0 All the impulse lines shall be isolated
horizontal section shall be used, but the from the instrument, and hydraulically
run shall revert to the vertical plane at the tested to 1.5 times the working pressure
nearest point. and isolated from the source of pressure.
18.23.0 The contractor’s scope shall include The pressure shall not fall by more than
cable laying harnessing/ dressings, 0.1kg/cm2 in ten minutes.
clamping on trays, making Aluminium 20.5.0 All the installation will have to be checked
tags with cable numbers punched on the and tested by the method of simulation
cable before entering the instruments, for working of entire Instrumentation loop
junction boxes or control room. The tags and its circuits to include the relevant,
may be tied to the cable using PVC primary, secondary and control elements.
insulated GI/ SS wires. PVC marking 20.6.0 All RTD electric and electronic
ferrules [contractor’s scope of supply], instrument wiring shall be tested for
shall be used at the termination end of resistance between conductors and earth
the cables. All single /multi-core tubing/ for 500V DC. These tests shall be carried
cables connecting the field instruments out with all conductors disconnected
/junction boxes with bulk heads/ junction except from the test instruments. The
boxes of control panel are to be laid on insulation resistance shall not be less
cable trays and properly clamped at than 10 mega ohms.
intervals not exceeding 1000mm on 20.7.0 Transmitter’s connections to the correct
horizontal runs and 300mm on vertical receiver and polarity shall be checked.
runs. 20.8.0 Controller connections to their correct
19.0.0 CIVIL WORKS control devices shall be checked.
All civil works such as grouting, chipping 20.9.0 Correct connection of pneumatic and
of the wall /concrete floor as required for electric switches shall be checked.
some fixtures of instrument, cable racks, 20.10.0 Correct operation of alarms and
instrument pedestal etc will have to be functioning of interlocks shall be
undertaken by the contractor. All the checked. This testing shall be in co-
chipped areas shall be re-plastered to ordinate with site engineer.
attain the same finish as before. For 20.11.0 The written results /certificates of all tests
opening up walls at any place, prior [loop tests and group tests] shall be
permission shall be obtained & the same approved by site engineer in writing.
shall be closed neatly after completion of 20.12.0 Reasonable evidence of the satisfactory
said work to the same specification & conditions of the test equipment shall be
finish as before such a work was provided, if required.
undertaken. 20.13.0 All errors of faulty workmanship
20.0.0 CALIBRATION AND FUNCTIONAL regarding the installation discovered
CHECK during the testing shall be corrected.
Instrument contractor shall possess all 20.14.0 All pneumatic, electro-pneumatic and
relevant test instruments and shall test electronic transmitters, indicators and
the installation in the following manner in recorders shall be calibrated, taking eight
the presence of site engineer. check points throughout the instrument
20.1.0 All pneumatic signal lines shall be range. Four each shall be taken on the
disconnected and blown through with upscale run and downscale run.
instrument air. 20.15.0 Contractor shall have signal sources and
20.2.0 The signal lines shall be blanked off and other precision calibration equipments for
14 ES008 /15
pressurized pneumatically using bubble all pneumatic and electronic instruments

bottle to 1.5Kg/cm2. The bubble rate as per the instrument list given. The
after pressurizing shall be less than 1 ranges of the instrument shall be set as
bubble in ten minutes. per the specifications. The instrument
20.3.0 All instrument air mains shall be isolated shall have required characteristics
from the instrument and pressure throughout their range as per

Page 17 of 30
specifications within the tolerance. Any 21.1.5. Wire to wire and wire to ground
deviations shall be brought to the notice resistance shall normally not exceed
of engineer in-charge. Contractor shall 10Mohms in most applications.
undertake any minor repairs of 21.1.6. The shield drain shall also be tested for
instruments found necessary, as part of accidental shorts or grounds as just
calibration work. However such work may another conductor requiring high
be under taken only with consent of the resistance to ground.
engineer in –charge. 21.1.7. Grounding circuits shall be tested for
20.16.0 Precaution shall be taken to see that no resistance low enough to operate over-
instrument is subjected to overloading or current devices incase a ground fault
unwanted signal is supplied to the occur within the instrument.
instrument. 21.1.8. Instrument erection shall be considered
20.17.0 Calibration work shall be undertaken only 100% complete only after all the checks
after studying the instruction manuals as indicated below are complete.
and other special instructions from 21.1.9. All instrument loops are to be checked for
manufacturer’s regarding each compliance of the installation drawings.
instrument. Wherever possible signals are to be
NOTE: simulated at the transmitter end and shall
a. All hydraulic test fluid shall be drained off be followed at the indicator / controller/
from the impulse line when hydraulic test alarm/ interlock components up to the
is over. final control element. Loop check shall be
b. All impulse line shall be blown off using carried out by simulation of signals from
instrument air before testing. transmitter end at minimum four points,
c. For float type level instrument the test 25%, 50%, 75% and 100%, all defects
pressure shall be the rated pressure. such as leaks at the instrument process
20.18.0 Procedure for testing and checking of piping / tubing, instrument air lines/
instruments is provided in Annexure-B. fittings etc insulation/ connection faults at
20.19.0 To identify the stage of inspection done, electrical wirings shall be rectified to the
small label with different colour shall be satisfaction of the owner. All the
attached on the field instrument as calibration variations, misalignment of
follows:- linkages of final control element are to be
a. Bench calibration rectified.
b. Pressure test flushing of impulse line 21.1.10. All the joints in the air lines and
c. Electrical test (megger continuity etc.) pneumatic signal lines are to be tested
d. Blowing in air supply. for leaks using soap solution. All
e. Loop checking. checking shall be done as per the
20.20.0 SMART transmitters shall be configured general notes on wiring & tubing.
using HART calibrator. All functionality to
be simulated and verified, prior to taking PART C- JOB COMPLETION
up installation/ put up with plant. REQUIREMENTS
22.0.0. COMPLETION OF ERECTION JOB
21.0.0. TESTING AND LOOP CHECKING The completion of the entire job on
21.1.0. TESTING instrumentation will be considered in
21.1.1. For analog instruments testing of wires following three major stages and the
shall be done after installation to verify payment will be accordingly made
freedom from grounds. subject to the other commercial terms.
21.1.2. After all connections are given the a. 60% of the job will be considered
complete loop shall be checked for completed when erection of the
satisfactory performance. instrument material is mechanically
21.1.3. Where meggers are used, care shall be completed.
taken not to use a voltage in excess of b. 20% of the job will be considered
14 ES008 /15
the insulations rated voltage. completed on completion of checking

