1

01 1993
36 1988

GENERAL SPECIFICATION FOR

COMPRESSED AIR INSTALATIONS

Table of Contents
3600 - General................................................................................................... 2
3601 – Equipment Installation......................................................................... 8
3602 – Air Collectors........................................................................................ 9
3603 – Piping System and Accessories......................................................... 12
3604 – Welding.................................................................................................. 20
3605 – Auxiliary Works.................................................................................... 24
3606 – Electricity, Command and Control..................................................... 26
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3600 - General
36000 - Scope
This specification covers the quality of material and workmanship of stationary compressed air
installations, producing compressed air up to 125 PSI (9 BAR) for operation of instruments, tools
and production equipment in the industry, laboratories and research institutions. However,
compressed air installations for medical applications, pneumatic transit, ventilation and similar
systems are not covered, unless supplemented through a special specification.

36001 - Standards
Relevant Israel Standards and Standards Institution of Israel (SII) and foreign specifications
applicable to this Chapter:

A. Israel Standards
No. Name
50.2 Pipe Threads, Pressure-Tight Joints Not Made on Threads: Dimensions,
Tolerances and Designation
50.3 Pipe Threads, Pressure-Tight Joints Made on Threads: Dimensions,
Tolerances and Designation
127 Accreditation Testing of Welders :Fusion Welders - Steels
206 Marking of Electrical Products
253 Malleable Cast Iron Pipe Fittings
286 Unified Screw Threads for Bolts and Nuts: Basic Sizes
298 Squirrel Cage Asynchronous Motors
374 Steel Hexagonal Black Screws and Bolts: UNC
379 Hexagonal Regular Steel Nuts: UNC
530 Steel Welded Pipes for General Use
549 Dimensions and Output Series for Rotating Electrical Machines
659 Identification Marks and Warning Signs for Equipment Containing Fluids,
Gases and Electrical Cables
697 Bourdon Type Pressure Gauges
981 Classification of Degrees Of Protection Provided by Enclosures of Electric
Equipment
1027 Radiographic Testing
1028 Ultrasonic Examination of Steel Welds
1029 Welded Joints : Recommended Practice for Liquid Penetrant Testing
1030 Welded Joints : Magnetic Particle Examination
1032 Welding Procedure Qualification
1125 Measurement of Fluid Flow by Means of Orifice Plates, Nozzles and Venturi
Tubes Inserted in Circular Cross-Section Conduits Running Full
1133 Welding: Definition of Terms
1143 Metal Diaphragm Valve
1144 Metal Ball Valve
1170 Steel Sockets for Steel Pipes
1171 Check Valve
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No. Name
1338 Low Alloy Steel Covered Arc Welding Electrodes
1340 Carbon Steel Covered Electrodes for Shielded Metal Arc Welding

B. Foreign Standards
1) ASME Boiler and Pressure Vessel Code
Section V – Non Destructive Examination
Section VIII – Pressure Vessels Div 1
Section IX – Welding Qualifications
2) ANSI B16.5 – Pipe Flanges and Flanged Fittings
3) ANSI B16.11 – Forged Steel Fittings, Socket Welding and Threaded
4) ANSI B16.25 – Butt Welding Ends
5) ANSI B16.9 – Wrought Steel Butt welding Fittings
6) ANSI B31.3 – Chemical Plant and Petroleum Refinery Piping
7) ANSI B31.8 – Gas Transmission and Distribution Piping Systems
8) ANSI B36.10– Welded and Seamless Distribution Piping Systems
9) ASTM B.62 – Specification for Composition Bronze or Ounce Metal Casting
10) ASTM A53 – Specification for Pipe, Steel, Black, and Hot dipped Zinc Coated Welded
and Seamless.
11) ASTM A105 – Specification for Forging, Carbon Steel, for Piping Components
12) ASTM A181 - Specification for Forging, Carbon Steel, for General Purpose Piping
13) ASTM A197 – Specification for Cupola Malleable Iron
14) ASTM A216 – Specification for Carbon Steel Casting Suitable for Fusion Welding for
High Temperature Service
15) ASTM A234 - Specification for Piping fittings for Wrought Carbon Steel and Alloy Steel
for Moderate and Elevate Temperatures
16) ASTM A283 – Specification for Low and Intermediate Tensile Strength Steel plates,
Shapes and Bars
17) ASTM A285 – Specification for Carbon Steel Externally Treaded Standard Fasteners
18) AWS 5.1 – Mild Steel Covered Arc Welding Electrodes
19) ASTM D2200-67 – Pictorial Surface Preparation Standards for Painting Steel Surfaces
(Swedish Standard SIS 05-5900).

36002 – Other Chapters of the Specification

All specification chapters listed below also apply to this chapter, unless otherwise specified.
01 Earthworks
02 On Site Cast Concrete Works
08 Electrical Installations
11 Painting Works
19 Locksmith Works
57 Water, Sewage and Channeling Piping Systems

36003 – Laws and Regulations

All parts of the installation shall be carried out according to all the requirements of the Law and
Regulation of the authorities published from tine to time including, but not limited to:
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A. Commodities and Services Control Order (Pressure Vessels) 1982, Regulations File 4279,
Regulation File 4505.
B. Safety in Work Order (Integrated Version)
C. Safety in Work Order (Air Collector Hydrostatic Pressure Test) 1986.
The contractor shall submit approvals and test certificates as specified in the laws and regulations.
36004 – Equipment and Materials
Equipment and materials shall be supplied by the customer or by the contractor.
A. Equipment and materials supply by the contractor
Equipment, materials and remaining accessories supplied by the contractor shall be of a known
and prominent make.
The equipment shall conform in details to the specification sheets, prepared by the designer and
constituting part of the special specification or drawings.
When equipment units of the same type are used repeatedly, they shall be of the same type and
the same producer and model unless otherwise specified.
The equipment shall be capable to operate continuously for long periods.
B. Equipment and materials supply by the customer
The customer retains all rights for self-supply of equipment, materials and accessories. This shall
be indicated explicitly in the special specification or in the contract documents.
The contract shall inspect and acknowledge reception of the equipment, materials and accessories
in normal conditions.
Use of materials supplied by the customer shall be made with minimum fall out.
36005 – Definitions
The following terms and definitions thereof are used in this specification:
A. Materials: Raw materials used for manufacturing of products and measured in weight,
volume, area or length such as: steel profiles, pipes, metal sheets, cement, gravel and paints.
B. Auxiliary Materials: Certain materials used for production, though non distinctive upon
completion of production, such as electrodes, welding and cutting gases, sealing tapes and shims.
C. Equipment: Finished product used as a component in as installation and generally, installed
on its special mount such as compressor, air collector, air cooler, and drier.
D. Accessories: Finished product used as a component in an installation, installed on equipment
or piping system such as air trap, safety valve, pressure regulator, line filter, valves, oiler, drop
separator etc.
The combination term Pipe Fitting indicates various elements used for contenting pipes, such as
flanges, couplings, unions, plugs, elbows, reducers, and T fittings.
36006 – Special Conditions
In addition to the requirements of the standard contract, to the details given in the drawings and the
remaining contract documents, the following are special conditions apply:
360061 – General
The contractor shall submit to the CO in writing, and shall acquire the CO written approval to the
said documents, prior to the beginning of works:
A. Work execution method plan, contract time schedule compatible. The plan shall include but
not be limited to the contractor work distribution between the shop and the site, phases of
production and assembly, delivery of equipment to site etc.
B. The name of his representative on site, in charge of the work execution.
C. List of subcontractors according to professions.
D. List of manufacturers of equipment and accessories to be supplied by him.
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360062 – Coordination of Execution

The contractor shall acquire the CO approval prior to each work execution phase and coordinate
the execution time with the CO.
360063 – Hoisting Equipment
The contractor shall use hoisting equipment approved by the Ministry of Labor.
360064 – Traffic and Work on Site
Traffic of workers and vehicles on site as well as working on site are subject site safety, hygiene
and operational instructions and regulations.
360065 – Surveying and Locations
The contractor is deemed responsible for checking the compliance of the building, foundations,
openings, constructions and all other elements with the assembly plans, whether executed by him
or by others. He shall notify the CO, within two weeks (unless otherwise specified), of
discrepancies prior to beginning his works on site.
The contractor assumes sole responsibility for the inspection and the measurements and he shall
amend any discrepancy or incompliant item affecting his work that result of his surveying and
locating mistakes as mentioned above.
360066 – Inspections and Supervision
The contractor shall provide every assistance, data and document necessary to the CO for work
control though the CO inspections do not relieve the contractor of his sole responsibility both for
the quality of work and dimensions and he shall amend any discrepancy as mentioned above on
his account even if the discrepancy is noticed after the CO inspection.
The CO shall have at all time access to the equipment produced in the shops, for production
control and follow-up.
Pressure test and operation tests shall be carried out in coordination with the CO only.
360067 – Documents
Prior to the beginning of works, the contractor shall submit to the CO for his approval in advance
the following documents:
A. Welding specifications and procedures the contractor is intending to use.
B. Qualification certificates of the welders that will execute welding works.
C. Documents of the materials and products to be supplied by the contractor.
D. Documents of the equipment supplied by the contractor.
In course of the work, the contractor shall submit to the CO additional documents as required by
the CO and upon completion of the work the contractor shall submit to the CO the documents
specified in paragraph 360085.
360068 – Operation and Run in Equipment
The contractor shall supply all equipment, labor, materials, auxiliary materials and accessories
required for operation, run-in and test of the equipment and installation including oils, lubricants,
test instruments, recorders, pressure pumps, temporary piping system, blocks, bypasses etc. Oils
and lubricants for the equipment supplied by the customer will be supplied by the customer.