21.1.4. While testing the wires, all the and calibration of individual instruments.
instruments shall be disconnected to c. 20% of the job will be considered
avoid damage to the instruments. completed after loop checking of
instruments.

Page 18 of 30
22.1.0. MATERIAL RECONCILATION/ WASTE Note: for wastage over and above the
ALLOWANCE figures indicated, contractor will be
The contractor shall plan and execute the charged at the cost of price +overheads
work in such a manner that wastage of + taxes.
materials shall be limited to minimum. 22.2.0. QUANTITY VARIATION
The contractor should take precaution to Quantities indicated in the bill of
ascertain the actual route and lengths quantities are tentative and are likely to
required before laying of cables and vary subsequently. The unit rates shall
tubes so that the lengths of cut pieces remain firm for any variations in the
are kept to the minimum possible and not scope of work to an extent of +/–25% of
exceed 0.5% of total Qty, for cables and total contract value.
SS tubes. As far as possible, total 23.0.0. COMMISSIONING AND START UP
wastage /scrap which cannot be For commissioning and start up
accounted for in receipt, consumption contractor shall deploy qualified skilled,
return statement should not exceed semi skilled and unskilled personal at the
following % allowances item wise. Items rates quoted under schedule of labour
supplied by the owner as free issue shall rates.
be returned to store with proper return The approximate number of personal that
notes. He shall also furnish reconciliation would be required is also indicated in the
statement for their material supplied to schedule of labour rates. The owner will
him. The Work will be deemed have option to engage partially, fully or
incomplete without submission of proper additional personals as required by him
material reconciliation report. The and the contractor shall provide the
responsibility of submitting ‘material personal at the rate indicated. Actual
reconciliation report’ without any delay requirement will be intimated to the
towards the end of the job lies solely with contractor at least 15 days in advance.
the contractor. The statement prepared These rates shall be applicable for any
by the contractor with proper references additional work done on ”labour supply
of receipts, dates etc should be basis” for the entire period of erection.
submitted which will be verified for the 24.0.0. BILL OF QUANTITIES AND
total quantum of job carried out and MATERIALS
materials / items installed. After checking 24.1.0. RATES
the three statements with due allowances The rates for installation of
for wastage /scrap, material statements instrumentation shall be included for:
can be accepted by FEDO/ OWNER/ 24.1.1. Handling, Transportation, care and
CLIENT. This marks the completion of protection of owner issued equipment
the job and final payment will be made and materials from owner’s stores to
only after this activity is completed. contractor’s stores or point of installation.
Allowances for unaccountable wastage 24.1.2. All installation works, fixing and testing.
for various categories of material will be 24.1.3. Maintaining proper inventory of owner
as given below supplied equipments and materials and
Item % returning all surplus equipment and
N allowances materials to stores of owner, after
oLength of S.S. pipes, completion of work.
t tubes alloy steel pipes. 0.5% 24.1.4. Provision of adequate and proper
e storage for owner’s equipment and
Electrical cables (3 meter 2%
: materials.
per length of cables or
24.1.5. Provision of complete instrument
which ever is less)
f workshop with testing and calibration
C.S pipes, Aluminium 1%
o equipments.
trays
r 24.1.6. Provision of all installation equipments,
14 ES008 /15
Structural material 2% tools, scaffolding, workshop, offices and

wValves, pipe fittings nil any other equipments and /or appliances
acompression fittings necessary to complete the installation, in
sglands etc. accordance with the specifications.
t Nut, bolt, gasket material 2%
a