36007 - Work Plans and Equipment Specifications

360071 – Plans
The contractor shall inspect the plans and in any event of error or conflict among the plans,
specification or the remaining work documents, he shall notify the CO that will decide how the
works shall be carried out. No contracotor request based on an argument that he did not notice the
errors or conflicts shall be recognized and the contractor shall bear the costs of all the financial
expenditures associated with the repairs and rework necessary. The contractor may prepare for his
convenience detailed work plans (shop plans) on his account and responsibility, though the
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prevailing instructions are those included in the plans, specifications and other documents handled
to the contractor is association with the work.
360072 – Contractor Planning
In addition to the aforementioned, when specified in the special specification, the contractor shall
prepare equipment specifications and plans following the customer instructions and shall submit
them for the CO approval. After the documents have been checked and approved by the CO, the
contractor will receive an approved copy, according to which the contractor shall execute the work.
In any case, the work plans prepared by the contractor shall contain the following drawings:

36008 - Tests, Operation, Adjustment and Delivery

360081 – General
During execution and upon completion of installation the contractor shall perform all pre-delivery
tests, operations and adjustments. The types of inspections, their sequence of execution and dates
of execution shall be approved by and coordinated in advance with the CO and approved by him.
All tests and operations shall be carried out by the contractor in presence of the CO. The
contractor shall verify the attendance of the equipment manufacturer in the tests and installation
operation attempts in order to ensure that the manufacturer warranty is not worn out. The test
results shall be entered in reports to be prepared by the contractor and approved by the CO and
shall consist part of the delivery documents to be submitted by the contractor. Equipment and
piping system pressure test as well as preliminary tests of the electrical boards as well as putting
them into operations are detailed in the relevant chapters. Non destructive tests (radiography,
ultrasound etc.) shall be carried out only if explicitly specified in the special specification (see
paragraph 36045 herein).
360082 – Preparations for Operation
After the contractor had installed the equipment, carried out all alignment works and connected all
accessories associated with the equipment and all piping system, electricity and control system
installations and after pressure tests and preliminary tests have been accomplished, the contractor
shall prepare the equipment for operation.
Preparation for operation shall be carried out according to the original equipment manufacturer
instruction and shall include, but not be limited to (according to the type of equipment):
 Bearing cleaning
 Filter replacement/cleaning
 Separation of couplings and alignment test, motor direction of turning test, reconnection of
couplings.
 Equipment cleaning
 Gear oil replacement
 Lubrication of bearings and shafts
 Hydraulic liquid filling (pumps), liquid draining and air bleeding from pipe lines
 Opening/closing of valves
 Installation of temporary filters
 Installation of measuring instrument.
360083 – Operation, Adjustment and Testing
During operation, the system shall be tested for normal operation, and capability to meet the
planning and execution requirements. The tests shall include, but not be limited to:
A. Compressors – normal operation, without abnormal noises and vibrations, testing air
temperature and pressure at the various stages, testing oil pressure and temperature .
B. Oil/air cooling systems – normal operation of pumps/fans, testing water pressures, testing
water discharge regulation, testing water temperature at the entries/exits of the coolers.
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C. Piping system – absence of vibrations, appropriate function of valves, quick disconnect

connectors and water/oil separators, correct connection of flexible couplings, appropriate
adjustment of safety valves and pressure relief valves.
D. Electrical system – testing motors for current consumption, adjustment and testing of
overcurrent switches used to interrupt motors at the designated current, grounding connections
and interlock systems.
E. Control system – testing the control, emergency, safety and alarm systems for normal
operation, testing compressor operation sequence, compressor operation upon pressure drop and
various interlocks.
F. Pressurized air test – testing pressure and discharge rates on main supply line and at other
controlled posts, testing the pressurized air for cleanliness (when special cleanliness is required).
G. Visual Test – testing the installation for quality of workmanship, including equipment and
piping system supports, removal of temporary supports, painting test, testing site for presence of
signs and identification markings, grout filling, tightness of electric and control boards etc.
360084 – Installation Delivery
Upon completion of tests and adjustments, and after all repairs were carried out to full satisfaction
of the CO, the contractor shall operate the installation and shall demonstrate its operation while the
CO and the operators attending, at a date coordinated and approved in advance. After
demonstration to full satisfaction of the CO the installation shall be run in by the contractor for a
period of time as specified in the contract documents, though no less than two weeks. Within this
time period, the contractor shall provide instruction course to the installation operators as well as
all required instructions, pertaining to the installation normal operation and maintenance. During
this time period, the contractor is responsible for the normal operation of the installation.
Upon completion of the run-up period and submittal of all documents as specified, the installation
shall be handed over to the CO, that will confirm in writing that the installation has been accepted.
360085 – As made Documents and Plans
Prior to submitting the installation as specified above, the contractor shall submit to the CO the
following document system:
A. Two sets of the installation plans. The contractor shall mark in the drawings all modifications
and deviations made through execution, in respect to original plans.
B. In case the contractor also had designed the installation, he shall submit five copies plus one
set of originals of updated installation plan, reflecting actual execution status and covering all
modification and deviations made through execution, in respect to original plans.
C. Operation and maintenance manuals in three copies, including preventive service and
maintenance manuals recommended by the original equipment manufacturer for the equipment
supplied by the contractor.
D. Catalogs of all equipment and accessories supplied by the contractor.
E. A list of spare-parts, recommended by the original equipment manufacturers, including
catalogue numbers.
F. This certificate of the air collector, signed by an authorized inspector after production and
installation and each and every document necessary by the law.
G. A list of motors and electric components, with identification marks and full technical data
such as manufacturer, type, model, power data, current, isolation, all according to the nameplates
attached to the equipment, measured currents, overcurrent protection adjustment etc.
H. Original test certificates and warranty documents of the original equipment and accessories
manufacturers.

36009 - Warranty and Service Period

A. General
The contractor warranty shall cover all equipment, accessories and materials supplied by him as
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well as the workmanship.

Warranty repairs and service shall be carried out by workers certified by the original equipment
manufacturers, in order not to jeopardize the manufacturer warranty liabilities.
B. Repairs during the warranty period
The duration of the warranty period shall be one year after completion of the work and receiving
installation delivery approvals.
Throughout the warranty period, the contractor shall repair every flaw or malfunction encountered
through the installation operation, pursuant to the CO call, within 24 hours from receiving the call.
The contractor shall replace any defective part of the equipment, accessories and materials found
defective within the warranty period, and shall supply and install a new and normal substitute part
with no charge to the customer.
C. Service Works during Warranty Period
Throughout the warranty period, the contractor shall carry out free of charge to the customer all
periodic service works, specified and required by the equipment manufacturers for compressors,
pumps, dryers, filters, oil/water separators and any other equipment as specified.
D. Faulty Service
Should the contractor refrain from arriving to carry out the aforementioned repairs or services, the
CO may instruct the purchase of parts and accomplishment of the works by others, and charge the
contractor for all expenses.
E. Records
All warranty works and services carried out by the contractor shall be recorded in the installation
log book.
F. Extension of the warranty period
If required, the contractor shall supply services for the period beyond the one year period as
specified above, following instructions set forth in the special specification.

3601 – Equipment Installation

36010 - General
This paragraph covers the general technical requirements for installation of equipment as set forth
in this specification.
In addition to all preparation and surveying works, the equipment installation works comprises
assembly of dismantled assemblies and subassemblies on mounts or equipment base into
complete equipment units, leveling of the equipment, installation and tightening of anchor bolts,
casting of grout, alignment and all other operations necessary for installation of the equipment and
preparation for operation.
The contractor shall recheck the levelling and alignment after completion of grout casting and
installtion fo the piping system and the instrumentation wherther these works has been executed
by him or by others.
Whenever the equipment manufacturer instucts on special assembly orders, the assembly shall be
accomplished accrding to these orders.
All drive wheels, belt puleys, couplings and shafts shall be protected by shields. When these are
not supplied by the equipment manufacturer , the contractor shall supply and install them.
The shields shall be made of steel frames and welded mesh and shall be removable.
Until the piping system is installed, all equipment flanges shall be sealed by means of plywood
plates. Threadened nozzles shall be sealed by means of appropriate plugs/caps.
36011 – Installation Stages
The installation shall be carried out in the following stages:
A. The contractor shall check the foundations prior to installation of the equipment on them and
shall verify the correctness of their location and level, existence of holes for anchor lugs and
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availability of anchoring bolts. The contractor shall inspect as well the conformance of the
equipment mount holes to the holes/lugs in the foundations.
B. The contractor shall prepare the foundations for the erection of the equipment. The work
shall include cleaning of the foundation and unscrew the anchoring nuts or their production and
anchoring in the holes provided.
C. The contractor shall use shims of various thickness. If possible, the contractor shall use
initially thicker shims (15 – 25 mm) and shall place on them thinner shims in order to reach the
necessary heights and levelling. The shims shall be installed so that they shall not protrude out of
the foundation and distributed appropriately in order to divide the load equally on the foundation
posts.
D. After positioning the equipment on the foundation and leveling the equipment, the anchoring
blots shall be closed, torqued and lubricant (grease) applied.
E. After casting and curing of the grout (see paragraph 36053 for details) for 40 hours minimum,
the contractor shall retighten the anchoring bolt nuts, recheck the leveling and amend s necessary.
36012 – Tolerances
Unless otherwise specified is the plans and the equipment installation specification, the reqired
accuracy in leveling after torquing of the anchor bolts shall be as follows:
A. Vertical equipment items:
 1 mm at the bottom of the item
0.2 mm for each meter of the equipment height in reference to vertical line.
B. Horizontal equipment items
 1 mm at the bottom of the item.
36013 – Compressor Installation
Unless otherwise specified in the special specification or the manufacturer installtion instructions,
the compressor chassis frames shall be anchored to the concrete floor.