Page 19 of 30
24.1.7. All consumable materials other than Owner prior to the commencement of any
those separately enumerated in the bid welding work.
items. b) If the contractor or sub contractor wants
24.1.8. Removal, re-calibration and re- to use other welding procedures not
installation of instrument as required listed in the table-1 the contractor or sub
during pre commissioning. contractor shall submit the detailed WPS
24.2.0. MEASUREMENT and PQR to owner and get the approval
24.2.1. As far as possible, all measurement for before use.
payment shall be taken from” good for 25.3.2 WELDING PROCEDURE FOR CARBON
construction drawings ‘released for STEEL
construction and schedules provided by a) All pressure retaining welds and
owner. attachment welds to the pressure
24.2.2. Only the items listed in the schedule shall retaining part shall be made by
be measured for payment. All other SHIELDED METAL ARC WELDING
labors and activities necessary to (SMAW) using low hydrogen type
complete the installation shall be deemed electrode AWSE 7018 except root pass.
included in the items in the schedule. b) Root pass of girth butt weld and branch
Note. For measurement & billing refer connection weld, where the complete
formats 25FT407& 25FT408. penetration is required shall be made by
GAS TUNGESTON ARC WELDING
PART D-PROCEDURES AND (GTAW) process or SMAW process. For
STANDARDS GTAW, filler metal shall comply with
25.0.0. GENERAL REQUIREMENTS AND AWS ER70S-2, 3, 6 or ER70S-G (TGS-
RECOMMENDATIONS FOR PIPE 50, KOBE STEEL LTD.). For SMAW,
WELDING electrodes shall comply with ASW
25.1.0. SCOPE E6010.
25.1.1. This specification covers the c) For small diameter piping (2” & smaller),
requirements and recommendations for all GTAW process may be used for all
welding procedure qualification test and passes.
welder’s performance qualification test of d) End preparation and root gap shall be in
piping/ instrumentation structural work. accordance with Fig.327.3.1 of
25.2.0. REFERENCES ANSI/ASME B31.3.
25.2.1. The following codes, standards and e) In case of ASW E 6010 for root pass,
specification in the latest editions as of minimum 80 degC pre-heating is required
now shall form a part of this specification for the thickness 1/2” and over.
unless otherwise mentioned. f) Weld progression for vertical position
a) ANSI/ASME B31.3 shall be uphill.
b) ASME CODE SECTION IX g) When post weld treatment (PWHT) is
c) “SPECIFICATION FOR FABRICATION necessary from the fluid service
AND INSTALLATION OF STEEL requirement PWHT conditions shall be as
PIPING”. follows.
d) “PIPING MATERIAL CLASSIFICATION” MATERIAL : Carbon steel.
25.3.0 WELDING PROCEDURE HOLDING TEMPRATURE : 625+/-
25.3.1 GENERAL 25 degC
a) TABLE-1 includes the several kinds of HOLDING TIME : Min 1 Hr.
welding procedure. 25.3.3 Welding procedure for C-1/2Mo Steel
The contractor or sub contractor who will (piping material service class).
do the actual welding work for piping a) Root pass of girth butt weld and branch
shall select the applicable welding connection weld where the complete
procedure for each kind of pipe welding penetration is required shall be, made by
from table-1. GTAW process.
14 ES008 /15
After that the contractor or sub contractor b) Filter pass and cover pass shall be made
shall prepare the detailed WPS and by GTAW or SMAW.
procedure Qualification record (PQR) in c) GTAW filler metal shall comply with ASW
accordance with ASME CODE SECTION ER80S-D2 or ER80S-G (TGS-M, KOBE
IX and obtain the written approval from STEEL LTD.). For SMAW, electrode shall
comply with AWS E7016-AI, low

Page 20 of 30
hydrogen type electrode. E7010-AI type E316L-16 NC36EL (K.S.L), WEL

(high cellulose type)) shall not be used. 316 ELC (NWR) (NWR—
d) For small diameter piping (2”&under), all NIPPON WELDING ROD
GTAW process is preferable. CO., LTD.).
e) End preparation and root gap shall be in
accordance with FIG 327.3.1 of ANSI/ d) End preparation and root gap shall be in
ASME B31.3. accordance with FIG.327.3.1 of ANSI/
f) Weld progression for vertical position ASME B31.3.
shall be uphill. e) Weld progression for vertical position
25.3.4 Welding procedure for austenitic shall be uphill.
stainless steel, SS TP–304, 304L, 316L, f) Internal back shielding with pure argon
316SS. gas (min 99.9%) shall be required during
a) Root pass of girth butt weld and branch the welding. Back shielding with nitrogen
connection weld where the complete gas shall not be permitted.
penetration is required shall be made by g) Maximum inter-pass temperature during
GTAW process. Root pass by SMAW welding shall be 150 degC.
process shall be prohibited. 25.3.5 Welding procedure for dissimilar metals.
b) Filler pass and cover pass shall be made a) Root pass of girth butt weld and branch
by GTAW or SMAW. For small diameter connections weld where the complete
piping (2” &under), all GTAW process is penetration is required shall be made by
preferable. GTAW process. Root pass by SMAW
c) Accepted filler metal and electrode shall process shall be prohibited.
be as follows: b) Filler pass and cover pass shall be made
by GTAW or SMAW. For small diameter
Piping Filler metal Electrode piping (2” & under), all GTAW process is
material (GTAW) (SMAW) preferable.
TP304 AWSER 308 AWSE 308- c) Acceptable filler metals and electrodes
16 for various combinations of base metals
TP304L AWSER AWSE 308L- shall be as follows.
308L 16 Piping C/S S.S S.S SS
TP316L AWSER AWSE 316L- material 304 304L 316L
316L 16 ER 309
316SS AWS ER 316 AWSE 316L- C/S ----- E309-16
10 S.S 304 ---------- ER308
E308-16
Notes: - SS.304L ----------------------- ER308
1. For welding electrodes AWSE 308L- L
16, the maximum carbon content E308L
shall be 0.03% (extra low carbon -16
type). At the time of purchasing S.S ---------------
these welding materials, maximum 316L
carbon content shall be specified,
because maximum carbon content of NOTE: for E308L-16 max. Carbon
normal AWS E308L-16 and AWS Content shall be 0.03 % (extra low
E316L-16 is 0.04%. carbon). See note 1 of 25.3.4.
2. The following are the acceptable d) End preparation and root gap shall be in
materials which comply with the accordance FIG 327.3.1 of ANSI/ ASME
above requirement. B31.3.
AWS Trade name & e) Weld progression for vertical position
class Manufacturer shall uphill.
14 ES008 /15
E308L-16 NC38EL(K.S.L),WEL 308 f) Internal back shielding with pure argon

ELC(N.W.R)(K.S.L— gas (min.99.9%) shall be required during
KOBE STEEL LTD) the welding. Back shielding with nitrogen
gas shall not be permitted.
g) Maximum interpass temperature during
welding shall be 150 degC.

Page 21 of 30
h) Welding between galvanized carbon 25.5.4 Visual inspection during welding and
steel or zinc rich primer coated carbon after welding is very important. Therefore
steel and stainless steel shall be the competent welding inspector or
prohibited to avoid the zinc embitterment welding supervisor who has enough
crack on the weld and heat affected zone experience for visual inspection of weld
(HAZ). shall witness the weld test and judge his
25.4.0 WELDING PROCEDURE capability before guided bend test or
QUALIFICATION TEST radiographic examination.
25.4.1. All welding procedure used for the 25.5.5 GTAW welder who passed the carbon
instrument piping construction works steel weld shall not be qualified for
shall be qualified or shall have been stainless TIG welding, even if the No. of
qualified by the contractor or ASME CODE SECTION IX is same, but
subcontractor as his responsibility in not vise versa.
accordance with ASME CODE SECTION 26.0.0 SPECIFICATION FOR PAINTING
IX and the requirements herein before WORK
the commencement of any welding work. 26.1.0 SCOPE
If the contractor or sub contractor does This specification covers the general
not have the procedure qualification requirements for painting of instruments
records (PQRs) for the applicable /accessories; steel structure’s and
welding procedure specifications (WPSs) instrument piping.
according to these specification 26.2.0 REFERENCE
requirements, he shall carry out the 26.2.1. The requirement given in the following
welding procedure qualifications tests specification in the manner and to thee
and shall submit the complete documents extend indicated therein.
as “WPSs & PQRs to owner for approval. 26.2.2. I.S for surface preparation.
25.4.2. TABLE –2 “ STANDARD PROCEDURE 26.3.0 SURFACES TO BE PAINTED AND
FOR WELDING PROCEDURE SURFACES NOT TO BE PAINTED
QUALIFICATION TEST” are the sample 26.3.1 The following surfaces shall be painted in
of procedure qualification test for each accordance with the painting classes of
welding procedure listed in TABLE -1 this specification; -
The contractor or sub contractor may carbon steel instrument accessories.
modify the test procedure as far as the 26.3.2 Steel supporting structures.
requirements of ASME CODE SECTION 26.3.3 Carbon steel instrument impulse piping.
IX and this specification are kept. 26.3.4 Other surfaces which are required to be
25.5.0 WELDER PERFORMANCE painted for any specified reason.
QUALIFICATION TESTS 26.3.5 However the following shall not be
25.5.1 All welders and welding operators painted:-
engaged in this job are required to pass a. Nonferrous metal, stainless steel or other
the performance qualification test in high alloy steel.
accordance with ASME CODE SECTION b. Name plates or identification tags.
IX. The contractor or sub contractor shall c. Valve stems or other machined contact
be wholly responsible for qualifying each surfaces.
welder and welding operator has enough d. Galvanized surfaces.
skill to make the sound welds by using e. Insulation covers.
the welding procedure to be used for this f. Plastic.
job. 26.4.0 PAINTING CLASSES
25.5.2 TABLE-3: STANDARD PROCEDURE The materials or paints specified in the
FOR WELDER PERFORMANCE CLASSES A to E are selected on the
QUALIFICATION TEST” are the sample basis of service conditions. Refer to
of performance qualification test for each Annexure-1 for details.
welding procedure listed in TABLE –1. 26.5.0 PREPRATION OF SURFACES
14 ES008 /15
25.5.3 The contractor or subcontractor may 26.5.1 General requirements.

modify the test procedure as far as the a) The surface shall be prepared to dry
requirements of ASME CODE metal after removing rust ,oil, grease,
SETCTION IX and the specification are dust , stain, or other extraneous matter
kept. by manual or mechanical cleaning such