3602 – Air Collectors

36020 – General
The air collectors produced or supplied by the contractor shall meet the requirements set forth in
the drawings, the special specification and the requirements of standards and regulation applicable
to air collectors.
The dimensions of air collectors shall be as specified in the plans. The contractor may recommend
slight deviations of dimensions following the features of his plant production machines but for this
purpose he should acquire the CO approval in advance.
The collector shall have openings and nozzles at the diameters, location and direction specified in
the plans. These shall include inspection port or manhole and nozzles for air inlet, air outlet, safety
valve, drainage (3/4 inch), pressure gage (1/2 inch), pressostat as the number of compressors plus
one (3/4 inch), and thermometer (1/2 inch).
Unless otherwise specified the collector shall be produced and tested according to the
requirements fo the standard: ASME Boiler and Pressure Vessel Code.
The contractor shall supply together with the vessel an official test certificate as required by the
laws and regulations regarding air collectors.
36021 – Air Collector Production
360211 – materials
Unless otherwise specified in the plans and the special specification the structural materials for the
collector production shall be as follows:
 Piping and pipe fittings as specified in paragraph 3603.
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 Metal sheets for supports and legs according to ASTM - A283 GR.C or equivalent.
 Profiles for production of legs according to DIN 17100 ST 37-2 or equivalent.
360212 – Cutting
Metal sheet cutting shall be carried out by means of guillotine (thin sheets), or thermal cutting or
mechanical cutting.
Bevel shall be prepared through machine processing or thermal cutting. In case of thermal cutting
the oxidation coat shall be grounded down to the bright metal surface. Piping system and fitting
cutting and preparation for welding shall be carried out as specified in paragraph 3603.
360213 - Welding
Welding shall be carried out according to paragraph 3604.
360214 – Rolling Housing Parts and Positioning of Nozzles
Rolling shall be carried out in appropriate rollers, including preliminary bending of edges. Use of
hammer strokes for edge rounding or producing any shape for housing parts in prohibited. After
welding length seam of the housing parts produced in the contractor shop, future rolling shall be
carried out, then the contractor shall inspect the arching by means of an appropriate template. The
precise shape of the rolled parts shall be retained by means of temporary support welding.
Unless otherwise specified in the plans no accessories and nozzles shall be located in welding
seams. Welding seams shall not be covered by compensation filler sheets. Length seams shall not
be located so that one continues the other in adjacent housing rings. Length seams shall be
spaced 50 mm minimum from each other. A 50 mm distance shall be maintained between any two
adjacent seams.
The nozzle location shall be carried out precisely maintaining correct dimensions and angles and in
adherence to the tolerances specified in this specification, the drawings and the relevant
standards. The contractor shall mark on the nozzles either by stamping or painting the
identification number of the nozzle shown in the plans.
Flanges shall be positioned so that bolt holes skip the main axes.
360215 – Production Tolerance
A. All nozzles shall be leveled and horizontal regarding the vessel horizontal plane or vertical
regarding the vessel vertical plane unless otherwise specified in the plans.
B. Unless otherwise specified the vessel production tolerance shall be:
1) Wall longitudinal line deviation from vertical: 0.75 mm per meter.
2) Position of the flange axis in reference to the vessel mount:  3 mm.
3) Position of flange surface regarding the vessel axis:  3 mm.
4) Flange surface planeness deviation: 0.5 degree.
5) Vessel diameter deviations:
Up to 1200 mm diameter -  3 mm.
1200 mm to 2150 mm diameter -  4.5 mm.
2150 mm to 4900 mm -  6 mm.
C. Allowed thickness steps between butt welded sheet edges:
To housing longitudinal joints – 4% of sheet thickness.
To housing peripheral joints – 8% of sheet thickness.
D. Processed surfaces, such as manhole flange body, distorted during welding, shall be
reprocessed after completion of welding.
360216 – Welding Spots and Temporary Supports
Welding temporary supports to the vessel body or other parts will be avoided as possible.
Spot welding or temporary support welding are regarded as permanent welding. These welding
shall be carried out according to the welding procedures approved and executed by certified
welders.
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The contractor shall carry out temporary welding strong enough to resist load application until the
permanent welding is performed. However, welding spots shall not be too large to interfere with the
normal accomplishment of permanent welding.
Temporary supports shall be removed by removing welding, using grinding, carbon-air arc or
burner, avoiding carefully damage to vessel sections. Tearing supports by means of hammer
strokes or bending is totally prohibited.
“Wounds” caused to the vessel parts as a result of temporary support removal, shall be filled in
welding and re-grounded. The CO is entitled to instruct penetrant liquid test or other non-
destructive test of such area. This test shall be carried out on the contractor expense.
360217 – Compensation Filler sheets
Where necessary according to the plan, the contractor shall install and weld nozzle compensation
filler sheets. The filler sheet shall be cut and bent into the necessary shape and then dressed on
the nozzle. The sheet external edges shall be welded to the vessel housing and its opening edge
shall be welded to the nozzle. All welds shall be full.
¼ inch BSP threadened hole shall be drilled in the compensation filler sheet to be used as gas
relief port and for testing the welding tightness using pressurized air and soap. The hole shall be
closed by means of an appropriate plug upon completion of the test.

36022 – Pressure Test

After completion of the air collector production, non destructive testing and repair as necessary,
and after all welding works on the vessel are completed, including leg welding, lifting eye welding,
support welding etc. the vessel shall be subject to pressure test in water. The pressure test shall
be carried out with the vessel mounted on legs and secured temporarily against falling. All vessel
ports shall be sealed with appropriate threatened flanges or plugs to be supplied by the contractor.
The vessel shall be carefully filled from bottom eliminating par pocket trapping in the vessel top
section. Two pressure gages, test pressure range compatible, shall be installed on the vessel.
After the vessel is filled with water, the pressure shall be increased gradually to reach 15 bar
pressure, unless otherwise specified in the plans and the special specification.
The vessel is regarded as passed the test when after 24 hours no pressure drop whatsoever is
noticed considering the temperature difference between the beginning of the test and the
completion of the test.
During the pressure test the vessel shall be positioned at a shadowed location. Early morning
hours consist the best time recommended t carry out the test.
After completion of the pressure test no further welding work shall be attempted on the collector.
36023 – Finishing
After completion fo the pressure test the vessel shall be drained of water, then dried and cleaned,
externally and internally. Collector equipped with manhole shall be cleaned internally and
externally by means of sand blast and then painted according to paragraph 3605. Collector without
manhole shall be cleaned and painted externally only.
Nameplate shall be applied to the collector indicating the collector serial number, production date,
test date, maximum test pressure, test pressure, collector volume, empty weight and metal sheet
thickness.
The nameplate shall be made of rust free material (stainless steel or brass) and the inscription
shall be engraved in the metal.
The nameplate shall be riveted to the an appropriate mount prepared in advance by means of
welding on the vessel.
All flanged nozzles shall be covered by means of plywood covers that will be secured by two bolts
each. Threadened nozzles shall be sealed by means of appropriate threadened plugs.
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3603 – Piping System and Accessories

36031 – Materials for Piping System and Accessories
360310 – General
The piping system materials used in pressurized air installations shall comply with the following
specifications unless otherwise specified in the plans and the special specification. Requirements
for galvanized pipes and accessories shall be incorporated in the special specification. Galvanized
pipes and accessories shall comply with the following requirements.
360311 – Pipes
A. ½ inch to 1½ inch diameter pipes
Black steel, seamless, in compliance with Standard ASTM – A53GR.B, schedule 80, BSP
threadened or pipes as mentioned, schedule 40 with straight ends ready for welding.
No threads shall be processed on schedule 40 pipes.
B. 2 inch diameter pipes
Black steel, seamless, in compliance with IS 530 type 530B or Standard ASTM – A53GR.B,
schedule 40, BSP threadened or with straight ends ready for welding.
C. 2½ inch to 6 inch diameter pipes
Black steel, seamless, in compliance with IS 530 type 530B or Standard ASTM – A53GR.B,
schedule 40, Beveled ends ready for butt welding.
The same pipes shall be used for underground piping system, with external coating of two plastic
tape layers. The use of bitumen coated piping system is subject to CO approval in writing or when
explicitly specified in the plans and the special specification (see paragraph 36035).
360312 – Elbows, T Fittings, Reducers
A. ½ inch to 2 inch diameter fittings
Treaded joints: black cast MI fittings in compliance with Standard ASTM – A197, grade 150 or
forged in compliance with Standard ASTM – A181, grade 2000/3000, BSP threadened. Welded
joints: steel fittings in compliance with Standard ASTM – A181, grade 2000/3000, ends ready for
socket weld.
B. 2½ inch to 6 inch diameter fittings
Steel fittings confirming to Standard ASTM – A234GR WPB, schedule 40, ends ready for socket
weld.
No use shall be made in bent pipes. The elbows and T fittings shall be of large radius type.
360313 – Unions
A. ½ inch to 2 inch diameter
Black cast MI fittings confirming to Standard ASTM – A197, grade 150 or forged confirming to
Standard ASTM – A181, grade 2000/3000, BSP threadened. Seat made of copper/iron.
B. Diameters 2½ inch and larger – flanges only.