Page 22 of 30
as wire brushing grinding ,power be done strictly as per manufacturer’s

brushing ,etc. specification/ recommendations.
b) Wet surfaces due to rain fall, dew-drop As far as practical, quantity of mixing
and frost etc shall be thoroughly wiped shall be sufficient to cover the given
with rags and dried before each painting. section or entire surface of the specific
c) Cleaning of wet or soiled surfaces shall colour.
be done immediately before application 26.7.2. Thinning whenever required shall be
of paint in such a manner that adjacent strictly as per recommended ratio.
wet paint surfaces are not damaged by 26.8.0 PAINTING
the cleaning operation. 26.8.1 General requirements.
d) Drying of wet surfaces may be expedited a) Painting on instrument equipment
by blowing warm air. /accessories and piping shall be done at
e) The painted /primed surfaces shall be plant site or at shop as required.
dry and clean before application of b) Painting shall be performed only in
subsequent coats. Deposits on the favorable weather conditions. Paintings
primed /painted surface must be cleaned shall not be performed in rainy, damp,
before the application of the next coat. windy, dusty, weather or on the day of
f) If the painted surfaces are exposed to such unfavorable weather is predicted.
rain while painting is in progress, the c) During painting, adjacent surface shall be
effected paint shall be entirely removed properly protected from paint splashes. If
and be repainted after making the blemishes or damages occur by accident,
surface clean. they shall be thoroughly cleaned,
26.5.2 Cleaning of surfaces. repaired or replaced.
a) Cleaning of rolled steel surfaces shall be d) Upon completions of paintings work, all
carried out in the manner that all staging, scaffolding, paint containers, etc,
crevices, corners and edges of sharp shall be removed from the job site and
steel, joints of steel plates ,especially the, premise shall be left clean.
around bolt heads ,welds beads etc. may e) Caution signs of “wet paint” shall be
be cleaned. posted around the areas where readily
b) Cleaned surfaces shall not be damaged visible, until the paint has completely
by unnecessary tapings, etc. dried.
c) Where sand blasting is required, the 26.8.2 Methods of application.
same shall be carried out to SA21/2 a) Painting shall be generally performed by
grade the sand blasted surfaces shall be hand brush method. Spray method may
painted with in 6 hours after sand be adopted for surfaces likes that of
blasting. control panels for specified reasons.
26.6.0 STORAGE OF PAINTING MATERIALS b) Whenever hand brush method is
26.6.1 Paints, varnishes, thinners or other employed for painting, painting shall be
volatile and inflammable painting done in alternate directions from vertical
materials shall be stored on a 150mm to horizontal or from horizontal to vertical
thick layer of sand in well ventilated and and shall be applied to all edges,
detached storage sheds. corners, crevices, joints, intersections
26.6.2 Fire extinguishers or sufficient amount of etc.
sand shall be placed where readily c) If brush marks, drags, adhesions of
accessible in case of fire. brushes bristles, dust or blemishes occur,
26.6.3 ‘No Smoking “ And Other Suitable the surfaces shall be lightly sand papered
Warnings Signs , Such as “No Open before further coats are applied.
Flames”,” Danger”, “Storage Of d) All surfaces that are inaccessible after
Inflammable Materials “ etc shall be installation and assembly except for
posted , around storage sheds. contact surfaces, shall be painted twice
26.7.0 MIXING AND THINNING that is after first coat, the same is
14 ES008 /15
Mixing and thinning shall be done only at repeated again. The second and final
well ventilated places where there are no coats are also repeated in same manner.
open flames. 26.9.0 PRECAUTIONS
26.7.1. MIXING 26.9.1 Open flames, smoking exposed elements
Whenever mixing of base paint and or sources of ignition of any and shall be
additives are involved, such mixing shall

Page 23 of 30
strictly prohibited in area where painting The tables for class-A to E are given in
is being performed annexure-A.
26.9.2 During painting operation and for a
sufficient time thereafter, welding or open 27.0.0 INSPECTION AND TEST PROCEDURE
flame work shall be prohibited in the FOR INSTRUMENT INSTALLATION
adjacent area. WORK
26.9.3 “No Smoking” and other warning panels 27.1.0 SCOPE
to read “Caution” “No open flames” etc 27.1.1. This specification covers the procedure
shall be posted in all areas where and for inspection and test of instruments
while painting is performed. The sign installation work.
shall remain posted for a sufficient time 27.2.0 REFERENCE
after painting has been completed. 27.3.0 GENERAL
26.9.4 Hand lamps, flash lights etc which will 27.3.1. Inspection and tests shall be performed
cause a fire shall be handled carefully. for the following work items:
26.9.5 Inflammable liquids with a flash point a) Instrument pressure piping
below 40 deg C shall not be used for b) Instrument electrical wiring and
cleaning purpose. temperature wiring.
26.9.6 Where it is practicable, adequate c) Instrument signal air tubing.
ventilation shall be provided to reduce d) Instrument supply air piping
the concentration of harmful vapours in 27.3.2. Test reports shall be prepared for all
the atmosphere. Otherwise workmen tests and be submitted to
shall wear vapor-proof mass, rubber CONSULTANT/ OWNER immediately
gloves etc for protection when he has to after tests are completed
work in a badly ventilated place. Typical report forms will be furnished
26.10.0 INSPECTION along with the erection tender or the
26.10.1. Finished surfaces shall be uniform and same may be requested by the
smooth, free from mass of drops, ridges, contractor to FEDO site in-charge.
waves, laps, wrinkles, brush marks, and 27.4.0 INSPECTION AND TEST –
other defects. INSTRUMENT PRESSURE PIPING
26.10.2. Finished surfaces shall be of uniform 27.4.1 Instrument pressure lead lines between
colour that presents good appearance, the process isolating valves and the
without spots, stains, and discolorations. instruments to which they are connected
26.10.3. Inconspicuous parts, such as the corner shall be tested. Prior to the test, the
of build up members, around bolts, following items shall be inspected
undersides and backsides of pipelines, visually:
pipe bends and valves etc shall be a) Whether instruments are correctly
closely checked so that they may not be installed according to the P&ID.
left unpainted. b) Whether the upstream and downstream
26.10.4. Paint colours for identification purposes connections of the instruments pressure
of piping shall be checked for correct leads line for differential pressure type
colour application, if required. instrument is correct.
26.10.5. Defective surfaces, if any, shall be c) Whether adequate slope is provided to
cleaned and repainted. instrument pressure lead line.
26.10.6. Additional requirements. d) Whether sufficient supports are provided
a) Any imperfect or damaged layer shall be to instrument pressure lead line.
repainted before the next layer is applied. e) Whether correct materials of the correct
b) The field welding for damaged layer shall rating are used for instrument pressure
be repaired before the next layer is lead lines.
applied. 27.4.2 TESTING DESCRIPTION
c) Bolts and nuts shall be provided with the Instruments with an operating pressure
relevant priming coat immediately after less than 40kgf/cm2g shall be
14 ES008 /15
mounting. pneumatically tested. Instruments with

d) Places where field welds are to be an operating pressure equal to or more
provided a section of 50 to 500 mm shall than 40kgf/cm2g shall be hydrostatically
remain unpainted on both sides and pneumatically tested.
26.11.0 TABLES

Page 24 of 30
Unless otherwise specified, test shall be pressure lead line. Details are as
performed with instrument connected to follows:
the line. Step 1-
1. Hydrostatic test Close valves 1 .2
a. Test fluid: water. Open valves 3, 4, 5, and 6
b. Test pressure. Pressurize system up to the test
Normally operating pressure x1.5 or 90% pressure.
of the maximum allowable pressure of Step 2
instrument (in the case of pressure Close valve 6
instrument, its measuring range), which Confirm that there is no leak by
ever lower. pouring soap water on each
c. Test procedure (see Annexure C) connection.
After closing the process isolation valves Step 3
and opening the equalizing valve, if Open valves 1
installed, fresh water shall be fed into the Confirm that valve 1 is not
pressure lead line. Details are as follows: blocked
Step 1- Step 4
Close valves 1, 2, and 8 Close valve 1
Open valves 3, 4, 5, 6, and 7 Pressurize system again and
Pump enough water and open valve 2 to confirm that
pressurize system up to test valve 2 is not blocked
pressure. Step 5
Step 2- Close valves 1, 2, 3, and 5
Close valves 6, 7 Open valve 4
Open valve 8 Notes:-
Confirm that pressure gauge a) The analyser pipeline shall be tested by
indication does not decrease disconnecting the lead line from
during 3 minutes. instrument. The test procedure shall be
Step 3- the same as that with process pipeline.
Close valves 8 b) Test may be performed separately or
Open valves 1, 6 and 7 together with the test for process piping
Then pump enough water to or equipment.
confirm that valve 1 is not c) All instrument piping systems shall be
blocked. cleaned by blowing air or flushing water
Step 4- before and or after the test, all joints
Close valve 1 &Open valve 2. which are defective shall be repaired
Then pump enough water to immediately and shall be re-tested by the
confirm that valve 2 is not original test method.
blocked 27.5.0 INSTRUMENT ELECTRICAL WIRING
Step 5 AND PENETRATING WIRING
Close valves 1, 2, 3, and 5 27.5.1. GENERAL
Open valves 4 Continuity, identification and cable
2. Pneumatic test insulation resistance test shall be
a.) Test fluid: Air, N2 gas or inert gas. performed. Prior to the test, the following
b.) Test pressure shall be inspected visually:
7 kgf/cm2g or 90% of the maximum a) Whether instruments are correctly
allowable pressure of the instrument (in installed according to the P&ID.
the case of pressure instruments its b) Whether wire marking and/ or colour
measuring range), which ever lower, with coding at terminals are correct.
a minimum test pressure of 1kgf/cm2g. If c) Whether sealing compound or packing is
instrument is not durable to1 kgf/cm2g, provided as specified at entry of each
14 ES008 /15
test shall be performed with instrument instrument.

disconnected from the line. 27.5.2. TEST PROCEDURE
c.) Test procedure (see Annexure D) STEP.1. Continuity and identification of
After closing the process isolating valves each wire and continuity of shield wire
and opening the equalizing valve, if shall be inspected between the field
installed, test fluid shall be fed into the instrument terminals and the control