360314 – Flanges
A. ½ inch to 2 inch diameter
Forged, material confirming to Standard ASTM – A105, grade 150 or, elevated face, BSP treaded.

B. 2½ inch to 6 inch diameter

Slide flanges (SO), or neck flanges (WO), forged ANSI, ASTM – A105, grade 150, elevated face.
When connecting to equipment or accessories, the opposite flange shall be identical with the
equipment flange. In case of flat face flange, identical opposite flange shall be used.
360315 – Seals
Seals shall conform to face elevated flange, work pressure and temperature.
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360316 – Bolts, Screws and Nuts

Dowels ASTM – A193 GR B7, UNC tread, with two hexagonal heavy nuts ASTM – A194 GR 2H or
machined heavy head nuts ASTM A307, UNC threadened. Screws, bolts and nuts shall be
passivated and cadmium coated.
360317 – Valves and Taps
A. ½ inch to 2 inch diameter
Cast iron diaphragm valve, BSP threadened, Weir type structure, natural rubber diaphragm, steel
spindle.
Gate valve, made of bronze, in compliance with Standard ASTM – B62, grade 200, bronze spindle.

Glove valve, made of bronze, in compliance with Standard ASTM – B62, grade 200, bronze
spindle.
Check valve with swing, or lift, made of bronze, in compliance with Standard ASTM – B62, bronze
spindle, grade 200.
Ball valve, made of bronze, in compliance with Standard ASTM – B62, BSP threadened, grade
150, fiberglass ruggedized teflon seats.
B. 2½ inch to 6 inch diameter
Cast iron diaphragm valve, flanged, grade 150, flat face, Weir type structure, natural rubber
diaphragm, equipped with operation wheel.
Cast iron butterfly valve, grade 150, stainless steel spindle, neoprene seat. The 6 inch valve should
be added gear operation mechanism. Cast iron ball valve, in compliance with Standard ASTM –
A216GR WCB, flanged, grade 150, elevated face, stainless steel ball, fiberglass ruggedized teflon
seats. The 6 inch valve should be added gear operation mechanism.
Check valve with swing, dual flap, non flanged, grade 150, of cast steel ASTM – A216 GR WCB,
BUNA N rubber seats.

360318 – Special Accessories

A. Safety Valve
Steel safety valve with stainless steel stem, in diameters up to 2 inch inclusive, BSP threadened.
Diameters 2½ inch and larger, flanged, grade 150, elevated face.
Unless otherwise specified in the plans and the specifications, the safety valve installed on the air
collector shall comply with 1.1 time working pressure, and at the appropriate discharge for the
compressor discharge under working pressure.
B. Compressor joint flexible hoses
The hoses shall be of metal type, with external armor, complying with 15 bar working pressure at
120 degree Celsius temperature. Unless otherwise specified in the plans, the hoses shall be 1.20
meter long with BSP threadened ends, or flanged in compliance with the pipe diameter.
C. Pressure Gages
The pressure gages shall be of Bordone type, with concentric scale 150 mm (6 inch) diameter and
connecting mouthpiece ½ inch BSP diameter, measuring range 0 to 16 bar. The pressure gage
shall be installed wit bronze ball valve, ½ inch diameter .
D. Thermometers
The thermometers shall be of the bi-metal type, installed in pocket, with concentric scale 150 mm
(6 inch) diameter. The bi-metal shall be 2.5 inch long (unless otherwise specified) and shall be
connected through 1/2 inch thread. Measuring range 0 to 100 degree Celsius/ The thermometer
shall be supplied with pocket appropriate for welding.
E. Quick Disconnect
The type of quick disconnects and diameters shall be subject to the CO approval. The quick
disconnect shall be in closed position when its second half not coupled.
 14

36032 - Piping System Laying and Installation

360320 – General
A. The piping system shall be laid in the piping system route and installation with the pipes
exposed. Laying pipes in walls or on flooring and underground shall be avoided. Whenever
possible the laying work shall be continuous while piping system joints (welding, flanges and
threads) as well as auxiliary works )supports, interment installation) shall be accomplished
sequentially, with no breaks and skipping.
B. Whenever possible, the contracotor shall produce piping system section in advance in his
shop while on site installation work only shall be carried out. Welding on site shall be kept to the
minimum and no pipe section shorter than 2 meters shall be prepared of even shorter sections
unless otherwise specified explicitly in the drawings.
The number of welding joints shall be kept to minimum when joining long pipe sections. However,
the contracotor shall design the production of sections so that cutting and modifying after
production for fitting during installation shall not be necessary.
C. Each pipe section, prior to installation and assembly, shall be cleaned well of any waste and
sealed temporary on both ends.
D. The pipes shall be laid on steel supports and hangers.
E. Main supply line branching shall emerge of the main supply line top section.
360321 – Branching
Branching shall be executed as follows:
A. From ½ inch through 2 inch diameter line through threaded or welded T fitting.
B. From 2½ inch through 6 inch to same diameter, through welded T.
C. From 2½ inch through 6 inch to 2 inch and smaller diameter, forged complete coupling,
welded. To 4 inch and larger diameter pipes – half coupling.
D. From 3 inch through 6 inch to 2½ inch ad larger diameter, but not to the same diameter, the
branch shall be carried out by means of pipe to pipe insertion.
NOTE: Main line branching shall not be smaller than ¾ inch.
360322 – Piping System Support
The steel supports for piping systems shall be produced and painted by the contractor. The
contractor shall install the supports in positions according to the piping system plan or CO
instruction. The support models, mounting and attaching to the structure shall be according to the
plans or CO instruction. Temporary supports deemed necessary by the contractor for laying in
course of the work, shall be produced, installed and removed then by the contractor and on his
expense.
Welding temporary supports to the piping system shall be avoided as possible while tying or
clamping method shall be preferred to support temporarily piping system sections. Existing pipe
shall never be used as lifting aid or foundation for fixed support. Heavy piping system shall not be
supported temporarily by constructions not designed to uphold these weights. For temporary type
of installtion the contractor shall acquire the CO approval for the nature and location of the
temporary support.

Unless otherwise specified in the plans, support intervals shall not exceed the following data:

Pipe Diameter Up to 1 inch 1½ to 2 inch 3 to 4 inch 6 inch and larger

Support Intervals 2 meters 3 meters 4 meters 6 meters

The contractor shall verify that the density of supports and type thereof ensure that the piping
system neither vibrates nor transfer vibrations to the adjacent structure sections.
 15

360323 – Piping System – Equipment Connection

In no case the pipe lines shall be stretched in order to match them to connect to the equipment
ports or to other piping system. When a gap is created between two piping system sections, they
should be cut and then re-matched.
In piping system connection to pump, compressor and any other rotating equipment ports, care
shall be exercised to eliminate stresses in the piping system or in the equipment unless otherwise
specified explicitly in the plans. After torching all flanges and completion of welding through the
entire piping system, the flange connected to the equipment shall be re-opened in presence of the
CO and prove that the piping system flanges not shifted regarding the equipment flange. When
refitting is required, it shall be carried out according to the CO instructions and on the contractor
expense. Reopening and closing of flanges, either for test or repair shall be accomplished on the
contractor expense. Piping system connection to equipment shall be carried out after the
equipment is leveled and stabilized.

36033 – Piping System Joints

360330 – General
Piping joints between two pipes, pipe and fitting and pipe to equipment shall be carried out though
either three methods, as specified in the plan or contract documents.
ㄱ Threadened joint
ㄴ Flanged joint
ㄷ Welded joint
Piping system joints shall be made after the pipe is cut to dimension and its end processed for the
required joint shape.
360331 – Cutting Piping Systems
Cutting shall be carried out by means of mechanical tool or flame cutting tool designed for this
purpose. Cutting pipes with manual cutting burner is prohibited.
Pipes up to 2 inch diameter shall be cut by means of mechanical tool only. The step created as a
result of mechanical cutting shall be removed. When using flame cutting, the cut surface shall be
smooth and clean, otherwise it shall be finished through grinding.
Pipes shall be cut in 90 degrees to the pipe axis or in slant plane when so specified in the plans.
The cutting shall be done after measuring the sections according to the dimensions specified in the
drawings and after they have been checked for compliance with the actual dimensions on site.
The cut pipe sections shall be numbered and marked using paint for identification while the pipes
shall be cleaned internally from sand and foreign particles.
Pipes designed for butt welding shall be beveled as specified in paragraph 36042.
360332 – Threadened Joint
A. threadened joints are allowed up to 2 inch diameter (Inclusive). For larger diameters the
contractor shall acquire the CO approval in writing.
B. The pipe ends designed for tapping shall be cleaned by means of cone punch and then the
thread produced using manual tool or machine. All threads shall be of BSP type unless otherwise
specified in the contract documents or reqired by the CO.
C. Prior to joining the pipes, teflon tape shall be applied for sealing purpose. Alternatively flax
may be used with sealing paste.
360333 – Flanged Joint
A. Flanged joints shall be generally accomplished when the pipe is connected to equipment or
accessory. However, use of flanged joints to connect pipes through running piping system shall be
avoided.
B. Flange contact surfaces shall be properly cleaned and checked for slot or bulge defects.
Then the seal shall be inserted between flange pair and the flange bolts torque. The bolts shall be
 16

lubricated entirely by means of grease supplied by the contractor and approved by the CO. The
length of bolts for flanged joint shall be standard and ensure that after torquing the bolt shall
protrude one to three threads.
C. When the flange pair surfaces are not parallel, the pipe shall be re-cut and re-welded so that
the flange surfaces shall be parallel.
D. Flange bolt holes shall skip the main symmetry axes.
E. The flange shall be connected to the pipe by threading or welding s specified herein.
F. Seal shall not be used more than once, unless otherwise established by the CO.
360334 – Welded Joint
Welding shall be carried out as specified in paragraph 3604 and subject to the following
instructions:
A. Welded joints shall be one of the following types:
- Socket weld joint for diameters up to 1.5 inch inclusive.
– Butt weld joint for diameters of 2 inch and larger.
B. Butt weld shall be carried out as specified in paragraph 3604.
C. Socket weld joints – shall be used for accessories including flanges, elbows and T fittings,
couplings, valves etc.
The pipe surface designed for socket weld shall be straight. The pipe shall be forced into the
accessory throughout its entire depth and then slightly released (1 to 2 mm) between the pipe end
and accessory seat. In this position the welding shall be carried out.
D. Flange welding – flanges shall be weld to pipes according to the following instructions and
paragraph 3604 instructions.
Weld neck flanges shall be welded to the pipes or accessories as specified in pipe welding
paragraphs after careful and precise mechanical matching to the pipe or accessory.
In case of differences between the pipe and flange neck internal diameters, the difference shall be
removed in grinding of the smaller diameter accessory and the bevel step corrected accordingly.
When welding flanges, the sealing area shall be perpendicular to the pipe axis and the flange holes
shall skip the main symmetry axes. The sealing area shall be protected against welding material
and slag spilling and against any other damage. All defects that may interfere with absolute sealing
of the flanges shall be removed.
When welding slip on flanges, the contractor shall weld, in addition to the external weld, an internal
weld inside the flange port.
E. Ready for weld elbows and T fittings – ready for weld T fittings and elbows of standard
angles are supplied with ends ready for welding and they shall be welded to the pipes both through
butt weld and socket weld, retaining accurate fit and correct position of the elbow or T.
F. T fitting production – right angle (T) and acute angle (Y) fittings shall be produced by precise
cutting of the piercing pipe into the main piping system, cutting the necessary hole in the main pipe
and welding the fitting to the main pipe. The welding quality is as specified for pipe joints. The
welding internal side shall be smoothed and well cleaned to provide smooth pass in full diameter of
the main pipe and the outlet port. Where reqired according to the plan, the contractor shall install
and weld reinforcing saddles for T and Y fittings. The saddle shall be cut and bent into the required
shape and then dressed on the fitting. The saddle external edges shall be welded to the main pipe
while its port edge shall be welded to the fitting. The quality of the welding shall be as required for
pipes. A ¼ inch hole shall be drilled in the saddle and BSP tapped for welding test.
G. Coupling welding – couplings shall be welded to the crest of the pipe with the coupling
positioned on the pipe and after a hole is drilled in the crest of the pipe at the inner diameter of the
coupling. Half coupling may be used as well. When the coupling is welded to smaller diameter
pipe, it shall fit the pipe contour by grinding. In this event full coupling only shall be in use. Special
couplings such as Weldolet shall be welded according to the manufacturer instructions.
 17

36034 – Accessory Installation

360340 – General
All accessories, pie fittings and measuring instruments shall be installed at their precise locations
accrding to the plan, adhering carefully to the appropriate position (vertical, horizontal, rotated
etc.), the correct flow direction, level and slope. Accessories and measuring instruments not to be
involved in the pressure test shall be replaced temporary by blind flanges or equal length spool
pieces, or shall be disconnected from the system by means of spades – all according to the
available options and subject to the CO approval.
Installtion of measuring instruments (level gages, flow gages, thermometer etc.) on the piping
system shall be carried out after finishing all installation works including hydrostatic tests and line
cleaning. However, all pipe fittings used to connect the instrumentation to the piping system shall
be installed on the pipes as part of the production work and piping installation and shall be sealed
with temporary plugs until the instrumentation is actually installed.
360341 – Installtion of Valves, Taps, and Control Valves
Prior to installtion of taps, valves and control valves they shall be cleaned and inspected for normal
operation.
Installtion of taps, valves and control valves shall be carried out considering the location and
direction of the accessory operating handle or operating system to avoid blocking of passages and
for convenient operation maintenance of the accessory.
No taps, valves and control valves shall be installed at levels higher more than 200 cm above the
working surface Unless otherwise specified in the plans or approved by the CO.
Relief and safety valves shall be installed accrding to the plan so that air pressure relief shall be
directed into unmanned spaces avoid hazard of personnel injury.
360542 – Installation of Expansion Joints
During installation of expansion joints the appropriate and precise gap between the pipe edges or
between flanges shall be carefully retained as well as retaining precise axis line of both pipes.
These conditions shall be maintained even when the piping system is released in its natural
position and not forced into that position.
Expansion joints with tie rods only shall be in use. The piping system shall be supported and
secured at the expansion joint area according to the manufacturer instructions in order to ensure
long term period of the joint normal operation.
During installation the expansion joint shall be properly covered to avoid welding spilling damage.
360343 – Installtion of Water Traps
Water traps shall be installed at each low point of piping system route direction change in the
verticals plan through the run of the piping system as well as along piping system lines at distances
and locations specified in the plan. The water trap shall be installed up to 1 meter above floor or
working surface and connected through appropriate diameter pipe to the line it is designed to drain.
When reqired, an appropriate diameter drain line shall be installed between the trap and a sewage
or drain post according to the CO instructions. At the end of the drain line, close to the trap the
contractor shall install a small funnel, through which the trap will drain the water in the open.
360344 – Installtion of Flexible Piping system
The compressors shall be connected to the stationary piping system through flexible hoses. The
flexible hoses shall be installed properly, at directions, distances and radius of curve recommended
by the accessory manufacturer, taking care not to twist or break the hose during installtion.
360345 – Thermometer Installation
Thermometers are specified in paragraph 360318 above. The thermometer pocket shall be welded
to the piping at depth and angle specified in the drawings or by the accessory manufacturer. In
case the pocket ins installed on small diameter pipe, the pipe diameter shall be increased at the
area where the accessory is installed.
 18

Installtion of pocket on air collector shall be accomplished by threadened joint screwed into the
coupling welded to the vessel or on blind flange of the vessel after a hole is drilled in it and tapped
into which the pocket shall be screwed.