Page 25 of 30
panel board terminals by using a joints and connections shall be tested

telephone, a buzzer, or other suitable with soap solution to facilitate the
means. detection of leaks.
STEP.2. Insulation resistance test shall Note:
be performed by using a 500 V or 1000V a) Test may be performed separately or
Megger. In this case, the wire shall be together with the test main air header.
disconnected from the terminal both at b) All joints & connections found to be
the field and the control panel. defective shall be repaired immediately
The minimum resistance value shall be and shall be re-tested by the original test
as follows method.
a) Line to line 27.8.0 CONFIGURATION OF SMART FIELD
b) Line to ground All min 10Mohm INSTRUMENTS
c) Line to shield. Normally HART/ FOUNDATION FIELD
STEP.3. the electricity charged in the BUS/ PROFIBUS –DP based SMART
wire by the insulation resistance shall be field instruments are used. The HART
discharged by grounding the wire and configuration shall be used for verifying /
then the wire shall be connected firmly to configuration/ calibration checks for tag
its terminal. no, range, engineering units, LRV, URV,
27.6.0 INSTRUMENT SIGNAL TUBING alarm settings ,functional blocks,
Continuity, identification and leak test configuration output function, trouble
shall be performed as per the instruction shooting etc. This is applicable with
of FDEO site-in-charge. Prior to test, a respect to all SMART field instruments,
visual inspection shall be made as to communicating with DCS/ PLC/ SCADA
whether instruments are correctly system. Re-ranging, download/ upload
installed according to the P&ID. from DCS/ SCADA, point data base
27.7.0 INSTRUMENT SUPPLY AIR PIPING verification etc shall be carried out for
27.7.1. GENERAL each tag/ transmitter. Cold loop check
Pneumatic test and air blowing of the and hot loop check shall be carried out.
supply air piping system shall be Diagnostic functions and communication
performed between the first take off valve shall be verified. Also any other
on the main air header and instruments. functionality required /specified shall be
Prior to the test, visual inspection shall be configured.
made as to whether instruments are 28.0.0 APPLICABLE STANDARDS
correctly installed according to the P&ID. API-RP-550- Installation of refinery
27.7.2. TEST FLUID AND PRESSURE instruments & control system
Test fluid shall be free of oil, dry air or N2 ISA Standard- Standard & practices for
gas. installation
Test pressure for air supply pipe from 28.1.0 OTHER STANDARDS
main header first take–off valve to Inspection & test procedure for
individual instrument air regulators shall instrument installation work
be equal to main air header operating General requirement and
pressure. recommendation for pipe welding
Short length of air tubes between Installation standards for instrumentation
instrument and its air regulator shall be
tested by the set pressure of the air PART E - ATTACHMENTS
regulator. 29.0.0 DRAWINGS - ANNEXURE I
27.7.3 TEST PROCEDURE The drawings issued for Instrument
STEP 1. Air blowing of the system shall erection are attached in Annexure I.
be performed by disconnecting air tube at The drawings provided are only typical
the inlet of the air regulator and opening and covers almost all type of instruments.
the shutoff valve. Air blowing shall be All the required drawing will be issued
14 ES008 /15
done by opening and closing the shut off before start of work or progressively
valve for a minimum of five times until the during erection. Modification/ deviation
air system is confirmed to be clean. (If any) in the drawings shall be informed
STEP 2 the air tube shall be connected to engineering department for approval.
again and the shutoff valve shall be 30.0.0 SCHEDULE OF WORK - ANNEXURE II
opened to pressurize the system. All

Page 26 of 30
The schedule of work is attached in the specified items purchased from

Annexure - II. The instrument contractor standard suppliers/ sub-vendors
shall follow standard erection procedure approved by FEDO / OWNER. The
and maintain good quality of work. The items supplied shall be inspected for
wastage of material shall be limited to damages and compliance with
minimum as possible. specifications given by the engineering
31.0.0 ITEMS TO BE SUPPLIED BY department. Any damage and
CONTRACTOR - ANNEXURE III unacceptable variation shall be recorded
The list of items to be supplied by the (Refer 25 FT 403) and brought to the
contractor is attached in Annexure-III. notice of concerned Engineer- in- charge.
The instrument contractor shall supply
14 ES008 /15

Page 27 of 30
ANNEXURE-A
PAINTING SPECIFICATION-SELECTION OF CLASS
Table 1-Painting classes

SERVICE CONDITION SCOPE OF SURFACE CLASS
APPLICATION PREPARATION
Ambient. Temp up to 65 deg C. A
Chemical splashing area, mild acid/ alkaline B
atmosphere.
Saline atmosphere Instrument
General use for surfaces 65 deg C to 120 deg C accessories such as C
Mechanical
Chemical splashing area particularly Urea, acid/ condensate pots, air
power tool
alkaline atmosphere. headers, instrument
cleaning /wire
Highly corrosive area particularly urea and abrasive pedestals, impulse
brushing
environment subject to wind /dripping etc piping, steel
General use for epoxy coatings structures etc. D
Highly corrosive and abrasive areas
Chemical splashing areas including fluorine
Surface at sub zero temperatures
120 to 400 deg C E
1. DETAILED SPECIFICATION OF PAINTING CLASSES

CLA Painting Process Paint No. of Film
SS Coats thick/co
at
Before shipment at Primer Red oxide zinc chromate 1 20
shop primer to IS -2074
Primer -Do- 1*/2 20
A First finish coat Synthetic enamel to IS-2932 or 1 15
At field Aluminium paint to IS-2339
Second finish coat -Do- 1 15
Before shipment at Primer Red oxide zinc chromate 1 25
shop primer chlorinated rubber
based
B Primer -Do- 1*/2 25
First finish coat Chlorinated rubber finished-un 1 25
At field
modified
Before shipment at Primer Epoxy red oxide zinc 1 25
shop phosphate primer
C Primer -Do- 1*/2 25
At field First finish coat Epoxy finish paint 1 40
Before shipment at Primer 2 pack polyurethane primer 1 25
shop
D
Primer -Do- 1*/2 25
At field
First finish coat 2 pack polyurethane finish 1 40
Before shipment at Primer Heat resistant silicone / 1 25
14 ES008 /15
shop aluminium paint

E Primer -Do- 1*/2 25
At field First finish coat -Do- 1 20
(*) Where primer is applied before shipment, one coat instead of two coats shall be applied.