36035 – Excavating and Laying of Underground Piping System

A. The excavation works and piping system laying shall be carried out at the locations marked
in the plan, as specified in Chapter 57 – General Specification for Water, Sewage and Channeling
Pipe Lines, regarding the paragraphs concerning steel piping systems and the data specified
herein.
B. No piping system flanged or threadened joints shall be located underground. However, when
the line dictates underground routing, the contractor shall construct a concrete control chamber
with cover providing access to the joint or accessory (see paragraph 36036 herein). Line sections
at building entry or under the building shall be laid so that access to them is enabled.
C. Unless otherwise specified in the plans and the special specification, underground piping
system shall be laid as follows (depth measured from top of pipe).
- Road and roadway passages minimum 90 cm under road surface.
– Under pavements and flooring minimum 60 m under floor.
– Unpaved areas minimum 60 cm under natural ground surface.
D. Underground piping system shall be laid horizontal with slight slope to one direction only.
Producing pockets, either upward or downward in underground piping system is prohibited. When
a reducer is to be used in an underground section, it shall be of eccentric type and installed flat on
bottom.
E. Drain valves and water traps shall be installed on both ends of each underground piping
system section. Chambers shall be installed providing access to the drain valves. The type and
model of chambers shall be determined according to their location on site (see paragraph 36036
herein).
F. Coated pipes only shall be in use. Pipe fittings such as elbows, T fittings etc. that are
supplied originally uncoated, shall be coated after welding. All welded areas shall be coated.
Welded area coating shall be carried out only after the line passed successfully non destructive
tests (when specified) and pressure tests.
G. Welding coated pipes shall be carried out according to this specification. The coating shall be
removed at the welded end for 10 cm section width and the metal surface cleaned of adhesive or
bitumen residues prior to welding.
H. Elbow and T fitting coating as well as welding areas shall be carried out according to the
coating manufacturer instructions. The following consists concise description of the coating
procedure:
Plastic Coating:
The coating area shall be cleaned by means of steel brush and all welding slug and rust removed.
Then special primer shall be applied, the pipe/fitting shall be coated by means of two plastic tape
plies. For fitting coating narrow tape shall be used.
Bitumen Coating:
The coating area shall be cleaned by means of steel brush. Then bitumen primer shall be applied,
and 2.5 cm thick bitumen coat shall be applied. On top of the bitumen coat, fiberglass sheet shall
be wrapped absorbing the bitumen. Then a second bitumen coat shall be applied, 1.5 cm thick and
a second fiberglass sheet shall be wrapped and absorbed. Finally, the system shall be
whitewashed.
I. After completion of the coating repairs as specified above, the coating shall be inspected for
completeness using spark detector. When breaks are noticed in faulty coating areas, the coating in
the said area shall be remove and repaired as specified above.
J. In road and roadway passages, the ground shall be compacted by means of vibrators. The
ditches shall be excavated at the appropriate widths allowing the use of this type of equipment.
 19

K. Ditch back filling and covering shall be accomplished after completion of the pressure tests
and other tests only, subject to meeting the CO requirements and his approval.

36036 – Control Chambers and Gate Valve Chambers

The type and design of control chambers and gate valve chambers shall be determined according
to their location on site (road, unpaved area etc.) as specified in the plans or according to the CO
instructions.
Round chambers shall be made of precast concrete or cast concrete on site. Rectangular
chambers shall be built of bricks or concrete casting.
The chamber covers shall of standard types and of the type specified in the contract documents.
36037 – Pressure Tests
360371 – Hydrostatic Pressure Tests
After completion of the piping system production and installation, non destructive test shall be
carried, if specified. After test the contractor shall accomplish repairs as necessary. Then the
piping system shall be supported. After the entire piping system is properly supported, water
hydrostatic pressure test shall be carried in presence of the CO.
For the pressure test, the contracotor shall submit for the CO approval test plan, including
description of the piping system sections he intends to test simultaneously. The plan shall indicate
where the contracotor is placing spades, remove accessories that should not be involved in the
pressure test as well as installtion of temporary bypass elements. The entire equipment required
for running the pressure tests as well as auxiliary materials labor, removal and reinstallation shall
be performed on the contractor expense.
All equipment, pressure pump, instruments, accessories and pressure gages used for the pressure
test are subject to the CO approval. Their installation plan for the test procedure is also subject to
the CO approval.
Two pressure gages shall be installed for each tested piping system. The pressure gage shall be of
the range matching the test pressure.
The contracotor shall lay temporary water line pipes and connect the line to the piping system
under test, for the test purpose.
The contractor shall make the necessary arrangements subject to the CO approval to drain the
water after the test, without damage or interference. No attempt to fill the line under test with water
shall be done unless the following requirements are fulfilled:
A. All joints, including weld joints, shall be exposed for visual test.
B. All welding tasks have been completed on the line or system under test including support
and hanger welding etc.
C. All temporary supports have been removed and all defects caused by support removal have
been repaired.
D. All control valves, globe valves, expansion accessories, vessels, pumps etc., equipment and
other sensitive accessories had been removed or disconnected or replaced with spool pieces.
E. Open ends of piping section unterminated by valve have been sealed safely.
F. The test procedure and execution have been approved by the CO.
The line shall be filled gradually and slowly in order to avoid shock or pipe vibration and allowing
bleeding of all air from the pipes. The filling shall be carried out flowing the water down upward.
Line high spot ports shall be opened to vent the entire air in the line.
At the beginning of the filling the top spot gate valve shall be open and then closed after the water
rinsed the entire dirt of the line. After all air is out, completion of filling but prior to pressure increase
in the line, all accessories and fittings shall be checked for tightness and all necessary repairs shall
be accomplished when leaks are noticed in the fitting sealing or in the stuffing boxes. When this
test reveals leaks in joints or defects in fittings, that should not be repaired when the line is full with
 20

water, the line shall be drained and the necessary repairs carried out. The test shall be repeated
until all leaks are repaired. After the line is rinsed and no leaks are noticed the pressure shall be
increased gradually up to 15 bar or to the pressure specified in the plans. The line shall be
maintained under this pressure for 24 hour period and when during this time period no pressure
drop associated with leakage is noticed, the line is regarded as meeting the pressure test
represents. In case of pressure drop during this 24 hour period, all leaks shall be located, defects
repaired and the test and repairs repeated as many times as necessary to verify that the line is
withstanding the specified pressure with no leaks for 24 hour period. However, pressure variations
shall be considered as a result of environment temperature variations.
Upon completion of the hydrostatic test, the lines shall be drained of the water and the dried using
forced airflow.
360372 – Pressurized Air Test
After completion of the hydrostatic test including draining, rinsing and drying, the contractor shall
remove all bypasses, spades and spools and install on the line all valves, accessories, equipment
and instrumentation that should be installed on the piping system according to the plan. After
acquiring the CO approval the contractor may start pressurized air test to locate leaks in the joints
of these accessories.
Pressurized air test shall encompass all lines and equipment of the pressurized air installation.
The compressor and all necessary accessories for the pressure test shall be supplied by the
contractor.
The air pressure test of the system lines shall be carried out after coordination and in presence of
the CO. The test shall be divided into two major phases:
A. Preliminary test under pressure of 1.5 bar. Under this pressure all joints shall be tested for
leakage and the entire pipe line shall be tested for pressure drop for a time period determined by
the CO. Shift to the second test phase shall not be done unless the CO is ensured that the line is
normal and all faults are repaired as necessary.
B. At the second test phase the pressure shall be increased gradually, keeping time intervals
between successive pressure changes in order to ensure pressure equalization throughout the
entire tested line. The maximum pressure shall be 1.1 times the line designed pressure but not
more than the pressure allowed for the valves and accessories on line. Leak detection shall be
accomplished by means of soapy water.

3604 – Welding
36040 – General
A. Welding works shall be executed in compliance with Chapter 19– General Requirements for
Locksmith Works. The requirements set forth herein supplements the welding requirements
associated the air collector and air piping system welding.
B. Though not lessening the generality of this paragraph and Chapter 19, the welding method
shall comply with the US Standard ANSI B-31.3 and the welding tests shall be carried according to
Standard ADME – Boiler Pressure Vessel Code.
The CO may not accept any execution method produced by the contractor and he keeps all rights
to reject in course of work any procedure or method deemed inappropriate for welding according to
this specification.
C. Dual head welding machine shall not be used. Each welder shall work using separate
machine.
D. The authorized welding methods are as follows:
1) SMAW – Shielded metal arc welding – manual welding using electric arc and coated
electrode.
2) SAW – Submerged arc welding – automatic welding using submerged arc.
 21

3) GTAW – Gas tungsten arc welding – argon shielded tungsten arc.

4) GMAW – Gas metal arc welding - argon shielded metal arc.
E. When the special specification or the contract documents specified use of galvanized piping
system and pipe fittings, welding of such shall be avoided. However, when this welding is
necessary, same electrodes and same welding procedures specified in this paragraph shall be
used.
36041 – Electrodes
A. Unless otherwise specified in the plans and the special specification ,SMAW welding
electrodes shall comply with standard ASW – 5.1 as follows:
Root welding and weld building up – E-6010
Weld filling only – E-7018
Galvanized pipe, root and filler welding – E-6013, E-6011, E-6010.
B. Electrodes used to weld different steel parts shall comply with the drawings, the special
specification and following the CO instructions.
C. Welding materials necessary for other welding methods are subject to the CO approval in
writing and in advance. The CO may instruct on running welding procedure qualification tests.
D. Electrodes shall be stored in their sealed original packing until entering use cycle.
E. Prior to using low-hydrogen electrodes, they shall be put in appropriate drying oven,
equipped with calibrated thermometer and thermostat. Normal pre-drying procedure shall be
carried out at 250 degree Celsius (or according to the electrode manufacturer instructions) for 2
hours minimum. The relative humidity in oven shall not exceed 50%. Low-hydrogen electrodes
absorbing high rate of humidity or left over night out of the oven, shall be dried at approximately
320 degree Celsius for 2 hours minimum.
F. SAW welding wires and rods for– argon tungsten and metal arc welding shall be stored in
their original sealed plastic packing. Rods and wires removed from the original packing shall be
stored in a dry room to protect them against rust.
G. SAW welding powders shall be dried in oven prior to use according to the powder
manufacturer instructions.
36042 – Pipe Welding
The ends of the pipes shall be inspected before they are welded to ascertain that they are
complete and rounded. Defective ends shall be cut off and discarded. The pipe edge, at least 10
cm from the pipe end, shall be thoroughly cleaned of any dirt, rust, paint and bitumen residues and
any other foreign substance which may to adversely affect the quality of the welding. Steel brush
and suitable solution shall be used to remove paint and oil residues.
The pipe edges designed for butt welding shall be beveled (“phase" processed) at an angle of 37.5
degrees with a deviation of 0 to 5 degrees in the direction of the edge plane, with 1.5 mm being left
unleveled.
The root aperture between pipes shall be 0.8-2.5 mm to ensure full penetration and it shall be
measured using a standard gage.
When the pipes are fitted care shall be taken to avoid any internal “steps” between the ends of
adjacent pipes and that there shall be horizontal shift of approximately 50 mm between the
longitudinal seams.
In order to ensure centering of the pipes and gripping of the ends clamps shall be used gripping
the pipes from outside. Flat sheet metal bridge nay be used instead of loops.
Using weld points inside the bevel for holding the pipe is not acceptable unless it is carried out by
qualified welder that completes immediately the root cycle. The defective weld points shall be
discarded in course of welding.
The clamp or the flat sheet metal shall not be removed until the root weld ensures that pipes
adjacent to each other are properly gripped. The root cycle shall be completed immediately after
the clamp has been removed.
 22

The number of welding cycles for each seam shall not be less than two and electrodes and filling
threads of suitable quality and diameter shall be used for each cycle. The root cycle (which is the
first welding cycle) shall be performed in either welding modes, circular or fixed position. A root
seam alone without filling seam shall not be left overnight. Moving the pipes shall be avoided as
much as possible until the entire root cycle has been completed.
The thickness of the cycles shall be 2.5 to 3 mm and their thickness and number shall be adjusted
so that the seam protrudes above the surface of the pipe no more than 1.5 mm. The top cycle shall
be 3 mm larger than the width of the groove before the welding.
The penetration of the root into the pipe space shall not exceed 3 mm for 3 inch and larger pipes,
while smaller diameter pipes will have root penetration not exceeding 1.5 mm. All welding material
shall be thoroughly fused with the base metal and the previous cycles. Two cycles shall not be
started at the same place.
After each cycle the seam shall be thoroughly cleaned of slag, scrapings and dirt. Similarly the
places where the electrodes are replaced shall also be cleaned. Manual cleaning using a hammer,
chisel and steel brush, or sand stone is allowed provided that cleaning is carried out as required
until bare white metal is exposed.
36043 – Air Collector Housing Welding
A. Preparation of the housing sheets for welding
The preparations shall include the following actions:
1) Preparation of the bevel in compliance with the drawings dimensions and data.
2) Cleaning the edges of the part to be welded of oil, paint, rust, oxides or other
obstructions. The cleaning shall be done to a distance of 20 cm each side using metal brush or
grinding.
3) Fastening the parts properly to ensure par4t matching while retaining the appropriate
gaps and avoiding offsets beyond limitations.
B. Butt Joints
1) Unless otherwise specified in the drawings the butt joints shall be carried out on both
sides of the joint (double welded butt) except those inaccessible from the inside. Joints with type V
bevel shall be welded from the root side (after root cleaning) at least on seam.
2) The root shall be cleaned on the opposite side using carbon, air, acetylene – oxygen
burner or by grinding. The cleaning is carried out as required until bare white metal is exposed.
3) When the drawings indicate that the welding shall be one sided, the root seam shall be
welded using a procedure that ensures full penetration and perfect fusion.
4) In butt welding, the weld cross-section thickness shall exceed that for the adjacent
sheet.
5) Butt joints of piping system and fittings shall be generally one sided, as common in
piping system welding. However, for weld neck nozzles of diameters exceeding 4 inch the root may
be cleaned and other seam weld accomplished on the inside.
C. Fillet weld joints
1) All fillet welds shall have equal sides and perfect root fusion. The weld thickness shall
be equal to the thinner sheet. In special events the thickness may be decreased to 70% of the thin
sheet thickness, subject to CO approval in writing.
2) All connections to the vessel housing, including supports, clips, clamps, reinforcing
rings, compensation sheets for nozzles, ruggedizing sheets for leg supports etc. shall be attached
to the housing by means of continuous weld.

36044 - Weld Finish

The completed seam shall be thoroughly cleaned from any base metal residues. The seam shall
be uniform and the welding surface shall be free of any pores, slits or sharp passages. The
 23

passage between the base metal and the welding material shall be gradual and continuous without
any markings. Crossings between lengthwise and widthwise seams shall be gradual and
continuous without steps and sharp breaks.

36045 - Weld Tests

A. In addition to the visual tests of the welds - while they are being made and on completion of
the welding – non destructive tests shall be carried out, if specified by the special specification, or
according to the CO requirement.
The non-destructive welding tests shall only be performed after the visual inspection, which shall
certify the completion of the welding area (removal of slag, welding splinters, repair of external
defects etc.)
Non destructive tests (NDT) relevant to this specification include the following tests:
- Radiographic test
– Ultrasonic tests
– Color liquid penetrant test
– Magnetic particles test
B. Non destructive tests are generally radiographic tests. Locating positions for NDT and
providing appropriate marking shall be carried out by the contractor according to the CO
instruction, on vessel outlines drawing and on piping system schematic diagrams submitted by the
contractor.
C. Preparation of the test areas, such as sanding for liquid penetrant test, shall be carried out by
the contractor at his own expense integrally with the production process.
D. Analysis of the results and determining the quality of the welds and acceptance or rejection
of the data is the sole decision of the CO.
E. When NDT are specified, they shall be performed in the workshop and at the work site with
the full cooperation of the contractor. The contractor shall supply the inspector with all the
assistance required for performing the tests including ladders, forms, electrical supply, water
supply etc. The contractor shall provide hoisting equipment for moving heavy items.
Defective welds or areas encountered in course of the non-destructive tests shall be repaired by
the contractor at his own expense. The repair shall be performed according to the definitions in the
relevant standards.
Each defective weld shall re-tested after it has been repaired under the same test procedure two
additional photographs shall also be taken of each defective weld. All photographs and tests
arising from a defective weld shall be made by the non-destructive test inspector at the contractor
expense.
F. The CO may instruct destructive tests of welds if he has a good reason to believe that the
quality of the welding does not conform to the specification.
These tests, that will be determined by the CO shall be part of those listed herein, or all.
– Break test
– Flexure test
– Tension test

3605 – Auxiliary Works

36051 – Building and Locksmith Works
Building works, including earthworks, walls, concrete casting including paving, foundation and
finishes as well as steel constructions and sheds, shall be executed by others as specified in the
appropriate chapters of the general specification. However, the contractor is required to execute,
as necessary, small building works used for local fit, associated with the contracotor work such as
opening holes in walls for passing pipes and cables, stonecutting and drilling in concrete,
excavation, small concrete castings, small electric works, finish works for the aforementioned
 24

tasks, small steel constructions s operating ramps etc. These works shall be carried out as
specified in the contract documents.

36052 – Acoustic Isolation

Acoustic isolation, if reqired, shall comply with the plans and the special specification.

36053 – Grout Works

360530 – General
Four types of grout are in use:
- Normal cement grout – filling gaps up to 4 cm high
- Aggregate grout - filling gaps exceeding 4 cm high
- Epoxy cement grout – used in area exposed to vibrations. This type shall be used by the CO
approval only.
- Prepared mixture – subject to the approval of the CO, appropriate mixtures may be used.
360531 – Types of Mixtures
A. Normal cement grout – the mixture shall contain natural sand according to IS 3 and cement
at 3:1. Mixing shall be done in an appropriate mixer. Water quantity shall not exceed 50% of the
cement weight. In the mixture.
B. Aggregate grout - the mixture shall contain natural sand, cement and aggregate (grains 10
mm size). In no case the grain size shall exceed ¼ of the grout height.
C. Epoxy cement grout – as specified in the special specification and subject to the approval of
the CO.
D. Prepared mixtures – subject to the CO approval.
The CO may instruct on preparation of experimental mixture prior to accomplishment of the work.
360532 – Preparation for Grout
The concrete area under the grout shall be cleaned.
The concrete area shall be wet prior to grout application. When bolt sleeves are encountered, care
shall be exercised not to fill them with water. Bolt sleeves shall be properly cleaned. When the
anchoring bolts are cast in the base table, they should be equally released.
External forms shall be built around the base plate to hold the grout material and providing
appropriate height to ensure the grout flow under the entire base plate.
The form shall be designed to cover with grout the shims as well.
An opening in the equipment base plate shall be drilled to verify visually that the grout fills the
entire area.
360533 – Grout Application
Grout application shall be carried out not later than 30 minutes after preparation of the mixture.
Prior to grout application, the equipment shall be leveled using shims. The grout shall be applied
so that no air pockets are left. The application shall start at one end and the arrival of the grout at
the other end shall be verified.
360534 – Grout Finish
The grout shall be maintained wet by means of wet cloth. The form shall be dismantled after 24
hour period. The anchor bolts shall be tightened 40 hours minimum after grout casting.
The contractor shall verify, that the grout and concrete base area consist integral unit without
defects. However, when defects are notices, they shall be repaired using epoxy adhesive.
 25