Page 28 of 30
ANNEXURE-B
CALIBRATION METHODS
Pressure vacuum gauge Dead weigh tester and By comparing with master gauge
vacuum gauge test
Pressure gauge Pneumatic rig By comparing with Hg manometer
Receiving instrument Using test rigs with -Do-
(pneumatic) accurate gauge
Receiving instrument Using electronic -Do-
(electronic.) calibrator &test rig
Receiving pressure Hydraulic/ pneumatic Check the operation using Multi-meter
switch tester
Receiver switches Pneumatic test rig -Do-
Electronic switch. Signal generator -Do-
Dial thermometer & Temperature bath with Checked at various temperature
temperature transmitter standard thermometer
Temperature switches Multivolt source or Checked increasing and decreasing the value
resistance source
Vibration /axial Bently Nevada testing This to be calibrated as per manufacturer’s
displacement system equipment instruction. If contractor does not have the
instrument, he shall do this on sub contractor under
his responsibility by BN Indian agent.
Control valve Pneumatic /electric test Lubricated stored &checked for smooth operation &
rig hysteresis I/P SOV, limit switch, valve opening
&closing time etc to be checked.
Controller Electronic& pneumatic Manufacturer’s instruction manuals
rigs
Temperature indicator Potentiometer/ decade Calibration to be checked giving known input of T/C
resistance box or resistance and comparing output standard
curves.
Differential pressure Hydraulic or pneumatic Output shall be measured using master output
transmitters Hg rig output meter (elect or gauge.
manometer pneumatic)
E/P transducer Field calibrator standard Checking shall be done by feeding input from field
gauge for Hg calibrator & noting the output reading.
manometer.
ANALYSERs
O2, H2, CO2 etc. Zero /span gas Calibration shall be checked using zero &span
&output meter gases &noting the output meter.
PH, conductivity dissolved Solution & output Using these std. solution & output meter, calibration
O2 meter to be checked.
14 ES008 /15

Page 29 of 30
ANNEXURE-C
HYDROSTATIC TEST ARRANGEMENT
14 ES008 /15

Page 30 of 30
ANNEXURE-D
PNEUMATIC TEST ARRANGEMENT
14 ES008 /15

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PROCESS 32644-11-SE-T1201D/E

FACT ENGINEERING AND DESIGN ORGANISATION

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Tag No. LI-101/2

P&ID No. 32644-11-PD-001

Service / Location Storage Tank, T-1201D/E

Mounting (L/P) L (Note:2)& P

Fluid Phosphoric Acid (54% Conc.)

Min. & Max. Level, mm 1,100 & 9,160 1

Density, kg/m3 1630 - 1700

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Tag No. LS-103

P&ID No. 32644-11-PD-001

Service / Location Phosphoric Acid/Sump Pit (S-1201)

Type Float type

Fluid Phosphoric Acid (54% Conc.)

Pressure, kg/cm2G Atmospheric

Density, kg/m3 1630 – 1700

Set point 350 mm1 from bottom

Material Of Construction PVC/Equivalent 1

FACT ENGINEERING AND DESIGN ORGANISATION

Remarks: Project: Construction of

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Stream / Fluid Phosphoric Acid 54% Piping Class

mm/Schedule/Class Fittings Sch.40 Sch.40 Sch.40 Sch.40 Sch.20 Sch.20 Sch.20

Part Standard Specification

FACT ENGINEERING AND DESIGN ORGANISATION

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Rev Details By Chkd. Apprd. Date

FACT ENGINEERING AND DESIGN ORGANISATION

Tag No. LS-104

P&ID No. 32644-11-PD-002

Service / Location Rain Water Sump Pit (S-1202)

Type Float type

Pressure, kg/cm2G Atmospheric

Density, kg/m3 1000

Set point 350 mm1 from bottom

Material Of Construction PVC Equivalent

FACT ENGINEERING AND DESIGN ORGANISATION

32 32644-02-PS-001 RN Rate of Addition/Deletion of Nozzles 1 A 0 0 1 1 1

FACT ENGINEERING AND DESIGN ORGANISATION

Sl. Sl. Offer from

1 Detailed design YES 23 Inspection YES

8 Site assembly YES 28 Shell stiffeners YES

0 09.06.20 Tank capacity revised GPG SK AAN

A 05.05.20 For Review GPG SK AAN

REV. NO. DATE DESCRIPTION PRPD CHKD APPRD

FACT ENGINEERING AND DESIGN ORGANISATION

Sl. Offer from Sl. Offer from

FACT ENGINEERING AND DESIGN ORGANISATION

ITEM : CENTRIFUGAL PUMP

0 09-06-2020 FOR ENQUIRY LA SK AAN

REV.NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

FACT ENGINEERING AND DESIGN ORGANISATION

FACT ENGINEERING AND DESIGN ORGANISATION

ITEM : PHOSPHORIC ACID STORAGE TANK (2 NO’S.)