36054 - Painting and Identification

360540 – General
Painting works shall be executed in compliance with Chapter 11 – General Specification for
Painting Works
Top coats shall be painted after completion of all production, installation and test works only,
subject to CO approval in advance. However, the contractor may paint parts and assemblies prior
to installation provided that the installation works do not damage the paint coats. The contractor
shall acquire the CO approval for this procedure.
Surface cleaning and primer application (one coat minimum) shall be done prior to the installation
on site.
360541 – Pre-paint Cleaning
When required in the special specification, all metal parts including steel pipes, supports and
vessels shall be sand blast cleaned to level Asa 2.5 of scale according to Sweden Standard SIS-
05-5900. Weld bulges, scars and flaws shall be removed by grinding. Scratches shall be filled and
grounded.
360542 – Paints
Metal surface painting shall be carried out using synthetic paint system. Painting epoxy resin
system shall be accomplished following a requirement in the special specification only. Unless
otherwise specified in the special specification, two red lead primer coats shall be applied to the
surface, 30  thick each. Then two glossy top coats paint (IS 750) or mat with equivalent quality.
The coats shall be 30  thick each. Total paint system thickness – 120 .
360543 – Paint Repairs
Areas where the paint system is damaged during work shall be cleaned with steel brush down to
the bare metal and then painted according to the instruction of this paragraph and the special
specification.
360544 – Equipment and Accessory Painting
Equipment and accessory shall be delivered from the original manufacturer painted, and shall not
be painted by the contractor except for paint repairs specified above.
360545 – Colors and Identification
The top coat colors and identification marking on equipment and piping system shall comply with
IS 659 unless otherwise specified in the special specification or following the CO instructions.
36055 – Signing
360550 – General
the signs shall be secured to panels or frames provided for them.
The signs dimension and inscription shall comply with the specification or the CO instructions.
Painted signs shall be painted with outdoor condition resistant paints.
Galvanized sheet signs shall be rigid and all edges processed without sharp corners.
360551 – Air Collector Signing
Air collectors shall be signed accrding to paragraph 36023.
360552 – Valve, Accessory, Instrument Signs
All system valves, accessories and instruments shall be marked by signs indicating their function
and use. The sign shall be made of engraved brass sheet. The sign shall be attached to the
operating handle or to the accessory adjacent pipe by means of clamps.
The original identification signs of the equipment and accessories applied by the original
manufacturer shall remain on the equipment upon delivery.
 26

360553 – Warning and Guidance Signs

The contractor shall supply and install warning and guidance signs to allow convenient operation
and service of the equipment. The signs shall be painted on galvanized steel sheet and positioned
in reading convenient location. These shall be installed near the compressor, the air drier and on
other item specified in the special specification.
360554 – Electric Switch Signs
All electric switches installed externally to the electric board shall carry signs indicating their
function. The signs shall be painted on top of galvanized steel sheet.

3606 – Electricity, Command and Control

36060 – General
The electrical systems, serving the compressed air facilities, shall comply with the requirements of
Chapter 08 - General Specification for Electric Installations, to the respective standards, to the laws
and regulations. The compressed air installation contractor shall supply, shall install and shall
connect all the feeding and control line systems from the electricity panels to the motors, the tools
and the control devices.
The types of the electric equipment for the installation, including panels, shall be approved by the
CO prior to the execution, and shall match as possible the types of equipment installed in the other
electric systems in the structure or plant.

36061 - Installation
Unless otherwise specified the electric installation shall be visible on walls or ceiling or on piping
system bridges in routes assigned in the plans, all according to the CO approval.
Should any electric equipment (such as motors, panels, cables, switches etc.) be installed
exposed outdoor, the equipment shall be built to meet the installation position conditions.

36062 - Conductors, Conduits and Cables

360621 - Conduits
The conduits are all kinds of pipes and ducts, as specified in this section according to the method
of installation:
Open installation - steel pipes or C type pipes.
Concealed installation - FD type pipes.
Exposed installation - PN type pipes (exposed installation - in cavities or above removable
ceilings).
Connections to motors and accessories - the connections shall be in flexible armored pipes with
plastic coating and the appropriate connectors. Pipes which internal diameter is smaller than 16
mm shall not be used.
Pipes installed on external walls shall be galvanized.
Ladders for the cables shall be as specified in Chapter 08.
Pipe brackets, duct brackets ladder and duct holders shall be either galvanized or made of non-
rusting materials
36063 - Electric Boards
360630- General
360631- Power Feed Panels
Electric boards feeding compressor motors shall be produced according to the plans and shall
incorporate at least the following devices and accessories specified in the following paragraphs
 27

and in paragraph Electric Boards in Chapter 08:

A. Main safety.
B. Main ammeter.
C. Voltmeter with phase selector.
D. Three indicator lamps for the main phases, and a three phase switch for the lamps.
E. Green lamps to indicate the operation of each motor.
F. Red lamps to indicate overload of each motor in the system associated with the panel.
G. Control selector switch (MANUAL – 0 - AUTO) for each motor in the system associated with
the board.
H. Ammeter for each motor, exceeding 10 HP.
I. A three phase relay to detect absence (inversion) and voltage drop, to shut down the control
system of the panel. The relay shall be of delayed type, and the delay range shall be determined
by the designer.
J. Three phase 15 Amp sockets outlet.
All warnings and protections shall be on the control phase side.
360632- Operation Panels
Secondary operation panels, and control panels shall be installed in the places indicated in the
contract documents. The panels shall be equipped with operation switches, indicator and warning
lamps only.
360633 - Capacitors
Capacitor system shall be installed to improve the power factor, with several stages in compliance
with the various operation modes, so that the power factor shall exceed 0.92 in any operational
mode.
36064 – Control Panels
The compressor control panel shall be installed integrally in the compressor electric board, or in a
separate cabinet as specified in the contract documents.
360641 – Panel Details
The control panel shall include:
A. Control panel main switch.
B. ON/OFF switch for each motor.
C. Selector switches and delay relays for sequential operation of the compressors.
D. Hour meter for each compressor motor exceeding 10 HP.
E. Voltage presence indicator lamps. ]
F. Green indicator lamps, indicating normal operation of motors.
G. Red lamps indicating special failures in the installations associated with the system, such as
compressor failures. Each failure in each facility shall have a separate indicator lamp. The lamps
shall be on unless the trouble is removed.
H. Alarm bell and flashing alarm lamp, including bell silencer switch, indicating the following
troubles:
1) Air pressure dropped below limitations.
2) Air pressure increased above limitations.
3) Cooling water temperature exceeded limitations.
4) Oil pressure dropped below limitations.
5) Various alarms according to the compressor manufacturer requirements.
I. Alarm test device.
J. Master failure relay to trigger the alarm and to send alarm signal to a central control board.
 28

36065- The Panel Equipment

360651 - Starters
Each motor shall be started with a direct on line starter, excluding the following:
A motor exceeding 3 HP shall be started by means of stepped starter, type star-delta or auto-
transformer or part winding or soft start type. A motor larger than 3 HP may be started directly on
line only when approved by the Electric Company and the CO.
Stepped starters shall be equipped with an arrangement, ensuring power supply, in case the
starter does not pass from one step to another.
The starters shall include contactors, adjustable thermal overcurrent protection on all three
phases, and all that required to ensure normal operation.
Alternatively, overcurrent protection may be integrated in the motor safety.
The contactors shall conform to the motor currents and shall be classified for one million
operations in work regime of 10% AC 1 + 90% AC 3, or alternatively, three million operations in
work regime of AC 3 under 400 volt. Control relays shall comply with maximum load, and 10
million operations under 230 Volt.
360652- Safeties
All panel safeties, including the main safety shall consist circuit breakers G characteristic, to
withstand short circuits current of 6 KA minimum. A requirement for short circuit currents exceeding
these values shall be indicated in the special specification.

36066 – Motors
The type of the electric motors, their size and their manner of operation shall be as indicated in the
drawings. All motors shall conform to operation under three-phase 400 VAC, 50Hz. When specified
explicitly, motors up to 1KW may be single phase 230 volt.
The motors shall meet the conditions and status specified, shall be silent in their operation, with no
overheating and no sparks. Tightness level shall be as specified in the plans or contract
documents, but not less than IP-4.
The motors shall be capable to resist 10% overload without overheating.
The motors shall be equipped with ball bearings, and shall be of the type of induction motor with
cage rotor. The start torque shall be according to the requirements of the driven equipment
manufacturers.
The maximum RPM of the motors shall be 1450 unless otherwise specified.
Motors operating in special environmental conditions shall be fit to operation under these
conditions.

36067 - Potential Equalization

All metal equipment, including compressor bodies, air vessels and air and water pipes shall be
connected to the building potential equalization bus. Electric continuity shall be maintained
throughout.
The grounding wire cross-section area shall be 10 mm2 minimum. In addition to the above, the
entire electric equipment shall be grounded as required by law.